FAT procedure for DCS

DCS (Distributed Control Systems)
1

FAT (Factory Acceptance Test) is carried out in order to demonstrate that the system and its components function properly, that manufacturing, assembly, configuration and software generation are done correctly and that system performance is in compliance with the approved functional specifications and relevant documents.

The same should be carried out for DCS also,

The basic requirements of FAT:

  • The test should be carried out with completely assembled system and complete I&C software performing all function expected out while in actual service.

  • Both computer code and technology programs to be installed and worked on the system until fat

Preliminary check:

  • General visual check and bill of materials check
  • Construction check as per over all general arrangement drawings
  • Dimensional check
  • Labelling , terminal arrangement and equipment identification check
  • Power supply voltage level check and power leeds -on check
  • Cooling fan operation check
  • Grounding network check

The fat treatment shall be prepared by the supplier and sent well in advance before the beginning of the fat for approval by the purchaser / consultant.

FAT procedure at control system:

  • Visual inspection

  • Terminal arrangement and wiring check

  • Power supply under voltage and over voltage check

  • Verification of jumper settings

  • Verification of healthiness of individual processors

  • Verification of operator interface displays

  • Verification of control functions: Start-up control, Acceleration control, Speed/Load control, Temperature control, Fired shutdown, Emergency shutdown

  • Verify protection systems: over speed, over temperature, vibration, master protection, flame detection.

  • System diagnostics

  • Redundancy test for controllers

  • Communication interface to DCS verification

FAT for Field instrument:

  • Pressure indicators

Calibration Hydro test (1.5 times max. pr.)

Calibration test / Hydro test / Contact rating test / Accuracy test / Repeatability

  • Differential Pressure Indicators

Calibration test / Hydro test / Leak test / Over range test / Accuracy test / Repeatability test.

  • Differential Pressure Switches

Calibration test / Hydro test / Contact rating test / Leak test / Accuracy test / Repeatability test.

  • Thermometers

Calibration / Material test / Accuracy test / Bore concentricity: + 5% of wall thickness / Hydrostatic test for TW (1.5 times max. pr.)

  • Temperature switch

Calibration / Material test / Accuracy test / Bore concentricity: 1.5% of wall thickness / Hydrostatic test for TW (1.5 times max. pr.) / Contact rating test.

Resistance temperature detector assembly. Calibration / Material test / Bore concentricity test / Insulation test (< 500 M at 500V DC) as per ISA, Hydro test for TW. Bore concentricity: + 5% of wall thickness, Accuracy test.

  • Thermocouple assembly

Calibration / Material test, Insulation test (> 500 at 500 V, DC) as per ISA, Hydro static test (1.5 times max. pr.), Bore concentricity: + 5% of wall thickness.

  • Thermo wells

Material test / Bore concentricity: + 5% of wall thickness / Hydrostatic test for TW (1.5 times max. pr.)

  • Level Gauges

Hydrostatic test / Material test / Seat leakage test / Ball check test.

  • Level switches (Magnetic)

Material test / Contact rating test / Hydro test / Calibration test.

  • Flow Switch

Material test / Hydro static test (1.5 times max. pr.) / function test.

Calibration test / Material test / Hydrostatic test (1.5 times max. pr.)

  • Flow element

100% Radiography test / Hydro test / Calibration test, IBR Certificate. Calibration test for flow element shall be witnessed by Purchaser/Consultant.

  • Position transmitters

  • Electro Pneumatic Converters

Calibration test / Accuracy test

  • Solenoid valves

Hydro test / Seat leakage test / CV test / Coil insulation test

  • Air filter regulators

Calibration test / Accuracy test

  • Junction Boxes

Test for degree of protection / Material test

  • Tests for terminal blocks

Test for moulding for flame resistant, Non-hygroscopic and Decarbonised / Insulation test between terminals / Insulation between terminal block and frame.

  • Thermocouple extension cable

Thermo-elf characteristic / Continuity test / Measurement on capacitance, inductance and loop resistance / Insulation resistance / High voltage test as per latest IS / Tensile and elongation test / Oxygen index test / Any other test applicable.

  • Mass flow meter

Performance test / Calibration test / Hydrostatic test.

Hydrostatic test / Material test / Seat leakage test / IBR Certificate

  • Local Panels

Visual inspection, wiring & continuity check, h.v. and i.r. tests on panels, checking of bill of materials, functional tests.