PLC BOOT UP & RIO POWER ON PLC COMMUNICATION PORTS I/O FUNCTION CHECKs DIGITAL INPUTS DIGITAL OUTPUTS ANALOG INPUTS RTD INPUTS POWER SUPPLY UNIT (PSU) 24V DC TEST RING REDUNDANCY TEST
SECTION 4 : PLC HARDWARE FUNCTIONING 4.1
PROCESSOR MEMORY RETENTION VERIFICATION
SECTION 5 : FAT CONCLUSION
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Title
Client
Factory Acceptance Tests Procedure Project th
CHS for 5
Berth
FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
INTRODUCTION, GENERAL & FAT SCHEDULE
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INTRODUCTION The Factory Acceptance test (FAT) is provided in accordance with Schneider India quality system & is in line with manufacturing quality plan. The Factory Acceptance test (FAT) is a procedure for inspection of each panel hardware and accessories.
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GENERAL
1) Objectives: The factory Acceptance Test is carried out in order to demonstrate that :
The system and its components function properly. Manufacturing, assembly, configuration are done correctly. performance is in compliance with the approved functional o System specification. o o
2) Records established during FAT: Result of each test is recorded in observation section. Collective result of FAT will be recorded on FAT conclusion section.
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FAT SCHEDULE The Project Manager is responsible for the overall execution of the FAT and will be the prime interface between the client inspectors and the Schneider engineers from the beginning, to the completion of the FAT. Schneider shall give formal Inspection call inviting inspectors to witness the FAT. The inspection call provides information on : FAT start Date FAT Place Duration of FAT Internal test reports
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5/02/13 18/02/13 RK PP
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Title
Client
Factory Acceptance Tests Procedure Project th
CHS for 5
Berth
FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
SECTION 1 : REVIEW OF DOCUMENTS & TEST EQUIPMENTS
1.1
REVIEW OF DOCUMENTS OBJECTIVE : Verify correct approved documents are referred for the FAT. PROCEDURE : Check that the ‘Construction’ drawings have been established on the basis of the approved drawings transmitted at the time of inspection call. Check that the modifications carried by the ‘Construction’ drawings are marked in blue pen and dated and signed by the engineer-in- charge. Check that the modifications carried in the drawings do not affect the design.
OBSERVATIONS:
1.2
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REVIEW OF TEST EQUIPMENTS OBJECTIVE
:
Check that all Test and measurement equipments to be used for inspection have a valid calibration status.
LIST OF TOOLS
:
Multimeters, Current source, Screw driver sets, RTD Simulator, Measurement Tape
OBSERVATIONS
:
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Title
Client
Factory Acceptance Tests Procedure Project th
CHS for 5
Berth
FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
SECTION 2 : SYSTEM HARDWARE
2.1
2.2
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BOM VERIFICATION OBJECTIVE
:
The purpose is to verify all offered components are available as per approved BOM.
REFERENCE
:
Approved Bill of material, Approved Data sheets
CRITERIA
:
Offered system (hardware & software) are as per approved BOM.
OBSERVATIONS
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DIMENSIONAL / MECHANICAL INSPECTION OBJECTIVE
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The purpose of this inspection is to verify that, Dimensions of the PLC Panel is in line with approved GA drawing. The Panels are free from any mechanical damage.
REFERENCE
:
Approved GA drawing.
PROCEDURE
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Visually check the dimensions of the panel as per approved drawings with measuring tape. Visually check that all panel are free from any deformity.
CRITERIA
:
Physical dimensions are as per the approved panel drawings.
The purpose of this inspection is to verify rating of protection devices as per approved power distribution drawing.
REFERENCE
:
Approved Panel power distribution drawing.
PROCEDURE
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Compare the rated capacity of each protection device with approved panel power distribution drawing.
CRITERIA
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Ratings of protection devices are as per the approved panel power distribution drawings.
OBSERVATIONS
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PANEL EARTHING TEST OBJECTIVE
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The purpose of this test is to ensure the safety of the Personnel and installed equipment from any electrical hazards / short– circuits.
PROCEDURE
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Check that the Electrical earth bus-bar is connected to Earth point of incoming s upply. Check the panel chassis is connected to the Electrical earth bus-bar. Check the continuity between Instrument earth and Electrical earth. Check the potential between neutral and Electrical earth bus-bar using Multimeter.
CRITERIA
:
Multimeter will not shows continuity between Instrument earth bus-bar and Electrical earth bus-bar Potential between panel earth bar and neutral should be Less than 4V.
OBSERVATIONS
:
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5/02/13 18/02/13 RK PP
RK PP
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Title
Client
Factory Acceptance Tests Procedure Project th
CHS for 5
Berth
FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
2.5
PANEL GENERAL ARRANGEMENT & WIRING INSPECTION OBJECTIVE
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The purpose of this inspection is to verify that, General Arrangement (GA) & wiring of the panel is as per approved Internal Layout drawing, Power Distribution drawing and IO wiring diagram
REFERENCE
:
Approved Internal Layout drawing, Power Distribution drawing and IO wiring diagram
PROCEDURE
:
Visually check GA of panel and wire color & sizes as per Approved Internal Layout drawing and IO wiring diagram. Check for wiring continuity as per Power Distribution drawing
CRITERIA
:
GA of panel and wire color & sizes are as per Approved Internal Layout drawing and IO wiring diagram.
OBSERVATIONS
:
.
2.6
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SYSTEM ARCHITECTURE VERIFICATION OBJECTIVE
:
The purpose is to verify that, the offered System architecture conforms to the approved System architecture .
REFERENCE
:
Approved System Architecture Diagram
PROCEDURE
:
Check the system components are integrated as per approved system architecture diagram.
EXCLUSION
:
Connection of Connexium Switches through LIU with FO cable. (Connection between Switches shall be through FO patch Cords)
CRITERIA
:
System architecture is integrated as per the approved System architecture diagram
OBSERVATIONS
:
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Rev 1
5/02/13 18/02/13 RK PP
RK PP
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Title
Client
Factory Acceptance Tests Procedure Project th
CHS for 5
Berth
FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
SECTION 3 : SYSTEM FUNCTIONING
3.1
3.2
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PLC BOOT UP & RIO POWER ON OBJECTIVE
:
PLC goes to normal operation on powering up, provided all configurations are stored in PLC.
PROCEDURE
:
Power ON the PLC system (CPU & RIO). Using Unity Pro, Build the configuration. Ensure “Automatic start in RUN” in CPU configuration is enabled and Download the same into the PLC. Check PLC is in RUN mode and all Modules “Active” LED are ON Power OFF the PLC and Power ON again
CRITERIA
:
On power cycling, the PLC displays Run mode automatically.
OBSERVATIONS
:
PLC COMMUNICATION PORTS OBJECTIVE
:
Connection of the programming PC to the PLC through programming connection ports (USB, Ethernet)
PROCEDURE
:
Connect the programming PC to programming connection port of CPU. Using Unity Pro configure communication protocol: Menu PLC Set Address PLC Media: USB, Address: SYS OK Connect to PLC : Menu PLC Connect Transfer Program to PLC : Menu PLC Transfer Project to PLC
CRITERIA
:
The PLC displays Run / Stop mode automatically after completion of program transfer.
OBSERVATIONS
:
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Title
Client
Factory Acceptance Tests Procedure Project th
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FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
3.3
I/O FUNCTION CHECK •
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DIGITAL INPUTS OBJECTIVE
:
The purpose of this test is to check the function of digital input module from DI Relay Board terminals.
REFERENCE
:
Approved IO wiring diagram.
PROCEDURE
:
Simulate the contact at DI Relay board terminal. Connect 24VDC from bus-bar 1BB to DI Relay board Field Interrogation terminal Short the individual Relay board field terminal by using short-link. Check the corresponding DI status LED indication on PLC Input module and also observe the same in the Unity Pro Animation table.
CRITERIA
:
Individual DI LED indication on Input module should be ON.
OBSERVATIONS
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DIGITAL OUTPUTS OBJECTIVE
:
The purpose of this test is to check the function of digital output module up to DO Relay Board terminals.
REFERENCE
:
Approved IO wiring diagram.
PROCEDURE
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Force the Output using Unity Pro from programming PC. Observe LED Indication in the corresponding digital output module. Check Relay Operation and continuity of corresponding contacts at DO Relay board terminal.
CRITERIA
:
Individual DO LED indication on Output module should be ON.
OBSERVATIONS
:
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Rev 1
5/02/13 18/02/13 RK PP
RK PP
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Title
Client
Factory Acceptance Tests Procedure Project th
CHS for 5
Berth
FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
•
•
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ANALOG INPUTS OBJECTIVE
:
The purpose of this test is to check the function of analog input module from marshalling terminal.
REFERENCE
:
Approved IO wiring diagram.
PROCEDURE
:
Connect the source meter to the corresponding marshalling terminal . Simulate 4-20mA in various steps Observe the counts in the Unity Pro Animation table through programming PC.
CRITERIA
:
Correct AI counts for corresponding 4-20mA Inputs are Observed in Unity Pro
OBSERVATIONS
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RTD INPUTS OBJECTIVE
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The purpose of this test is to check the function of RTD Input module from marshalling terminal.
REFERENCE
:
Approved IO wiring diagram and RTD table
PROCEDURE
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Connect variable resistor to the corresponding marshalling terminal . Simulate resistor in various steps Observe the value in the Unity Pro Animation table through programming PC.
CRITERIA
:
Correct RTD value for corresponding resistance Inputs are Observed in Unity Pro
OBSERVATIONS
:
Rev0
Rev 1
5/02/13 18/02/13 RK PP
RK PP
Rev 2
Title
Client
Factory Acceptance Tests Procedure Project th
CHS for 5
Berth
FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
3.4
3.5
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POWER SUPPLY UNIT (PSU) 24V DC TEST OBJECTIVE
:
The purpose of this test is to ensure that the control panel is powered in normal conditions and the Bulk Power Supply delivers interrogation voltage
PROCEDURE
:
Measure the voltage of incoming power supplies Measure the Output voltage of Bulk Power Supply generated inside the panel. Check the Voltage in Bus Bar’s
CRITERIA
:
The Bulk Power Supply generating 24V DC inside the panel.
OBSERVATIONS
:
RING REDUNDANCY TEST OBJECTIVE
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The purpose of this test is to ensure that the Modbus TCP/IP & FO communication works in RING topology
PROCEDURE
:
Check the system components for Ring type communication are integrated as per approved system architecture diagram. Check for the Network Switch as per the specification
EXCLUSION
:
Connection of Connexium Switches through LIU with FO cable. (Connection between Switches shall be through FO patch Cords)
CRITERIA
:
Communication works in any direction (failure of one line) All network ports in Switch will be working
OBSERVATIONS
:
Rev0
Rev 1
5/02/13 18/02/13 RK PP
RK PP
Rev 2
Title
Client
Factory Acceptance Tests Procedure Project th
CHS for 5
Berth
FGI Prepared By Schneider Electric India Ltd.
Factory Acceptance Test Procedure
SECTION 4 : PLC HARDWARE FUNCTIONING
4.1
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PROCESSOR MEMORY RETENTION VERIFICATION OBJECTIVE
:
Purpose of this verification is to check program retention (in PLC Processor) in case of power failure.
PROCEDURE
:
1. Check the CPU battery is installed. 2. Download program to PLC. 3. Switch OFF the power supply of PLC rack and wait for 5 minutes. 4. Switch ON the power supply of PLC. 5. Check with programming PC that PLC has retained program.
