Download Table of Contents - Control Direction

Control Direction Pty Ltd
www.controldirection.com
CD-Quality-I-003
Procedure
for
System Testing & Staging
Version 2.0
14 Feb 2014
Revision History
.CD-Quality-I-003....Procedure: System Testing & Staging
Name
Date
Michael Turnbull
Barry Heap
26/08/12
14/02/14
File: Document1
Reason for Change
Initial Document Version
Updated layout and new Logo.
Version 2.0
Version
1.0
2.0
Page ii
.CD-Quality-I-003....Procedure: System Testing & Staging
Table of Contents
Table of Contents .............................................................................................................iii
1 Purpose ......................................................................................................................... 1
2 Scope ............................................................................................................................. 1
3 Background & Design Premise ............................................................................... 1
4 Procedure Objectives ................................................................................................. 2
4.1
Hardware Checkout .............................................................................................................2
4.2
Software Checkout ...............................................................................................................2
4.3
System Connections Checkout .......................................................................................3
4.4
System Software Checkout ...............................................................................................3
5 Attendees ..................................................................................................................... 3
6 Staging Requirements ............................................................................................... 4
7 Test Equipment ........................................................................................................... 4
8 Test Process ................................................................................................................. 5
9 Inspection and Test Plans ......................................................................................... 5
Table 1 Hardware Visual Checkout ................................................... 1
Table 2 Hardware Functional Checkout ........................................... 1
Table 3. Continuity/ High Voltage Test ............................................ 1
Table 4. Software Checkout ................................................................ 1
Table 5. Software HMI Checkout ....................................................... 1
Table 6 Hardware Field Checkout ...................................................... 1
Table 7. Software Field Checkout ...................................................... 1
Table 8. For Future or Client Requirements .................................... 1
Table 9. For Future or Client Requirements .................................... 1
Table 10. Punchlist ................................................................................ 1
Table 11. Final Inspection .................................................................. 1
File: Document1
Version 2.0
Page iii
.CD-Quality-I-003....Procedure: System Testing & Staging
File: Document1
Version 2.0
Page iv
.CD-Quality-I-003....Procedure: System Testing & Staging
1 Purpose
This engineering document defines a set of minimum requirements for control
system hardware and software verification before the control system is
commissioned. To validate these requirements testing is performed to ensure that
the system is properly installed and functions in accordance with the intended
design.
To the extent it is economic and better supports a project schedule, the procedure
defines the requirements in the event staging of hardware and software is carried
out at a third party’s facility. To the extent that a factory acceptance test is
deemed unnecessary, the fundamental performance requirements are intended to
be carried out in the field.
2 Scope
This standard applies to all control systems and their ancillary devices and software
as applied to Control Direction designed and engineered systems.
3 Background & Design Premise
The sequence of events shown below is representative of the work process steps
that need to be completed to properly specify and install a control system.
This procedure provides the minimum requirements for Control Direction
conducting items 4 through 11 on the list below:
1. Specifier/Client prepares a detailed specification (or design basis) for
Control Direction.
2. Project-specific system hardware drawings are made and approved.
3. Control Direction integrates and builds the system.
4. Control Direction performs initial tests (i.e. the hardware FAT). This may
be done without the client. .
5. The system is approved and shipped to the field site.
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
6. The FAT or a staging report is prepared and used as the inspection
report for the project file.
7. Note that in some cases, software ONLY staging may be carried out post
system shipment. 8. Control Direction issues a final "as-built" set of hardware drawings as
needed.
9. The client and Control Direction supplier perform an SAT at the job site.
10. Control system loop check and function test) conducted at site.
11. Control system validation according to design requirements) conducted
on site.
12. Project commissioning.
13. Products on-stream.
14. Project "as-built" drawings are prepared.
4 Procedure Objectives
4.1 Hardware Checkout
The first objective is commonly referred to as the hardware checkout.
The first activity is to conduct an FAT on the selected and supplied hardware. In
this step the quality of workmanship, integrity, and function of the system
hardware is inspected and checked.
Hardware inspection test plans are conducted and supplied to the client by
Control Direction.
4.2 Software Checkout
The second objective is commonly referred to as a software checkout.
This activity is to test, correct, and finalize all software application configurations
that are required to meet the functional intent of the system. This step may be
completed on a virtual machine or offline (simulated) system.
File: Document1
Version 2.0
Page 2
.CD-Quality-I-003....Procedure: System Testing & Staging
The software checkout is conducted and supplied to the client by Control
Direction.
4.3 System Connections Checkout
The third objective is commonly referred to as a system connections checkout.
This activity is to test, correct and finalize all devices and subsystems connected to
the main control system.
System connections checkout are conducted and records supplied to the client by
Control Direction.
4.4 System Software Checkout
A fourth objective is commonly referred to as a system software design
checkout.
This activity is a fully integrated test and usually conducted with the client. It is the
step completed just prior to commissioning. It is often referred to as S.A.T.
Note: Frequently, an additional objective is to introduce plant operating and/or
maintenance personnel to the control system. This can form part of the overall
client training requirements.
5 Attendees
For Control Direction engineered systems the responsible Project Manager shall
extend an invitation to the responsible client representative to attend the system
staging. Client attendance is not compulsory and in the event the client cannot
attend Control Direction will complete the staging and supply all documented
results and outstanding items to the client.
File: Document1
Version 2.0
Page 3
.CD-Quality-I-003....Procedure: System Testing & Staging
6 Staging Requirements
Hardware and software staging is accomplished by simulating process inputs and
measuring the resulting outputs. The overall goals are to simulate the control
schemes and to check for proper interactions and operating modes of the system.
The control system shall be functionally checked regarding the following projectspecific documents (latest revision), which must be available for inspection:
1. System Manufacturing Drawings.
2. HMI / Console Configuration.
3. Instrument Specifications (for transmitter ranging, flow element PT
compensation).
4. Alarm and Trip Summary.
5. Electrical Schematics
6. Relevant calculations and process data (e.g., heat and material balance,
sequence data, motor data sheets and flow element calculations).
7. Any relevant data needed for interface to sub systems and equipment.
As staging progresses, the following documents or drawings must be used to
check the completeness of work. At the end of each task, appropriate
documents/drawings need to be checked or marked (e.g., with yellow highlighter)
to provide easy visual inspection for completed and noncompleted tasks:
1. P&ID (with clear marked P&ID revision and date of release).
2. Control system I/O list with input/output ranges.
3. Control system alarm and trip setpoint summary.
4. Control System Shutdown Matrix/Table (with clear marked P&ID revision
and date of release).
7 Test Equipment
Various types of test equipment might be needed to perform a successful staging.
With the possible exception of pulse generator/counters, this list of essential
File: Document1
Version 2.0
Page 4
.CD-Quality-I-003....Procedure: System Testing & Staging
equipment is shown below. The supplier of the equipment, either Control Diection
or the client, shall be determined before staging.
Some typical test equipment could include?

Digital Multimeter

DC mA Source

DC mV Source

Pulse Generator

Pulse Counter

Decade Resistance Box

CT Current Source

Single Phase/3 Phase supply

Proprietary test equipment
8 Test Process
The inspection and test process is to use the Inspection and Test Plan checklists as
a basis for all activities.
Each test is witnessed and recorded on existing documents listed in the checklist
Reference column. Once complete the tester initials the Chkd column. Exceptions
are recorded in the checklist and defects that require future work are recorded in
the staging punchlist form. The client may or may not be present for all tests. This
depends on availability and the client process for each inspection and test stage.
All documents used in this process are scanned and provided to the client for their
records.
9 Inspection and Test Plans
Table 1.
Hardware Visual Checkout - check for compliance to documents,
quality of work, damage, appearance.
Table 2.
Hardware Functional Checkout- check for continuity, insulation, pointto point, voltages, polarity.
File: Document1
Version 2.0
Page 5
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 3.
Continuity/ High Voltage Test – check insulation resistance and earth
continuity.
Table 4.
Software Checkout - check list for system software items.
Table 5.
Software HMI Checkout - checklist for operator interface items.
Table 6.
Hardware Field Checkout - checklist for hardware items when installed
in the field.
Table 7.
Software Field Checkout – checklist for software items when installed
in the field.
Table 8.
Spare. Reserved for client specific requirements.
Table 9.
Spare. Reserved for client specific requirements.
Table 10.
Punchlist form to be used during and after staging to document
control system issues that need resolving.
Table 11.
File: Document1
Final Inspection – final checks prior to delivery.
Version 2.0
Page 6
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 1 Hardware Visual Checkout
Cubicle Number: ____________________
Date:________________
Exterior
Item Description
Chkd Reference
1
Cubicle exterior scratch free
Visual
2
Cubicle exterior correct colour
Visual
3
Cubicle dimensions correct
Drawings
(LxWxH)
4
Plinth correct dimensions
Drawings
5
Exterior labels correct letters
Drawings
6
Exterior labels correct size
Drawings
7
Exterior labels correct colour
Drawings
8
Fitted accessories correctly
Drawings
positioned (e.g. fans)
9
Confirm photos taken of all
Records
exterior panels
Interior
Ite
Description
Chkd Reference
m
1
Cubicle interior scratch free
Visual
2
Cubicle interior correct colour
Visual
3
Gear tray/rack layout (matches
Drawings
drawings)
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
4
Equipment, ducting and DIN
Visual
rails straight
5
AC distribution (matches
Drawings
drawings)
6
DC distribution (matches
Drawings
drawings)
7
Correct terminal types used
Drawings
(matches drawings)
8
Every circuit breaker, main
Visual
switch and fuse holder(s)
provided with up-to-date,
legible and durable rating labels
giving their ratings.
9
Every circuit breaker and main
Drawings
switch provided with a legible
and durable identification label.
10
All accessible live parts
Visual
screened with insulating plate
or earthed metal.
11
Cables correct size and color
Drawings
12
No visible damage to any
Visual
cables
13
Earthing (matches drawings)
Drawings
14
Fuse and Circuit Breakers
Drawings
correct Rating
15
Confirm photos taken of all
Records
interior panels
.
File: Document1
Version 2.0
Page 2
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 2 Hardware Functional Checkout
Cubicle Number: ____________________
Date:________________
Item Description
Chkd Reference
1
Isolate all circuits
Drawings
2
Disconnect Main Earth/Neutral
Visual, Drawings
(M.E.N). While disconnected,
check it the correct size.
3
Check Cables, Busbars and
Visual
Terminals for tightness
4
Set Overloads to drawings
Visual, Drawings
5
Set Time Clocks, Timers
Visual, Drawings
6
Check settings of multifunction
Visual, Drawings
meters
7
Check Polarity of Current
Visual, Drawings
Transformers
8
Check CT Links wired correctly
Visual, Drawings
and closed or opened (as
required)
9
Check output voltages of power
Visual, Drawings
supplies/transformers.
10
Check voltages of contacts,
Visual, Drawings
relays, pilot lights, etc.
11
Perform Continuity Test Min
Continuity/HV Test Sheet
5kV
12
Perform HV Insulation Test
Continuity/HV Test Sheet
13
Check continuity from line to
Visual, Drawings
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
load on motor starters
.
File: Document1
Version 2.0
Page 2
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 3. Continuity/ High Voltage Test
Cubicle Number: ____________________
THE FOLLOWING
INSPECTION WAS
COMPLETED AS PER
SEQUENCE BELOW TO
AS3439.1-2002
PASS
REJECTED
AC BUSBAR
PHASES
TEST 1
RED TO WHITE
INSULATION
TEST
RED TO BLUE
BLUE TO WHITE
.5 - 1 Kv
INSULATION
TEST
Date:________________
DC BUS BAR
VALUE
IN Meg

PHASES
VALUE
IN Meg

COMMENTS
POS TO NEG
POS TO
EARTH
NEG TO
EARTH
3 PHASE TO
NEUTRAL
3 PHASE TO
EARTH
TEST ALL
BUSBARS IN
CIRCUIT
TEST 2
RED TO WHITE
HIGH VOLTAGE
TEST
RED TO BLUE
EARTH TO
NEUTRAL
BLUE TO WHITE
2.5 KV FOR
ONE MINUTE
ALL BUSBARS
IN CIRCUIT
POS TO NEG
POS TO
EARTH
NEG TO
EARTH
3 PHASE TO
NEUTRAL
3 PHASE TO
EARTH
EARTH TO
NEUTRAL
TEST 3
RED TO WHITE
INSULATION
TEST
RED TO BLUE
BLUE TO WHITE
DO NOT HV TEST WITH
ELECTRONIC EQUIPMENT
ATTACHED TO EARTH AND
NEUTRAL
POS TO NEG
POS TO
EARTH
NEG TO
EARTH
3 PHASE TO
NEUTRAL
.5 - 1 Kv
INSULATION
TEST ALL
BUSBARS IN
CIRCUIT
File: Document1
3 PHASE TO
EARTH
EARTH TO
NEUTRAL
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
.
File: Document1
Version 2.0
Page 2
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 4. Software Checkout
System Item: ____________________
Date:________________
Item Description
1
Chkd Reference
All system software packages
List software packages
are properly installed according
here:
to the project control system
specification.
2
Verify software configurations
List any exceptions here:
interface properly with electrical
schematics where applicable
(soft and hard logic work
together properly).
3
Verify all alarm tags annunciate
Alarm / Tag list
when in the alarm state.
4
Verify all analogue faceplates
Tag list
display the correct engineering
units and scale. Verify scale
settings in I/O modules and
configuration blocks match.
5
Verify that all module power-up
List any exceptions here:
initialization logic works
properly.
6
Verify proper operation of any
List any exceptions here:
critical timing functions.
7
Verify proper operation of any
Alarm / Tag list
first-out alarming logic.
8
Verify engineering unit
Tag List
descriptors for all tags.
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
9
Verify proper operation of any
List exceptions here:
Foreign Device Interfaces.
(Fieldbuses, Modbus etc.)
10
Verify node addressing and
List exceptions here:
connections are in accordance
with system topology drawing.
.
File: Document1
Version 2.0
Page 2
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 5. Software HMI Checkout
System Item: ____________________
Date:________________
Item Description
1
Chkd Reference
Verify proper and functional
Graphic prints
layout of interface screens and
graphics, including alarm
screens.
2
Verify all software applications
List any exceptions here:
perform as intended, without
any errors.
3
Check linking of screens; i.e., all
Graphic prints
screens in a group shall be
linked via "page- up"/"pagedown" keys, software menus,
links etc.
4
5
6
Verify correct colour for normal
Red line mark up Graphic
and abnormal conditions.
prints
Verify all trends are included on
Red line mark up Graphic
an HMI trend.
prints
Verify proper operation of any
List any exceptions here:
Foreign Device Interfaces from
application displays.
7
8
Verify correct unit operation
Red line mark up Graphic
shapes and symbols
prints
Logic solvers are correctly
configured:
a. Proper control action for PIDs
(direct or reverse).
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
b. Split ranges are correctly
configured.
c. Appropriate default tuning
constants installed.
d. Proper fail mode is set (F.O.
or F.C.).
e. All valve outputs consistently
displayed (100%=open).
.
File: Document1
Version 2.0
Page 2
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 6 Hardware Field Checkout
Cubicle Number: ____________________
Date:________________
Item Description
1
Chkd Reference
Verify digital I/O - 100%
Tag List
channel test (terminal assembly
to screen).
2
Verify all analogue input
Tag List
specifications for the following:
a. Correct zero and range
specifications.
b. Correct signal level
specification, i.e.: T/C, RTD, -10
to +10V, 4 to 20 mA, etc.
c. Enable or disable supplierspecific diagnostics as
documented in the prescriptive
documents.
d. Verify proper failsafe modes
are set properly in each I/O
channel.
3
Verify all analogue outputs to
Tag List
proper location and
configuration. Valve outputs set
to fail to designated output
value on loss of logic solver
communication.
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
4
Verify all digital inputs and
Tag List
outputs for proper locations
and configuration. Enable or
disable supplier-specific
diagnostics as documented in
the prescriptive documents.
5
Check power supplies,
List exceptions here:
communication cables and
processors for correct level of
redundancy:
Remove, and reinsert, each
item, one at a time, to verify
the system status remains
healthy, that a status alarm is
generated.
6
Check all cable connections are
Cable schedules
secure and deficient of stress.
7
Check wire and cable tagging
Cable schedules
for accuracy and ease of
identification.
8
Inter-cabinet wiring and cabling
Cable schedules
is neat and professional.
9
Make certain wire connections
Cable schedules
are mechanically strong. Visually
inspect all; tug on a random
sample.
File: Document1
Version 2.0
Page 2
.CD-Quality-I-003....Procedure: System Testing & Staging
10
Verify proper isolation of dc
List exceptions here:
ground from cabinet. Verify that
the power and ground connects
are correct according to the
prescriptive standard for the
control system.
11
Verify correct operation of fans,
List exceptions here:
cabinet alarms, lights, GPO’s,
data interfaces etc.
12
Verify labeling of wires
Cable schedules
.
File: Document1
Version 2.0
Page 3
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 7. Software Field Checkout
System: ___________________________
Date:_________________
Item
Description
Chkd
Reference
1
Verify valve operation
P&ID
2
Verify motor operation
P&ID
3
Verify interlocks
Control Logic List
4
Verify shutdown conditions
Shutdown matrix
5
Verify sequence operations
Control Logic List
6
Verify control loops
Control Logic List
7
Verify calculations
Control Logic List
8
Verify alarms and shutdowns
Alarm / Tag list
.
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 8. For Future or Client Requirements
System: ___________________________
Item
Description
Date:_________________
Chkd
Reference
1
2
.
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 9. For Future or Client Requirements
System: ___________________________
Item
Description
Date:_________________
Chkd
Reference
1
2
.
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 10.
Punchlist
Categories:
1. Minor Defect

Defect requiring minimal effort to resolve.

It may be resolved during the test day.
2. Medium Defect

Defect requiring effort to resolve.

It may be resolved at the conclusion of the test day and witnessed in future test days.
3. Major Defect

Defect requiring significant effort to resolve.

It may be resolved post test and could be witnessed via Teamviewer or from site
Punchlist: ___________________________
Item
Description:
Date
Date:_________________
Action
Category
Resolved
(1,2,3)
File: Document1
Version 2.0
Page 1
.CD-Quality-I-003....Procedure: System Testing & Staging
.
File: Document1
Version 2.0
Page 2
.CD-Quality-I-003....Procedure: System Testing & Staging
Table 11.
Final Inspection
Cubicle Number: ___________________________
Item
1
Description
Date:______________
Chkd
Paintwork clean and scratch
Reference
Visual
free.
2
Cabinet clean inside.
Visual
3
Check hinges, locks and door
Visual
seals.
4
Check shrouds and covers are
Visual
installed.
5
Check cable ducts and ensure
Visual
covers fitted.
6
Check all labels fitted Internal /
Visual, Drawings
External / Warning / Caution
7
Circuit Breaker Schedule
Visual, Drawings
8
Compliance Plate Attached
Visual, Drawings
(where required).
9
Manuals and/or Technical
Visual, Drawings
information enclosed.
10
Final Photos taken.
Visual
11
Keys attached to locking
Visual
device(s).
12
Wrapped or crated for
Visual
transport.
13
Delivery Docket attached.
File: Document1
Visual
Version 2.0
Page 1