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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