FAT and SAT is a big part of project execution and installation. Many projects require a Factory Acceptance Test before going on site. This testing period involves How to the specified design has been properly implemented in the software. Input are simulated to test the operation of the software. also software documents have kept up to date these same documents and that documents can be used to verify the operations of the software.
Factory Acceptance Test
The main objective of the FAT is to test the instrumented safety system (logic solver and associated software). The tests are normally carried out during the final part of the design and engineering phase before the final installation in the plant. The FAT is a customized procedure to verify the instrumented safety system and the instrumented safety functions according to the specification of safety requirements.
The FAT includes appropriate general test procedures for the verification of the proper functioning of the safety instrumented system. Since test activities are general methods, the FAT is applied to programmable or non-programmable safety instrumented systems. The most important part of the FAT addresses the specification of test cases, that is, a clear description of test cases, well-structured test procedures and relevant test cases.
It is important to note here that there are different levels of a FAT. They can be done at a very basic level, such as configuring the main parts of the system with temporary wiring and making sure that everything moves as it is supposed to, or a more complete FAT can be carried out where the manufacturer physically constructs the entire system in your store to test it completely. In the last example, the system is dismantled, moved to the client’s site and reassembled
For example if we start pump from field so actually that indication show in the scada. In shorts the software should then behave as per documentation. verification logic for testing that pumps start and stop and pump run status also. through simulation and then not turning them on to verify that the check logic is functioning correctly.
There are changes identified during the FAT. These changes should be done before going commissioning or installation. The contractor will have only small changes to make in the software documentation rather than a time consuming effort at the end of the project
Best advantage of FAT is another milestone in the project as the software has been proven in design. The next step is to place SCADA software or equipment in the field and Verify everything again using the real world inputs and outputs
Benefits of the factory acceptance test
- Clients can “touch and feel” the equipment while in operational mode before sending it.
- The manufacturer can provide some initial customer training, which gives operations personnel more confidence when using the machinery for the first time in real environments.
- The key people of the project from both sides are together, which makes it the ideal time to review the list of materials, analyze the necessary and recommended parts (for the start-up and the first year of operation) and review the procedures for maintenance and equipment limitations.
- The comprehensive FAT documentation can be used as a template for the Validated installation / installation installation qualification part.
- Based on the results of the FAT, both parties can create a list of additional elements that must be addressed before shipment.
Commissioning and Site Acceptance Testing
The Site Acceptance Test(SAT) is performed after all system have been tested and Verified. Before this final stage, the complete system must be tested and commissioned.
Step Of Commissioning is usually to verify all of the physical input and output to the each of the PLCs A copy of point list means input and output list can be generated with a column for checking off the points as they are verified. One of the issue is the sense of discrete inputs: are they Normally Open or Normally Closed type. This is thing that can differ between the original design and the field implemented system. The programmer can then make whatever changes are required and again markup the document.
One final step in many SCADA projects is the SAT. This is usually a continuous operation or run of the complete system for a period of 1–2 weeks without any major problems. if some problem is occur The parties must again meet to discuss how to handle the situation and decide if the current operation is correct or if a change is required.
The SAT (acceptance test of the site) will include the following tests:
- Ending visual control
- Visual verification of the main components
- Internal adjustment of pressure and ventilation of the box
- Functionality of utilities and configuration verification
- Verification of Functionality / Interlocks (Mechanics and Software)
- Hot testing for dispensing systems (source of activity provided by the Client)
- Verification of the dose calibrator (source of activity provided by the Client)
- Checking of safety devices and interlocks
- Operator training
- Delivery of the FAT protocol and documentation package, which includes:
- FAT Protocol Realized
- Maintenance and user manual
- List of recommended spare parts
- Certificate of Compliance
- As technical drawings constructed (electrical, mechanical, pneumatic and process diagrams)
- Certificates of materials / data sheets
- Main equipment data sheets
- Instrument calibration certificates
- Qualification of welding processes