Factory Acceptance Test – Equipment

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1.0 FACTORY ACCEPTANCE TESTS COMPRISES OF THE FOLLOWING:

1.1 Design Document Review
1.2 Mechanical Inspection test/component Test
1.3 Electrical Hardware Tests
1.4 Software Acceptance Test
1.5 System Acceptance Test/Equipment Functional Tests

At the conclusion of the study a section shall describe in detail any deviation or exceptions that were noted during the test along with the resolution retest results. This section shall include the list of persons who executed the tests along with their detail, company, signature and initials.

2. OVERVIEW AND THE TEST PLAN:
This document applies to all testing of the equipment referred in the project plan. This document shall be reviewed by the Project Manager & approved by quality assurance department. The factory acceptance test consist of design documentation review, electrical hardware, Mechanical Inspection test/component Test, Software acceptance Test & system acceptance test. The Mechanical Component acceptance test & the Electrical Hardware acceptance test shall be completed before the software acceptance test or the system acceptance test is begun. The software acceptance test and the system acceptance test may be performed simultaneously.

The performance of FAT procedures which have satisfied the laid down acceptance criteria shall be considered as evidence which will ensure the correct construction & performance of the equipment as specified in the User Requirement Specification. The procedure shall be deemed to have “passed” if, and only if, every step in the procedure results in the specified outcome. If any step in a procedure results in an outcome other than
the specified results, that entire procedure shall “fail”.

At the conclusion of the testing, FAT team shall review the FAT results and specifies any corrective action that the vendor/supplier shall take. The FAT team has the option of specifying how and when the corrective actions will be made. A close out report shall be prepared, which shall include the issues arose, agreed direction/decision, person responsible for resolution, resolve due date, severity of deviation, date, signatures of team members & vendor.

3. DESIGN DOCUMENT REVIEW:

To ensure that the required documents are available and are accurate, the first step at the FAT is to perform a documentation review. This should consist of two parts:

3.1 Confirmation of the availability of the approved design documents and specifications
3.2 Confirmation that all support documentation is available and accurate.

4. MECHANICAL COMPONENT ACCEPTANCE TEST:

The mechanical component acceptance test applies to the verification of the installation and configuration of the mechanical components on assembled equipment. The equipment shall be fully assembled before these test procedures are begun. The personnel required to perform these test procedure shall consist of at least one “Tester” and at least one “Witness”. The tester & the witness shall be designated by the Project Team of the project plan. Before beginning these test procedures, the tester and witness shall read & thoroughly understand the P&ID. Following shall be checked and compared to the P&ID.

4.1 Component Make
4.2 Tag No. of the Component
4.3 Type of components
4.4 Location of the component

The results of the comparison shall be recorded in the appropriate record format. The tester and witness shall place his or her “initials” irrespective of the test procedure was completed satisfactorily. If the results are not satisfactory full checking (100%) of the pre-executed work shall be performed with appropriate deviations/resolutions being noted. If the resolution is to be performed at later date, this also should be noted in appropriate section.

5. ELECTRICAL HARDWARE TESTS:

After the completion of the mechanical component installation verification is over, the execution team shall perform the physical inspection of the electrical hardware which is checked for installation, configuration and calibration. Component installation verification shall be performed visually. The make and the model of the components, tag number of the components, and configuration of the components if applicable shall be compared to the P&ID.
Wiring installation verification testing shall be performed visually. The physical wiring of the terminal blocks and components shall be compared to the Electric Schematics. The wire number at each terminal point shall be identical to that specified on the corresponding electrical schematic. The results of the comparison shall be recorded in appropriate record form The personnel required to perform these test procedure shall consist of at least one “Tester” and at least one “Witness”. The tester & the witness shall be designated by the Project Team of the project plan. . The tester and witness shall place his or her “initials” irrespective of the test procedure was completed satisfactorily. If the results are not satisfactory full checking (100%) of the pre-executed work shall be performed with appropriate deviations/resolutions being noted. If the resolution is to be performed at later
date, this also should be noted in appropriate section
.
6. SOFTWARE ACCEPTANCE TEST:

The software acceptance test applies to the verification of the operation of the software of the equipment.
The PLC logic, the embedded software, shall be written, documented & installed in completely assembled fully functional equipment before the test procedures are begun.

The personnel required to perform these test procedure shall consist of at least one “Tester” and at least one “Witness”. The tester & the witness shall be designated by the Project Team of the project plan. Before beginning these test tests procedures, the Tester & Witness shall read and thoroughly understand the electrical schematic, concerned drawings, logic program.
Software acceptance testing shall be performed visually. All the alarms, faults and the operational sequences verification shall be included in the software acceptance tests and all these tests shall be performed under the simulated conditions.. The state of the inputs & outputs shall be compared to those described in the electrical schematics and the logic program. The results of the comparison shall be recorded in the appropriate record
form The tester and witness shall place his or her “initials” irrespective of the test procedure was completed satisfactorily. If the results are not satisfactory full checking (100%) of the pre-executed work shall be performed with appropriate deviations/resolutions being noted. If the resolution is to be performed at later date, this also should be noted in appropriate section.

7. SYSTEM ACCEPTANCE TEST/EQUIPMENT FUNCTIONAL TEST:

Once the electrical & hardware checks are completed the functional testing can begin. The equipment shall be completely assembled and fully functional before these test procedures are begun. All the critical instruments shall be calibrated before these test procedures are begun. System acceptance testing shall be performed visually. All the operational sequences, faults and alarms shall be verified in the system acceptance test and these tests shall be performed under the simulated conditions. The position of the components and the operating parameters shall be compared to those described in the functional and design specifications. The result of the comparison shall be recorded in the appropriate record form. . The tester and witness shall place his or her “initials” irrespective of the test procedure was completed satisfactorily. If the results are not satisfactory full checking (100%) of the pre-executed work shall be performed with appropriate deviations/resolutions being noted. If the resolution is to be performed at later date, this
also should be noted in appropriate section. Any test that requires support documentation shall be supported with printouts of data from the PC that is controlling the equipment. These printouts from the equipment shall become the integral part of the FAT and shall be mentioned under the “Attachments to the FAT” heading.

8. REVIEW REPORT:

At the conclusion of testing the team reviews the test results/deviations and specifies any corrective action that the vendor should take. Reviews shall be held at the completion of each section of the FAT (i.e. at the completion of the Mechanical Component acceptance test, Electrical Hardware acceptance test, Software acceptance test & System acceptance test.) The FAT team specifies how and when the corrective actions will be made. In the worst case, the testing team will return at a later date to retest the resolution (or entire FAT). More typically the resolutions and the required due dates will be agreed upon with acceptance being given conditionally, or the resolution will be implemented as they occur with the equipment being accepted and shipped at the end of the FAT. More significant deviations that involve electrical or software modifications have to be retested in a subsequent FAT addendum or in the SAT.

9. DEVIATIONS AND CORRECTIVE ACTIONS:

For the deviations encountered if, any during the factory acceptance test a deviation investigation report shall be filled and it shall also include the action required to be taken to tackle the deviation with justification and the person responsible for it

10. FACTORY ACCEPTANCE TEST REPORT:

A factory acceptance test report shall be filled after all the deviations have been tackled with justification. The report shall bear the conclusion of the FAT and shall be approved by the Project Manager, Projects & Vendor Representative for the final acceptance.

Check Availability of the following deliverable:


1. Material specification & certification, Passivation Certificates,Product Contact Certificates,
2. Product contact weld certificates and Surface Finish Certificates.
3. Detailed list of modifications after contract
4. Description of control system
5. Warranty Terms
6. Calibration certificates with reference to the calibration protocol & traceable calibration standards
7. Calibration reports for electrical instruments
8. Certification of safety valves and devices
9. Test Protocols/Methods
10. Welding Protocols of the chamber
11. Hydro Test certificates (for pressure vessel)
12. As built drawings
13. Engineering Drawings of the equipment
14. Installation & construction drawings
15. Control & instrumentation diagram
16. Electrical Circuit Diagram
17. Pneumatic Circuit Diagram
18. Confirmed Layout Plan
19. P&ID diagram
20. Isometric Piping Diagram
21. Material Specifications
22. Instrument Specifications
23. Equipment & instrument list with component description
24. Electrical component part list with description
25. Spare Part List
Document Checklist
26. List of all equipment suppliers
27. List of all possible failure & alarms
28. List of all sequences
29. List of all safety equipment
30 Parts List with Part Number
31. List of test parameters with diagram showing position of all measuring points
32. Equipment description Manual & Operational Manual
33. Maintenance Manual/Instructions
34. Lubrication specifications
35. Lubrication plan
36. Utility Requirement
37. Software validation plan
38. Software validation report
Software validation report contains a statement confirming that the system has been fully validated
.
Following test are Conducted during factory acceptance testing:

Mechanical Component Verification
Electrical Component Verification
Electrical Component Verification(PLC Verification)
Wiring Installation Verification
Software Acceptance Testing: Here each procedure step(Sequence, Faults or alarms) is checked for the Actual Input/Output against the specified Input/Output

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