Custom Process Equipment

4727 NW Evangeline Thruway

Carencro, LA 70520
Tel : (337) 896-3815

DPSD DOCUMENT NO.

DPS-2010-1105-Q-KA-0005
FAT PROCEDURE
Abu Qir Thermal Power Plant
Supplier: DPS

Contents
1

Introduction

1.1
1.3

Objective
Supplier Reference Documents
Necessary Material

FAT Overall Planning

Procedures

1.2

3.1
3.1.1
3.1.2
3.1.3
3.1.4

Mechanical Checklist
Package General
Piping
Vessels
Access

3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6

Instrument Checklist
Level Gauges
Level Control Valves
Differential Pressure Transmitters
Pressure Indicators/Pressure Differential Indicator/Temperature Indicators/Flow Indicators
Pressure Relief Valves
Level Switches

3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5

Electrical Checklist
Junction Boxes
General Inspections
Documentation
Conformity
Cable Installation and Tests

3.4

Document Verification

Manufacturer: CPE

Client PO:10-118-26

Custom Process Equipment

DPSD DOCUMENT NO.

DPS-2010-1105-Q-KA-0005

4727 NW Evangeline Thruway

Carencro, LA 70520
Tel : (337) 896-3815

FAT PROCEDURE
Abu Qir Thermal Power Plant
Supplier: DPS

1
1.1

Objective
The Objective of this document is to provide a detailed Factory Acceptance Test Plan for DPS purchase order PO-2010-1105-001, which consist of a Filter
Separator and Drain Tank Skid Assembly. The major components of the package include the following:
1. Filter Separator Skid Assembly
a .Filter Separator Vessel 6-FG-MT001
b. Filter Separator Vessel 7-FG-MT001
c. Drain Tank 9-FG-MT-001
The test procedures containted in Section 3 of this document will be utilized to determine the following:
1. Product compliance with the purchase order document
2. Product compliance with the purchase order specifications
3. Acceptability of workmanship
4. Integrity if components
5. Verification of Functionality

It should be noted that process control is being performed in the Plant Control System. The instruments and valving
associated with these functions will be checked for calibration and functionality using a hand held communicator.

FAT will be considered complete when all items on the checklist have be brought into conformity.
All Equipment from sub-vendors will have been tested and calibrated prior to delivery.
1.2

Client PO:10-118-26

Introduction

Supplier Reference Documents

DPS Document No.
DPSD-2010-1105-I-LA-0001 Rev.H
DPS-2010-1105-TST-001
DPS-2010-1105-TST-002
DPS-2010-1105-R-STD-003
DPS-2010-1105-R-STD-006
DPS-2010-1105-402
DPS-2010-1105-500
DPS-2010-1105-201
DPS-2010-1105-101
DPS-2010-1105-102
DPS-2010-1105-201
2010-D-1105-202
2010-D-1105-203
DSP-2010-1105-400
DSP-2010-1105-401
DPS-2010-1105-I-VD-0001

Client Doc. No.

Document Title
Instrument List Rev H
Manufacturer's Hydrotest Reports
Manufacturer's NDE Reports
Manufacturer's Coating Reports
Material Test Certificates
Cause & Effect Matrix / Logic Function
Pipe & Instrument Diagrams (P&ID)
Piping GA (Plans & Elevations)
Filter Separator GAt Drawing
Drain Tank GA Drawing
Skid Assembly Drawing
Structural Skid Drawing
Filter Separator Platform Drawing
Electrical / Wiring Drawings
Junction Box Layout Drawing
Instrument Calibrations and Certification

Client Reference Documents

Purchaser's Minimum Quality Surveillance Summary Data Sheet
Client Document Number
7929-511-413-03-18
DPS-2010-1105-R-DS-00001
DPS-2010-1105-R-DS-00002
99999-9-3DS-P72-00001
10054-9-3PS-JQ07-00001
DPS-2010-1105-R-K-0002
99999-9-3SS-NX00-00003

Document Title
Purchase Order Number
Fuel Gas Filter Separator Data Sheet
Drain Tank Data Sheet
Design of Piping on skids
Instrumentation & Electrical Requirements for
packaged equipment
ITP Form
Surface Preparation and Painting

Custom Process Equipment

4727 NW Evangeline Thruway
Carencro, LA 70520
Tel : (337) 896-3815

DPSD DOCUMENT NO.

DPS-2010-1105-Q-KA-0005
FAT PROCEDURE
Abu Qir Thermal Power Plant
Supplier: DPS

1.3

Client PO:10-118-26

Necessary Material
HART COMMUNICATOR FOR PDIT
MANOMETER PRESSURE SET FOR PDIT
24VDC POWER SUPPLY
FLUKE MULTIMETER
WATER SOURCE
COMPRESSED AIR SOURCE

FAT Overall Planning

The FAT is intended to cover the following major areas:
1. Documentation Review. A review of the project documentation will be conducted by Supplier personnel as well as the Client
representative. The following are the major areas of review.
a. Manufacturing data review
b. Valve and instrument data review
c. Miscellaneous Equipment data review
2. Equipment Inspection and Testing. The checklists contained in Section 3 of this document will be used to verify their functionality and
conformance with project requirements. Supplier personnel along with the customer representative will proceed through the lists and perform the necessary
evaluation. The checklists are divided into the following major categories:
a. Mechanical
b. Instruments
c. Electrical

Custom Process Equipment

4727 NW Evangeline Thruway
Carencro, LA 70520
Tel : (337) 896-3815

DPSD DOCUMENT NO.

DPS-2010-1105-Q-KA-0005
FAT PROCEDURE
Abu Qir Thermal Power Plant
Supplier: DPS

3
3.1

Client PO:10-118-26

Procedures
Mechanical Checklist
Checklist

3.1.1

3.1.2

3.1.3

3.1.4

Package General
Verify package completed to P&ID: DPS-2010-1105-500
All tagging to be checked in position and correct to P&ID for all items.
Verify package completed to all General Arrangement drawings.
Confirm all TP locations.
Check for any visible signs of damage.
Review project documentattion.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________

SIGN

DATE

TS
TS
TS
TS
TS
TS
TS

3/31/2011

Piping
Confirm that all flanged joints are made up correctly.
Confirm pipe routing, supporting and painting are in accordance to Project Specifications.
Confirm all paintwork is undamaged.
Confirm piping color banding and identification is correct (if applicable).
Review project documentation.
Check for any required actions: Conforming _________X_________ Non-Conforming _______________

TS
TS
TS
TS
TS
TS

3/31/2011

Vessels
Confirm all hold down bolts are correctly fitted.
Confirm vessel nameplates are correct and securely fitted
Confirm vessel hand hole bolts and gaskets are correctly fitted.
Confirm all paintwork is undamaged.
Review project documentation.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________

TS
TS
TS
TS
TS
TS

3/31/2011

Access
Confirm access for operation and maintenance of all valves,and instruments.
Review project documentation.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________

TS
TS
TS

3/31/2011

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Checklist
3.2
3.2.1

3.2.2

Instrument Checklist

SIGN

DATE

Level Gauges
Check mechanical mounting is correct and firm.
Check instrument for any visible sign of damage.
Verify material certification available with instrument
Verify nameplate is correct and securely fitted.
Review project documentattion.
Check for any required actions: Conforming _______X________ Non-Conforming _______________

TS
TS
TS
TS
TS
TS

3/31/2011

Level Control Valves

Check valve failure mode for loss of air supply.
Check wiring termination cable tag is correct and securely fastened
Check mechanical mounting is correct and firm.
Confirm that instrument is installed in correct position
Test with increasing and decreasing signal 0%, 25%, 50%, 75%, 100%, 75%, 50%, 25%, 0%
Check instrument for any visible sign of damage.
Verify material certification available
Verify nameplate is correct and securely fitted.
Review project documentattion.
Check for any required actions: Conforming _______X_______ Non-Conforming _______________

TS
TS
TS
TS
TS
TS
TS
TS
TS
TS

3/31/2011

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Custom Process Equipment

4727 NW Evangeline Thruway
Carencro, LA 70520
Tel : (337) 896-3815

DPSD DOCUMENT NO.

DPS-2010-1105-Q-KA-0005
FAT PROCEDURE
Abu Qir Thermal Power Plant
Supplier: DPS

3.2.3

3.2.4

3.2.5

3.2.6

Client PO:10-118-26

Differential Pressure Transmitters

Will be powered and checked at ambient pressure.
Check wiring termination cable tag is correct and securely fastened
Confirm that instrument is installed in correct postion
Check wiring termination cable tag is correct and securely fastened
Confirm that instrument is installed in correct postion
Check mechanical mounting is correct and firm.
Check instrument installed in correct position.
Check instrument for any visible sign of damage.
Verify nameplate is correct and securely fitted.
Review project documentattion.
Check for any required actions: Conforming _______X________ Non-Conforming _______________

TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS

3/31/2011

Pressure Indicators/Pressure Differential Indicator/Temperature Indicators/Flow Indicators

Check mechanical mounting is correct and firm.
Check instrument installed in correct position.
Check indicator is reading correct ambient conditions.
Check instrument for any visible sign of damage.
Verify that instrument is installed with correct accessories
Verify nameplate is correct and securely fitted.
Review project documentattion.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________

TS
TS
TS
TS
TS
TS
TS
TS

3/31/2011

Pressure Relief Valves

Check mechanical mounting is correct and firm.
Check instrument installed in correct position.
Check for any visible sign of damage.
Verify nameplate is correct and securely fitted.
Review manufacturers set pressure certification.
Review project documentattion.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________

TS
TS
TS
TS
TS
TS
TS

3/31/2011

Level Switches
Check mechanical mounting is correct and firm.
Check instrument installed in correct position.
Check for any visible sign of damage.
Verify nameplate is correct and securely fitted.
Review manufacturers set pressure certification.
Review project documentattion.
Check for any required actions: Conforming _______X________ Non-Conforming _______________

TS
TS
TS
TS
TS
TS
TS

3/31/2011

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Checklist
3.3
3.3.1

3.3.2

3.3.3

3.3.4

Electrical Checklist

SIGN

DATE

Junction Box Installation and Tests

Confirm junction box and wiring installation is complete and in accordance with project approved documents and contract specifications.

TS

Confirm all junction boxes are adequately supported and the installation does not foul operators access.
Verify junction box is tagged as per the cable schedule.
Confirm all items are correctly earth bonded.

TS
TS
TS

Confirm all electrical equipment is certified for the hazardous environment and that correct certification is available for review.

TS

Confirm that all spare entries are plugged with certified plugs
Review project documentattion.
Check for any required actions: Conforming ______X_________ Non-Conforming _______________

TS
TS
TS

3/31/2011

General Inspections
Verify materials agree with Bill of Material
Verify dimensions agree with Assembly
Verify component layout agrees with Assembly
Verify fuses are installed and ratings
Verify equipment grounding connections to chassis and instrument ground busses

TS
TS
TS
TS
TS

3/31/2011

Documentation
Junction Box Layout drawing number DSP-2010-1105-401
Junction Box Wiring drawing number DSP-2010-1105-402

TS
TS

3/31/2011

Conformity
Check for any required actions: Conforming _______X________ Non-Conforming _______________

TS

3/31/2011

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Custom Process Equipment

4727 NW Evangeline Thruway
Carencro, LA 70520
Tel : (337) 896-3815

DPSD DOCUMENT NO.

DPS-2010-1105-Q-KA-0005
FAT PROCEDURE
Abu Qir Thermal Power Plant
Supplier: DPS

3.3.5

Client PO:10-118-26

Cable Installation and Tests

Confirm the instrument wiring installation is complete and in accordance with project approved documents and contract specifications.
Confirm all cable and cable tray is adequately supported and the installation does not foul operators access.
Confirm all cable tray edges are smooth and protected.
Verify all cables are tagged as per the cable schedule.
Confirm all items are correctly earth bonded.
Confirm all electrical equipment is certified for the hazardous environment and that correct certification is available for review.
Review project documentattion.
Check for any required actions: Conforming ________X_______ Non-Conforming _______________

TS
TS
TS
TS
TS
TS
TS
TS

3/31/2011
3/31/2011
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Checklist
3.4

Documentation Verification
Verify completion of hydrotest record and stamp from customer inspector.
Verify completion of NDE record and stamp from customer inspector..
Verify completion of coating record and stamp from customer inspector..
Verify availability of Material Test Record and stamp from customer inspector..
Verify availability of instrument calibrations and verification, and stamp from customer inspector..
Verify all instruments' data against the instrument list.
Verify Cause & Effect is approved with no customer comments.
Verify P&ID is approved with no customer comments.
Verify Junction Box Diagram is approved with no customer comments.
Verify Instrument Calibrations and Certification is approved with no customer comments.
Verify on-skid cable routing and earthing is approved with no customer comments.

CPE Representative:

Date:

Client Representative:

Date:

SIGN

DATE

DD

3/31/2011

DD

3/31/2011

DD

3/31/2011

DD

3/31/2011

DD

3/31/2011

TS
TS
TS
TS
TS
TS

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