PW DS 06 HMI 01ssr

ET-PW/DS-06/01-VR-
DOCUMENT #
001
PLC & HMI VALIDATION REPORT
REVISION 00
DATE: 26-04-2021
EQUIPMENT NAME: PW/DISTRIBUTION SYSTEM-06/01
LOCATION: HETERO DRUGS LTD, BONTHAPALLY
FOR
PW/DISTRUBUTION SYSTEM-06/01
(PW/DS-06/01/HMI-01)
HETERO DRUGS LTD.

UNIT-I
BONTHAPALLY
______________________________________________________________________
Proprietary Information of Entune Labs Pvt. Ltd. Page 1 of 20

ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021
Table of Contents
1 Introduction..............................................................................................................................3
2 Purpose.....................................................................................................................................3
3 Scope........................................................................................................................................3
4 References................................................................................................................................3
4.1 Glossary.............................................................................................................................3
5 Tests to Perform.......................................................................................................................4
6 Signature Log...........................................................................................................................4
7 Test Cases................................................................................................................................5
7.1 Verification of HMI and PLC Make and Model No.........................................................5
7.2 Verification of PLC Inputs and Outputs...........................................................................6
7.3 Navigation Testing..........................................................................................................11
7.4 Screen Functionality Testing...........................................................................................12
7.5 Set Parameters Screen Testing........................................................................................15
7.6 Alarm testing...................................................................................................................18
8 Deviation Reports Log...........................................................................................................20
9 Conclusion.............................................................................................................................21
10 Approval Form.......................................................................................................................21
______________________________________________________________________

ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021
1 Introduction
This document describes the PLC and HMI Validation of PW/DISTRIBUTION
SYSTEM-06/01 for Hetero Drugs Ltd Unit-1.
2 Purpose
This document details the PLC and HMI Validation is to ensure that the system software
complies with the user requirements.
3 Scope
This scope includes testing the software of the PLC and HMI software used to control the
PW/DISTRIBUTION SYSTEM-06/01 as per the user requirements.
1 References
The table below lists the documents and drawings used in the development of this document.
Table a
Description Document Number Document Date Revision
1.1 Glossary
Table b
Acronym Description
HMI Human Machine Interface
PLC Programmable Logic Controller
QA Quality Assurance
DR Deviation Report
2 Tests to Perform
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ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021
Table c
Test ID Test Name Test Objective
Verification of
7.1 To verify the HMI and PLC Make and Model No
Hardware Components
Verification of PLC
7.2 To verify the functionality of Inputs and Outputs.
Inputs and Outputs
7.3 Navigation Testing To verify the HMI screens Navigation
7.4 Set Parameters Testing To verify the Set Parameters functionality
7.5 Alarm Testing To verify the Alarm functionality
3 Signature Log
The purpose of the signature log is to capture the names and signatures of all individuals
who executed any part of this Report. Participant should record his/her name, company
affiliation, personal signature, and personal initials in this log.
Signature Log
Name Company Signature Initials
7 Test Cases
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ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021
Tester Name
Tester Signature
Test Date
Test Case Results
3.1 Verification of HMI and PLC Make and Model No
S. No Description / Action Result Acceptance Signature &

(Yes/No) Date
Check the PLC make and MITSUBISHI

1
model No FX3u-32M
MISTUBISHI
2 Check the PLC Analog Input
FX2N-8AD
MISTUBISHI
3 Check the PLC Analog Output
FX2N-2DA
Check the HMI make and model MISTUBISHI

4
No GT2507-WTBD
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ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021
3.2 Verification of PLC Inputs and Outputs

(Yes/No) Date
Digital Inputs
Source the +24VDC to the input

1 ‘Feedback’ status will change
IP:0.0

IP:0.1

IP:0.2
Source the +24VDC to the input ‘ Mother loop Healthy’ status

4
IP:0.3 will change
Source the +24VDC to the input ‘Electric board power on ’
5
IP:0.4 status will change
6 Control on
IP:0.5

7 Hooter reset
IP:0.6
8 Spare
IP:0.7

9 Spare
IP:0.8

10 Spare
IP:0.9

11 Spare
IP:0.10
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ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021

(Yes/No) Date

12 Spare
IP:0.11

13 Spare
IP:0.12

14 Spare
IP:0.13

15 Spare
IP:0.14

16 Spare
IP:0.15
17 Spare
IP:0.16

18 Spare
IP:0.17
Digital Outputs
+24VDC will measures in

19 Start ‘VFD’
output OP:0.0

20 Start ‘F201A’
output OP:0.1

21 Start ‘F201B’
output OP:0.2

22 Start ‘Tank inlet valve’
output OP:0.3
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ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021

(Yes/No) Date

23 Start ‘Tank steam valve’
output OP:0.4

24 Start ‘Return line dumping’
output OP:0.5

25 Start ‘UV201 Relay’
output OP:0.6
Start ‘EH 201 vent filter heat +24VDC will measures in

26
tracer Relay’ output OP:0.7
Start ‘Water request to mother +24VDC will measures in

27
loop Relay’ output OP:10

28 Start ‘Hooter’
output OP:11

29 Start ‘Alarm lamp’
output OP:0.12

30 SPARE
output OP:0.13

31 SPARE
output OP:0.14

32 SPARE
output OP:0.15
______________________________________________________________________

ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021

(Yes/No) Date

33 SPARE
output OP:0.16

34 SPARE
output OP:0.16
Analog Input
‘CT201 Transmitter’ values

35 Source the 4-20mA in AI1.0
will change
‘LT201 Transmitter’ values

will change
‘FT201 Transmitter’ values

will change
‘TT201 Transmitter’ values

will change
‘TT202 Transmitter’ values

will change
‘IM201 Transmitter’ values

will change
______________________________________________________________________

ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021

(Yes/No) Date
41 Source the 4-20mA in AI1.6 Spare
Analog Output
1 Measure the 4-20mA in AO1.0 Spare
3.3 Navigation Testing

(Yes/No) Date
1 Click on the Main button Main screen will open
2 Click on the Login button Login screen will open
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ET-PW/DS-06/01-VR-
DOCUMENT #
001
REVISION 00
DATE: 26-04-2021

(Yes/No) Date
3 Click on the Mode button Mode screen will open
Click on the Set Parameters Set Parameters screen will

4
button open
5 Click on the Start/stop button Start/stop screen will open
6 Click on the Alarm button Alarm screen will open
7 Click on the Settings button Settings screen will open
Access management screen

8 Click on Access management
will open
9 Click on HMI utilities HMI utilities screen will open
10 Click on Raw value Raw value screen will open
______________________________________________________________________

3.4 Screen Functionality Testing

(Yes/No) Date
Main screen will open

The following go to screen
Select and Press Enter main
11 buttons are available
button in welcome screen
Home, mode, Set parameters,
login,start/stop,alarms,settings,
Mode screen will open
Select and Press Enter mode
12 buttons are available
button in main screen
Auto,manual,hot water
sanitization,off
Set parameters screen will
open
buttons are available
Select and Press Enter set STT201
13
parameters button in main screen parameters,TT201/202
parameter,CT/IM201
parameters,LT201
parameter,FT201
parameter,P201A/B parameter
login Screen will open
Select login button main The following go to screen
14
screen buttons are available
Login/logout, password change
Login Screen will open
Select password change button in The following go to screen
15
login screen buttons are available
Switch,logout,cancel
Start/stop Screen will open
Select start/stop button in main The following go to screen
16
Screen buttons are available
Start,stop
______________________________________________________________________

(Yes/No) Date
alarms Screen will open

Select alarms button in main buttons are available
17
Screen Date,time message,hotter reset,
delete alarm, delete
alarms,alarm reset
Settings screen will open

buttons are available
CT201-return line
Select settings button in Main conductivity, LT201-pw tank
18
screen level, FT201 return line
flow,TT201 return line
temperature,TT202 tank
temperature, STT201 vent
filter temparature.
Access management will open

Select access management in buttons are available
19
settings screen Mode select, manual mode, set
parameters, analog simulation,
controller, alarm reset
HMI utilities screen will open
Select HMI utilities settings
20 buttons are available add,
screen
import, export
Raw value screen will open

Select raw value screen in The following go to screen
21
settings screen buttons are exit,home, access
management, hmi utilities
______________________________________________________________________

3.5 Set Parameters Screen Testing
S. No Description / Action Expected Result Actual Result Signature

& Date
Alarm Set Points
Click on STT201 set point and

STT201 set point value will be STT201 Alarm
1 try to change the values
changed will indicate
TT201/202
Click on TT201/202 set point TT201/202 set point value
2 Alarm will
and try to change the values will be changed
indicate
CT/IM201
Click on CT/IM201 set point and CT/IM201 set point value will
3 Alarm will
try to change the values be changed
indicate
LT201 set point value will be

Click on LT201 set point and try LT201Alarm
4 changed
to change the values will indicate
Click on FT201 set point and try FT201 set point value will be FT201 Alarm
5
to change the values changed will indicate
P201A/B
Click on P201A/B set point and P201A/B set point value will
6 Alarm will
try to change the values be changed
indicate
Click on STT201
STT201 set point value will be STT201 Alarm
7 SanitizationTime Min set point
changed will indicate
and try to change the values
STT201
Cumulative
Click on STT201 Cumulative
STT201 Cumulative Time Min Time Min set
8 Time Min set point and try to
set point value will be changed point value
change the values
will be
changed
______________________________________________________________________

& Date
STT201Start
Click on STT201 Start up drain up drain min
STT201 Start up drain Min set
9 Min set point and try to change set point value
point value will be changed
the values will be
changed
TT201/202
Vent filter off
Click on TT201/202 Vent filter TT201/202 Vent filter off sp
sp min set
10 off sp Min set point and try to Min set point value will be
point value
change the values changed
will be
changed
TT201/202 -Ve
Control
Click on TT201/202 -Ve Control TT201/202 -Ve Control
hysteresis min
11 hysteresis Min set point and try hysteresis Min set point value
set point value
to change the values will be changed
will be
changed
TT201/ 202
Temparature
Click on TT201/202 Temparature TT201/202 Temparature low
low min set
12 low Min set point and try to Min set point value will be
point value
will be
changed
TT201/ 202
Temparature
Click on TT201/202 Temparature TT201/202 Temparature high
high min set
13 high Min set point and try to Min set point value will be
point value
will be
changed
CT201 H min
Click on CT201 H Min set point CT201 H Min set point value set point value
14
and try to change the values will be changed will be
changed
CT201HH min
Click on CT201 HH Min set CT201 HH Min set point set point value
15
point and try to change the values value will be changed will be
changed
______________________________________________________________________

& Date
CT201HH
Click on CT201 HH dumping dumping time
CT201 HH dumping time Min
16 time Min set point and try to min set point
set point value will be changed
change the values value will be
changed
CT201 IM201-
Click on CT201 IM201-L sp Min L sp min set
CT201 IM201-L sp Min set
17 set point and try to change the point value
values will be
changed
LT201 HH sp
Click on LT201 HH sp Min set LT201 HH sp Min set point min set point
18
point and try to change the values value will be changed value will be
changed
LT201 H sp
Click on LT201 H sp Min set LT201 H sp Min set point min set point
19
changed
LT201 L sp
Click on LT201 L sp Min set LT201 L sp Min set point min set point
20
changed
LT201 LL sp
Click on LT201 LL sp Min set LT201 LL sp Min set point min set point
21
changed
P201A/B
Normal mode
Click on P201A/B Normal mode P201A/B Normal mode fixed
spees sp Min
22 fixed speed sp Min set point and speed sp Min set point value
set point value
try to change the values will be changed
will be
changed
P201A/B
Click on P201A/B Draining Draining speed
P201A/B Draining speed set
23 speed Min set point and try to Min set point
change the values value will be
changed
______________________________________________________________________

3.6 Alarm testing

Date
(Yes/No)
Low levcl in distribution storage Alarm actuates and distribution

1
tank pump and UV system will trip
Mid-level in distribution storage Distribution pump and UV

2
tank system will trip
High levcl in distribution storage Distribution storage tank inlet

3
tank valve will open
High High level in distribution Distribution storage tank inlet

4
storage tank valve will close
Alarm actuates and VFD will
Return line flow transmitter flow increase the return line flow by
5
below set point increasing of distribution pump
speed
VFD will decrease the return
Return line flow transmitter flow
6 line flow by decreasing of
more than set point
distribution pump
Return line conductivity meter
7 Alarm actuates
conductivity more than alert limit
Return line conductivity meter
Alarm actuates and return line
8 conductivity more than action
dump valve will open
limit
Return line temperature
Steam line inlet valve will
9 transmitter temperature below set
open
point
Alarm actuate and return line
10 Hot water sanitization cycle over
dump valve will open
Hot water sanitization cycle Alarm actuates and distribution

11
aborted pump will trip
______________________________________________________________________

______________________________________________________________________

4 Deviation Reports Log
Deviation Report Log
Report Date Date
Test ID Incident Description
# Initiated Resolved
5
Conclusion
______________________________________________________________________

Signature & Date
6 Approval Form
Reviewed by: Name & Department Signature& Date
Entune Labs Pvt. Ltd.

Hyderabad
Reviewed by: Name & Department Signature& Date
Hetero Drugs Ltd. (Unit-I)

Bonthapally
Approved by: Name & Department Signature& Date
Hetero Drugs Ltd. (Unit-I)

Bonthapally
______________________________________________________________________

PW DS 06 HMI 01ssr

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ET-PW/DS-06/01-VR-

PLC & HMI VALIDATION REPORT

HETERO DRUGS LTD.

Proprietary Information of Entune Labs Pvt. Ltd. Page 1 of 20

Proprietary Information of Entune Labs Pvt. Ltd. Page 2 of 20

Proprietary Information of Entune Labs Pvt. Ltd. Page 3 of 20

7.4 Set Parameters Testing To verify the Set Parameters functionality

7.5 Alarm Testing To verify the Alarm functionality

Proprietary Information of Entune Labs Pvt. Ltd. Page 4 of 20

Test Case Results

3.1 Verification of HMI and PLC Make and Model No

S. No Description / Action Result Acceptance Signature &

Check the PLC make and MITSUBISHI

Check the HMI make and model MISTUBISHI

Proprietary Information of Entune Labs Pvt. Ltd. Page 5 of 20

3.2 Verification of PLC Inputs and Outputs

S. No Description / Action Result Acceptance Signature &

Source the +24VDC to the input

Source the +24VDC to the input

Source the +24VDC to the input

Source the +24VDC to the input ‘ Mother loop Healthy’ status

Source the +24VDC to the input

Source the +24VDC to the input

Source the +24VDC to the input

Source the +24VDC to the input

Proprietary Information of Entune Labs Pvt. Ltd. Page 6 of 20

S. No Description / Action Result Acceptance Signature &

Source the +24VDC to the input

Source the +24VDC to the input

Source the +24VDC to the input

Source the +24VDC to the input

Source the +24VDC to the input

Source the +24VDC to the input

+24VDC will measures in

+24VDC will measures in

+24VDC will measures in

+24VDC will measures in

Proprietary Information of Entune Labs Pvt. Ltd. Page 7 of 20

S. No Description / Action Result Acceptance Signature &

+24VDC will measures in

+24VDC will measures in

+24VDC will measures in

Start ‘EH 201 vent filter heat +24VDC will measures in

Start ‘Water request to mother +24VDC will measures in

+24VDC will measures in

+24VDC will measures in

+24VDC will measures in

+24VDC will measures in

+24VDC will measures in

Proprietary Information of Entune Labs Pvt. Ltd. Page 8 of 20

S. No Description / Action Result Acceptance Signature &

+24VDC will measures in

+24VDC will measures in

‘CT201 Transmitter’ values

‘LT201 Transmitter’ values

‘FT201 Transmitter’ values

‘TT201 Transmitter’ values

‘TT202 Transmitter’ values

‘IM201 Transmitter’ values

Proprietary Information of Entune Labs Pvt. Ltd. Page 9 of 20

S. No Description / Action Result Acceptance Signature &

41 Source the 4-20mA in AI1.6 Spare