BCT 228 16 r0 PDB+PLC Fat Procedure

PROJECT: SAFFRON B PROJECT
VENDOR: SAI SR ENGINEERG PTE LTD
Doc. No: XXXX_FAT END USER : SHPP Singapore Pte Ltd Rev.0
FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL
CLIENT: SHPP Singapore Pte Ltd
PANEL SUPPLIER: SAI SR ENGINEERG PTE LTD
PANEL TAG:____________________
DOCUMENT NO: TBA
Page 1 of 22
DOCUMENT INFORMATION
Document Title : Factory Acceptance Test Procedure
Document Description : Factory Acceptance Test Procedure explains the

Procedure to inspect and witness the system for
Functionality by the Customer as per specification
BCT Doc. Number : XXXXX
No. Of Pages : - 22
DOCUMENT REVISION HISTORY
Sr. # Rev Date Description Prep. Check. App.
1 0 28/10/2021 Issued For Approval XX XX XX
CONTENTS
Page 2 of 22
TITLE# TITLE PAGE#
1.0.0 Preface 04
1.1.0 Abbreviation 05
2.0.0 FAT Agenda 06
3.0.0 Required Documents List 07
3.1.0 Review of Testing Tools 08
3.2.0 Test Standards 08
4.0.0 General - Inspection of MCC Panel 09

4.1.0 Cabinet Check 09
4.2.0 Paint Work Check 09
4.3.0 Cut Outs- General 10
4.4.0 Labels- Internal 10
4.5.0 Labels- External 11
4.6.0 Isolator/MCCB Check 11
4.7.0 Earth Bonding Check 12
4.8.0 Mechanical Fixing Check 13
4.9.0 Electrical equipment Check 14
4.10.0 Electrical Wiring Check 15
5.0.0 Panel Power on Check 15

6.0.0 Resistance Test 16
7.0.0 PLC Functional Check 16
8.0.0 Overall Comments 21

9.0.0 Conclusions 22
1.0.0 PREFACE
Page 3 of 22
Base Control Tech (FZC) has manufactured the MCC & PLC Panel as per Quality Standards given by
Johnson Controls Inc. The Factory Acceptance Test Procedure is given as per concurrence with Base
Control Tech Standards.
The Factory Acceptance Test is carried out in order to prove that the system should be validated and
demonstrated the compliance with Customer requirements
Validation based on design and requirement specifications, in order to determine the need for a validation of
the control systems. This will state, that the system and its components function properly, that
manufacturing, assembly, are done correctly and that system performance is in compliance with the
approved functional specifications and relevant documents.
Also, this report represents the actual quality status of the control system.
1.1.0 Abbreviations
Page 4 of 22
FAT – FACTORY ACCEEPTANCE TEST

AC – ALTERNATING CURRENT
DC – DIRECT CURRENT
P & ID – PROCESS AND INSTRUMENTATION DIAGRAM
SAT – SITE ACCEPTANCE TEST
BOM – BILL OF MATERIAL
MCC -MOTOR CONTROL CENTER
PLC – PROGRAMMABLE LOGIC CONTROLLER
CPU – CENTRAL PROCESSING UNIT
MCC – MOTOR CONTROL CENTRE
IO – INPUT & OUTPUT
DI – DIGITAL INPUT
DO – DIGITAL OUTPUT
AI – ANALOG INPUT
AO – ANALOG OUTPUT
SCADA – SUPERVISORY CONTROL AND DATA ACQUISITION
2.0.0 FAT AGENDA
Page 5 of 22
Date :-
Place :- Base Control Tech (FZC)

P.O. Box 120974
Ware House # Q4-276
SAIF-Zone, Sharjah
U.A.E
Tel: 06-5579958
Fax: 06-5579959
Test Performer :- Base Control Tech (FZC)

(Hereafter mentioned as “BCT”)
Test Witness :- 1. Johnson Controls Inc

(Hereafter mentioned as “JCI”)
Responsible :- BCT :-
JCI :-
Page 6 of 22
3.0.0 REQUIRED DOCUMENTS
S/No Document Document Ref- CIL

1 Required mail Correspondence if any ---
2 PDB,PLC GA DRAWING ----
3 PDB,PLC WIRING DRAWING ----
4 Input Output List ----
5 System Configuration ----
6 Control Philosophy ----
7 P & ID Drawing ----
8 Documents given by customer by mail/during visit ----
9 Internal Panel Test Report ----
10 Technical Manuals
11 --------
* The changes marked in drawing will be incorporated in original drawing before Panel dispatch.
3.1.0 Review of Testing Tools
Page 7 of 22
Instrument Calibration
S NO Description of Test Remarks
Make / Sr No Details
1 Multi-meter
2 Calibration source
3.2.0 Test Standards
S NO Description of Test Brief Details Remarks

1 Continuity Test For Control and Power
Circuit to ensure proper
connections and desired
logic.
2 Input power given to panels, individual Power Circuit and
schemes checked Control Circuit as per
approved SLD and
Panel Drawings.
3 Power on check To check the circuit
operations.
4.0.0 GENERAL - INSPECTION OF MCC & CONTROL PANEL
Page 8 of 22
4.1.0 CABINET CHECK
S NO DESCRIPTION PASS FAIL REMARKS

1 Panel type as per approved drawing
2 Panel size as per approved drawing
3 Correct lifting Eyes fitted
4 Bottom Gland plates fitted
5 Bottom gland plates material check
6 Side panels fitted
7 Panel debris removed and cleaned
8 Plinth end panels fitted
9 Correct handles fitted
10 Correct lock fitted
11 Drawing pocket fitted if specified
12 Doors close without undue pressure
4.2.0 PAINT WORK CHECK

1 Panel color as per approved drawing
2 Paint work on doors undamaged
3 Paint work on side panels undamaged
4 Paint work on plinth undamaged
4.3.0 CUTOUTS – GENERAL
Page 9 of 22

1 Metering instruments cut-out edges painted
2 Lamps, selector switch cutout painted.
3 Gland plate edges painted (if cut-outs are made)

All sharp edges removed and edging strip fitted
4
if required
5 Fan / Filters Cut-out Edges painted
4.4.0 LABELS – INTERNAL

Hazard labels fitted to equipment fed from live
1
side of main isolator
2 Components label marking available
3 Terminal rail labels fitted
4 Terminal numbers fitted
4.5.0 LABELS – EXTERNAL
Page 10 of 22

1 Cabinet labels are fitted
2 Cabinet labels correct size (As Per drawing)
3 Cabinet labels mechanically secured
4.6.0 ISOLATORS/MCCB/ACB/CHASSIS CHECK

1 MCCB/ACB placement – correct position
2 MCCB handle unobstructed by cutout
3 MCCB handle door interlock operation ok
4 Terminal shrouds fitted
5 All live terminals for the MCCB/MCB shrouded
4.7.0 EARTH BONDING CHECK:
Page 11 of 22

1 Main earth stud or earth bar fitted
2 Doors bonded
3 Side panels bonded
4 Gland plates bonded
5 Rear panels bonded
6 Back plates bonded
7 Roof panel bonded
8 Marshalling plates bonded

Correct size earth conductors used for panel
9
bonding
10 All transformers earth bonded
11 Chassis earth bonded
4.8.0 MECHANICAL FIXING CHECK:
Page 12 of 22

1 Lifting eyes securely fitted
2 Door hinges securely fitted
3 Side panels securely fitted
4 Backplate securely fitted
5 Equipment on back plate securely fitted
6 Plug and socket connectors securely fitted
7 Earth studs securely fitted

All mechanical interlocks/door interlocks fitted
8
and correctly aligned
All high voltage exposed terminals covered
9
against touch
10 All bus bars tightened with correct torque
11 Trunk covers properly fitted.

Bus bars properly supported on the bus bars
12
supports.
13 CT’s properly clamped in the bus bars
4.9.0 ELECTRICAL EQUIPMENT CHECK:
Page 13 of 22

Component positions correct to back plate
1
layout
2 All components fitted
3 All fuses to correct rating fitted

Circuit breakers and auxiliaries operate correctly
4
and are of the correct rating and type.
5 All link bars fitted
6 Selector switch operation correct.
7 CT’s secondary earthed. (S2)
8 Starter operation checked with the rating
9 PFR operation checked
10 Voltmeter & Ammeter operation checked
11 Service socket operation checked
4.10.0 ELECTRICAL WIRING CHECK:
Page 14 of 22

1 Conductors size and color as per schematics
Conductors ferrule and identification as per
2
schematics
3 Conductors crimped with correct ferrule type
4 Correct terminals size used.
5 Point to Point wiring check
5.0.0 PANEL POWER ON CHECK:

Notes:
1. Ensure WARNING signs are displayed and
panel area is cordoned off.
2. Remove all supplies to PLC cards, drives,
safety relays & other cross polarity sensitive
devices.
3. Remove internal panel fuses.
4. Switch off isolators and circuit breakers.
5. Connect supply to main MCCB.
Individually turn circuit breakers ON and test all
1 relevant circuit voltages through panel hardware &
circuitry.
2 Check Isolator operation
Check voltages at out-going plugs, terminals and
3
termination points
4 Check for correct polarity sensitive devices
5 Check voltage across polarity sensitive devices
Link out safety devices and check for correct
6
operation
Emergency stop operation check
8
9
Check The PLC configuration
6.0.0 RESISTANCE TEST:
Page 15 of 22
1000 V Between Phases

1000 V Between Phase & Neutral
1000 V Between Phase & Earth
Megger Values measured as below:
MEGGER VALUES 1000VDC INJECTED (ALL VALUES IN MEGA OHMS)

BETWEEN R-Y Y-B B-R R-N Y-N B-N R-E Y-E B-E N-E
VALUES
Page 16 of 22
7.0.0 PLC Functional Check
7.1.0 PLC Hardware functionality
Summary: - The purpose of this test is to verify during the startup of the PLC system processor has to go
normal operational mode without any error indication except for field inputs.
Objective: - The purpose of this test is to ensure that PLC automatically boots up when
going from ‘Power Off” environment to “Operating environment”.
Practice : -
1. Power on the entire system
2. Power off the PLC
3. Power on the PLC again
Note: For Document Number refer 3.0.0 Required Documents
Principle: - Each component boots up automatically. All LED’s are normal. The plant is ready to resume
operation normally through the plc system
Comments:-
Page 17 of 22
7.2.0 PLC Modules Operation Check
Summary: - The purpose of this test is to verify wiring of all the IO modules (includes DI, DO, AI and AO
modules) .
Objective: - The purpose of this test is to ensure that PLC IO modules are wired to
accept the field signals safely without damaging the hardware of the
system.
Practice : -
1. Check all the Digital inputs by injecting volts from TB and observe signals in module and
Programming Station.
2. Check all the Digital Outputs by forcing them one by one from Programming Station and
verify by using either relay or Lamps etc
3. Check all the Analogue input feed from terminals by 0%, 25%, 75% and 100%
proportional to 4 to 20mA using current source and read the values in Programming
Station.
4. Check all the AO by forcing 0%, 25%, 75% from Programming Station & read the
proportional mA values at Terminal Block on Process Meter.
5. Check all the IO-Link Modules communicating with PLC & DOL Starters
6. Check the SCADA Communication with PLC
Principle: - Depends upon the type of the IO module it has to perform as defined in the manual and the
indicated locations.
Reference: - 1. PLC IO list
Comments:-
Page 18 of 22
7.3.0 SCADA/HMI Screens Functionality:
Summary: - The SCADA/HMI screens are drawn as per the P & I diagram given by the Company and the
same was approved by the Company.
Objective: - To verify that the screens are built to meet the Company requirement and operational
easiness, Identifiable for objects clearly.
Reference: -
1. P & I Diagram
2. Cause and effect chart
Practice: - 1. Verify the Graphic display with the P&I diagram

2. Operate and simulate the logics screens from HMI and verify that the operation is accepted
by the controller and the action is performed based on the operation done on the HMI
Principle: - The controller should perform and produce output as expected in the control philosophy based
on the operation done on the HMI
Comments:-
Page 19 of 22
7.4.0 Application Logic Verification
Summary: - 1. Checking the application logic are done as per the approved control philosophy provide by
the Company.
2. Modbus signals are available for the existing MODBUS Master system, shall be tested by
any modbus compatible device.
Objective: - To verify the logics built inside the controller is according the control philosophy provided by
the Company and its meeting the required application. Logic will be tested by simulation on
inputs to the PLC by activating simulation in SCADA / simulator panel.
Reference: - 1. Control philosophy

2. P & I diagram
3. System architecture
4. Logic/loop Diagram- If applicable
Practice: - 1. Simulate the logics from the test jig/ Software simulation for testing the application.
Sample for random application can be performed.
2. Check the Alarms and trip for each input
3. Check the Communication between compressor local panel to PLC
Principle: - The controller should perform and produce output as expected in the control philosophy.
Comments:-
Page 20 of 22
8.0.0 Overall Comments
Page 21 of 22
9.0.0 CONCLUSION
The Factory Acceptance Test was conducted by Base Control Tech (FZC) in front of Johnson
Controls Inc.
The Factory acceptance test was conducted and ensured the objectives given in each title and
there is no deviations found with the approved documents and standards. The Factory Acceptance Test
was done as per the documents and all test results were met the requirements, specifications and standards
of Johnson Controls.
JCI has to give the clearance to dispatch the system.
TEST CARRIED OUT BY
ORGANIZATION NAME SIGNATURE
TEST WITNESSED BY
ORGANIZATION NAME SIGNATURE
Page 22 of 22

BCT 228 16 r0 PDB+PLC Fat Procedure

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PROJECT: SAFFRON B PROJECT

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

PROJECT: SAFFRON B PROJECT

CLIENT: SHPP Singapore Pte Ltd

PANEL SUPPLIER: SAI SR ENGINEERG PTE LTD

DOCUMENT NO: TBA

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

Document Title : Factory Acceptance Test Procedure

Document Description : Factory Acceptance Test Procedure explains the

BCT Doc. Number : XXXXX

DOCUMENT REVISION HISTORY

Sr. # Rev Date Description Prep. Check. App.

1 0 28/10/2021 Issued For Approval XX XX XX

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

TITLE# TITLE PAGE#

4.0.0 General - Inspection of MCC Panel 09

5.0.0 Panel Power on Check 15

8.0.0 Overall Comments 21

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

FAT – FACTORY ACCEEPTANCE TEST

2.0.0 FAT AGENDA

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

Place :- Base Control Tech (FZC)

Test Performer :- Base Control Tech (FZC)

Test Witness :- 1. Johnson Controls Inc

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

3.0.0 REQUIRED DOCUMENTS

S/No Document Document Ref- CIL

3.1.0 Review of Testing Tools

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

3.2.0 Test Standards

S NO Description of Test Brief Details Remarks

4.0.0 GENERAL - INSPECTION OF MCC & CONTROL PANEL

VENDOR: SAI SR ENGINEERG PTE LTD

FACTORY ACCEPTANCE TEST PROCEDURE – PDB,PLC CONTROL PANEL

4.1.0 CABINET CHECK

S NO DESCRIPTION PASS FAIL REMARKS

2 Panel size as per approved drawing

3 Correct lifting Eyes fitted

4 Bottom Gland plates fitted

5 Bottom gland plates material check

6 Side panels fitted

7 Panel debris removed and cleaned

8 Plinth end panels fitted

9 Correct handles fitted

10 Correct lock fitted

11 Drawing pocket fitted if specified

12 Doors close without undue pressure

4.2.0 PAINT WORK CHECK

S NO DESCRIPTION PASS FAIL REMARKS

2 Paint work on doors undamaged

3 Paint work on side panels undamaged

4 Paint work on plinth undamaged

4.3.0 CUTOUTS – GENERAL