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Introduction:
FAT (Factory Acceptance Test) is carried out for every instrument before the final installation, according to the standard IEC
61511 . The FAT process involves testing the machinery during and after the assembly process by ensuring that it is designed and
working according to design specifications.
FAT ensures the proper functioning of the components and controls according to the functionality of the equipment itself. As the name
suggests, the factory performs this testing.
As FAT is the final check carried out before the final installation the check should ensure the complete and proper working of the entire
PLC system. The check includes all aspects of the PLC machine, such that:
Hardware
Software
Power supply
Earthing
Programming logics
Communication ports etc.,
Visual Check:
The panel developed for this project is subject to visual review by the customer to ensure that all parts and accessories conform with
the final approved panel specifications.
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Procedure:
https://forumautomation.com/t/fat-procedure-for-plc-panel/7420 1/7
11/20/23, 1:24 AM FAT procedure for PLC panel: - PLC (Programmable Logic Controllers) - Industrial Automation, PLC Programming, scada & Pid C…
Visual inspection to confirm that all material is as per panel drawings.
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Confirm that all components and accessories are mounted as per panel drawings.
The appearance & construction check is to review the panel drawing and other construction documents on the basis of which the
inspection is conducted. The check ensures the panel is constructed as per the design.
Procedure:
The purpose of this test is to ensure that panels are free from scratches and deformities
Check that the ‘construction’ sketches were drawn based on the accepted drawings distributed at the time of the call for an
inspection.
Check that the modifications carried out by the’ Construction’ drawings are marked in blue pen and the engineer-in-charge is
dated and signed.
Check that the changes made in the sketches have no effect on the model.
Panel Earthing:
Earthing of the PLC panel should be checked and verified for proper earthing which ensures the safety of the personals working on the
PLC panel and from other electrical hazardous situations.
Procedure:
Check that the earth point of the board is on the earth of the building.
Test that 0V is attached to the earth bar inside the board.
Check that the base of the panel is attached to the earth ring.
Power supply to the PLC and the supply generated inside the panel is crossed checked with reference of power supply data sheet.
Procedure:
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11/20/23, 1:24 AM FAT procedure for PLC panel: - PLC (Programmable Logic Controllers) - Industrial Automation, PLC Programming, scada & Pid C…
Panel Wiring check:
Panel wiring is subjected to visual and functional inspection to confirm the wiring done with the terminal assessment, panel drawings
and wire colors as per the drawing.
Procedure:
Visually and functionally test that each panel wiring is in order on the basis of the above objectives.
To verify the PLC architecture with reference to the approved PLC System Architecture drawing.
Procedure:
Test visually that processors and I / Os are linked to EHTERNET Bus according to the approved system architecture.
Visually check the availability of the Ethernet port that is used for programming & SCADA to connect to the Ethernet network.
PLC start-up:
PLC goes to normal power up operation, as long as all application software is stored in the respective PLCs.
Procedure:
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11/20/23, 1:24 AM FAT procedure for PLC panel: - PLC (Programmable Logic Controllers) - Industrial Automation, PLC Programming, scada & Pid C…
Procedure:
Attach jumper to the termination block of the digital output field as shown in the cable diagrams to toggle field data.
Observe the PLC input module LED warning.
Observe the correct status on the programming terminal in the PLC memory.
Procedure:
Analog input:
All analog inputs should only be terminated at the right terminal
Procedure:
Analog output:
All analog output should only be terminated at the right terminal
Force the Output memory location with the help of programming software.
Observe corresponding value on SCADA screen.
The programming terminal is controlled via the programming port of the PLC.
Procedure:
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11/20/23, 1:24 AM FAT procedure for PLC panel: - PLC (Programmable Logic Controllers) - Industrial Automation, PLC Programming, scada & Pid C…
This test is intended to check that the Ethernet communication ports are working. The programming terminal is connected to the PLC
through all the connection points available: Ethernet.
Procedure:
The aim of this test is to check the redundancy of the CPUs and network.
Procedure:
To switch off the Primary PLC and see whether the network switches to secondary PLC.
MMI check:
The aim of these tests is to verify that the displays, security feature, data archiving, alarms, trends and reporting are generated as
requested by the customer.
Procedure:
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11/20/23, 1:24 AM FAT procedure for PLC panel: - PLC (Programmable Logic Controllers) - Industrial Automation, PLC Programming, scada & Pid C…
Check SCADA screens
Check security feature
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Check Alarm history
Check trending
This experiment is intended to verify that the console controls the PLC system.
Procedure:
Force any fault condition and check for the trip/interlock fucntioning
The aim of this test is to confirm that the online system configuration is correct.
Procedure:
The object of this test is to verify the functional logic of the electronic interlocks.
Procedure:
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11/20/23, 1:24 AM FAT procedure for PLC panel: - PLC (Programmable Logic Controllers) - Industrial Automation, PLC Programming, scada & Pid C…
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