C & I SYSTEMS GROUP

61A1
INSPECTION & TESTING (Reading)
OF ELECTRONIC FOSTER WHEELER PAGE: 1
CONTROL SYSTEMS ENGINEERING STANDARD REV: O

C & I SYSTEMS GROUP

INSPECTION & TESTING 61A1 (Reading)

OF ELECTRONIC FOSTER WHEELER PAGE: 1 OF 7
CONTROL SYSTEMS ENGINEERING STANDARD REV: O

REVISION O 1 2 3 4 5
DATE Feb. 96
ORIG. BY S Jack
APP. BY
SIGNATURE

Contract:

Client's Name:

Project Title:

Project Location:

Document Category: CLASS

CONTENTS

SECTION SUBJECT

1 INTRODUCTION .................................................................... 2
2 APPLICABLE CODES, STANDARDS AND DRAWINGS ................ 2
3 PROGRESS INSPECTION ........................................................ 2
4 SPECIFIC TESTS ................................................................... 3
5 FACTORY ACCEPTANCE TEST ............................................... 3
6 TEST PROCEDURE................................................................. 6
7 SITE ACCEPTANCE TEST ....................................................... 6
8 MODIFICATION KITS ............................................................. 7
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9 POST-TEST DRAWING REVISION ............................................ 7

INTRODUCTION

1.1 General

This standard details the requirements for the testing and inspection of electronic
systems including Distributed Control Systems, Protective Systems, Fire & Gas
Systems, Fiscal Metering Systems and Analyser Systems. These systems all have
common the fact that they are, to a certain extent, programmable (in the widest
sense).

The main testing effort shall be directed at those aspects of the system which are
specific to this project. Standard functions with a proven service history (eg PID control
blocks) shall not be subject to detailed testing.

Notes in italics are for Foster Wheeler internal use during the development of a project
specific version of this specification.

1.2 Modification Kits

Section 8 only applies to modification kits to existing systems. When applicable, it

takes precedence over sections 5 and 7.

2 APPLICABLE CODES, STANDARDS AND DRAWINGS

2.1 Codes & Directives

EN 50081-1 Generic emission standard; Part 2: Industrial Environment

EN 50082-2 Generic immunity standard; Part 2: Industrial Environment

IEC 801

2.2 Client Standards

As applicable.

2.3 Project Standards

As applicable.

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3 PROGRESS INSPECTION

The buyer shall be permitted access to the suppliers works for equipment and
manufacturing inspection at any time between quotation and shipment.

4 SPECIFIC TESTS

The following tests shall either be included in the Factory Acceptance Test or evidence
for them shall be produced.

4.1 Electromagnetic Compatibility

The system shall have a European Union CE mark covering EMC to EN 50081-2 and EN
50081-2. Copies of any type or specific certificates shall be supplied with the system
documentation.

EMC tests for susceptibility to radiated energy, shall, in general, be done at a field
strength of 10 V/m.

For systems being purchased outside the EU for use outside the EU, compatibility with
the relevant sections of IEC 801 is acceptable as an alternative to the EU EN s referred
to above.

4.2 Burn In

Systems containing components without a proven service history or which are not
burnt-in during manufacture shall be subject to an elevated temperature test.

During this test, the system shall be in an installed configuration, fully powered up and
all outputs and inputs shall be exercised. The performance of the system and
temperatures of all cabinets (external and at three points inside) shall be logged during
the test. The test shall last at least 48 hours from the time when the internal cabinet
temperatures stabilize. The external temperature during the test shall be maintained at
40 C.

The purchaser shall be given the option of witnessing this test.

4.3 Insulation Tests

Hi-Pot or Megger tests. If a burn in test is deemed necessary, insulation tests shall
be carried out after it.

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5 FACTORY ACCEPTANCE TEST

1.1 The buyer shall perform and/or witness complete testing of the systems at the
suppliers works. This will be a 100 % test of all systems.

5.2 A test procedure (see below) shall be prepared by the supplier and submitted the buyer
for approval at least 60 days prior to the test. The drafts of these procedures shall be
submitted to the buyer early enough to allow the buyers comments to be incorporated
in the procedures prior to the tests. For the purposes of producing this procedure, it
may be assumed that the test will include, but not be limited to, the following :

5.2.1 Visual Inspection

This shall ensure that the system has been constructed in accordance with
specifications, data sheets and drawings agreed with the purchaser. The inspection
shall include, but not be limited to :-

a) Standard of workmanship.
b) Agreement with the General Arrangement and any other layout drawings.
c) Use of agreed components.
d) Rigidity of framework and supports for both static and transit conditions.
e) Accessibility of components for adjustment and maintenance.
f) Provisions for ventilation, cooling etc.
g) Labeling.
h) Compliance with the segregation requirements.
i) Sizing of trunking etc.
j) Terminations in accordance with drawings.
k) Provision of spare capacity.
l) Earthing of cabinet metalwork, agreement with the Earthing Philosophy
Diagram.
m) Ease of installation on site.

5.2.2 Power Distribution / Supply Test

Power supply redundancy, blocking diode arrangement, voltage levels, fault alarms,
segregation etc to be checked.

5.2.3 Display Tests

All custom graphics and a sample of standard displays shall be inspected to verify that
the backgrounds and live data points are in accordance with the specifications. All
dynamic points shall be exercised during either the I/O or functional tests.

5.2.4 Input / Output Tests

All inputs and outputs to be checked to ensure that tagged points within the system
are driven from the correct terminals. Transmitters to be simulated and the accuracy of
the system display to be checked. Any redundancy of inputs or outputs shall be
checked at this time.

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If the I/O is marshalled through cabinets being supplied by others, the supplier shall
allow for these marshalling cabinets to be shipped to their works for an integrated test.

5.2.5 Communication Link Tests

All serial data links are to be checked in the same configuration that they are to be
used in when installed on site. Ideally the links should be tested against the same
hardware that will be used with on site, if this is impractical, a PC or similar may be
used to test the link.

As a minimum, addressing, data formatting, error detection and recovery, and a

representative sample of points shall be checked. The precise scope and details of
serial link testing are to be described in the test procedure.

Note that this is for testing of links from this system to other equipment. Links within
the system which have a proven service history shall, in general, not be checked with
the exception of the behaviour of redundant links during the failure and recovery of one
or more channels.

5.2.6 Structured Functional Test

Systematic testing of all required functions including :-

a) Alarm handling.
b) Sequencing.
c) Any driver modules, eg motor control interfaces, on/off valves with position
feedback.
d) Complex controllers.

5.2.7 Random Functional Test

Sample tests simulating actual operational use.

5.3 All equipment shall be fully assembled and powered up 72 hours prior to the start of
the test. The supplier shall have completed their own internal testing prior to the start
of this 72 hour period.

A log of faults found during the suppliers own testing and the fixes performed shall be
available for review by the purchaser.

5.4 The supplier shall provide power supplies, switch/lamp/timer panels, simulators and any
other equipment required to exercise all the I/O and logic functions.

5.5 The supplier shall ensure that all documentation is available prior to the start of the
tests and that it is up to date.

5.6 The supplier shall provide tools (hand tools, multimeters etc) and materials as required
by the buyers team during the test. Supplier technicians familiar with the equipment
shall be available to assist as required during the test. The suppliers quote will include
an allowance for changes to the systems which can be expected to be made during the
FAT.
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5.7 A log of all faults, fixes and changes made during the FAT shall be maintained by the
supplier (see below).

All faults logged during the FAT shall be signed off as cleared or as waived by the
purchaser prior to shipment.

5.8 If possible, faults shall be corrected at times when the equipment is not required for
scheduled tests. The timing for fixes which invalidate previously accepted tests shall
be agreed with the purchaser.

6 TEST PROCEDURE

6.1 The overall FAT procedure shall include the following :-

6.1.1 A schedule indicating the order of tests and the time allocated to each test.

6.1.2 Details of the supplier resources that will be made available during the FAT.

6.1.3 A detailed description of each test stating :

a) The objective of the test.

b) Relevant drawings and documents.
c) Test equipment to be used and sketches showing how it is to be connected.
d) A step-by-step procedure for the test.
e) Checklists and sign off sheets.

6.2 A detailed fault log shall be maintained during the FAT. All faults shall be recorded in a
central log maintained by a test manager nominated by the supplier. Each entry in this
log shall record the following :

a) Date of the original test and the names of the persons performing the test.
b) A description of the fault including the actions that led up to the fault being
observed.
c) An analysis of the fault by the supplier.
d) A description of how the fault is to be remedied by the supplier.
e) A list of documents that will be affected by the fix.
f) Dates when the fault was fixed and tested by the supplier.
g) The date when tested and signed off or waived by the purchaser.
h) The date and revision of any documentation changed because of the fix.

All faults shall be corrected prior to shipping unless waived or it is agreed that the fix
can be performed on site.

7 SITE ACCEPTANCE TEST

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7.1 The supplier shall include with their quote, rates for supervising the installation of the
systems at site and for supporting the buyer during the site checkout of the system.

7.2 A test procedure, similar to that described in 6 above, shall be prepared by the supplier
and submitted the buyer for approval prior to the test. The drafts of these procedures
shall be submitted to the buyer early enough to allow the buyers comments to be
incorporated in the procedures prior to the tests.

7.3 The tests shall include, but not be limited to, the following :-

7.3.1 A sub-set of all the tests carried out during the FAT, but using real plant inputs instead
of simulated inputs.

This may be combined with loop testing or carried out separately.

7.3.2 A retest of all FAT faults not fixed and tested before the end of the FAT. Such fault
shall be either signed off as cleared or added to a SAT butt list.

7.3.3 A review of all documentation, including documents revised after the FAT, to assess its
correctness and its suitability to be part of the AS-BUILT documentation for the
system. Any documents failing this review will be added to the SAT butt list.

7.4 All butt list items shall be cleared or waived before the system is handed over.

8 MODIFICATION KITS

As far as is possible, mod-kits shall be tested at the factory.

If practical, pre-assembled wiring looms shall be connected to logic racks, terminals,

dummy I/O and simulation equipment for the duration of the test in order to perform as
complete as test as possible.

It is accepted that it may not be possible to perform a complete test. The precise scope
of testing, facilities to be provided and the duration of the test shall be agreed prior to
the start of the test.

9 POST-TEST DRAWING REVISION

9.1 Drawings shall be reissued AS TESTED following the FAT if any changes are made
during the FAT. A list of all drawings shall be produced indicating which drawings have
been revised.

9.2 The system shall not be shipped until the AS TESTED drawings are finished and issued.

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