AMERICAN TECHNOLOGY & CONTROLS INSURCOL

SITE ACCEPTANCE TEST PROCEDURE

(HAZARD WATCH SYSTEM - 2)

PROJECT : INSURCOL COLOMBIA CARTAGENA REFINERY

PO NO. : 16303

CONTRACTOR : AMERICAN TECHNOLOGY & CONTROLS

DOCUMENT NO. : J1525-HW2-010

DOCUMENT STATUS
X 1 : APPROVED
□
□ 2 : APPROVED AS NOTED
□ 3 : NOT APPROVED/REJECTED–Resubmit
□ 4 : INFORMATION ONLY
NOTE :
This permission to proceed or review on VENDOR data shall
not relieve VENDOR from its responsibilities and liabilities
under PURCHASE ORDER

RETURN DATE :

REVIEW BY: CHECK BY :

KENNY G OSCAR C

A 13-Jan-09 FOR APPROVAL EP VJ TD

REV DATE DESCRIPTION PREPARED CHECKED APPROVED

General Monitors Systems

 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

COLOMBIA CARTAGENA REFINERY PROJECT

HAZARD WATCH SYSTEM

Item Title

FIRE & GAS DETECTION PANEL

(HW#2)

Client

INSURCOL LTDA

Document Title

SITE ACCEPTANCE TEST (SAT) PROCEDURE

This document was prepared and submitted by:

GENERAL MONITORS SYSTEM ASIA

Block 5, Ang Mo Kio Industrial Park 2A, #05-22/23. AMK TECH II. Singapore 567760
Tel: 65-6-4821921 Fax: 65-6-4823-582

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

Table of Contents

1 INTRODUCTION.............................................................................................................................................. 3

2 TEST PLAN ....................................................................................................................................................... 4

2.1 OBJECTIVE .................................................................................................................................................. 4
2.2 SCHEDULING ............................................................................................................................................... 4
2.3 EXECUTION ................................................................................................................................................. 5
2.4 DOCUMENTATION ....................................................................................................................................... 5
3 INSPECTION & TEST PROCEDURES ......................................................................................................... 7
3.1 FAT TEST REPORT CHECK .......................................................................................................................... 7
3.2 FIELD DEVICES/EQUIPMENT INSTALLATION CHECK.................................................................................... 8
3.3 SYSTEM CABINETS/ENCLOSURE INSTALLATION AND WIRING CHECK......................................................... 9
3.4 SYSTEM FUNCTIONAL TESTS ..................................................................................................................... 10
3.4.1 Power Distribution and Switchover Test ............................................................................................. 10
3.4.2 Hazard Watch System Test .................................................................................................................. 11
3.4.3 Network Communication Test.............................................................................................................. 13
CERTIFICATION ................................................................................................................................................... 14

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

1 Introduction

This document contains the Site Acceptance Test (SAT) procedures for Hazard Watch Fire
& Gas Detection System for INSURCOL COLOMBIA CARTAGENA REFINERY. The
objective of this document is to provide a systematic and documented approach for testing of
the completed system.

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

2 Test Plan

2.1 Objective

a. The objective of this site acceptance test is to allow the customer to verify the
correctness of the completed system against the purchase order requirements.
The following types of test will be conducted:

• Type 1 Test : FAT Test Report Check.

• Type 2 Test : Field Devices/Equipment Installation Check.

• Type 3 Test : System Cabinets/Enclosure Installation and Wiring Check.

• Type 4 Test : System Functional Tests.

b. For Type 1 Tests, the customer is required to verify formal FAT document record.
The customer will identify any outstanding punch lists that are not being signed off
and also items that are agreed to be tested at site.

c. For Type 2 Tests, the customer is required to verify the location and quantities of
installed field devices/equipment. All field devices/equipment at installed location
will be inspected for correct wiring termination. For all gas detectors, calibration or
zeroing will be done at site before execution of SAT.

d. For Type 3 Test, the customer is required to inspect the system

cabinets/enclosures and verify that they have been installed in accordance to the
Approved Drawings. The customer is also required to verify that all external cabling
termination is completed in accordance to project requirements, industry standards
and practices, and acceptable neatness.

e. For Type 4 Test, the customer is required to re-verify the System Functional
Testing of the Hazard Watch Fire & Gas Detection. Functional Test includes Power
Distribution & Switchover Test, Hazard Watch System Test, Notifier Fire Alarm
System Test and Network Communication Test. Loop Check shall be performed in
accordance to the Approved Loop Wiring Drawings. The customer is then required
to re-verify the correctness in functionality of the completed system in accordance
to the Cause & Effect Chart. This test shall be conducted against one or all of the
reference documents in section 2.5.

2.2 Scheduling

a. Four weeks prior to SAT/commissioning commencement, a formal invitation will

be sent by Insurcol LTDA to General Monitors through the established
communications channel.

b. General Monitors will confirm acceptance of the commissioning schedule by

responding formally through the established communication channel.

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

2.3 Execution

a. Insurcol LTDA will obtain on behalf of General Monitors the necessary permits at
site and arranged for transportation to the work site and related Site Safety
Trainings.

b. Prior to the SAT/commissioning, the field devices and system panel shall be
installed and field cablings shall be inspected for correct termination. Customer
also needs to make sure that the incoming feed to the system panel is ready.

c. During the SAT/commissioning, system cabinets will be powered up and all field
devices powered on one by one after verifying the loop connection.

d. The Fire and Gas Detection / Fire Alarm equipment will be tested as a complete
system in accordance to the Cause & Effect Chart. Testing will be conducted on
each element of the system with all other elements energized and active.

i) Input devices such as Manual Call Points, Smoke Detectors and Thermal
Detectors shall be activated in the field.

ii) Gas & Flame Detectors shall be tested using suitable calibration/testing
equipment.

iii) Output devices such as field mounted Horns and Strobes shall be
monitored during activation of the appropriate loop.

e. All battery backup systems shall be fully operable to facilitate power switchover
testing.

f. Ethernet Fiber Optic Network shall be fully connected and operable using field
installed FO cables.

g. Fire Alarm Panel Fiber Optic Network shall also be fully connected and operable
using field installed FO cables.

2.4 Documentation

a. An approved copy of the SAT Test Procedure and customer’s Cause & Effect
Chart shall be used for functional verification test.

b. All tested results shall be recorded on the SAT procedure document that is
prepared. The customer shall record any defect or non-compliance clearly on this
document in the problem log sheets provided.

c. As each defect or non-compliant item on the punch-list is rectified, the customer

is required to verify the correctness of the repair work and sign-off the punch-list
item.

d. The official copy of the SAT procedure document with all markings and remarks
made by the customer shall be retained as the official record of SAT.

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

e. At the end of the SAT, the customer shall record the overall result of the test on
the last section of this document.

f. A copy of NFPA 72 Sections 4.5 (Testing Documentation) and 10.4 (System

Testing and Test Procedures) will be available for guidance and reference during
the SAT.

g. Fire Alarm System Test Completion Report will be issued in accordance with
applicable requirements of NFPA 72.

2.5 Reference Documents

No. Document Title Document No.

a. Bill Of Material J1525-HW2-001
b. Power Calculation & Heat Dissipation J1525-HW2-002
c. System Configuration Drawings J1525-HW2-003
d. Panel Layout Drawings J1525-HW2-004
Power Distribution & Earth Connection
e. J1525-HW2-005
Drawings
f. Loop Wiring Drawing J1525-HW2-006
g. Hardware I/O List J1525-HW2-007
h. Software I/O List J1525-HW2-008
i. FAT Test Report for HW2
j. Customer’s Cause & Effect Chart

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

3 Inspection & Test Procedures

3.1 FAT Test Report Check

Checking Procedure:

Item Description Check

a. Verify General Monitors FAT records to indicate system was
completely tested and signed by respective representatives.

b. Check if all punch lists has been rectified.

Identify those item need to be recheck during SAT.

c. Identify items not being tested during FAT and will be checked in
SAT.

Remarks:

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

3.2 Field Devices/Equipment Installation Check

Checking Procedure:

Item Description Check

a. Inspect all Field Devices/Equipment Location and Installation.
Check if installation is good and in accordance to industrial
standards and approved drawings.

b. Check that the installed Field Devices/Equipment are new and in

good condition. No physical damage occurs during transportation
and installation.

c. Calibration/Zeroing of Gas Detectors will be done on site. Verify that

all the Gas Detectors installed has been calibrated/zeroed as per
the Check List below.

Gas Detector Calibration Check List:

S/N Device Tag Description Model Check

1 TK3503-GDBR01 Combustible GD OPEN PATH IR5000
2 TK3502-GDBR02 Combustible GD OPEN PATH IR5000
3 TK3502-GDBR03 Combustible GD OPEN PATH IR5000
4 TK3502-GDBR04 Combustible GD OPEN PATH IR5000

Remarks:

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

3.3 System Cabinets/Enclosure Installation and Wiring Check

Checking procedure:

Item Description Check

a. Check to ensure that there is no physical damage inside or outside
cabinets/enclosure.

b. Check to ensure that all Field Wirings inside the panel are neat, well
supported/ restrained and correctly terminated as per Approved
Loop Wiring Drawing.

c. Check and ensure that the incoming feeder circuit is +24VDC and is
correctly terminated to the incoming DC MCB.

d. Verify that all earth wiring is in accordance with the Specification

and Approved Drawing.

e. Check and ensure that all main level power connections are
suitable protected to prevent shocks to personnel.

Remarks:

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

3.4 System Functional Tests

3.4.1 Power Distribution and Switchover Test

Checking Procedure:

Item Description Check

a. The Hazard Watch panels shall be powered via the LaMarche
Battery Charger with battery strings attached. Ensure that the all
fuses and circuit breakers are properly sized and connected to the
correct circuit loads in accordance with the Approved Drawings.

b. Check and verify that when the AC power supply to each of the
LaMarche power systems is interrupted to the Hazard Watch
System, there is no service interruption. Faults and alarms are
generated accordingly.

c. After the power interruption test, the AC power supply shall be

restored to ensure proper swapping over from the battery unit.

d. Check and verify that the Hazard Watch power system diagnostic
tests are captured and properly displayed on the Central Station
HMI.

Remarks:

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

3.4.2 Hazard Watch System Test

Checking procedure:

3.3.2.1 Hardware Checks

Item Description Check

a. Check and re-verify that the PLC Hardware is configured as per the
Approved System Configuration drawing.

b. PLC System Check:

Ensure that the “OK LED” on the modules shows steady green light
after startup. This is to indicate that the system is functioning OK
and stable. (Appropriate module faults and system faults should be
annunciated on the Panel View Terminal and Central Station HMI
when fault is simulated.)

c. Hardware I/O Check:

i) Field devices shall be connected to field terminal block only.
Check and verify that each of the I/O is configured accordingly as
per the Approved Hardware I/O List.

ii) Circuits shall be tested one at a time. However, where cascade

or voting logic is involved, they shall be tested as one complete
system to ensure correct functionality.

d. With PLC systems and other computer equipment disconnected

from a “Black Start” (power off), verify PLC startup and initialization
process.

Remarks:

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

3.3.2.2 Software Checks

Item Description Check

a. PLC Application Software Check:
Check to ensure that all application software is pre-loaded into the
PLC.

i) Select On-Line on the screen of the operator workstation, this will

start the program flow check of the system.

ii) Logic Equal will be displayed at the bottom of the screen to

verify that the software is the same as the program in the operator
workstation as well as in the PLC.

iii) Ensure that the PLC is in the RUN mode and carry a quick
verification that the system is function normally.

iv) PLC ladder logic shall be tested and verified against the ladder
listing and address scheme contained in the Approved Wiring
Diagrams.

b. Panel View Terminal & Central Station HMI

Application Functional Check:
Panel operation shall be tested by simulating input(s) signals and
observing the consequent output(s) in accordance to Customer’s
Cause & Effect Chart. Check and verify the followings as per the
Approval Software I/O List.

i) Correct scaling action on appropriate channel (up/down)

ii) Correct color change and tagging information on the HMI display.

iii) Correct alarm logging on the HMI graphic display for each I/O
point simulated.

iv) Correct field devices locations shown on HMI graphic display.

Remarks:

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

3.4.3 Network Communication Test

Checking procedure:

Item Description Check

a. All Hazard Watch Systems communicate to the Central Station HMI
via Ethernet Fiber Optic Switches in a Ring Network.

i) Check and ensure that the ring network communication at all

nodes is healthy.

ii) Check and verify that any single Hazard Watch System failure
will not interfere with communication between central and other
Hazard Watch Systems.

iii) Check and verify that when there is a broken ring at any node,
the system communication is not interrupted.

b. The Remote I/O PLC communicates to Hazard Watch System #2

via Control Net Fiber Optic Modem.

i) Check and ensure that the Control Net communication at both the
nodes is healthy.

ii) Check and verify that when a single fiber optic media is faulty, the
Control Net communication is not interrupted.

Remarks:

The customer shall record any defect or non-compliance clearly on this document
in the problem log sheets provided.

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 SITE ACCEPTANCE TEST (SAT) PROCEDURE – Rev A

CERTIFICATION

This certifies for HAZARDWATCH FIRE & GAS DETECTION SYSTEM (HW#2) :

i. The site acceptance test was started on ________________ and ended on

__________________.

ii. The system was tested and passed all tests and checks specified in this
document;

iii. All faults detected in the system have been rectified and re-tested;

iv. All tests were conducted during the Customer presence;

v. The tested system is acceptable and hand-over to the customer.

Test conducted by : Witnessed & certified by:

.......................... .............................
GENERAL MONITORS SYSTEMS INSURCOL LTDA

Name : Name :
Date : Date :

Attachments:

1. Summary of Problem Log Sheet

2. Cause & Effect Chart

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 General Monitors Systems

PROBLEM LOG SHEET

Sheet No:
Project Name: Insurcol Colombia Cartagena Project

Client: Insurcol LTDA

Action Type: SOFTWARE HARDWARE (Check one)

Action Code: 1 2 3 4 (Refer definitions below)

Problem Description

Submittal Name: Date:

General Monitors Response

Responder Name: Date:

Accepted By: Date:

Comment:

Action Codes:
1 - Problem must be resolved before testing can continue
2 - Problem must be resolved before shipment
3 - Problem must be resolved before SAT at site.
4 - Issue is determined to be a VO to the project.