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TEST REPORT
CLIENT APPROVAL
REVISION RECORD
ISSUE ORIGINATED CHECKED APPROVED
REV DESRIPTION
DATE BY BY BY
SMSO/PGB-POD/2013/0079
ITEM REMARKS
1. VISUAL CHECK
SURFACE
FINISHING
PAINTING
WELDING
DIMENSION
STRUCTURAL
2. GENERAL LAYOUT
EQUIPMENT
WIRING
INSTRUMENT
3. CABLING ROUTING/ARRANGEMENT
5. OPERATIONAL CHECK
6. FUNCTIONAL CHECK
COMPLETED INCOMPLETED
INSPECTOR: VENDOR:
SIGNATURE: SIGNATURE:
DATE: DATE:
1 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
Content
1.0 INTRODUCTION 2
1.1 SCOPE 2
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Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
1.0 Introduction
1.1 Scope
The purpose of this document is to describe the extent of the testing to be carried out on the
system and provide a record of the Factory Acceptance Test. The Sedia Teguh Sdn Bhd
signature would be signed by Sedia Teguhs engineer when a test has been carried out. The
Client would then sign to denote that the test conducted by Sedia Teguhs engineer has been
witnessed and accepted.
This document covers the testing of all inputs and outputs of the hardware and software. The
tests shall be divided in 6 phases. In-house internal test report shall be submitted for review prior
to the FAT witnessed by Client.
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Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
An Engineering Workstation (EWS) running the RSLogix 5000 programming software shall be
used for communicating with the system, downloading program and monitoring system variables
and application logic.
All test equipment to be used for the testing shall be listed below. All test equipment shall be
properly calibrated and tested with valid calibration certificates if appropriate. Under no
circumstances shall non-calibrated test instruments be used.
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Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
The following are a list of documents which will be used as a reference during the tests.
A complete set of system drawings stamped "Test Copy" shall be issued by the Engineering
Department. They shall be referred to as the "Test Copy Drawings" (TCD).
Any non-conformance found in the systems shall be identified on the TCD and corrected with red
or blue ink (red-additions and blue-deletions).
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Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
Visually inspect the mounting plate and assembly items to ensure the layout is similar to the
approved drawings (TCD). For hardware, check the power distribution and earthing. Any
discrepancies shall be markup in the TCD and listed in the punch list for corrective action.
In this phase all layout drawings shall be checked against actual layout. The checks verify all
physical layouts of modules, and I/O cards in the panel.
ACCCEPTANCE BY CLIENT
WITNESS BY
6 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
Upon successful power up of the Processor, check the module status LEDs. The OK LEDs in
yellow indicates a healthy condition and solid green, flashing red or solid red flashing indicates a
faulty condition.
For HMI unit, before loading the program to controller, connect an Ethernet cable to the RJ45 port
on HMI unit and to a EWS running Factory Talk View Site Edition Operator Interface Engineering
Software. Using the EWS, open the Factory Talk View Site Edition Operator Interface
Engineering Software and open the Applications. Initiate download of the application developed
into the HMI. Upon a successful download, check the error logged and make sure no faults and
error
ACCCEPTANCE BY CLIENT
WITNESS BY
7 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
This test is to verify the RSLogix 5000 programs and the functionality of the logic and controls.
The Logic Tests shall be conducted and verified together with existing PLC5 program and new
ControlLogix program.
Compare both existing PLC5 program and new ControlLogix program rung by rung. Verify that all
ladder diagram is similar for existing and new program; with new tag assigned for ControlLogix
program.
ACCCEPTANCE BY CLIENT
WITNESS BY
8 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
This test is to verify the communication between the PLC and Bently Nevada.
The Communication Tests shall be conducted and verified together with the Software I/O
Schedule.
Communication test shall be performed by first make sure the hardware status is healthy and the
communication settings are correct.
For BN communication test, based on the Modbus I/O list, for feedback signal, simulate the value
by forcing the signal from BN. Verify that value change for the particular point by monitoring the
system variables on the EWS.
ACCCEPTANCE BY CLIENT
WITNESS BY
9 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
The Communication Tests shall be conducted and verified together with the Modbus I/O
Schedule. Modbus Simulator software will be used for the testing to works as third party DCS
software.
For DCS communication test, based on the Modbus I/O list, for commands signal, simulate the
value by forcing the signal from Modbus Simulator software or DCS (if available). Verify that value
change for the particular point by monitoring the system variables on the EWS. For feedback
signal, simulate the value by forcing the value in EWS. Verify that value change for the particular
point by monitoring the system variables on the Modbus Simulator software or DCS (if available).
Control Narrative between DCS and SCADA shall be tested according to the narrative agreed.
ACCCEPTANCE BY CLIENT
WITNESS BY
10 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
Verify the hardware is installed according to the TCD. Whenever the power applied, the primary
chassis should switch the power on first followed by the secondary chassis (whichever chassis is
switched on first will become the primary one).
When the system is completely powered up and booted, the Primary RM will display a message
of PRIM, and the CNB will display PwQS or Primary with Qualified Secondary. The
Secondary RM will display a message of SYNC, meaning it has synchronized with the primary
system, and secondary CNB will display a message of QS, or Qualified Secondary
To simulate the actual problem which will cause the switchover occur, remove the ControlNet tap
from CN2R, observe the primary and secondary chassis. The SRM that was primary now say
disqualified. The secondary chassis RM should now say PRIM. This is because the secondary
chassis has taken over primary control of the system. The front of the CN2R should state PwDS
which means Primary with Disqualified Secondary
Replace the ControlNet tap on the CN2R. The original CN2R will display a qfng message stating
that it is trying to qualify and then a QS which means Qualified Secondary. The RM will say
SYNC, which means it is synchronized and ready to switchover.
The original Secondary chassis is the current Primary chassis, and the original Primary chassis is
now the Secondary chassis.
Repeat the redundancy test above by pulling the primary processor to simulate the failed
processor and monitor the status of the module indication and also the output status.
ACCCEPTANCE BY CLIENT
WITNESS BY
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Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
This test is to verify the response of PLC & HMI when power failure happens and restore back.
Verification will include communication and all the I/O.
Simulate a power failure by switching off the supply power. Wait for about 5 ~ 10 minutes. Switch
on the power again. Check on the communication link and all the I/O signals. All the
communication link and I/O signal should be automatically restore once the power is switched on.
ACCCEPTANCE BY CLIENT
WITNESS BY
12 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
This inspection will take place at the end of the test period and will finalize the release of the
product to the customer. The inspection will also ensure that the total quantity of item is correct
against the Bill of Material.
Perform the final inspection and ensure the quantity of items is correct and that the system is
ready for packing.
For those items that are deemed not practical at this stage, agreement will be reached with
customer for rectification at site.
ACCCEPTANCE BY CLIENT
WITNESS BY
13 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
This is to certify that the system has been tested according to the Factory Test procedures. The
System is now released for shipment subjected to the following conditions:-
ACCCEPTANCE BY CLIENT
WITNESS BY
14 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
15 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
16 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-005
Item: ControlLogix PLC for A5-1302B Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079
17 of 17
SEDIA TEGUH SDN BHD Company No. 195647H Document No.
: STP052-13-
G01-005
No. 6 & 6-1, Jalan Wangsa Delima 2A, Rev. No. :0
KLSC III, Section 5,Wangsa Maju,
Page No. : 1 of 1
53300 Kuala Lumpur.
Tel : 603-4143 6896/ 6897
Fax : 603-4143 6898
E-mail : sales@sediateguh.com.my
PUNCH-LIST
Project Name GPP AB PLC5 System Upgrade Customer Name Petronas Gas Berhad
Signature: Signature:
Date: Date:
Document No. :
STP052-13-G01-005
EQUIPMENT FUNCTIONAL CHECKLIST Rev. No. : A
Page No. : 1 of 1
Project Name GPP AB PLC5 System Upgrade Customer Name Petronas Gas Berhad
Project No. STP052 Customer PO No. SMSO/PGB-POD/2013/0079
Item ControlLogix PLC for A5- 1302B
Harware Test
Remarks
No. Tag Name Description Brand Model Serial Number Position Power Normal Faulty Last Checked
1 Chassis 1756 4 slots Allen Bradley 1756-A4 26755835 PC1
2 Chassis 1756 4 slots Allen Bradley 1756-A4 26549043 PC2
3 VAC Power Supply 85-265 (5V @ 10 Amp) Allen Bradley 1756-PA72 26391711 PC1
4 VAC Power Supply 85-265 (5V @ 10 Amp) Allen Bradley 1756-PA72 26653813 PC2
5 ControlNet Interface Module Allen Bradley 1756-CN2R 26317562 PC1S0
6 ControlNet Interface Module Allen Bradley 1756-CN2R 26741313 PC2S0
7 Processor Logix5571 With 2 Mbytes Memory Allen Bradley 1756-L71 26742579 PC1S1
8 Processor Logix5571 With 2 Mbytes Memory Allen Bradley 1756-L71 26742577 PC2S1
9 EtherNet 10-100M Bridege Module Allen Bradley 1756-EN2T 26921361 PC1S2
10 EtherNet 10-100M Bridege Module Allen Bradley 1756-EN2T 26921384 PC2S2
11 Redundancy Module Allen Bradley 1756-RM2 26966785 PC1S3
12 Redundancy Module Allen Bradley 1756-RM2 26966716 PC2S3
13 Redundancy Module Cable, 1M Allen Bradley 1756-RMC1 2 units PC1
14 Mounting Assembly for 1771 to 1756 I/O Field Wiring ConvAllen Bradley 1492-MUA1B-A7-A10 - C1
15 Redundant Power Chassis Adapter Allen Bradley 1756-PSCA2 27995450 C1
16 Redundant Power Chassis Adapter Cable Allen Bradley 1756-CPR2 2 units C1
17 Chassis 1756 7 slots Allen Bradley 1756-A7 27814152 C1
18 Redundant Power Supply Assembly 85-256 VAC Allen Bradley 1756-PA75R 27778415 C1
19 Redundant Power Supply Assembly 85-256 VAC Allen Bradley 1756-PA75R 27778424 C1
20 ControlNet Redundant Interface Module Allen Bradley 1756-CN2R 26741294 C1S0
21 VDC Input 10-31 16 Pts (20Pin) Allen Bradley 1756-IB16 26240307 C1S1
22 Elec Fused Output 10-31 VDC 16 Pts (20 Pin) Allen Bradley 1756-OB16E 28419714 C1S2
23 Elec Fused Output 10-31 VDC 16 Pts (20 Pin) Allen Bradley 1756-OB16E 28419573 C1S3
24 Analog Input - Current/ Voltage 16 Pts (36 Pin) Allen Bradley 1756-IF16 26271997 C1S4
25 Analog Input - Current/ Voltage 16 Pts (36 Pin) Allen Bradley 1756-IF16 26272028 C1S5
26 Communication Module DH+ and RIO Allen Bradley 1756-DHRIO 27278317 C1S6
27 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CM1771-LD001 1 UNIT
28 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CONACAB005X 3 UNIT
29 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CM1771-LA001 2 UNIT
30 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CONACAB005B 2 UNIT
31 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CM1771-LD006 2 UNIT
32 ControlNet T-Tap/Straight Allen Bradley 1786-TPS 6 UNIT
33 ControlNet 75 OHM Terminator Plug Allen Bradley 1786-XT 4 UNIT
Tested By: Witnessed By: Approved By: