SAT PROCEDURE

Retrofit Panel Control Tugu Barat

PROJECT : Retrofit Panel Control Tugu Barat

CLIENT : PT. PERTAMINA EP

LOCATION : TUGU BARAT

A ISSUED FOR REVIEW 12-Feb-19 AH ESW ADP

REV. DESCRIPTION DATE PREPARED CHECKED APP'D CLIENT APP'D

Sesuaikan CLIENT : Job No :

jaraknya PT. PERTAMINA EP Disesuaikan

Doc No :
TUGU BARAT jarak doc no
PEP-TUGU-PRC-010
Page No :
dan job no
CONTRACTOR :
dengan page
REV
no
1 Of 12 A
1. INTRODUCTION
1.1. SAT Location
1.2. SAT Organization
1.3. SAT Schedule
1.4. Safety
1.5. Required Test Equipment
1.6. Required Document

2. TEST PROCEDURE
2.1 Physical Inspection
2.1.1 PLC System Configuration Check
2.1.2 General Inspection
2.1.3 Cabinet Accessories
2.2 Functional Inspection
2.2.1 Digital Input
2.2.2 Digital Output
2.2.3 Analog Input
2.3 Application Program Test
2.3.1 HMI
2.3.2 Alarm and Shutdown Logic

3. TEST COMPLETION

4. PUNCH LIST

5. ATTACHMENTS
1. INTRODUCTION
This document describes the test and inspection procedures for the system under test. Site
Acceptance Test (SAT) will be carried out the presence of representatives from Client.

This SAT Procedure covers all vital system functionally test. They are demonstrative rather
than exhaustive test.

In some instances, when mutually agreed by the representative of Pertamina and Milway at
testing during SAT is impractical and/or impossible, the project quality assurance records of
MILWAY and/or equipment manufacturer shall be provided as evidence of compliance
instead of testing during SAT.

Test results and data shall be recorded in the Test Result Box with both Representatives
initials. There will be two lists attached to the SAT Report:

Punch List Any deviations from the design requirements shall be recorded on the Punch
List. Corrective action shall be taken by Milway to make good any defects or
problems. Where mutually agreed, corrective action for certain punch list
items may be deferred to a later date.

Upon successful completion of SAT, the Client is expected to sign Systems Acceptance
Certificate.

1.1 SAT LOCATION

The SAT Location will be at: Mundu-Cirebon, Stasiun Kompresi Gas-mundu.

1.2 SAT ORGANIZATION

PT. SPAE End User

Agung Dwi.P QA / QC
Eko Satriyo.W Project
Engineer

1.3 SAT SCHEDULE

Date Day Activity
Physical Inspection and Function
Inspection

Factory Acceptance Test Procedure Rev. A Page 1 of 10

 1.4 SAFETY

In the course of testing care shall be exercised to ensure personnel safety and also to
ensure equipment is not at risk of being damaged.

1.5 REQUIRED TEST EQUIPMENT

The following equipment will be provided rot the SAT:

1. Standard PC IBM compatible
2. PC-PLC Communication Cable (Serial Cable or Ethernet Cable)
3. Multimeter
4. Current Injector and Frequency Injector
5. Temperature Injector

1.6 REQUIRED DOCUMENT

Documents will be provided as follows:

1. Allen Bradley CompactlLogix Manual
2. Allen Bradley Input and Output Module Manual
3. Panel Control Wiring Diagram
4. I/O Address Print Out
5. Ladder Logic Print Out
6. Bill Of Materials
7. Engineering Drawing
8. SAT Procedure (This Document)
9. Punch List Record Form

Factory Acceptance Test Procedure Rev. A Page 2 of 10

2. TEST PROCEDURE
The client is expected to sign-off each successful demonstration of system functionality in
accordance with the test procedures defined in this document. Upon discovery of any non-
compliance, the Client shall notify the Milway Representative and record it in the Punch List.

1.3 PHYSICAL INSPECTION

IMPORTANT: DO NOT APPLY POWER YET

5.1.1. PLC System Configuration Check YES NO EMARK

1. Identity and verify each component in the system

cabinets.
YES NO REMARK
2. Verify the placement of each component as per the
System Configuration Sheet.

2.1.2. General Inspection

YES NO REMARK

1. Inspect general appearance of cabinet and compliance

with approved drawings and specifications.
YES NO REMARK

2. Equipment and terminal block layout.

YES NO REMARK

3. Inspect the result of Clean Up the used Cabinet.

YES NO REMARK

4. Verify that access to carry out cabinet installation is

possible.

Factory Acceptance Test Procedure Rev. A Page 3 of 10

 2.1.3. Cabinet Accessories
YES NO REMARK

1. Check cabinet accessories against the Bill of Materials.

YES NO REMARK
2. Check all installed components against the approved
drawings for model number and making.
YES NO REMARK

3. Visually inspect the cabinet to ensure that all

equipment is correctly installed, wired and marker.
YES NO REMARK

4. Push Buttons, relays, installation, etc. – check layout,

nameplate and installation.
YES NO REMARK

5. Verify ducting size and spare capacity, and physical

accessibility in cabinet.

2.2 FUNCTIONAL INSPECTION

2.2.1 Digital Input YES NO REMARK

1. Use digital input field to turn on (energize) the first

digital input points.
YES NO REMARK

2. Verify at the digital input module that the point

energized.
YES NO REMARK
3. Verify at programming terminal and on the Operator
Station that the digital input point energized.

YES NO REMARK
4. Verify the digital input point is de-energized when the
field is used to de-energized the point
YES NO REMARK

5. Repeat for all digital input points.

2.2.2 Digital Output

YES NO REMARK

1. Use the digital output field to act as typical load for

digital output point.
YES NO REMARK

2. Use the programming terminal to force the digital

output on.

Factory Acceptance Test Procedure Rev. A Page 4 of 10

 YES NO REMARK
3. Verify the digital output point is energized on the
module and field
YES NO REMARKR

4. Verify the digital output is de-energized when forcing is

removed
YES NO REMARK

5. Repeat for all digital output points.

2.2.3. Analog Input YES NO REMARK

1. The I/O list and cabinet termination drawing will be used

as reference.
YES NO REMARK

2. Based on the termination drawings, test few points

across the terminals by means of a mA current injector
or 2-wire field. Perform 3-point check (0%, 50% and
100%) for analog input points.
YES NO REMARK

3. Verify the results of Analog Input on the Operator Station

in actual range and on the programming terminal in
engineering unit range.

5-Point Check EU Operator Station

4 mA (0%) 0 % scale 0%
8 mA (25%) 25 % scale 25 %
12 mA (50%) 50 % scale 50 %
16 mA (75%) 75 % scale 75 %
20 mA (100%) 100 % scale 100%

YES NO REMARK

4. Repeat for all Analog Input points.

Factory Acceptance Test Procedure Rev. A Page 5 of 10

2.3. APPLICATION PROGRAM TEST

2.3.1. HMI
YES NO REMARK
1. Set all inputs to normal state.

YES NO REMARK
2. Simulate Analog Inputs and observe the expected
outputs value.

YES NO REMARK
3. Simulate inputs and observe the expected outputs based
on the sequence logic diagrams. Simulation of inputs and
outputs will be done using a programming
terminal/operator station. Refer to the Safe Chart. YES NO REMARK

4. Monitor sequence at HMI screen.

YES NO REMARK

5. Restore all inputs/outputs back to normal state.

2.3.2 Alarm and Shutdown Logic

YES NO REMARK

1. Set all input to normal state

YES NO REMARK

2. Simulate the system is Running

YES NO REMARK
3. Simulate Alarm & Shutdown signal.

YES NO REMARK
4. Monitor all alarm and shutdown effect on HMI screen.

YES NO REMARK
5. Restore all inputs/output and logic simulate back to
normal.

Factory Acceptance Test Procedure Rev. A Page 6 of 10

3. TEST COMPLETION
Any modules that failed in any testing and were replaces must be tested. The system
configuration sheets and test discrepancy sheets must be updated whenever a module fails
and is replaced.

Ensure that the documentation such as ladder logic, I/O list etc. are updated wherever
modification are made.
YES NO REMARK

1. Clear all disable points in the development software

YES NO REMARK
2. Verify that retentive variables if use, are at their desired
state.
YES NO REMARK

3. Restore timer/counter/set point values to its

original if changed during testing.
YES NO REMARK

4. Remove any temporary variables created unless they are

required to be used in future testing/commissioning
YES NO REMARK

5. Secure all module, connectors or any mechanical

fasteners that was loosen during testing

Factory Acceptance Test Procedure Rev. A Page 7 of 10

Comment :
________________________________________________________________________________________
________________________________________________________________________________________
_________________

Witnessed By : _______________________ _____________________

Date : _______________________ _____________________

Witnessed By : _______________________

Date : _______________________

Factory Acceptance Test Procedure Rev. A Page 8 of 10

4. PUNCH LIST

Item Description Closed Acknowledge

Date By

Factory Acceptance Test Procedure Rev. A Page 9 of 10

 5. ATTACHMENTS

A. BILL OF MATERIALS

B. I/O TEST SHEET DIGITAL INPUT

C. I/O TEST SHEET DIGITAL OUTPUT

D. I/O TEST SHEET ANALOG INPUT

E. I/O TEST SHEET ANALOG OUTPUT

F. SAFE CHART

G. PANEL CONTROL WIRING DIAGRAM

H. P&ID DRAWING

Factory Acceptance Test Procedure Rev. A Page 10 of 10