CREST SPECIALITY RESINS PRIVATE LIMITED

Factory Acceptance Test

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TABLE OF CONTENTS

1 PURPOSE...............................................................................................................................................4

2 OBJECTIVE..........................................................................................................................................4

3 FAT SCHEDULE.................................................................................................................................4

4 SCOPE.....................................................................................................................................................4

5 TEST EQUIPMENT............................................................................................................................4

6 LIST OF DOCUMENTS FOR REFERENCES...........................................................................5

7 INSTALLMENT ..................................................................................................................................5

8 DEVELOPMENT.................................................................................................................................6

9 DISPATCH............................................................................................................................................7

10 SYSTEM CABINET VERIFICATION FOR PLC......................................................................7

I. CABINET GA BOM & HARDWARE INSTALLATION VERIFICATION...................................................7
II. PAINT WORK CHECK........................................................................................................7
III. CUT OUTS - GENERAL.......................................................................................................8
IV. LABEL – INTERNAL..........................................................................................................8
V. LABEL – EXTERNAL..........................................................................................................8
VI. EARTH BONDING CHECKS..................................................................................................9
VII. MECHANICAL FIXING CHECKS.............................................................................................9
VIII. ELECTRICAL EQUIPMENT CHECK..........................................................................................9
IX. ELECTRICAL WIRING CHECK..............................................................................................10
11 BILL OF MATERIAL VERIFICATION....................................................................................10

12 PLC FUNCTIONALITY CHECK.................................................................................................10

13 PLC LOGIC FUNCTIONALITY TEST......................................................................................11

14 EQUIPMENTS FOR TESTING.....................................................................................................12

15 SOFTWARE FOR TESTING.........................................................................................................12

16 SCADA DEVELOPMENT SCREENS CHECK........................................................................12

17 HMI GRAPHICS CHECK..............................................................................................................13

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REV DATE REASON FOR ISSUE Prep Chkd Apprd Approved

EM PM COMPANY
0 01-AUG-22 FAT Procedure PP KD PP KD CREST

Abbreviation List :
FAT- Factory Acceptance Test
Prep – Prepared by VENDOR/SUPPLIER’s Specialist
Chkd – Checked by VENDOR/SUPPLIER’s Specialist
Apprd – Approval by VENDOR/SUPPLIER’s Specialist, if required as per job quality plan
EM – Engineering Manager
PM – Project Manager
NA – Not Applicable
DI-Digital Input
DO- Digital Output
PLC- Programmable Logic Controller
SMPS- Switch mode power supplies
GA- General Arrangements
BOM- Bill of Material
SCADA- Supervisory Control and Data Acquisition
HMI- Human Machine Interface

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their permission in writing.

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1 PURPOSE

- The purpose of this document is to describe the testing procedures for PLC Panel and SCADA
System as per Requirement of Plant Process.

2 OBJECTIVE

- The Objective of the FAT is to check that the manufactured system is in conformance to the
approved design documents.
- Every item and functional check has a checkbox to be marked as appropriate and comments
noted, where required.

3 FAT SCHEDULE
Sr. No. Activities
1 Introduction
2 Approved BOM checking For PLC Panel
3 PLC power up checking
4 System checking as per FAT procedure For PLC Panel
5 Logic Tested for Siren Control
6 Approved Logic testing
7 SCADA screens Development Testing
8 HMI Graphics checking
- FAT schedule shell be conduct as per Customers Schedule.

4 SCOPE

- The following sub-system, shall be tested for conformance with the approved documents.

5 TEST EQUIPMENT

- The following test equipment shall be used for the FAT

- Digital Multi-meter
- Standard Tools and Cables

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their permission in writing.

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6 LIST OF DOCUMENTS FOR REFERENCES

- The following Documents are used as Reference

 Component Datasheet ---Annexure-1
 Part List / Bill of Material--- Annexure-2
 PLC Panel GA Drawings--- Annexure-2
 PLC Panel Wiring Schematic --- Annexure-2
 SCADA Screens Snapshots --- Annexure-2
 HMI Graphics images--- Annexure-2

7 INSTALLMENT

- We have a wide area of workspace where skilled technicians work on Panel Assembly, in which
they follow the standard procedure for Panel Wiring.

Firstly, the technical engineer creates a General Arrangement Diagram for the received project.
If the General Arrangement Diagram gets approved, then Drawing Manual will be developed by
the technical engineer which will be verified by the technical team. If it gets approved
technicians will start the panel works.

- Before working on the Panel, technician will take the measurements for the Cut-Outs wherever
required in the panel by standard scale measurement to make cut-outs by panel cutting
machine, then they work on GA of Components as per the GA Diagram. After arranging them in
panel, the technical team will check the panel. If it is approved, technicians starts work on panel
wiring of 3-phase, 1-phase, & 24V DC as per mentioned in the Drawing Manual.

After the Panel wiring get completed , Technical Engineer test the Panel wiring with instrument
like Multi meter with standard accessories and also check working of panel as per PLC Logic.

- In the Back Office our SCADA Developers work on Project development and prepare a system,
as per instructions given by customer. They confirms the development after final completion
with customer.

- As per requirement of Client, HMI Graphics will be created by our Engineers.

- All these elements will be checked together at final stage by our Team and after confirming
ready for FAT we will invite Client to carry FAT Activities at our Premises.

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their permission in writing.

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8 DEVELOPMENT

- Firstly, our project manager visit the site and understand the control philosophy of the project
and the requirements of client and collects the details of project like Existing PLC Logic, Details
of the IO List, Alarms, Events and Sequence of Events Documents.

 PLC

- After Understanding the control philosophy, the project engineer built a logic of PLC as per the
Existing PLC Logic and/or as per the requirement of Client, the Logic will be developed in
respective Software required for selected PLC.

- The Languages used in this software are Functional Block Diagram, Ladder Logic & Structure
Text Language, either one or many from these. Prepared PLC Logic as per given control
philosophy, Backup to Software and verify fully PLC Logic. Our Project Engineer executed all the
Comments as per the provided documents by CREST, Also Sent PLC backup for the Verification
of the PLC Logic and Comments.

- Our Project Engineer tested all the function block after downloading PLC Backup from Software
to the selected PLC.

 SCADA and HMI

- As per requirement of the Customer, SCADA engineer developed a system with Graphics
Screens to Interface and Control Process Selection with PLC logic.
- After Approval of customer for created Industrial Symbols, Development proceed using it as a
Platform for all Screens.
- After All graphics of SCADA created, HMI Program developed as per base of SCADA graphics
and Required Navigation.
- Our Project Engineer tested all the functions of SCADA and HMI along with Communications
with PLC.

9 DISPATCH

- The dispatch process in our organization starts with FAT report which is signed by customer
after completing the FAT procedure & Dispatch Clearance from Customer. Furthermore, the
test report is generated by PLC engineer and BOM is verified by the purchase team before
generating invoice. As invoice gets generated, the packing procedure of the Panel get started.

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their permission in writing.

M/S SSM Infotech

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10 SYSTEM CABINET VERIFICATION FOR PLC

I. CABINET GA, BOM & HARDWARE INSTALLATION VERIFICATION

- Panel shall be checked for general workmanship and wiring practices. Check individual wire for
continuity as per following Document.

1. PLC Panel GA Drawings --- Annexure-2

2. Part List / Bill of Material --- Annexure-2

Sr. No. Description Pass Fail Remarks

1 Panel General appearance

2 Dimension Check & mechanical Check
3 Panel general arrangement
verification as per approved drawings
4 Panel BOM verification

5 Panel debris removed & cleaned

6 Doors close without undue pressure

7 Unused holes suitably plugged

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

II. PAINT WORK CHECK

Sr. No. Description Pass Fail Remarks

1 Paint Works of door interior &
exterior undamaged and as per specs
2 Paint works on shell interior &
exterior undamaged

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

III. CUT OUTS - GENERAL

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Sr. No. Description Pass Fail Remarks

1 Cutouts for fan and filter

2 All sharp edges removed and edge
strip installed if required
ACCEPTED ACCEPTED WITH COMMENTS REJECTED

IV. LABEL – INTERNAL

Sr. No. Description Pass Fail Remarks

1 Earth labels adjacent to bonding

points
2 Components labels
3 Terminal rail labels
4 All Terminal labels

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

V. LABEL – EXTERNAL

Sr. No. Description Pass Fail Remarks

1 Panel name plates as per approved

drawings
2 Panel labels mechanically secure

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

VI. EARTH BONDING CHECKS

Sr. No. Description Pass Fail Remarks

1 Earth terminals installed correctly

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2 Doors bonded
3 Side Plate bonded
4 Earth Cables of correct size
5 All Earth connections properly
tightened

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

VII. MECHANICAL FIXING CHECKS

Sr. No. Description Pass Fail Remarks

1 Door hinges installed securely
2 Equipment on back plate installed
securely
3 Terminals connectors installed
securely
4 Earth studs installed securely

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

VIII. ELECTRICAL EQUIPMENT CHECK

Sr. No. Description Pass Fail Remarks

1 Component layout as per approved

drawings
2 All components securely attached
3 Fuses & MCB’s of correct rating
installed
4 Relays of proper rating installed &
operating correctly
5 Fan Working Properly
6 Tube Light Working Properly
7 Utility Socket working Properly

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

IX. ELECTRICAL WIRING CHECK

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Sr. No. Description Pass Fail Remarks

1 Cable Size and color as per approved
drawings
2 Cable ferrules and identification as per
approved drawings
3 Cables clamped & tightened properly
4 Cables crimped correctly
5 Wiring as per approved drawings
6 Point to point continuity check
conducted and found correct
ACCEPTED ACCEPTED WITH COMMENTS REJECTED

11 BILL OF MATERIAL VERIFICATION

- Bill of material shall be checked as per following Document. Make, Model & quantity shall be
verified as per owing Document approved BOM.
1. Part List / Bill of Material --- Annexure-2

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

12 PLC FUNCTIONALITY CHECK

Sr. No. Description Pass Fail Remarks

1. PLC power on test
2. Online PLC Logic modification and
downloading Functionalities Check
3. I/O check – visually check that each I/O
are installed in the correct slot.
4. Simulate DI and Force DO and check
the LED on palette as per DI or DO
Simulated. Also monitor on System
monitoring window of PLC software.
ACCEPTED ACCEPTED WITH COMMENTS REJECTED

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their permission in writing.

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13 PLC LOGIC FUNCTIONALITY TEST

- PLC logic functionality test as per the logic philosophy.

Sr. No. Description Pass Fail Remarks

1 PLC Logic Operation test as per the Logic testing Document which is Provided by CREST.
1. Operation testing as per Control
Philosophy for Different
Selection of Combinations
includes Tanks, Blenders, SOVs,
Reactors and IBCs.
2. After applying various selected
Combination, Testing sequence
of events containing Operation
of whole process.
2 Interlock test as per the Logic testing Document which is Provided by CREST.
1. Interlock Testing as per Control
Philosophy for Selection of
different Combinations of
Tanks, Blenders, Reactors and
SOVs.
2. Interlock Testing Control
Philosophy in operation of
mentioned devices.
ACCEPTED ACCEPTED WITH COMMENTS REJECTED

14 EQUIPMENTS FOR TESTING

Sr. No. Description Pass Fail Remarks

1 Multimeter
2 Tools kit

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

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15 PLC SOFTWARE FOR TESTING

Sr. No. Description Pass Fail Remarks

1 Simulation mode available.

2 Monitoring Screen for the IO Module
Status.

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

16 SCADA DEVELOPMENT SCREENS CHECK

Sr. No. Description Pass Fail Remarks

1 Check Graphics and Symbols used in

Program as per instructions.
2 All Screens and their Navigations
check while selection as well as
operation of Process.
3 Checking Operation Process and Monitoring Status of devices and parameters in all possible
Combinations as per Control Philosophy.
Screen-1 for Tanks to Blenders Process
Operation.
Screen-2 for Tank-2 to IBC 1 and IBC 2.
Screen-3 for Tanks to Reactors.
Screen-4 for Blenders to Filtration
Room Operation.
Screen-5 for Filtration Room to
Storage goods area.
4 Available Inputs and commands check
on all screens, used for Process
Operation.
5 Communication with PLC check for
each Tags used in all screens.
6 Required Interlocks on screens while
Selections and Operations.

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

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17 HMI GRAPHICS CHECK

Sr. No. Description Pass Fail Remarks

1 All Screens and Navigations.

2 Selection of available Inputs as per
Operation Process.
3 Communication with PLC and SCADA
check for each used Tag in Program

ACCEPTED ACCEPTED WITH COMMENTS REJECTED

This document is the property of SSM InfoTech Solutions Pvt. Ltd and must not be copied or lent without
their permission in writing.

M/S SSM Infotech

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