Gpe-Fat Overview

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Overview of Factory Acceptance

Testing (FAT) at GPE


Setting up a process plant is a complex task involving not just hundreds of suppliers,
consultants and service providers from across the world but multiple internal verticals and several
stakeholders. Most projects end up getting delayed and invariably commissioning, integrated cold
and hot trials are always on the critical path. With billions of dollars invested and sales orders in
the pipeline, end users are hardly amused when a particular equipment develops a snag during
commissioning – potentially delaying the start-up of the whole plant.

Based on decades of commissioning experience, we have developed a comprehensive factory


acceptance testing regime which beings with days of continuous internal trials and culminates in
thorough examination by customer representatives at our factory. This helps to identify any
functional defects and saves precious commissioning downtime. All identified punch points are
resolved as soon as possible, in co-ordination with various internal departments, sub-vendors,
consultants and the end user.

This type of testing is the next best thing to a full blown performance test (which can only be
carried out at site where all utilities and safety measures are available) and ensures the following:

 Construction has been verified with respect to the project approved P&ID.
 All component tag numbers are verified as per the P&ID.
 Continuity testing from field to junction boxes and panels have been checked along with cross
ferruling.
 Panels have been powered-on and sequence of operation checked.
 All transmitters are simulated using special apparatus and signal values at PLC panel
checked.
 All actuated valves are operated several times and feedback from limit switches checked.
 All control valves are operated manually and through control loops in the PLC panel.
Feedbacks of positioners are checked.
 The package meets the specifications and expectations of the end user.
MANUFACTURERS NAME & ADDRESS FAT PROCEDURE
End User Consultant Revision No
Project PMC Date
Package TPIA Customer PO No
Customer Document FAT PROCEDURE GPEL Project No
T-181/1/B, MIDC, Bhosari, Pune - 411026, Maharashtra, India A
Contractor Doc. No Inspection Class
SR. INSPECTION ACTIVITY CHARACTERISTICS EXTENT OF REFERENCE ACCEPTABLE FORMAT OF INSPECTION BY
REMARKS
NO. CHECK DOCUMENTS STANDARD RECORD 1 2 3 4
1 2 3 4 5 6 7 8 9
1 FAT PROCEDURE

1.1 Approval of Factory Acceptance Test (FAT) PROCEDURE Verification of inspection stages, hold points, locations and agencies 100% - - FAT Report P R A NIL

2 FINAL INSPECTION
Final dimensions of skid
Approved P&ID Approved P&ID
2.1 Dimensional & visual inspection Final dimensions of tie-in points 100% FAT Report P W RW NIL
Approved GAD Approved GAD
Visual inspection of complete skid assembly
ASME BPVC Sec V, ASME BPVC Sec V,
DPT, RT completion check
2.2 NDE completeness check 100% VIII Div. 1,Piping VIII Div. 1,Piping FAT Report P W RW NIL
Visual inspection of welds in painted condition
Isometrics Isometrics
Completeness check with P&ID
2.3 Compliance with P&ID Tag number checking of equipment, valves, instruments, JBs 100% Approved P&ID Approved P&ID FAT Report P W RW NIL
Checking of valve flow directions

Visual inspection of painting finish / workmanship Approved Painting Approved Painting


2.4 Inspection of skid assembly painting 100% FAT Report P W RW NIL
Review of painting reports Standard Standard

3 LEAKAGE TEST

Leakage check of piping assembly by soap solution pneumatic testing at


3.1 Leakage testing of piping assembly 100% - - FAT Report P W R NIL
operating pressure

4 FUNCTIONAL TEST
Continuity check from PLC to field
Approved GAD and Approved GAD and
PLC logic check
4.1 Test of PLC panel after temporary wiring with field instruments / valves 100% wiring diagram for wiring diagram for FAT Report P P W RW NIL
Purge check of panel
PLC Panel PLC Panel
Ferruling Check
Resistance test Approved heater Approved heater
4.2 Test of heater after installation in heater vessel IR test 100% datasheet and datasheet and FAT Report P P W RW NIL
Visual inspection of terminal assembly drawing drawing
Functional test Approved GAD and Approved GAD and
With incandescent
4.3 Test of heater control panel Interfacing test with PLC 100% wiring diagram for wiring diagram for FAT Report P P W RW
lamp
heater panel heater panel

4.4 Actuated valve operation test Functional test 100% - - FAT Report P W RW NIL

5 FINAL DOCUMENTATION CHECK


Verification, compilation of inspection and test records for submission to
Approved Index for Approved Index for
5.1 Final documentation check customer as part of Material Data Record, 100% Material Data Record P W R NIL
Material Data Record Material Data Record
Stamping of "As-Built" on P&ID and GA drawing
6 ISSUANCE OF IRN / DISPATCH CLEARANCE
a) Blanking of all open nozzle flanges
b) Wrapping with plastic sheets, bubble sheets, thermocol layers, vacuum
6.1 Dispatch clearance and issuance of IRN 100% - - FAT Report P W A NIL
wrapping with silver foil
c) Sea worthy packing in wooden crates
Prepared by Approved by

Gas Processing Equipment Pvt. Ltd.


1 - Sub-vendor / testing agency / Lab 2 - GPEL (OEM) 3 - Third Party Inspection Agency 4 - Consultant / Customer
LEGEND
P - Perform W - Witness RW - Random Witness - No Role R - Review A - Approval Required H - Full Witness / Hold
Functional Test of PLC System

 Review of PLC panel FAT which was carried out at panel


vendor’s works.

 Detailed check of sequence of operation and HMI.

 Discussion with end user to decide various levels of access to be


provided to the system.

 Re-confirmation of communication scheme between system PLC


and plant DCS.

 Sign-off from end user on the HMI and sequence of operation.


Incorporation of minor comments which are invariably missed
during the engineering stages

 Continuity check from field to JBs and JBs to PLC panel.

 Powering on PLC panel and transmitters, positioners, solenoid


valves and limit switches.

 Simulation of transmitters (pressure, temperature, differential


pressure, level and flow) using special apparatus and checking
of signal values in PLC.

 Operation of all actuated on-off and control valves and feedback


check.

 Operation of complete system in auto mode as per sequence of


operation

 Checking glands and gland plates.

Functional Test – Heater after installation

 Opening heater head cover to check that electrical parameters


have not been affected during international transit and storage.

 Checking of limited electrical parameters of heater bundle such


as resistance per bundle, maximum leakage, minimum
megohms and comparison with heater traveler report issued by
supplier.

 Checking heater junction box for visual inspection of


thermocouple terminations.

 Checking of glands installed on the heater.


Functional Test – Heater Control Panel

 Review of heater control panel FAT which was carried out at


panel vendor’s works.

 Hardware and loop checking.

 Control circuit checking in Local / Remote by Injecting the control


supply externally.

 Temperature limits and PID limits setting for element and flange.

 Testing of panel with lamp for SCR healthiness – 3 star


connected bulb load used for checking of SCR healthiness by
injecting 4-20 mA source to the firing circuit. .

Functional Test – Interface between Heater / PLC Panel

 Checking of inputs and outputs between heater panel and PLC.

 Provision of heater set point and process temperature from PLC


and heater operation in auto mode.

Functional Test – Actuated Valves

On-off valves
 Valve operation by 24 V (DO) signal from PLC and checking of
open/ close positions and limit switch feedback signals.
 Operation of valves in PLC auto mode as per sequence of
operation.
Control valves
 Manual operation by 4-20 mA (AO) signal from PLC and
checking of proportionate opening.
 Checking of feedback in PLC.
 Setting of gain values in PID loop.
 Operation of valves through PID loop and in sequence.

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