Enclosure flatness, finish, and color.
Once the 100-hour test has been successfully completed, the contractor should certify this success in writing, submit the document to the design engineer, and schedule witness testing.
3.1.6.2 Hardware Testing
Each hardware component should be tested to verify that it operates properly by itself. Such tests should include
• Alternating current and direct current power checks,
• Power-failure and -restart tests,
• Diagnostics checks, and
• Proof of all specified functions.
In addition, all I/O devices and their components should be tested to verify operability and basic calibration. Where applicable, proper communication among system components should be verified. Communication between each remote I/O and control panel PLC and the master control panel PLC should also be demonstrated.
3.1.6.3 Software Testing
The contractor should demonstrate that all system software, especially its security components, works as intended. For small or simple systems, this test may involve wiring some simulated signals (toggle switches, lights, analog signal from a signal generator, etc.) to the control panel. For larger or more complex systems, this test should involve the use of simulation software installed on a separate computer. During this test, the contractor should demonstrate operation and display of all software based on a simulation involving 100% of physical I/Os, including analog, discrete, and virtual I/Os.
3.1.6.4 Simulation Software
Many system integrators now use simulation software to test program logic before scheduling a factory test. The contract should specify that simulation software be used during testing as well. This software should have the following features:
• Process-specific libraries of unit operations and physical properties;
• The ability to define characteristics (e.g., flow, level, temperature, and pressure) of discrete devices, loops, and objects in the control system model;
• The ability to simulate all process control system signals, alarms, and shutdown scenarios in real time;
• The ability to model all process feedback using graphics and symbols;
• Full, workstation-based control over the behavior of each object in the model;
• The ability to develop custom graphics;
• “Point-and-click” access to object parameters as they are being executed in the background;
• The ability to communicate directly with operator interface terminal (OIT) software;
• The ability to communicate with specified PLCs;
• Operator-training tools that meet Occupational Safety and Health Administration 1910.119 recommendations; and
• Tag numbers for panels, equipment, and instruments used in simulation software should be identical to those in the contract P&IDs.
In addition, the contractor should be required to retain the services of the simulation software supplier’s factory-trained technician. These services should be provided during factory testing, startup, field testing, and training. The contractor should bear all costs (including transportation and lodging expenses) related to these services. A comprehensive guide to factory testing is presented in ISA’s (2011) Automated Systems in the Process Industry—Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT).
3.1.6.5 Operator Interface Terminals and Operator Workstations
Before the control system is staged and tested, OIT and operator workstation (OWS) displays must be configured as agreed upon (e.g., layout, passwords, and security), loaded onto the process control system server or stand-alone personal computer OIT, and tested. The control system’s OIT and OWS software should include the following:
• Graphic symbols of the project’s process schematics, as shown on the contract P&IDs;
• Graphic symbols of each field panel, as shown on the contract P&IDs; and
• Graphic symbols of each field instrument, as shown on the contract P&IDs.
During OIT and OWS testing, testers should
• Review the main menu display contents and demonstrate how an operator will navigate within the overall display structure (the main menu display should provide a list of all available displays and a link to the various subsystem displays);
• Demonstrate which displays are assigned to which keys on the workstation keyboard;
• Confirm that all graphic display components (e.g., layout, symbols, and color scheme) are correct;
• Prove that standard-alarm management displays (e.g., current alarm display and alarm history) function as intended; and
• Show that each specified type of report can be generated and printed.
3.2 Construction Management
Once the new control system is delivered to the site, the construction management team is responsible for installation, field tests, and other related activities. Manufacturers may need to certify the installation of specialized equipment (e.g., process analyzers). They can also test equipment, provide startup assistance, and train users.
Intelligent field instruments and asset-management software can simplify commissioning activities such as system configuration and loop checkout. Intelligent field devices or instruments generate equipment status and diagnostic information that are gathered by asset-management software at a central site (e.g., a control room or maintenance shop) where the installation team can review it all. This approach is more efficient than the traditional method of having team members travel throughout the facility to test each device individually (Johnson and Bailey, 2000; Raven, 2001).
3.2.1 Installation Inspections
Every instrument, control panel, field device, and control valve should be inspected by site inspectors to ensure that they have been installed correctly in accordance with approved installation details. In addition, instrument and other manufacturers should be on-site to certify that their equipment has been installed correctly. Manufacturer-authorized representatives should then certify installation in writing by providing an installation certificate. This will ensure that equipment or device malfunctions discovered during testing are not caused by improper installation. It is also a good idea to involve the owner or facility personnel at this stage so that they can identify any concerns they have with installation.
3.2.2 Instrument Calibrations
As with installation verifications, all instrument calibrations should be field-verified whenever possible. Most devices should be factory-calibrated;
