1 Scope
The Site Acceptance Test (SAT) Plan covered by this procedure shall be considered as one of the Non-Material Requirements (NMR) in accordance with SAEP-16.
1.1 This Saudi Aramco Engineering Procedure (SAEP) provides instructions for the development and approval of the process automation system project Site Acceptance Test (SAT) Plan. The document is not required to follow the format provided in this SAEP, but shall contain the information specified.
1.2 The SAT Plan is a document which specifies and describes the conditions, requirements, plans, procedures, success criteria, and responsibilities for performance of the SAT.
1.3 The SAT Plan will be used by the Contractor to guide and control the performance of the SAT. The SAT Plan will be used by the Company as the basis for monitoring performance of the SAT and for determining satisfactory completion of the SAT.
1.4 This document is not applicable to royalty/custody measurement applications.
2 Conflicts and Deviations
2.1 Any conflicts between this Procedure and other applicable Saudi Aramco Engineering Procedures (SAEPs), Saudi Aramco Engineering Standards (SAESs), Saudi Aramco Materials System Specifications (SAMSSs), Saudi Aramco Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.
2.2 Direct all requests to deviate from this Procedure in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.
3 Applicable Documents
All referenced Procedures, Standards, Specifications, Codes, Forms, Drawings, and similar material or equipment supplied shall be considered part of this Procedure to the extent specified herein and shall be of the latest issue (including all revisions, addenda, and supplements) unless stated otherwise.
Saudi Aramco Engineering Procedures
SAEP-16 Project Execution Guide for Process Automation Systems
SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement
SAEP-1634 Factory Acceptance Test
SAEP-1636 Installation and Checkout Plan
4 Definitions
The following is a list of definitions of terms whose meanings may not be obvious from their usage in this document. Terms that have special meanings when capitalized are shown in that form.
Company: refers to a Saudi Arabian Oil Company (Saudi Aramco).
Contract: refers to a specific contract.
Contractor/Vendor: is an organization under contract to Company.
Factory Acceptance Test (FAT): demonstrates compliance of the System with all requirements, to the extent possible in the Contractor's factory environment.
FAT Plan: is a document which specifies and describes the conditions, requirements, plans, procedures, success criteria, and responsibilities for performance of the FAT. The FAT Plan shall contain sufficient content and detail such that successful completion of the FAT, according to the FAT Plan, will demonstrate and document that the System satisfies all requirements of the Job Specification.
Functional Specification Document (FSD): provides the technical requirements for the System.
Job Specification: is the scope of the work to be performed pursuant to a contract; it describes or references the applicable drawings, standards, specifications, as well as the administrative, procedural, and technical requirements that the contractor shall satisfy or adhere to in accomplishing the work.
Non-Material Requirements (NMRs): The complete set of documentation required in the electronic form from the vendor and/or the contractor during the design and development phase of the project. There are three categories of NMRs:
601 NMRs Preliminary drawings for review and approval
· 602 NMRs Certified drawings, literature, photographs, and parts data/requirements
603 NMRs Operations, maintenance manuals, installation instructions, test certificates, etc.
Process automation system: A network of computer-based or microprocessor-based modules whose primary purpose is process automation. The functions of a PAS may include process control, safety, data acquisition, advanced control and optimization, historical archiving, and decision support. Examples of process automation systems are DCS, SCADA, MIS, ESD, PC and PLC-based systems.
Project Management Team (PMT): The team of Company individuals who are assigned the responsibility of managing the project.
Site Acceptance Test (SAT): The acceptance test, performed on the installed System that demonstrates compliance with all requirements, except availability.
System: is the process automation system that is procured under the Contract.
System Design Document: A document prepared by the vendor and/or the design contractor that contains the design narratives and the key design issues of the system.
5 Responsibilities
4.1 The PMT has overall responsibility for the development of the SAT Plan. The SAT Plan is to be delivered with 601 NMRs and 602 NMRs, which require approval by both PMT and the Operating Organization (OO). Process & Control Systems Department may be requested to review the SAT Plan at any time as a consultant to either PMT or the OO.
4.2 Per SAEP-16, PMT and the OO are responsible to perform the SAT. Typically, PMT includes in the Job Specification that the Contractor will perform the structured testing. The Company has pass/fail approval authority. The OO typically performs unstructured testing.
6 Instructions
5.1 After completion of installation and checkout per SAEP-1636, Installation and Checkout Plan, SAT is performed to verify that the System is installed properly, hardware and software are per specification, grounding/earth connections are properly carried out, and the system is powered up properly. The system is checked for damage of any kind during packing, shipment, installation, or power up.
5.2 Tests not conducted during the FAT due to subsystem unavailability or due to any other reason including integration shall be performed during the SAT as PMT considers appropriate. FAT plan and FAT test procedures developed as per SAEP-1634 during detailed design or at the time of FAT shall be used.
5.3 The SAT Plan shall provide a complete definition of the SAT, including detailed step-by-step procedures. Appendix 1 describes a suggested outline for the SAT Plan. The plan need not follow this outline but shall contain, as a minimum the information specified.
Revision Summary
11 July 2012 Revised the "Next Planned Update." Reaffirmed the content of the document, and reissued with no other changes.
APPENDIX 1 – SAT PLAN
The SAT Plan serves as a checklist to "sign-off" each of the tests as they are completed. After a test has been satisfactorily completed, the person responsible for the test will sign and date the appropriate section of the document. This signed document will provide the basis for the acceptance of the Site Acceptance Test.
The SAT will consist of the following categories of testing as defined by subsequent sections in this document.
Section 4 Visual System Inspection
Section 5 System Hardware Testing
Section 6 FAT Untestable Items
1. MANAGEMENT AND REPORTING
All test activities will be managed by Vendor's Site Manager or his designated representative, whose primary role is to monitor progress and manage test activities such that all tests are completed within the planned schedule.
Contractor will be responsible for maintaining a record of the test in specific forms designed for the test. It is expected that Contractor and Saudi Aramco representatives will endorse their signatures on the test reports for documented proof of test activities.
If the test is interrupted for any reason that portion of the test may be re-run, in whole or part, subject to agreement by Contractor and Saudi Aramco.
2. RECORDING AND RESOLVING EXCEPTIONS
A document called "Exception Item List" contains sheets that allow the recording and resolution of any exceptions encountered during testing. This document is considered part of the SAT records.
Each exception reported is classified as one of the following types of defects:
PJ - Project issue
PD - Product issue
DC - Design Change
Each exception reported is further classified into one of the following resolution categories:
Type 1 - Exception must be corrected before SAT can continue.
Type 2 - Exception must be corrected before SAT completion.
Type 3 - Exception will be corrected before Final Acceptance.
Type 4 - Exception noted for resolution later by CONTRACTOR and Saudi Aramco.
3. ACCEPTANCE
SAT shall be considered successful and completed when Contractor has demonstrated and Saudi Aramco has accepted all functions stated in the test document. At that time there should be no outstanding type 1 or type 2 exceptions. However, a list of outstanding type 3 or 4 action items may be included on a formal Exception Item List, together with a schedule for their resolution.
4. VISUAL SYSTEM INSPECTION
The purpose of this section of the test is to ensure that all of the required system components are installed per the documents and are free of defects.
This section is intended for an engineering review and that a certified Quality Assurance inspection has been performed. This section may be eliminated or minimized as deemed by the project team.
4.1 MECHANICAL DEFECT INSPECTION
Verify that all the DCS system and vendor subsystem components are free of damage or manufacturing defects by visually inspecting them.
4.2 HARDWARE INVENTORY
Verify that all of the system components are installed by checking their installation against the Cabinet Internal Arrangement and Wiring Drawings. Checking is to include:
a) Subsystem quantity and interconnection.
b) Enclosure loading and cabling.
4.3 MODULE IDENTIFICATION
Verify that the module identification of all DCS and sub-system modules
and/or devices are correctly installed by checking them against the Cabinet Internal Arrangement Drawings.
4.4 GENERAL LABELING
Verify that the proper labels are attached, per the requirements of the Saudi Aramco specification as documented on the enclosure and console drawings, for the following items:
a) DCS and Subsystem Enclosures
b) Workstations
c) I/O termination blocks
d) Printers
e) System Cables
f) Marshalling Cabinets
4.5 VISUAL INSPECTION CHECKOUT SHEETS Cabinet | Mechanical Defects Inspection | H/W Inventory | Module ID | General Label | Complete Date | Contractor | Saudi Aramco | Remarks | |||||||
CONSOLES | |||||||||||||||
_________ _________ | ________ ________ | _______ _______ | _______ _______ | __/__/__ __/__/__ | ________ ________ | _______ _______ | ________ ________ | ||||||||
DCS PROCESSOR & I/O | |||||||||||||||
_________ _________ _________ _________ | ________ ________ ________ ________ | _______ _______ _______ _______ | _______ _______ _______ _______ | _______ _______ _______ _______ | ________ ________ ________ ________ | _______ _______ _______ _______ | ________ ________ ________ ________ | ||||||||
DCS M/C | |||||||||||||||
_________ _________ _________ | ________ ________ ________ | _______ _______ _______ | _______ _______ _______ | _______ _______ _______ | ________ ________ ________ | _______ _______ _______ | ________ ________ ________ | ||||||||
VMS | |||||||||||||||
_________ _________ | ________ ________ | _______ _______ | _______ _______ | __/__/__ __/__/__ | ________ ________ | _______ _______ | ________ ________ | ||||||||
ESD | |||||||||||||||
_________ _________ | ________ ________ | _______ _______ | _______ _______ | __/__/__ __/__/__ | ________ ________ | _______ _______ | ________ ________ | ||||||||
COMM | |||||||||||||||
_________ _________ | ________ ________ | _______ _______ | _______ _______ | __/__/__ __/__/__ | ________ ________ | _______ _______ | ________ ________ | ||||||||
5. SYSTEM HARDWARE TESTING
The purpose of this section of the test is to ensure that all of the system hardware components are functioning properly.
5.1 SYSTEM POWER FAILURE
Turn power off to all of the enclosures and wait 30 seconds for the power to drain. Turn the power on to all of the enclosures and allow the system to boot. Verify that all of the modules pass their diagnostics and are running.
5.2 SYSTEM REDUNDANCY & FAIL-SAFE
5.2.1 POWER SUPPLIES
Turn off the main power supplies and verify that the back-up power supply maintains power to all modules and that an alarm is generated to notify the operator that power has been disrupted. Carry out this test for all the systems.
5.2.2 NETWORK
The system monitor network display is used to monitor the current status of the network and stations. Test for switch over of the network by failing primary network. Ensure that network failure alarm is generated. Verify that communications are operative over the 2nd network by accessing displays and confirming proper data updating. Repeat the test for 2nd network.
5.2.3 FIELDBUS
Perform the following procedure for each fieldbus isolator:
Disconnect the network cable from a fieldbus that is currently transmitting and receiving messages. System alarm messages are reported following the disconnection. Fieldbus modules automatically switch to the alternate network. Verify that the correct data value appears on the graphic as the input is varied.
5.2.4 DCS CONTROL PROCESSOR
Perform the test to ensure that fault-tolerant control processor switches to its back up module and functions appropriately.
Upon returning back online, the failed processor should become the back up.
5.2.5 PERIPHERAL DEVICES
Verify that all peripheral devices function as expected.
5.2.6 FAT UNTESTABLE ITEMS
Using FAT test procedures FAT untestable items needs to be tested as planned by Saudi Aramco.
