Engineering Procedure

SAEP-1638 11 July 2012

Site Acceptance Test Plan
Document Responsibility: Process Control Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................ 2
2 Conflicts and Deviations................................ 2
3 Applicable Documents................................... 2
4 Definitions...................................................... 3
5 Responsibilities............................................. 4
6 Instructions.................................................... 4

APPENDIX 1 – SAT PLAN.................................. 6

Previous Issue: 14 September 2009 Next Planned Update: 11 July 2017

Revised paragraphs are indicated in the right margin Page 1 of 10
Primary contact: Chawla, Farrukh Nawaz on 966-3-880-1828

Copyright©Saudi Aramco 2012. All rights reserved.

Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

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.

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Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

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

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Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

 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.

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Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

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.

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Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

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

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Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

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

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Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

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

Mechanical
H/W Module General Complete Saudi
Cabinet Defects Contractor Remarks
Inventory ID Label Date Aramco
Inspection
CONSOLES
_________ ________ _______ _______ __/__/__ ________ _______ ________
_________ ________ _______ _______ __/__/__ ________ _______ ________

DCS
PROCESSOR &
I/O
_________ ________ _______ _______ _______ ________ _______ ________
_________ ________ _______ _______ _______ ________ _______ ________
_________ ________ _______ _______ _______ ________ _______ ________
_________ ________ _______ _______ _______ ________ _______ ________

DCS M/C
_________ ________ _______ _______ _______ ________ _______ ________
_________ ________ _______ _______ _______ ________ _______ ________
_________ ________ _______ _______ _______ ________ _______ ________

VMS
_________ ________ _______ _______ __/__/__ ________ _______ ________
_________ ________ _______ _______ __/__/__ ________ _______ ________

ESD
_________ ________ _______ _______ __/__/__ ________ _______ ________
_________ ________ _______ _______ __/__/__ ________ _______ ________

COMM
_________ ________ _______ _______ __/__/__ ________ _______ ________
_________ ________ _______ _______ __/__/__ ________ _______ ________

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Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

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.

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Document Responsibility: Process Control Standards Committee SAEP-1638
Issue Date: 11 July 2012
Next Planned Update: 11 July 2017 Site Acceptance Test Plan

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.

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