Control System

FAT & SAT Test

By Eng. Ahmed Adel A. Megeid

Control System FAT Test

The purpose of FAT test:
The purpose of the FAT is to demonstrate total functions of the control system, proper function of the
control communication, monitoring, logic systems, and the OWS.
The FAT shall be done simultaneously for control system cabinets in order to check
completely the hardware, software and communication system between terminal boards and CPUs.
REQUIREMENT PRIOR TO FAT:
Prior to the FAT the supplier shall provide all internal Test Reports previously
executed:
a) all hardware tests reports
b) all calibration reports
c) data sheets for all components installed
e) CPU card certificate & I/O cards certificates/specifications to be
available
f) All tester tool calibration certificates to be available.
Documents required for FAT test:
1)Detail Loop Diagram
2)Interconnection wiring diagram
3)P&IDs, Cause & Effect
4)Instrument Index, Cable schedule List
5)FAT procedure
6)Vendor drawings/documents as Cabinets General Arrangement, BOM, System Architecture, Logic
diagram, I/O assignment
7)PO

Control System FAT Test

FAT Test main topics:
1- Hardware Testing Procedure:
Overall system configuration Check
Visual Inspection Check
Electrical Checks
Power Connection and Grounding Check
Wiring Check
2- Software Testing Procedure
Devices check
Loop Check up to HMI Graphics
Loop Function Test
Cause & Effect Test
Graphics / Faceplate Check
Performance Test

Control System FAT Test

1) Hardware Testing Procedure
1.1) Overall system configuration Check
OBJECTIVE:
The purpose of this test is to verify that the following are in accordance with the reference
drawings /documents.
1. Model No. and Serial No. of each component
2. Quantity of each component
3. Location and accessibility of each component.
REFERENCE DOCUMENT/DRAWING:
1. Bill of Materials
2. Cabinet General Arrangement Drawing
3. FAT Procedure

Cabinet General
Arrangement

Control System FAT Test

1.2)Visual Inspection Check
OBJECTIVE:
The purpose of this test is to ensure that all components and accessories
are free from scratches, deformities and properly labelled for
identification.
REFERENCE DOCUMENT/DRAWING:
1) Cabinet General Arrangement Drawing
Cabinet General
2) FAT Procedures
Visual check FAT
Arrangement
procedure

1.3) Electrical Checks:

OBJECTIVE:
The purpose of this test is to ensure that all electrical wires are of proper
type, size and color.
REFERENCE DOCUMENT/DRAWING:
Electrical Check
3) Cabinet General Arrangement Drawing
FAT procedure
4) FAT Procedures
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Control System FAT Test

1.4) Power Connection and Grounding checks
OBJECTIVE:
The purpose of this test is to ensure proper power and earth
connection as well as system voltage level prior to power on.
REFERENCE DOCUMENT/DRAWING:
1) Cabinet General Arrangement Drawing

Cabinet General
Arrangement

Power/Grounding/
Wiring FAT Procedure

1.5) Wiring Checks

OBJECTIVE:
The purpose of this test is to ensure proper signal wiring
connection prior to Loop checks.
REFERENCE DOCUMENT/DRAWING:
System Wiring
2) Wiring Diagram
Diagram

Control System FAT Test

2) Software Testing Procedures
2.1) Devices checks:
OBJECTIVE:
The purpose of this test is to verify the proper operation of mouse,
alpha-numeric keyboard and CD drives, LCD monitor and printer in line
with Project specifications.
2.2) Loop Check up to HMI Graphics:
OBJECTIVE:
The purpose of this test is to ensure the I/O loops are complete with all
design inputs information. The simulation panels have been wired up to
the field TB in the DCS Marshalling Cabinets to allow all I/O points
simulation during software testing without any delay.
Open Loop
REFERENCE DOCUMENT/DRAWING:
1. I/O Loop drawing
2. Wiring Diagram
3. FAT Procedure

FAT Loop Check

Control System FAT Test

2.3) Loop Function Test:
OBJECTIVE:
The purpose of this test is to ensure the closed
loops and complex loop are implemented as per
process control philosophy and narrative.
REFERENCE DOCUMENT/DRAWING:
1. I/O Loop drawing
2. Control Narrative
3. FAT Procedure

Closed Loop

FAT Function
loop test procedure

Control System FAT Test

2.4) Cause & Effect Test:
OBJECTIVE:
The purpose of this test is to verify that the logic is implemented and working
as per design (C&E). The logic sequence will be tested exactly as per C&E and
normal plant operating conditions, with each steps performed in sequence.

REFERENCE DOCUMENT/DRAWING:
1.
2.
3.
4.

Cause and effect

I/O wiring data base
Loop diagram
Logic Diagram

Cause & Effect

Pump 5901 Logic

Control System FAT Test

2.5) Graphics / Faceplate check:
OBJECTIVE:
The purpose of this section is to check the Static Displays
against the P&ID, and that the graphic symbols developed in
the graphics are as per the project specifications.
REFERENCE DOCUMENT/DRAWING:
1. All Applicable P&ID Sheets

2.6) Performance Check

OBJECTIVE:
The purpose of this section is to check and list the
workstation and FCP loading and available free space in each
hard disk drive of all the workstations and to check and list
each FCP Scan time.
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Control System FAT Test

Control System SAT test:

1)SAT test shall perform same as FAT
test procedures but the difference shall
be in INPUT /OUTPUT checks where 2 or
3 signals per module shall be tested as
FAT test in order to ensure that the
communications between systems &
marshalling cabinets, HMI, and system
network are established
2) SAT test results shall be recorded in
Pre-commissioning check list.
ESD check list

DCS cabinet
check list

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Control System FAT Test

General Note:

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