SIST EN 62381:2012
(Main)Automation systems in the process industry - Factory Acceptance Test (FAT), Site Acceptance Test (SAT) and Site Integration Test (SIT) (IEC 62381:2012)
Automation systems in the process industry - Factory Acceptance Test (FAT), Site Acceptance Test (SAT) and Site Integration Test (SIT) (IEC 62381:2012)
IEC 62381:2012 defines the procedures and specifications for the Factory Acceptance Test (FAT), the Site Acceptance Test (SAT), and the Site Integration Test (SIT). These tests are carried out to prove that the automation system is in accordance with the specification. The description of activities given in this standard can be taken as a guideline and adapted to the specific requirements of the process, plant or equipment. This second edition cancels and replaces the first edition published in 2006. This edition constitutes a technical revision. The main changes with respect to the previous edition are: The definition of the documents mentioned in this standard is in accordance with future IEC 62708.
Automatisierungssysteme in der vefahrenstechnischen Industrie - Werksabnahme (FAT), Abnahme der installierten Anlage (SAT) und Integrationstest (SIT) (IEC 62381:2012)
Actions menées pendant les essais d’acceptation en usine (FAT), les essais d’acceptation sur site (SAT) et les essais d’intégration sur site (SIT) des systèmes d’automatisme pour les procèdes industriels (CEI 62381:2012)
LA CEI 6238:2012 définit les procédures et spécifications des essais d'acceptation en usine (FAT), des essais d'acceptation sur site (SAT) et des essais d'intégration sur site (SIT). Ces essais sont réalisés pour démontrer la conformité du système d'automatisation à la spécification. La description des activités détaillées dans la présente norme peut être considérée comme une ligne directrice et être adaptée aux exigences spécifiques du processus, de l'usine ou de l'équipement. Cette deuxième édition annule et remplace la première édition parue en 2006. Elle constitue une révision technique. Les principales modifications par rapport à l'édition précédente sont: La définition des documents mentionnés dans la présente norme est conforme à la future CEI 62708.
Avtomatizacijski sistemi v procesni industriji - Tovarniški prevzemni preskus (FAT), prevzemni preskus pri prevzemniku (SAT) in preskus integracije pri prevzemniku (SIT) (IEC 62381:2012)
Ta mednarodni standard določa postopke in specifikacije za tovarniški prevzemni preskus (FAT), prevzemni preskus pri prevzemniku (SAT) in preskus integracije pri prevzemniku (SIT), S temi preskusi se dokaže, da je avtomatizacijski sistem v skladu s specifikacijo. Ta standard ne zajema inženirskih in proizvodnih dejavnosti pred temi preskusi. Pri uporabi v farmacevtski industriji in drugih zelo specializiranih industrijah je treba upoštevati dodatne smernice (na primer smernice Good Automated Manufacturing Practice (GAMP)), definicije in določbe v skladu z obstoječimi standardi, na primer za skladnost z dobro proizvodno prakso (GMP) 21 CFR (FDA) in standardni delovni postopek Evropske agencije za zdravila (SOP/INSP/2003). Opis dejavnosti iz tega standarda se lahko uporabi kot smernico in prilagodi posebnim zahtevam procesa, obrate ali opreme. Značilno zaporedje dejavnosti in dogodkov je prikazano na sliki 1, povezava med njimi pa na slikah 2 in 3.
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 62381:2012
01-junij-2012
1DGRPHãþD
SIST EN 62381:2007
Avtomatizacijski sistemi v procesni industriji - Tovarniški prevzemni preskus
(FAT), prevzemni preskus pri prevzemniku (SAT) in preskus integracije pri
prevzemniku (SIT) (IEC 62381:2012)
Automation systems in the process industry - Factory Acceptance Test (FAT), Site
Acceptance Test (SAT) and Site Integration Test (SIT) (IEC 62381:2012)
Automatisierungssysteme in der vefahrenstechnischen Industrie - Werksabnahme (FAT),
Abnahme der installierten Anlage (SAT) und Integrationstest (SIT) (IEC 62381:2012)
Actions menées pendant les essais d’acceptation en usine (FAT), les essais
d’acceptation sur site (SAT) et les essais d’intégration sur site (SIT) des systèmes
d’automatisme pour les procèdes industriels (CEI 62381:2012)
Ta slovenski standard je istoveten z: EN 62381:2012
ICS:
25.040.01 Sistemi za avtomatizacijo v Industrial automation
industriji na splošno systems in general
SIST EN 62381:2012 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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EUROPEAN STANDARD
EN 62381
NORME EUROPÉENNE
April 2012
EUROPÄISCHE NORM
ICS 25.040 Supersedes EN 62381:2007
English version
Automation systems in the process industry -
Factory acceptance test (FAT), site acceptance test (SAT) and site
integration test (SIT)
(IEC 62381:2012)
Systèmes d'automatisation pour les Automatisierungssysteme in der
procédés industriels - vefahrenstechnischen Industrie -
Essais d’acceptation en usine (FAT), Werksabnahme (FAT), Abnahme der
essais d’acceptation sur site (SAT) et installierten Anlage (SAT) und
essais d’intégration sur site (SIT) Integrationstest (SIT)
(CEI 62381:2012) (IEC 62381:2012)
This European Standard was approved by CENELEC on 2012-03-28. CENELEC members are bound to comply
with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard
the status of a national standard without any alteration.
Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the CEN-CENELEC Management Centre or to any CENELEC member.
This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and notified
to the CEN-CENELEC Management Centre has the same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus,
the Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,
Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia,
Spain, Sweden, Switzerland, Turkey and the United Kingdom.
CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
Management Centre: Avenue Marnix 17, B - 1000 Brussels
© 2012 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 62381:2012 E
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EN 62381:2012 - 2 -
Foreword
The text of document 65E/222/FDIS, future edition 2 of IEC 62381, prepared by SC 65E, "Devices and
integration in enterprise systems", of IEC TC 65, "Industrial-process measurement, control and
automation" was submitted to the IEC-CENELEC parallel vote and approved by CENELEC as
EN 62381:2012.
The following dates are fixed:
• latest date by which the document has (dop) 2012-12-28
to be implemented at national level by
publication of an identical national
standard or by endorsement
(dow) 2015-03-28
• latest date by which the national
standards conflicting with the
document have to be withdrawn
This document supersedes EN 62381:2007.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CENELEC [and/or CEN] shall not be held responsible for identifying any or all such patent
rights.
Endorsement notice
The text of the International Standard IEC 62381:2012 was approved by CENELEC as a European
Standard without any modification.
In the official version, for Bibliography, the following notes have to be added for the standards indicated:
IEC 61331 series NOTE Harmonized in EN 61331 series.
IEC 62337 NOTE Harmonized as EN 62337.
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IEC 62381
®
Edition 2.0 2012-02
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Automation systems in the process industry – Factory acceptance test (FAT),
site acceptance test (SAT), and site integration test (SIT)
Systèmes d'automatisation pour les procédés industriels – Essais d'acceptation
en usine (FAT), essais d'acceptation sur site (SAT) et essais d'intégration sur
site (SIT)
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX W
ICS 25.040 ISBN 978-2-88912-917-1
Warning! Make sure that you obtained this publication from an authorized distributor.
Attention! Veuillez vous assurer que vous avez obtenu cette publication via un distributeur agréé.
® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
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– 2 – 62381 © IEC:2012
CONTENTS
FOREWORD . 3
INTRODUCTION . 5
1 Scope . 6
2 Normative references . 9
3 Terms, definitions and abbreviated terms . 9
3.1 Terms and definitions . 9
3.2 Abbreviated terms . 11
4 General preparation before conducting the FAT . 11
4.1 Overview . 11
4.2 Documents typically prepared by owner/contractor . 12
4.3 Documents typically prepared by vendor . 12
5 Factory acceptance test . 12
5.1 General . 12
5.2 FAT test plan . 13
5.3 Test procedure . 13
5.3.1 Test set-up . 13
5.3.2 Conducting of test . 14
5.3.3 Application check procedures . 15
5.4 FAT rework . 16
5.5 Documentation of FAT in accordance with Annex A . 16
6 Site acceptance test . 17
6.1 General . 17
6.2 SAT test plan . 17
7 Site integration test . 17
7.1 General . 17
7.2 SIT test plan . 18
Annex A (informative) FAT test report . 19
Annex B (informative) SAT check list . 31
Annex C (informative) SIT check list . 32
Annex D (informative) FAT certificate . 33
Annex E (informative) SAT certificate . 34
Annex F (informative) SIT certificate . 35
Annex G (informative) Automation system acceptance certificate . 36
Annex H (informative) FAT punch list . 37
Annex I (informative) SAT punch list . 38
Annex J (informative) SIT punch list . 39
Bibliography . 40
Figure 1 – Diagram depicting typical sequence of events for FAT, SAT and SIT with
respect to the project milestones . 7
Figure 2 – Diagram depicting the relationship for the SAT and SIT between the DCS
and subsystems . 8
Figure 3 – Diagram depicting the relationship between the FAT, SAT and SIT with the
relevant plant levels . 8
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62381 © IEC:2012 – 3 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
AUTOMATION SYSTEMS IN THE PROCESS INDUSTRY –
FACTORY ACCEPTANCE TEST (FAT), SITE ACCEPTANCE TEST (SAT),
AND SITE INTEGRATION TEST (SIT)
FOREWORD
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8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62381 has been prepared by subcommittee 65E: Devices and
integration in enterprise systems, of IEC technical committee 65: Industrial-process
measurement, control and automation.
This second edition cancels and replaces the first edition published in 2006. This edition
constitutes a technical revision.
The main changes with respect to the previous edition are listed below:
– The definition of the documents mentioned in this standard is in accordance with future
1
IEC 62708 .
___________
1
To be published.
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The text of this standard is based on the following documents:
FDIS Report on voting
65E/222/FDIS 65E/227/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
The committee has decided that the contents of this publication will remain unchanged until
the stability date indicated on the IEC web site under "http://webstore.iec.ch" in the data
related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
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62381 © IEC:2012 – 5 –
INTRODUCTION
There is an increasing trend in the process industry to shorten the time period for project
execution. At the same time, the complexity of automation systems is being increased due to
the number of connected systems and the use of new technologies, for example, fieldbus
systems.
Experience has shown that the owner, the contractor and the vendor have long and extensive
discussions to unambiguously lay down the scope of activities and responsibilities in order to
achieve a timely delivery and acceptance of automation systems.
This standard is intended to lead to an improvement and acceleration of the negotiation phase
and to a mutual understanding about the scope of activities of each party
The annexes of this standard contain forms which may be used in the test procedures. Buyers
of this standard may copy these forms for their own purposes only in the required amount.
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AUTOMATION SYSTEMS IN THE PROCESS INDUSTRY –
FACTORY ACCEPTANCE TEST (FAT), SITE ACCEPTANCE TEST (SAT),
AND SITE INTEGRATION TEST (SIT)
1 Scope
This International Standard defines procedures and specifications for the Factory Acceptance
Test (FAT), the Site Acceptance Test (SAT), and the Site Integration Test (SIT). These tests
are carried out to prove that the automation system is in accordance with the specification.
Engineering and manufacturing activities prior to these tests are not covered by this standard.
For application in the pharmaceutical or other highly specialized industries, additional
guidelines (for example, Good Automated Manufacturing Practice (GAMP)), definitions and
stipulations should apply in accordance with existing standards, for example, for GMP
Compliance 21 CFR (FDA) and the Standard Operating Procedure of the European Medicines
Agency (SOP/INSP/2003).
The description of activities given in this standard can be taken as a guideline and adapted to
the specific requirements of the process, plant or equipment. A typical sequence of activities
and events is shown in Figure 1, and their relationship are shown in Figures 2 and Figure 3.
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62381 © IEC:2012 – 7 –
Construction Precommissioning Commissioning
Mechanical Completion
Start up
Loop check Cold commissioning Hot commissioning
Process control system completion
ESD ESD
ESD/DCS
DCS DCS
FAT SAT SIT
Prerequisite for FAT Prerequisite for SAT Prerequisite for SIT
- SW complete - Shipment of system to site - Systems properly connected
- System hooked up - SAT complete
- Proper installation
- Vendor in-house test completed
- System start-up
IEC 136/12
NOTE The loop check can actually be started during the construction phase once the required infrastructure has been installed.
Figure 1 – Diagram depicting typical sequence of events for FAT, SAT and SIT with respect to the project milestones
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– 8 – 62381 © IEC:2012
DCS Subsystem 1
Subsystem n
Communication SIT System SAT
IEC 137/12
Figure 2 – Diagram depicting the relationship for the SAT and SIT
between the DCS and subsystems
Typical DCS
Operator level
FAT
SAT
Process level
FAT FAT, partly
SAT SAT or SIT
Rack I/O
Fieldbus
Remote I/O
Fieldbus
Field device
device
Hart, etc
Loop check Loop check Loop check
Process
IEC 138/12
Figure 3 – Diagram depicting the relationship between the FAT, SAT and SIT
with the relevant plant levels
Wiring test
Wiring test
Wiring test
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62381 © IEC:2012 – 9 –
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and
are indispensable for its application. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any
amendments) applies.
None
3 Terms, definitions and abbreviated terms
3.1 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1.1
automation system
DCS- or PLC-based system for the monitoring and controlling of production facilities in the
process industry, including control systems based on fieldbus technologies
3.1.2
tag
unambiguous alphanumerical descriptor which identifies a sensor or actuator
3.1.3
factory acceptance test
activity to demonstrate that the vendor system and additionally supplied systems are in
accordance with the specification
3.1.4
site acceptance test
activity to demonstrate that the installation of the various vendor systems are in accordance
with the applicable specifications and installation instructions
3.1.5
site integration test
activity to demonstrate that the merging of the various systems to one overall system is
completed and that all components work together as specified
3.1.6
buyer
company which is functionally responsible for the automation system purchased from vendor,
i.e. either the owner or the contractor
3.1.7
owner
company that hired a contractor to build a chemical plant, petrochemical plant, etc.
3.1.8
contractor
company which is hired by the owner to design and build a chemical plant, petrochemical
plant, etc.
NOTE The function of contractor can be fulfilled by the owner.
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3.1.9
vendor
manufacturer or distributor of the automation system
3.1.10
process industry
industry that uses chemical reactions, separations, or mixing techniques in order to create
new products, modify existing products or treat waste and includes the following types of
industries: chemical, petrochemical, waste treatment, paper, cement, etc. It does not include
such industries as equipment/machine manufacturing or other similar industries. Industries
which are subject to special requirements and or validation, etc. are also not included.
3.1.11
vendor documentation
product describing documents
EXAMPLE Datasheets, handbooks, operating manuals and spare part lists of supplied devices or systems.
3.1.12
test report
documentation of test sequence and results
3.1.13
test plan
overview of tests as provided in the contract
3.1.14
punch list
list of all open tasks
3.1.15
loop list
tabulated list of all E&I tags with tagging, function and PID references
3.1.16
loop sheet
data sheet with essential E&I data concerning tagging, function, description, measuring range,
location, process data, instrument data, etc.
3.1.17
cabinet layout drawing
drawing to scale of equipment, terminal strips, cable trays etc. in cabinets, consoles and
similar
3.1.18
function diagram or logic diagram
description of the E&I functions according to the IEC 61131 series. Use of this term/such a
diagram is limited to digital signal processing only
3.1.19
cause & effect matrix
actuators and sensors assigned to columns and rows according to their function, including
their related switching and/or alarm function and their safety integrity level (SIL)
3.1.20
user requirement specification
rough user specification in view of the customer to be detailed by the requirement
specification
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62381 © IEC:2012 – 11 –
3.1.21
requirement specification
complete description of all requirements for the realisation (e.g. of an automation system)
3.1.22
control loop description
description of task, function and operator interface of complex continous control loops
3.1.23
HMI specification
specification containing detailed graphic standards and hierarchy of the human machine
interface e.g. group-, trend-, alarm- and operator display
3.1.24
trip point list & configuration parameter list
tabulated list of all variable parameter for E&I equipment
3.1.25
structure diagram DCS/PLC/SIS
simplified schematic drawing of control systems and their network topology by graphical
symbols, not showing any secondary wiring
3.1.26
safety requirement specification
complete description of all tasks and equipment of the safety instrumented functions,
including their check procedures
3.2 Abbreviated terms
C&E Cause and effect matrix
DCS Distributed control system
ESD Emergency shut-down system
EX-i Intrinsic safety
FAT Factory acceptance testing
FUP Function or logic diagram
HMI Human machine interface
HW Hardware
MC Mechanical completion
PLC Programmable logic controller
SAT Site acceptance test
SIF Safety instrumented function (safety loop)
SIS Safety instrumented system
SIL Safety integrity level
SIT Site integration test
SRS Safety requirement specification
SW Software
4 General preparation before conducting the FAT
4.1 Overview
Prior to commencing the FAT, the vendor shall complete full in-house testing. Test reports
shall be available for inspection.
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All relevant documents shall be prepared for use during the FAT. The following list shows
documents typically used. The list should be adapted to be project specific.
4.2 Documents typically prepared by owner/contractor
For example, the following documents:
• User requirement specification:
• Preceding agreement(s):
• Function or logic diagrams:
• Cause and effect matrix:
• Sketches of operator displays and relevant text:
• Control loop description:
• Loop list;
• HMI specification;
• Loop sheet;
• Trip point list & configuration parameter list.
• Safety manuals
• Test procedures for all safety instrumented functions
• Classification for each safety instrumented function into the levels SIL1, or SIL 2; or SIL3,
or none.
4.3 Documents typically prepared by vendor
For example, the following documents:
• Requirement specification;
• Vendor documents, operating manual, certificates;
• Structural diagram DCS/PLC, SIS;
• Cabinet layout drawings;
• I/O list;
• Graphic printouts;
• Configuration printout;
• In-house test reports;
• Test plan.
5 Factory acceptance test
5.1 General
The FAT shall be performed by the vendor. The buyer should witness the test activities. There
may be buyers who want to carry out some parts of the FAT themselves. This has to be laid
down on a project-related basis.
The FAT shall comprise the following areas:
• project-relevant scope of supply;
• application-related functions of the automation system from signal source;
• system-related functions;
• adequate infrastructure shall be provided by the vendor.
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62381 © IEC:2012 – 13 –
The FAT shall be conducted using the test report given in Annex A.
With respect to the specification, any incomplete work or nonconformances detected during
the FAT shall be recorded on a punch list (Annex H).
Punch list items will be categorized as follows:
• to be cleared on the spot, FAT to continue after rectification;
• on-going rectification during FAT;
• FAT to be repeated;
• modifications to be made after FAT, before the system is shipped to the site;
• remaining work to be rectified, i.e. at site.
The FAT shall be considered complete when the vendor has successfully proven all
necessary functions according to the FAT procedures and specifications, with the exception of
the mutually agreed remaining items of the punch-list.
Upon successful completion of the FAT, authorized representatives of the buyer and the
vendor shall sign the FAT certificate (for an example, see Annex D).
5.2 FAT test plan
A test plan (activities and time-schedule) shall be mutually agreed upon between the buyer
and the vendor. The schedule shall include, but is not limited to, the following activities:
Item Description
1 Start-up meeting (document review, schedule, etc.)
2 Vendor documentation (including in-house test reports) check
3 HW and SW inventory check
4 Mechanical inspection
5 Wiring and termination inspection
6 Start-up test
7 General system functions including hardware redundancy and diagnostic check
8 Visualization/operation
9 Test of functionality against all documents mentioned in Clause 3
10 Complex functionality and operation modes (for example, batch, sequence control)
11 Subsystem interface test
12 FAT rework, punch list for onsite (SAT) work
13 FAT close-out meeting
5.3 Test procedure
5.3.1 Test set-up
5.3.1.1 Rack/remote I/O
According to one or more of the following typical scenarios, a complete test shall be carried
out.
The following scenario is customary.
• Forcing of rack/remote I/O by means of simulation devices hooked up at I/O modules.
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The scenarios listed below depend upon contract/specification requirements.
• Forcing of I/O by means of SW simulation on processor level.
• Forcing of I/O by means of SW simulation on the I/O modules.
• Forcing of I/O by means of simulation devices hooked up at field terminals (thus test
inclusive marshalling, process interface (Ex), cross-wiring, system cabling, and I/O
modules).
5.3.1.2 Bus interfaces
A generic test shall be carried out for each specified type of field device which is compliant to
the relevant standard. This test shall cover the interoperability of the automation system and
the device.
• One segment shall be built up and tested with all associated devices linked to it. Selection
of the segment shall be mutually agreed upon.
• In the case of distributed control functionality, all concerned segments shall be tested.
• Signals related to segments not built up shall be simulated.
• All relevant documents, data sheets, figures (load, cycle time, architecture) shall be
reviewed for all segments.
5.3.1.3 Subsystem connec
...
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