SIST EN 62381:2007
(Main)Automation systems in the process industry - Factory acceptance test (FAT), site acceptance test (SAT) and site integration test (SIT)
Automation systems in the process industry - Factory acceptance test (FAT), site acceptance test (SAT) and site integration test (SIT)
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. The description of activities described in this standard can be taken as a guideline and adapted to the specific requirements of the process/plant/equipment. A typical sequence of activities and events is shown in Figure 1, their relationship in Figures 2 and 3.
Automatisierungssysteme in der Prozessindustrie - Werksabnahme (FAT), Abnahme der installierten Anlage (SAT) und Integrationstest (SIT)
Systèmes d'automatisme dans les industries de processus - Essais d'acceptation en usine, essais d'acceptation sur site et essais d'intégration sur site
Avtomatizacijski sistemi v procesni industriji – Tovarniški prevzemni preskus (FAT), prevzemni preskus pri prevzemniku (SAT) in preskus integracije pri prevzemniku (SIT) (IEC 62381:2006)
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 62381:2007
01-julij-2007
Avtomatizacijski sistemi v procesni industriji – Tovarniški prevzemni preskus
(FAT), prevzemni preskus pri prevzemniku (SAT) in preskus integracije pri
prevzemniku (SIT) (IEC 62381:2006)
Automation systems in the process industry - Factory acceptance test (FAT), site
acceptance test (SAT) and site integration test (SIT) (IEC 62381:2006)
Automatisierungssysteme in der Prozessindustrie - Werksabnahme (FAT), Abnahme der
installierten Anlage (SAT) und Integrationstest (SIT)) (IEC 62381:2006)
Systemes d'automatisme dans les industries de processus - Essais d'acceptation en
usine, essais d'acceptation sur site et essais d'intégration sur site (IEC 62381:2006)
Ta slovenski standard je istoveten z: EN 62381:2007
ICS:
25.040.01 Sistemi za avtomatizacijo v Industrial automation
industriji na splošno systems in general
SIST EN 62381:2007 en;de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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EUROPEAN STANDARD
EN 62381
NORME EUROPÉENNE
March 2007
EUROPÄISCHE NORM
ICS 25.040.01
English version
Automation systems in the process industry -
Factory acceptance test (FAT), site acceptance test (SAT)
and site integration test (SIT)
(IEC 62381:2006)
Systèmes d'automatisme Automatisierungssysteme
dans les industries de processus - in der Prozessindustrie -
Essais d'acceptation en usine, Werksabnahme (FAT),
essais d'acceptation sur site Abnahme der installierten Anlage (SAT)
et essais d'intégration sur site und Integrationstest (SIT)
(CEI 62381:2006) (IEC 62381:2006)
This European Standard was approved by CENELEC on 2007-02-01. 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 Central Secretariat 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 Central Secretariat has the same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, 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 and the United Kingdom.
CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
Central Secretariat: rue de Stassart 35, B - 1050 Brussels
© 2007 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 62381:2007 E
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EN 62381:2007 - 2 -
Foreword
The text of document 65/385/FDIS, future edition 1 of IEC 62381, prepared by IEC TC 65,
Industrial-process measurement and control, was submitted to the IEC-CENELEC parallel vote and was
approved by CENELEC as EN 62381 on 2007-02-01.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2007-11-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2010-02-01
__________
Endorsement notice
The text of the International Standard IEC 62381:2006 was approved by CENELEC as a European
Standard without any modification.
__________
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INTERNATIONAL IEC
STANDARD 62381
First edition
2006-11
Automation systems in the process industry –
Factory acceptance test (FAT), site acceptance
test (SAT), and site integration test (SIT)
© IEC 2006 ⎯ Copyright - all rights reserved
No part of this publication may be reproduced or utilized in any form or by any means, electronic or
mechanical, including photocopying and microfilm, without permission in writing from the publisher.
International Electrotechnical Commission, 3, rue de Varembé, PO Box 131, CH-1211 Geneva 20, Switzerland
Telephone: +41 22 919 02 11 Telefax: +41 22 919 03 00 E-mail: inmail@iec.ch Web: www.iec.ch
PRICE CODE
Commission Electrotechnique Internationale w
International Electrotechnical Commission
МеждународнаяЭлектротехническаяКомиссия
For price, see current catalogue
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CONTENTS
INTRODUCTION.5
FOREWORD.3
1 Scope.6
2 Terms and definitions.9
3 Abbreviations .10
4 General preparation before conducting the FAT .11
4.1 Documents typically prepared by owner/contractor .11
4.2 Documents typically prepared by vendor .11
5 Factory acceptance test .12
5.1 General .12
5.2 FAT test schedule .12
5.3 Test procedure .13
5.4 FAT rework .16
5.5 Documentation of FAT in accordance with Annex A.16
6 Site acceptance test .16
6.1 General .16
6.2 SAT test schedule .16
7 Site integration test .17
7.1 General .17
7.2 SIT test schedule .17
Annex A (informative) FAT checklists.18
Annex B (informative) SAT checklist .30
Annex C (informative) SIT checklist .31
Annex D (informative) FAT certificate .32
Annex E (informative) SAT certificate .33
Annex F (informative) SIT certificate .34
Annex G (informative) Automation system acceptance certificate.35
Annex H (informative) FAT punch list.36
Annex I (informative) SAT punch list .37
Annex J (informative) SIT punch list.38
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.9
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62381 © IEC:2006(E) – 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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all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
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agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
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3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
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equipment declared to be in conformity with an IEC Publication.
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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 IEC technical committee 65:
Industrial-process measurement and control.
This standard cancels and replaces IEC/PAS 62381 published in 2004. This first edition
constitutes a technical revision.
The text of this standard is based on the following documents:
FDIS Report on voting
65/385/FDIS 65/394/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.
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– 4 – 62381 © IEC:2006(E)
The committee has decided that the contents of this publication will remain unchanged until
the maintenance result 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.
A bilingual version of this publication may be issued at a later date.
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62381 © IEC:2006(E) – 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 should 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.
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).
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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.
The description of activities described in this standard can be taken as a guideline and
adapted to the specific requirements of the process/plant/equipment. A typical sequence of
activities and events is shown in Figure 1, their relationship in Figures 2 and 3.
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62381 © IEC:2006(E) – 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 2059/06
*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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DCS Subsystem 1
Subsystem n
Communication SIT System SAT
IEC 2060/06
Figure 2 – Diagram depicting the relationship for the SAT and SIT
between the DCS and subsystems
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62381 © IEC:2006(E) – 9 –
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 2061/06
Figure 3 – Diagram depicting the relationship between the FAT, SAT and SIT
with the relevant plant levels
2 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
2.1
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
2.2
tag
unambiguous alphanumerical descriptor which identifies a sensor or actuator
2.3
factory acceptance test
activity to demonstrate that the vendor system and additionally supplied systems are in
accordance with the specification
2.4
site acceptance test
activity to demonstrate that the installation of the various vendor systems are in accordance
with the applicable specifications and installation instructions
Wiring test
Wiring test
Wiring test
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2.5
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
2.6
buyer
company which is functionally responsible for the automation system purchased from vendor,
i.e. either the owner or the contractor
2.7
owner
company that hired a contractor to build a chemical plant, petrochemical plant, etc.
2.8
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.
2.9
vendor
manufacturer or distributor of the automation system.
2.10
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
2.11
project design specification
PDS
document that defines detailed information needed to implement the functionality described in
the PFS
2.12
project functional specification
PFS
document that contains the vendor's response to the requirements the buyer stipulated prior
to starting the project with the vendor
3 Abbreviations
C&E Cause and effect diagram
DCS Distributed control system
ESD Emergency shut-down system
FAT Factory acceptance testing
FBD Functional block diagram
FUP Function plan
HMI Human machine interface
HW Hardware
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62381 © IEC:2006(E) – 11 –
MC Mechanical completion
PDS Project design specifications
PFS Project functional specification
PLC Programmable logic controller
SAT Site acceptance test
SIT Site integration test
SW Software
4 General preparation before conducting the FAT
Prior to commencing the FAT, the vendor shall complete full in-house testing. Test reports
shall be available for inspection.
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 specific project.
4.1 Documents typically prepared by OWNER/CONTRACTOR
– Specifications
– Preceding agreement(s)
– Function plans
– Cause and effect diagrams
– Sequential functional charts
– Sketches of operator displays and relevant text
– Control narratives
– Instrument index, for example, TAG – service text – I/O type – scaling – units
– Alarm message list, for example, TAG – type of alarm –sorting criteria (priority, plant area)
– Setpoint, control, effect and safety directions
– Interlock list, for example, interlocks assigned to each sensor/actuator, software (DCS)
and hardware (ESD)
4.2 Documents typically prepared by vendor
– System documentation
– Manuals, system data sheets, certificates
– System layout
– Hardware layout
– Description of interfaces
– I/O list and tag name conventions
– Graphic printouts
– Configuration printout
– In-house test reports
– Loop typicals (hardware and software) list of deliveries (hardware, software, application
and licenses)
– Test plan
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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 vendor.
The FAT shall be conducted using the checklists 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 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 punch-list items.
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 schedule
A test schedule (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 4
10 Complex functionality and operation modes (for example, batch, sequence control)
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62381 © IEC:2006(E) – 13 –
Item Description
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.
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 connection
The following scenario is customary.
The test of the link itself and selected loops should be performed by means of a subsystem
simulation device. The value of the signal is forced/monitored in the simulation
device/automation system. The specified architecture, for example, redundancy, medium of
link, for example, glass-fibre or copper cable connection, etc. should be provided as far as
practicable.
Other scenarios such as listed below depend upon contract/specification requirements.
• Subsystem is emulated in the automation system; the signals are forced/monitored in the
automation system.
• Subsystem with limited configuration (processor and link devices only) are available to
check real communication and the signals are simulated in the subsystem.
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• Complete subsystem, link devices and automation system are available, forcing/monitoring
of I/O at the subsystem/automation system.
The manner of testing shall be defined for each subsystem individually and after consideration
of the project requirements.
5.3.2 Conducting of test
The test activities can be divided into check of system features, project-related scope of
supply and application. For checklists, see Annex A.
5.3.2.1 Checklists for the test of system features
– Start-up test
– General system functions including hardware redundancy and diagnostic check
5.3.2.2 Checklists for project-related scope of supply
– Documentation check
– HW and SW inventory check
– Mechanical inspection
– Wiring and termination inspection
5.3.2.3 Reference documents
The documents listed below shall serve as the basis for the functionality test. Completed tags
shall be marked and the resulting documents shall be considered as FAT record.
– P&ID
– Function plan
– Control narrative
– Cause and effects, interlock lists
– Function logic diagrams
– Complex control schemes
– Interface documents
– Colour coding information (process stream colours, block status colours, etc.)
– Definition of plant units and alarm philosophy
– Assignment of plant units to operator workstations
– Operating philosophy (access from graphic displays, group displays or faceplates)
– History collection definition
5.3.3 Application check procedures
5.3.3.1 Check of HMI displays
Prior to the loop-oriented test, the static parts of the HMI displays shall be tested.
The following display functionality (static) shall be verified.
– Symbols for vessels, process lines, valves, transmitters, motors, pumps, etc.
– Colours for static items, for example, hand valves, process lines, etc.
– Process flow direction and path, i.e., process line arrows, shall be verified.
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62381 © IEC:2006(E) – 15 –
– Correct linking of split range control schemes shall be verified.
– Hierarchies and linking of displays shall be verified.
– The dynamic changes of colours, subpictures and data entry points shall be verified.
5.3.3.2 Tag-oriented test
A master document shall be identified prior to the FAT to ensure complete coverage of all
tags. The instrument index including all tags connected to DCS and all subsystems visible on
DCS (ESD, PLC, unit controllers, analyser subsystems, etc.) is the preferred master.
All tags shall be tested as follows.
The faceplate, for example, functionality, service text, range, units, etc., shall be checked.
– Link to I/O level
– Related group display
– Related trends
It shall be verified that the tag target on the graphic is in the correct location and that the
colour changes for dynamic targets, for example, valves, motors, bar graphs, etc. are correct.
Check of alarm assignments – Sorting criteria (priority, plant area, etc.)
Check of user log-on level for operation and control
5.3.3.3 Check of complex functionality and interlocks
The test of complex functionality and interlocks shall be carried out after the tag-oriented test
for the related tags.
5.3.3.4 Additional functionality (reporting)
To be defined by the project.
5.3.3.5 Test of communication links to subsystems
The simulation of signals shall be carried out according to the chosen scenario.
The related functions shall be checked according to the tag-oriented test specification.
In addition to the
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