PIONEER GAS POWER LIMITED

380-425 MW COMBINED CYCLE POWER PLANT

APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 1 of 11

FACTORY ACCEPTANCE TESTS FOR DCS

GENERAL:

1) FACTORY ACCEPTENCE TEST (FAT): REF NOTE-1

2) FACTORY ACCEPTENCE TEST (FAT) PROCEDURE: REF.NOTE -2


TEST REQUIRMENTS:

1) Test shall be performed with the completely assembled system and also with
complete.
2) I&C Software and performing all functions expected out while in actual service
and with system configuration as finalised.
3) Process input/output conditions and other load on the system to be stimulated
either by hardware/software.
4) All system software and application software to be loaded and operational on the
system prior to fat.
5) Fat to be conducted at elevated temp. Of 45 deg c for minimum 48 hours
6) Fat under four cycles of voltage fluctuations viz nominal at 110 % of rated
voltage.
7) Performance test as specified

TEST DOCUMENTS DRAWINGS:

1) TOTAL SYSTEM CONFIGARATION DRAWINGS
2) FAT PROCEDURE CONSITING OF :

(i) TEST EQUIPMENT
(ii) TEST ENVIRONMENT
(iii) TEST CONFIGURATION
(iv) TEST PROCEDURE
(v) TEST SCHEDULE
(vi) TEST VENUE
(vii) TEST REPORTS-SPECIMEN COPIES

Function Design Specification for each equipment / System





PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 2 of 11


PRELIMINARY CHECKS

1) General appearance check and bill of materials check
2) Construction check as per over all general arrangement drawings
3) Dimensional check
4) Labelling , terminal arrangement and equipment identification check
5) Power supply voltage level check and power leeds -on check
6) Cooling fan operation check
7) Grounding network check


1) The intent of the fat is to demonstrate and ensure that the I&C system meets all
the f integrated test of the system shall be carried out at vendor's works in the
presence functional requirements as intended in the specification / contract. A
completed of shipment of I&C equipment to site will be effected only after the
FAT has been accepted by Owner/consultant on completion of integration /
manufacturing of the system by the Purchaser/consultant.

2) Fat procedure shall be prepared by vendor and to be submitted for purchasers/
consultant's approval well in advance prior to the commencement of fat


SYSTEM

1) Power supply under voltage and over voltage check ( 10%)
2) Processor and main data bus network redundancy check, if applicable.
3) Communication coupler if applicable redundancy check
4) Communication module of the controller to network redundancy check ,if
applicable
5) Power supply redundancy check
6) Hardware on-line maintainability check








PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 3 of 11

CONTROLLER ENGINEER:

1) CLOSED LOOP CONTROL SIMULATION CHECK
2) OPEN LOOP CONTROL SIMULATION CHECK
3) CONTROL LOOP RESPONSE CHECK
4) BUMPLESS AUTO MANUAL TRANSFER CHECK
5) CRT GRAPHIC OVERVIEW CHECK
6) CRT- TREND CHECK
7) CRT- REAL TIME TREND CHECK
8) CRT- MIMICS CHECK
9) CRT- CHECK FOR OPERATING CONTROL DIRECTLY FROM MIMICS
10) CRT- FUNCTION KEYS CHECK
11) CRT- TOUCH SCREEN FUNCTION CHECK
12) CRT- ANALOG CONTROL DISPLAY CHECK
13) CRT- SEQUENCE CONTROL DISPLAY CHECK
14) CRT- OPERATOR GUIDENCE MESSAGE CHECK
15) CRT- ALARM MANAGEMENT FUNCTION CHECK
16) CRT LOGGING FUNCTION CHECK
17) CRT / RESPONSE / UPDATING CHECK
18) KEYBOARD LOCK FUNCTION CHECK
19) CRT INTERCHANGEBILITY and ASSIGNABILITY CHECK
20) PRINTER ASSIGNABILITY and BACK-UP FUNCTION CHECK
21) FLOPPY DISK/ STD / OPTICAL DISK UNIT STORAGE and RETRIEVAL
CHECK
22) CRT ASSIGNABILITY CHECK FOR HARD COPIER FUNCTION
23) PLANT PERFORMANCE CALCULATION CHECK
24) COMMUNICATION INTERFACE TO OTHERS SYSTEM SIMULATION
CHECK
25) DATA BUS DISTANCE BUILDING CHECK (REFER NOTE- 3)
26) GRAPHIC DISPLAY BUILDING FUNCTION CHECK

MAINTENANCE

1) CLOSED LOOP CONTROL SYSTEM MODIFICATION CHECK
2) OPEN LOOP CONTROL SYSTEM MODIFICATION CHECK
3) ALARM DISPLAY PRIORITISATION CHECK
4) SYSTEM SECURITY CHECK



PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 4 of 11

5) SYSTEM ALARM CHECK
6) SYSTEM DIAGNOSTIC FUNCTION CHECK
7) POINT DETAIL CONFIGURATION CHECK
8) CONTROL LOOP TUNING CHECK
9) SYSTEM SELF DOCUMENTATION CHECK


NOTES

FAT shall be conducted with the distance between the processor and other supporting
peripherals as per the final layout in the control room.

TEST PROCEDURE FOR GT CONTROL SYSTEM

TEST OVERVIEW
1. Visual inspection and random dimensional check
2. Bill of Material check
3. Terminal arrangement and wiring check
4. Power supply under voltage and over voltage check
5. Verification of jumper settings
6. Verification of healthiness of individual processors
7. Verification of operator interface displays
8. Verification of control functions
Start-up control
Acceleration control
Speed/Load control
Temperature control
Fired shutdown
Emergency shutdown
9. Verification of Protection functions
Over speed
Over temperature



PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 5 of 11

Vibration
Master protection
Flame detection
10. System diagnostics
11. Redundancy test for controllers
12. Communication interface to DCS verification

TESTS TO BE PERFORMED FOR FIELD INSTRUMENTS


1. Pressure indicators
Calibration Hydro test (1.5 times max. pr.)
2. Pressure switches
Calibration test / Hydro test / Contact rating test / Accuracy test /
Repeatability
3. Differential Pressure Indicators
Calibration test / Hydro test / Leak test / Over range test /
Accuracy test / Repeatability test.
4. Differential Pressure Switches
Calibration test / Hydro test / Contact rating test / Leak test /
Accuracy test / Repeatability test.
5. Thermometers
Calibration / Material test / Accuracy test / Bore concentricity: +
5% of wall thickness / Hydrostatic test for TW (1.5 times max.
pr.)
6. Temperature switch
Calibration / Material test / Accuracy test / Bore concentricity:
1.5% of wall thickness / Hydrostatic test for TW (1.5 times max.
pr.) / Contact rating test.
7. Resistance temperature detector assembly.
Calibration / Material test / Bore concentricity test / Insulation
test (< 500 M at 500V DC) as per ISA, Hydro test for TW. Bore
concentricity: + 5% of wall thickness, Accuracy test.
8. Thermocouple assembly



PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 6 of 11

Calibration / Material test, Insulation test (> 500 at 500 V, DC)
as per ISA, Hydro static test (1.5 times max. pr.), Bore
concentricity: + 5% of wall thickness.
9. Thermo wells
Material test / Bore concentricity: + 5% of wall thickness /
Hydrostatic test for TW (1.5 times max. pr.)
10. Level Gauges
Hydrostatic test / Material test / Seat leakage test / Ball check
test.
11. Level switches (Magnetic)
Material test / Contact rating test / Hydro test / Calibration test.
12. Flow Switch
Material test / Hydro static test (1.5 times max. pr.) / function
test.
13. Flow glasses
14. Variable area flow meters
Calibration test / Material test / Hydrostatic test (1.5 times max.
pr.)
15. Flow element
100% Radiography test / Hydro test / Calibration test, IBR
Certificate.
Calibration test for flow element shall be witnessed by
Purchaser/Consultant.

17. Position transmitters
18. Electro Pneumatic Converters
Calibration test / Accuracy test
19. Solenoid valves
Hydro test / Seat leakage test / CV test / Coil insulation test
20. Air filter regulators
Calibration test / Accuracy test
21. Junction Boxes
Test for degree of protection / Material test
22. Tests for terminal blocks
Test for moulding for flame resistant, Non-hygroscopic and
Decarbonised / Insulation test between terminals / Insulation



PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 7 of 11

between terminal block and frame.
23. Thermocouple extension cable
Thermo-elf characteristic / Continuity test / Measurement on
capacitance, inductance and loop resistance / Insulation
resistance / High voltage test as per latest IS / Tensile and
elongation test / Oxygen index test / Any other test applicable.
24. Mass flow meter
Performance test / Calibration test / Hydrostatic test.
25. Boiler Drum Level Gauge
Hydrostatic test / Material test / Seat leakage test / IBR
Certificate
26. pH/Conductivity measurement / Silica / Dissolved oxygen
analysers:
Calibration test, Accuracy test
27. Sample cooler :
Hydro test, IBR Certificate
28. Sampling racks :
Hydro test, IBR Certificate for tubes and fittings.
29. S02 / Knox analyser / SPM analyser:
Calibration test, accuracy test
Functional test, temperature rise test, H.V test, Insulation test
31. Transmitter Racks :
Hydro test, air leak test for piping / tubing and fittings. IBR
certification as required for tubing / piping and fittings.
32. Local Panels :
Visual inspection, wiring & continuity check, h.v. and i.r. tests on
panels, checking of bill of materials, functional tests.

Notes:

1) Test Certificates shall be furnished for all the instruments for
Purchaser / Consultant's review.






PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 8 of 11

INSPECTION REQUIREMENTS
SPECIFICATIO
N No.

SUB - ITEM CONTROL VALVE,
PNEUMATIC
BLOCK VALVE,
PRESSURE
REDUCING VALVE


COMPONENT /
OPERATION
CHARACTERISTICS
CHECKED
TYPE /
METHOD
OF
CHECK
EXTENT REF.
DOCUMENT /
ACCEPTANCE
NORM
FORMAT
OF
RECORD
agency
S.NO
1 2 3 4 5 6 7
1.0 MATERIALS :
1.1 Body & Bonnet
or Cover
castings :
Chem., Mech.
properties, Dimness.
Review
of docs.
100% Material
specification,
IBR
TC
a) Carbon steel
valves &
Stainless
Soundness RT 100% ASME B 16.34 TC
steel valves
600 class

b) Ferritic Alloy
steel valves of
all
Soundness RT 100% ASME B 16.34 TC
classes
c) Carbon steel
and Alloy steel
Surface defects MPI/LPI 100% ASME B 16.34 TC
valves of all
classes

1.2 Body & Bonnet
or Cover
Forgings :
Chem., Mech.
properties, Dimns.
Review
of docs.
100% Material
specification,
IBR
TC
a) Carbon steel
and Alloy steel
Soundness UT 100% ASME B 16.34 TC
valves of
1500 class

b) Carbon steel
and Alloy steel
Surface defects MPI/LPI 100% ASME B 16.34 TC
valves of all
classes

1.3 Valve stem Chem., Mech.
properties, Dimness.
Review
of docs.
100% Material
specification,
IBR
TC
Soundness (for
diameter > 50 mm)
UT 100% AM 203.2 of
Sec. VIII Div. 2
TC





PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 9 of 11


Notes:

A. STATUTORY REQUIREMENTS SHALL BE COMPLITED BY THE VENDOR BY THE
VENDOR
B. MATERIAL TESTS OF SAMPLES DRAWN BY TCE SHALL BE WITNESSED BY
OWNER
C. FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY OWNER, COPIES OF
RELEVANT DOCUMENTS SHALL BE FURNISHED TO OWNER
D. OWNERS IDENTIFICATION STAMP ON MATERIALS SHALL BE PRESERVED / GOT
TRANSFERRED BY OWNER AT APPROPRIATE STAGES.
E. THE EXTENT INDICATED IN COLUMN 5 IS IN VENDORS SCOPE. OWNER MAY
INSPECT AS PER THIS COLUMN OR RANDOM SAMPLES.
F. COLUMN 6 SHALL BE AS PER OWNER APPROVED DRAWINGS / DATA SHEETS /
SPECIFICATIONS WHEREVER APPLICABLE.
G. INSTRUMENTS FOR LEAK TESTS AND PERFORMANCE TESTS SHALL HAVE
VALID CALIBRATION CERTIFICATE WITH TRACEABILITY TO NATIONAL LEVEL.
H. LEGENDS : S - SUB - VENDOR, M - MAIN VENDOR, T- TCE, W -
WITNESS, V - DOCUMENTS REVIEW, H - HOLD POINT.






























PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 10 of 11


INSPECTION REQUIREMENTS




SPECIFICATIO
N No.

SUB - ITEM CONTROL VALVE,
PNEUMATIC
BLOCK VALVE,
PRESSURE
REDUCING VALVE

SR. COMPONENT /
OPERATION
CHARACTERISTIC
S
CHECKED
TYPE /
METHOD
OF CHECK
EXTEN
T
REF.
DOCUMENT /
ACCEPTANC
E NORM
FORMAT
OF
RECORD
NO
.

1 2 3 4 5 6 7
2.0 IN-PROCESS
INSPECTION :

2.1 Welding Procedure,
Personnel
qualification
Review of
docs.
100% ASME Sec. IX,
IBR
WPS,
PQR,
WPQ
2.2 Weld inspection Surface defects Visual 100% ASME B 16.34 Inspectio
n report
2.3 NDE of stellited
seats
Surface defects LPI 100% ASME B 16.34 LPI report
2.4 Hardness test on
seat and
backseat
Hardness Measurement 10% Drawing Hardness
report
2.5 NDE of full
penetration
welds
Soundness RT/UT 100% ASME B 16.34 RT/UT
report
2.6 NDE of fillet
welds
Surface defects MPI/LPI 100% ASME B 16.34 MPI/LPI
report
2.7 Machined
Surface of all
components
Surface defects MPI/LPI 100% ASME B 16.34 MPI/LPI
report
2.8 PWHT Temp. and time
control
HT chart
review
100% ASME Sec. I,
IBR
HT chart
3.0 FINAL :
3.1 Visual and
dimensional
inspection
Overall dimns.,
Surface cond., etc.
Visual,
Measurement
100 % Drawing Inspectio
n report
3.2 Testing Shell test Hydro test 100 % ASME B 16.34 Inspectio
n report
Seat leakage test Hydro test & 100 % ASME B
16.104 & data
Inspectio
n report
Air test sheets
Actuator chamber Air test 100 % ASME B Inspectio



PIONEER GAS POWER LIMITED
380-425 MW COMBINED CYCLE POWER PLANT
APSIPL-05-EPC-
3-C3
FACTORY ACCEPTANCE TESTS FOR DCS



. Page 11 of 11

leakage test 16.104 n report
Operation test Calibration, 100 % Data sheets Inspectio
n report
Hysteresis,
etc.

Flow characteristic CV test (1 per
type)
Data sheets &
ISA
75.02/75.11
Inspectio
n report
3.3 Completeness,
IBR certification
Paint thk.,
Identification, etc.
Visual,
Measurement
,
100 % Drawing, IBR Inspectio
n report
Document
review