wsnabati-f01-003 sat procedures (apibio)
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TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 1 of 14
End User: PT WILMAR NABATI INDONESIA
Customer: PT WILMAR NABATI INDONESIA
P.O No.:
Project Name: WILMAR SURABAYA APIBIO PROJECT
DCS S.A.T PROCEDURE
WSNABATI-F01-003
(APIBIO)
CUSTOMER APPROVAL APPROVED BY: DATE:
F O R I N F O R M A T I O N O N L Y A P P R O V E D W I T H C O M M E N T S
P R O C E E D W I T H P U R C H A S I N G / F A B R I C A T I O N
A P P R O V E D W I T H N O C O M M E N T S
P R O C E E D W I T H P U R C H A S I N G / F A B R I C A T I O N D O N O T P R O C E E D W I T H
P U R C H A S I N G / F A B I R I C A T I O N
0 13 Oct 2012 New Issue for approval Jack Chong Jack Chong YongWP
REV DATE DESCRIPTION PREPARED CHECKED APPROVED
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 2 of 14
Revision History
Rev No. Description
0 New issue for approval
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TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 3 of 14
TABLE OF CONTENTS
DESCRIPTION
Cover Sheet
Table Of Contents
Introduction
General
Test Equipment
S.A.T Schedule
1. INSPECTION FOR CS3000
1.1 Visual Inspection
1.2 System Cable Laying
1.3 Grounding
1.4 System Power
2. SYSTEM FUNCTIONALITY CHECK
2.1 Node Interface Unit
APPENDIX A – Certificate of S.A.T
APPENDIX B – Punch List
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 4 of 14
INTRODUCTION
The Site Acceptance Test (S.A.T.) for the Wilmar Surabaya APIBIO Project for
PT. Wilmar Nabati Indonesia shall be conducted in accordance with the test procedures
detailed here in this document as approved by OWNER.
The scope of this SAT at Gresik, Indonesia shall include hardware power-up check and
functional tests of the CS-3000 System in accordance to this SAT documents.
The purpose of this test is to ensure the system and software function properly during the power-
up.
GENERAL
(1) The Site Acceptance Test will be conducted based on the following 2 main inspection items:-
a. Hardware Inspection For CS3000
b. System Function Check For CS3000
The Site Acceptance Test shall focus mainly on those items specific to this project.
(2) Attached Hardware checklist shall be used during SAT in order to keep a record of all items,
which have been tested, and their test results.
(3) Any non-conforming items discovered during the SAT will be recorded in the Punch List.
Corrective action to be taken and schedule for action must be mutually agreed by Yokogawa and
customer. Punched item of which has been completed, will be re-inspected by customer and date
of inspection and comment to be indicated in the punch list.
(4) KOM will be conducted on the first day and daily progress meeting will be held before
end of the day to check on progress, problems and etc.
(5) The documentation for SAT will consist of site inspection report.
.
TEST EQUIPMENT
The following Test Equipment will be used during the SAT. All models are standard
instruments manufactured by Yokogawa.
a. Portable Calibrator :
b. Digital Multimeter :
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 5 of 14
SITE ACCEPTANCE TEST SCHEDULE
The Commissioning Engineer is responsible for the overall of the SAT and will be the prime
interface for the client Inspectors, from the beginning to the completion of the SAT.
a. Date of SAT :
b. Place of SAT : Wilmar Gresik plant
c. Witness : PT. Wilmar Nabati Indonesia
d. Test Conductor :
Items listed in the SAT Records will be duly re-tested whenever possible at the beginning of the
next working day or at the end of the SAT.
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 6 of 14
1. INSPECTION FOR CS3000
1.1 VISUAL INSPECTION
OUTLINE : The environment condition must fulfill the system requirement
before the power up. All the system installation must be
completed and in proper order.
OBJECTIVE : The purpose of this test is to verify that all external conditions
such as temperature, humidity should pass Yokogawa
requirement. All equipment are fully installed and cables/wires
are connected and in good condition.
PROCEDURE : 1. Check for any physical damage to DCS equipments
2. Room temperature shall not exceed 50 DegC
3. Avoid exposure to direct sun light (FCS & HIS)
4. No condensation (if there is, DO NOT POWER ON)
5. No excessive vibration (< 0.5mm in amplitude)
CRITERIA : Result of each evaluation should show good.
COMMENTS :
TEST RESULT : PASS / FAIL
CUSTOMER : ___________________________
YOKOGAWA : ___________________________
DATE : ___________________________
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 7 of 14
1.2 SYSTEM CABLE LAYING
OUTLINE : All system cables (OR CAT5e cable) should be fully connected
to ensure the continuity of data transfer in the system.
OBJECTIVE : The purpose of this check is to verify that the following are in
accordance with the termination drawing.
1. Cable condition
2. Cable identification/labeling
3. Cable grounding
PROCEDURE : 1. Visually inspect each component for any cut/damage
2. Verify that all system cables connected firmly & tightly
3. Verify that all system cables screen are terminated
4. Verify that power cables are separated 150mm from system
cable (e.g. ER bus )
5. Verify that all system cables are laid in ambient temperature
ranges
6. Verify all Vnet (Ethernet) are connected correctly
CRITERIA : The cables connection should be properly connected and in
accordance with termination drawing/system configuration
COMMENTS :
TEST RESULT : PASS / FAIL
CUSTOMER : ___________________________
YOKOGAWA : ___________________________
DATE : ___________________________
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 8 of 14
1.3 GROUNDING
OUTLINE : Proper grounding is required to protect people from electrical
shock hazards and prevent external noise effects.
OBJECTIVE : The purpose of this check is to verify that the installed grounding
meets system requirement.
PROCEDURE : 1. Verify that Protective earth, system earth and instrument earth
are connected correctly
2. Measure the resistance between earth bar and plant earth
CRITERIA : Resistance between relevant earth bar and plant earth should be
less than 10 ohms.
COMMENTS :
TEST RESULT : PASS / FAIL
CUSTOMER : ___________________________
YOKOGAWA : ___________________________
DATE : ___________________________
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 9 of 14
1.4 SYSTEM POWER
OUTLINE : All the power supplies and distribution should be within the
safety ranges for the operation of the system.
OBJECTIVE : The purpose of this check is to verify that the following are in
accordance with the system requirement.
1. AC power supply
2. DC power supply
PROCEDURE : The following MUST be verified prior to power on of the DCS
1. Verify that power supply connections are in accordance with
the drawing
2. Verify incoming AC is 220VAC within +/- 10% tolerance
3. Verify that 24VDC power supply’s output is within +/- 10%
tolerance.
CRITERIA : Result of each evaluation should show good.
COMMENTS :
TEST RESULT : PASS / FAIL
CUSTOMER : ___________________________
YOKOGAWA : ___________________________
DATE : ___________________________
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 10 of 14
2. SYSTEM FUNCTIONALITY CHECK
2.1 NODE INTERFACE UNIT
OUTLINE : Node unit provide installation for IOM unit on max 8 number
slot available. And it divides into LOCAL node (system expand
through ESB cable) and REMOTE node (system expand through
ER bus cable or CAT5e cable)
OBJECTIVE : The purpose of this check is to ensure that condition particular
node unit works properly.
PROCEDURE : Inspect the following items:
1. Make sure the ER bus master module (EB402) is connected
and online in system.
2. Check CAT5e cables of each remote node and EB402 are
terminated at both ends from node to switch.
3. Check at System Overview page on HIS to verify the node
healthy status and ER bus link healthy status.
CRITERIA : The node should function in good condition.
COMMENTS :
TEST RESULT : PASS / FAIL
CUSTOMER : ___________________________
YOKOGAWA : ___________________________
DATE : ___________________________
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 11 of 14
2.2 FIELD CONTROL STATION
OUTLINE : FCS provides regulatory/discrete and sequential control in
addition to computer functions.
OBJECTIVE : The purpose of this check is to ensure that condition for
FCS is within the tolerable range and the FCS work
properly.
REFERENCE : (Attached DCS Inspection Record For CS-3000.)
PROCEDURE : Inspect the check items listed in the DCS Inspection Record
for CS-3000 (FCS)
CRITERIA : The FCS should function in good condition.
COMMENT :
TEST RESULT : PASS / FAIL
CUSTOMER : ___________________________
YOKOGAWA : ___________________________
DATE : ___________________________
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 12 of 14
APPENDIX A
CERTIFICATE OF
SITE ACCEPTANCE TEST
(S.A.T)
TITLE: DCS F.A.T PROCEDURE DOC. NO.: WSNABATI-F01-003 REV. 0
Form no. ENG-STD-F001 Eff. Date: 2/5/2010 Rev.0
Page 13 of 14
CERTIFICATE OF
SITE ACCEPTANCE TEST (S.A.T)
PROJECT : Wilmar Surabaya APIBIO Pjt
~APIBIO
CUSTOMER : PT. WILMAR NABATI INDONESIA
END USER : PT. WILMAR NABATI INDONESIA
PO NO :
COMMENTS : Refer Punch List Items If Any
OVERALL TEST RESULT : PASS / FAIL
CUSTOMER :
YOKOGAWA :
DATE :
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