Hi notone8,

I don't envy your position.

You must have a P&ID (process and instrumentation diagram). The very first thing you need to do is know the entire installation according to the P&ID. Then you need to physically inspect the system to determine what has and has not been completed. Do this BEFORE you talk to the subcontractor. That way, if he tries to lie or hide something, you will be able to call them on it.

As far as testing it's as simple as checking power sources for and the signals to and from the individual components. Make sure that the signals you are supposed to get are actually being transmitted and received.

Without having the P&ID, that's about as far as I can help you.

Good Luck,

Mike

I will get a hold of any requirements documents associated with the performance of the applications that you must test. I also will create a test script based on that follows each expected outout for each each application. This a what people in the QA field do when they need to test a new tool.

You will have to create a very very extensive set of requirememts and test protocols to cover each aspect of your application. I hope this information can give you some clues on what to do. If you need any additional info feel free to contact me.

Good Luck, Rey.

I have handled two projects of this nature though not as big as yours.

Your project seems to big and I hope you have the required manpower.

Here are the steps

1. Go through the PID diagram. (As alresdy suggested). This is very important. You say you are an elctrical engineer. So familiarise yourself about the process. Understand the function of each component.

2. Make a risk analysis if have not already done so. Normally this has to be done before you award a contract.

3. Demand for a loop diagram from your contractor.

3a. Demand for calibration certificate from the contractor and check its validity and traceability.

4. Check the mechanical looping of each wire and inspect that the diagram and as built are same.

5. Check and familiarise about the SCADA software.

6. Supply simulated input to each sensor end and inspect that the reading you see on the screen is valid

7. Operate each valve from the PC and inspect that they operate perfectly.

8. Check all digital I/O s for their operation and respective displays.

9. You might have a list of system interlocks.

10. Inspect each of them. Supply simulated signal and check that the interlocks activate.

11. Check all the alarms are displayed on the SCADA screen.

12. Check the data of all parameters are being logged into a database. This is very very important.

13. With this you must be through for commissioning. However depending on your process step 2 and 9 are to be thoroughly debated.

14. Check the SCADA is protected with proper user rights and you know all the passwords.

15. Documentation for all the systems, software codes, software auth codes, software auth certificates, operation and maintenance manual.

while making the list I have considered that you are a NOVICE. I apologise for that.The above is only an indication. You may have to prepare an exhaustive list.

Please free to contact me sub20563bu@vsnl.net

Hi, There are a number of things that should be in place before the tender is accepted. I will list a copy of the headings for a complete job as yours appears to be. You should be able to find at least the minimum criteria for the control of the job from inspection prior to tendering through to the final commissioning with the follow up Post commissioning check sheets for the warranty period. The documentation should be in a format something like the following of mine. I list the headings below for reference.

Headings of each "Tick and Flick" sheets in the Index in each section. These sheets cover everything in the Mechanical, Electrical, Movement/Operation of machinery, OH&S, Documentation etc. and are placed into an archive for future reference.

1/ Audit Sheets 2/ Check Sheets Index to differing fields 3/ Documentation Control Check Sheets 4/ ITP's Inspection & Test Plans 5/ Mechanical/Electrical/OH&S/ Test Check Sheets 6/ Installation Check Sheets 7/ Miscellaneous Check Sheets 8/ Equipment/Operations Pre Commissioning Check Sheets 9/ Equipment/Operations Commissioning Check Sheets 10/ Post Commissioning Test Check Sheets (This also is used as a paper trail during the warranty Period).

This folder of Indexed check sheets (about 1300 sheets in all) has been used in numerous tenders. The folder has proved to be a safeguard when something went wrong and the Mines Inspectorate done interviews following an accident 18 months later. There was a proper logical 'Paper Trail' that showed that certain actions that had been undertaken after the warranty period was the Primary cause. The reply by Guest is indeed accurate and I am sure that there will be an electronic format of similar check sheets for you to follow. Be thorough in doing your inspections and every P&ID is followed and checked as correct before final handover. There should also be a client representative member who should be assigned to you to cross sign off on behalf of the clients company. They also should have all the documentation you should need.

I hope this has helped you on where to look for documentation.

Your testing of the DAQ part, should have been split in 3 parts: FAT, Installation tests and commissioning.

Depending on businesses and habits, SAT might cover the Installation Tests and/or the commissioning tests.

Functional testing should have been performed during FAT: check that it has been done and there is no outstanding functional tests i.e. ones which require re-testing on site or ones which couldn't be make in factory for whatever reason. Once the function tests have been done, you have no obligation to re-do them except some tests and regression tests if some firmware or software or configuration have been updated since FAT: any versionning available to track that?

Performances tests should have also been done in FAT. Doing them on site, is quite vicious because time is usually running out and you'll be under pressure to proceed with commissioning: this is common practice for forcing a Customer to accept a non-finished system.

If your system has some reliability/redundancy features: again FAT is the normal stage to do them. You may do some sampling tests during installation and commissioning but you must ensure the supplier has properly tested that before sending the system to site otherwise you expose yourselves to problems.

Installation tests i.e., everything is wired in order to be switched on but nothing or very little is connected to process. It allows you to check that installation has been properly achieved and check that everything communicating device properly communicates with which ever other device it should.

During either the Installation tests or commissioning, again this depends on habits, businesses, system supplied common practices you'll have to demonstrate that, still without IO connection to process, the end-to-end tests are OK. End-to-end tests will consist of activating the IO at terminal blocks or similar to check that they are visible e.g. on the HMI (local to the device, SCADA one and remote one if any, printers, ...). The fact the activation triggers whatever PLC action is not part of that test -this has been proven in FAT and should be done again during commissioning if not. So try to limit these installation tests to end-to-end tests: this will make easier your life above all if a 3rd party has done the wiring to process.

To do the end-to-end tests, you need an IO list and a column per output -with the appropriate wording: a row for one input/output-command with the wording on the SCADA HMI, ditto for each printers, mimic, ... here again, depending on businesses, some people take the risk of no doing a 100% end-to-end tests: god bless them... and us if we live close to the processes these mad men deal with -where is your project by the way!

Don't bother with 'internal' variables they have been tested during FAT or will be during commissioning and in any case they do not relate to on site installation, so they're not part of this testing phase.

Commissioning relates to the validation that the overall system: the tests should be arranged/scheduled on a per process item basis. What I mean here, is that you look at your SCADA / DAQ as a mean to control that when an operator for instance operate a valve, a switch it is properly reported to the SCADA HMI-printers i.e. any 'output' used by the operators. In the same way you test the commands.

If you want you may also perform some sampling tests to ensure the functional tests are still OK. You can also do negative tests: you disconnect for instance a device in the system you test and you check what happens. Your technical specifications will help you during that kind of tests: some of the automation functions may have surprising behaviours when they miss data!

What you said is a flag of existing issues and for future problems, my last advice is to look for expert support right away: they are plenty of either companies or freelance guys which can help you though the price may be high considering your project status. The implications of that are another story but it would be interesting to know why your supplier wants to bail out now: not a usual behaviour.

Patrice

As listed in other responses, this is an intricate procedure that should have been written in the project specifications. The design engineer or construction firm responsible for the commissioning should have a procedure for customer turnover of the project.

If the procedure that you are requesting help for is for your company's internal documentation, see what I have given you below. This is a section on a commissioning procedure for a previous project of which I was involved:

*****************************************************

PERFORM THE PREPARE FOR TEST PROCEDURE
Time / Initials
_____|_____ 12. DISABLE generator DG-5. Install start wiring from MTC using procedures by ASCO.
_____|_____ 13. Energize / Verify ASCO MTC
_____|_____ 14. At SWB-E201, VERIFY that circuit breaker EG-5 is racked in.
_____|_____ 15. At SWB-E201, Lock Out-Tag Out circuit breaker EO-ATS7.
_____|_____ 16. At SWB-M201, REMOVE Lock Out-Tag Out and RACK IN circuit breaker EO-M201
_____|_____ 17. At SWB-M201, REMOVE Lock Out-Tag Out and RACK IN circuit breaker EG INPUT.

Generator DG-5 is in the standby mode.

SWITCHBOARD CIRCUIT BREAKERS, VERIFY INITIAL CONDITIONS
_____|_____ 18. At switchboard SWB-E201, TRIP and VERIFY that DG-5 circuit breaker EG-5 is in the OPEN position.

_____|_____ 19. At switchboard SWB-E201, TRIP and VERIFY that SWB-M201 circuit breaker EO-M201 is in the OPEN position.

_____|_____ 20. At the ASCO MTC, VERIFY that the automatic transfer SYSTEM CONTROL SWITCH is in LOCKOUT position.

_____|_____ 21. At switchboard DP-C201, TRIP and VERIFY that ALL load circuit breakers are in the OPEN position.

_____|_____ 22. At switchboard DP-C201, TRIP the main circuit breaker UPS201 and verify that it is in the OPEN position.

_____|_____ 23. At switchboard DP-C202, TRIP and VERIFY that ALL load circuit breakers are in the OPEN position.

_____|_____ 24. At switchboard DP-C202, TRIP the main circuit breaker UPS202 and verify that it is in the OPEN position.

_____|_____ 25. At switchboard SWB-BYP, TRIP and VERIFY that the DP-CR02 feeder circuit breaker CR02 is in the OPEN and LOCKED-OUT position.

_____|_____ 26. At switchboard SWB-M201, except for UA200 and BYP-1 (MOD-201 bypass) breakers, TRIP ALL other load side circuit breakers (as applicable) and verify that they are in the OPEN position.

_____|_____ 27. At switchboard SWB-BYP, except for feeders to CP1 and MOD-202, TRIP ALL other load side circuit breakers (as applicable) and verify that they are in the OPEN position.

PROCEDURE TO ENERGIZE AND TEST UPS MOD-202

_____|_____ 28. At UPS MOD-202, CONNECT the Event Recorder to the OUTPUT BUS.

_____|_____ 29. At DP-C202, Connect three (3) 300 kW 480 volt load banks each to a 400 amp circuit breaker. Circuit breakers shall remain in the OPEN position.

_____|_____ 30. Verify that all load banks are in the OFF mode, with local unit switches in the OPEN position, 480 VOLT operation selected.
UPS MOD-202

_____|_____ 31. At UPS MOD-202, verify that battery string is on line and that there are no UPS alarms present.
Record: DC VOLTAGE: _______, DC AMPS ________

DP-C202
_____|_____ 32. At DP-C202, VERIFY proper voltage and phase rotation on the input bus to MAIN circuit breaker UPS202.

_____|_____ 33. At DP-C202, CLOSE main circuit breaker UPS202.

_____|_____ 34. At DP-C202 VERIFY proper voltage on the power quality meter.

Main source:
Vab =
Vbc =
Vca =
Rotation
Bypass source:
Vab =
Vbc =
Vca =
Rotation

_____|_____ 35. At DP-C202, CLOSE the Load Bank circuit breakers.

UPS SYSTEM

_____|_____ 36. VERIFY that UPS MOD-202 is operating properly and no alarms.

_____|_____ 37. At UPS MOD-202 GUI panel read total KW Output: ___________.

TEST PROCEDURE

RFI SENSITIVITY OF MOD-202

_____|_____ 38. At UPS MOD-202, OPEN the control section door for MOD-202 and "KEY" the 2-way radio.
Observations: _________________________________________

ELECTRICAL CHARACTERISTICS OF MOD-202

_____|_____ 39. At UPS MOD202, RECORD no load input Voltage (Vab/Vbc/Vca) :

Input Voltage:
Vab =
Vbc =
Vca =

_____|_____ 40. At UPS MOD202, RECORD no load output Voltage (Vab/Vbc/Vca) :

Output Voltage:
Vab =
Vbc =
Vca =

_____|_____ 41. At SWB-M202, RECORD, with no UPS load applied:

Voltage:
Vab =
Vbc =
Vca =

Current:
Ia =
Ib =
Ic =

Power:
kW =
kVA =
kVAr =

True pf:
Lead / Lag
Apparent pf:
Lead / Lag

_____|_____ 42. Record Input Voltage at 675 kW load bank(s) (Vab/Vbc/Vca).

Voltage @ LB-1:
Vab =
Vbc =
Vca =

Voltage @ LB-2:
Vab =
Vbc =
Vca =

Voltage @ LB-3:
Vab =
Vbc =
Vca =

_____|_____ 43. Load UPS system with a Power Walk-in: Gradual rise 0% to 100% of full rated load over 15 seconds. (Dial in a total of 675 kW equally across the three load banks and close their output switches to place the evenly distributed 675kW total load on DP-C201 over a 15-second time period).

_____|_____ 44. Verify Power Factor: Unity to .95 lagging at full load, 0.3 leading or higher at no load.

_____|_____ 45. Record Output Voltage at 675 kW load (Vab/Vbc/Vca):

Output Voltage:
Vab =
Vbc =
Vca =

_____|_____ 46. Record Output Frequency at 675 kW load: ______________Hz

EFFICIENCY OF MOD-202 CALCULATION:

_____|_____ 47. 100% MODULE Load (675 kW) kW: _____________

At SWB-M201, with ~100 % UPS Load RECORD:

Voltage:
Vab =
Vbc =
Vca =

Current:
Ia =
Ib =
Ic =

Power:
kW =
kVA =
kVAr =

True pf:
Lead / Lag
Apparent pf:
Lead / Lag

_____|_____ 48. 75% MODULE Load (500 kW) kW: _____________

At SWB-M201, with ~75 % UPS Load RECORD:

Voltage:
Vab =
Vbc =
Vca =

Current:
Ia =
Ib =
Ic =

Power:
kW =
kVA =
kVAr =

True pf:
Lead / Lag
Apparent pf:
Lead / Lag

_____|_____ 49. 50% MODULE Load (338 kW) kW: _____________

At SWB-M201, with ~50 % UPS Load RECORD:

Voltage:
Vab =
Vbc =
Vca =

Current:
Ia =
Ib =
Ic =

Power:
kW =
kVA =
kVAr =

True pf:
Lead / Lag
Apparent pf:
Lead / Lag

OVERLOADING CAPABILITY OF MOD-202

_____|_____ 50. Verify UPS MOD-202 operation at 125% (±3%) load of 840 kW for 10 minutes.
Note:
Overload alarm at _____ kW, _______% loaded
Battery Discharge alarm at ______ kW, ______% loaded
Battery discharge current at 840 kW load __________Amps
Note: Other alarms, displays:_____________________________________

_____|_____ 51. Perform an infrared thermographic scan of the UPS bus system including connections.

*******************************************************

There are pages more to complete this commissioning. You should hire a commissioning engineer to create the procedures and observe the testing as well as sign off on all results. This is for your company's protection.

Good Luck!

look for a commissioning agent locally - member of the assoc of commissioning agents - pay him to third party the commissioninmg and produce the report. These guys are licensed, insured and are P E 's. The liability is off of your back by using a third party pro.

Dear Friend,

Sometimes the "lie(s) is becoming "true" once it is repeatedly advertized and discussed especially with other people with or without knowhow and knowledge about it.

What's your company was asking from you is work of the "System Integrator" specifically on SCADA.

I will ask onething.... Are you Instrumentation and Control Engineer? or Electrical Engineer? or Mechanical Engineering having knowledge with Instrumentation? If none of the above... don't dare to accept SCADA SAT.

Ask your Boss to have "help" from System Integrator, I hope your company has, as you said you are working with big company.

Since you are asking about it.... here are some points you "must" considered:

1. Have the Process Flow Schemes and P&ID

2. Have a lists of instruments with their respective I/Os. They called this list "Instrument Index"

3. Have the "Sequence of Operations" (SOO)

4. From the Contractor's Side, they must submit to you or request the following for your review and comments.

4.1 Overview and P&ID

4.2 ISS with ILD

4.3 Recommended SOO (if you don't have of the above, ask for the "system descriptions")

4.4 Tests and Commissioning Procedures per system

From the above requirements: Try to open up a little of your technical capability to digest these from the help of your "System Integrator".

WE, as "System Intergrator" having experience of electromechanical system for 30 years don'[t dare to do a thing, which we don't know.... it is a professional attitude and codes.

Eren

Site acceptance test?

• Verify that the equipment behaves in the same way as is described in the Client-approved Functional Design Specification, and obtain Client witness to that effect.

I think you have a very large job on your hands.

If this level of project is new to you , you should consider hiring a consultant.

While the tips and guidelines given by members of this forum would be helpful,

proper commissioning and resolution of all commissioning issues would be vital for longterm reliable operation of your plant , both technically and commercially.

I have seen projects where outstanding commissioning issues dragged on, and in some instances , never got resolved , to the detriment of the plant owner.

Issues such as alarms, digital communications between packages requiring interface software by different manufacturers. HMIs not configured for operator friendly useage.

You should have specified a couple of industry standards for this type commissioning and site acceptance. ANSI/NETA Acceptance Testing Standard 2009 may be a good guide.

In that way , your expectations are clear as to what the contractor must deliver.

Perform loop checks of all loops and generate a "punch list" stating clear actions required by contractor and deadline.

Contractors like tio stay away fro "critical" testing , where things can go wrong and require them to do a lot of corrections and repairs if systems get damaged during the testing . One common instance is a Emergency Shutdown, ESD.

You should do an ESD with the contractor present to ensure all emergency equipment functions properly and not wait six months from now when you have areal emergency only to find out that some backup systems did not work the way it should.

Ensure that all schematic drawings are correct. While the contractor usually maintains a " master copy " of the working drawings, you can also keep your copy.Mark up all wiring errors and ensure that they are corrected in the final documentation issue.

Ensure the contractor give you a listing of "As Built " schematics, drawings showing revision number and dates.

THANK YOU EVERY ENGINEER >>>>>I WAS SURPRIESED TO SEE ALL OF THOSE REPLIES ........ MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY MANY THANKS