UNIT CONTROL SYSTEM FACTORY ACCEPTANCE TEST PROCEDURE

14.FEB.13

REVISED

12.DEC.12

REVISED

23.SEP.11

REVISED

DAELIM INDUSTRIAL CO., LTD.

JOB NO.

090768

:
A1

- APPROVED

A2

- APPROVED AS NOTED

A3

- RETURN FOR CORRECTION

NA

- NOT APPLICABLE

SIGNED BY :

DATE

DAELIM PERMISSION TO PROCEED OR REVIEW TAKEN ON VE

PRINTS SHALL NOT RELIEVE VENDOR FROM ITS RESPONSIB
OR LIABILITIES UNDER THE PURCHASE ORDER.

PROMEL

C.I. 3047-3046

FIRENZE ITALIA

1
0

REVISED
ISSUE FOR APPROVAL

Bargellini
Bargellini

Peccianti
Peccianti

Lazzeri
Lazzeri

REV

DESCRITPTION

PREPD

CHKD

APPRD

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

REVISION DESCRIPTION:
REVISED SH.: 1, 18

DATE

APPROVED

Electronically Stored

CHECKED

Electronically Stored

REVISION DATE

14-Feb-13

23.09.11
13.05.11

EXECUTED

REVISION

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1st EXECUTION

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13-May-11

180.0057-58

THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE
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GE NuovoPignone - Electronically Approved Drawing - Checked: Chakraborty A.; Approved: Stoppa L. - Internal DT-'N'

LPG TRAIN-4 PROJECT

AT MINA AL-AHMADI REFINERY

1. INTRODUCTION....................................................................................................................4
2. WAYOFCARRYINGOUTTHEINSPECTION............................................................................5
2.1 INSTRUMENTFORCARRYINGOUTTHEFAT............................................................................5
2.2 CORRECTIVEMEASURES..........................................................................................................5
2.3 REFERENCEDOCUMENTS&DRAWINGS:................................................................................6
3. PHYSICALCONTROLOFTHESYSTEM....................................................................................7
3.1 VISUAL&DIMENSIONALTEST.................................................................................................7
3.2 INSULATIONANDDIELECTRICTEST.........................................................................................8
3.3 EARTHINGCHECK....................................................................................................................8
4. POINTTOPOINTWIRINGTEST.............................................................................................9
THERELEVANTTESTCERTIFICATEWILLBEINCLUDEDINUCSTESTREPORT...........................9
5. UCSPOWERDISTRIBUTIONCHECK.......................................................................................9
5.1 110VDCFROMDCPFEEDER1(10H)POWERSUPPLYDISTRIBUTION...................................9
5.2 110VDCFROMDCPFEEDER2(30MIN)POWERSUPPLYDISTRIBUTION...........................10
5.3 110VDCFROMDCPFEEDER3(10H)POWERSUPPLYDISTRIBUTION(FORFFSECTION
PANEL)...........................................................................................................................................10
5.4 230VAC50HZFROMMAINPOWERSUPPLYDISTRIBUTION...............................................11
5.5 110VACINTERNALLYGENERATEDPOWERSUPPLYDISTRIBUTION....................................12
5.6 24VDCINTERNALLYGENERATEDPOWERSUPPLYDISTRIBUTION......................................13
6. TRAINVIEWSERVERPANELPOWERDISTRIBUTIONCHECK................................................14
6.1 110VDCFROMDCPFEEDER4(10H)POWERSUPPLYDISTRIBUTION.................................14
6.2 230VAC50HZFROMMAINSPOWERSUPPLYDISTRIBUTION.............................................14
6.3 230VAC50HZFROMMAINPOWERSUPPLYDISTRIBUTION...............................................15
6.4 110VACINTERNALLYGENERATEDPOWERSUPPLYDISTRIBUTION...................................15
6.5 110VACINTERNALLYGENERATEDPOWERSUPPLYDISTRIBUTION...................................16
7. SIMULATORPANELDESCRIPTION.......................................................................................16
8. MARKVIESYSTEMTEST......................................................................................................17
9. MARKVIESSYSTEMTEST....................................................................................................17
10. CHECKI/OSIGNAL..............................................................................................................18
11. AUXILIARYSUBSYSTEM......................................................................................................20
11.1 FIREFIGHTINGDETECTIONSYSTEM..................................................................................20
11.2 ANTISURGECONTROLLER(CCCSERIES5).........................................................................20
11.3 BENTLYNEVADAVIBRATIONANDTEMPERATURESYSTEMTEST.....................................21
12. ESDPUSHBUTTONTEST.....................................................................................................22
13. UCSSUBSYSTEMSINTEGRATIONTEST................................................................................22
14. LCPINTEGRATIONTEST......................................................................................................22
TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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15.
16.
17.
18.
19.

SOFTWAREFUNCTIONALTEST............................................................................................23
HEATSOAKTEST.................................................................................................................23
BURNINTEST.....................................................................................................................23
CERTIFICATIONCHECK........................................................................................................24
PUNCHLISTFORMAT..........................................................................................................25

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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1.

INTRODUCTION

The scope of this procedure is to define the Unit Control System test activity that will be
carried out at Unit Control System supplier factory.
The aim of the FAT of this system is to check its conformance with the following:

Inspection and correspondence of the carpentry to the job specifications;

Inspection and correspondence of the assembly to the job specifications and to the
Supply Layout;
Electrical inspection and control;
Inspection and correspondence of the individual subsystems to the project documents;
Inspection and correspondence of the logics implemented in the FUNCTIONAL
DESCRIPTION.

A fundamental and essential prerequisite for carrying out the Factory Acceptance Test is the
performance of the internal inspection, along with the certificates, relevant checklist and
product quality plan (PQP).

ACRONIMS:
FAT = Factory Acceptance Test
UCS = Unit Control System
HMI= Human Machine Interface
DCS = Distributed Control System
MCC = Motor Control Center
PQP = Product Quality Plan
BN = Bently Nevada 3500 System
FF = Fire Fighting
I/O = Input/Output
DCP = Direct Current Panel
DACA= AC/DC Power Conversion Module
NTSW = Network Switch
LCP = Local Control Panel

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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2.

WAY OF CARRYING OUT THE INSPECTION

The test of this system can be divided into two distinct phases:

Inspection and test of the equipment (system HARDWARE);

Inspection and test of the control logics implemented (system SOFTWARE);

The tests of the Hardware precede those of the Software.

2.1

INSTRUMENT FOR CARRYING OUT THE FAT

In order to carry out the tests, instruments, with an appropriate precision, that are able to
simulate the signals of the field instruments are used where possible.
The following types of simulator are used and available:
Simulator Panel, as described at 7.
Measuring instruments (multimeter, Megaohmeter, etc.) used during the internal inspection
phases and the certification documents of the equipment by third parties are also available.

2.2 CORRECTIVE MEASURES

In case of hardware failure, the test will be temporarily suspended in order to look for the
damaged part.
According to the situation or to the urgency, the breakdown shall be detected either at
component or at card level.
Following the repair and/or the replacement, the test on the relevant subsystem shall start
again from the beginning until its positive conclusion.
In case of software problems, the test will be temporarily suspended, if the severity of error
detected is high, to carry out investigations regarding the error, its location and finally its
removal. For software problems that have low severity, the problem is registered and will
scheduled an investigation to solve it subsequently.
The failed test, after investigation and necessary correction, will be repeated.

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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2.3 REFERENCE DOCUMENTS & DRAWINGS:

DOCUMENT DESCRIPTION

NP Code

Customer Code

UCP supply and test general specification

ITN 04240/A

N.A.

Control System and Power Supply Schematic

SOM5464708 /3

U.C.S. Construction Drawing & Equipment List

SOM6629532 /3

U.C.S. Wiring Diagram

SOM6629520 /3

CCC Trainview Server Panel Wiring Diagram

SOM6751158 /3

U.C.S. Input / Output List

SOM6628418 /3

Process and Instrument Diagrams (P&ID)

SOM5081820 /1

Control System Functional Description

SOM6629548 /4

U.C.S. Modbus List

SOM6629523 /4

U.C.S. Cause & Effects

SOM6629813 /3

Quality Control Plan (Q.C.P.)

SOM6750807/4

VP-18-101-C-231-001A/B-SK006
VP-18-101-C-231-001A/B-SK0017
VP-18-101-C-231-001A/B-SK002
VP-18-101-C-231-001A/B-SK004
VP-18-101-C-231-010A/B-SK001
VP-18-101-C-231-001A/B-SK003
VP-18-101-C-231-001A/B-SK005
VP-18-101-C-231-001A/B-SK010
VP-18-101-C-231-001A/B-SK100

Generally this test will be carried out according to N.P. standard document ITN 04240/A.

On positive result, acceptance signs will be placed on the relevant PQP (Product Quality
Plan) test report prepared by panel manufacturer. This document is a sequence of check
lists according to the Factory Acceptance Test Procedure (this document).

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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3. PHYSICAL CONTROL OF THE SYSTEM

Visual and dimensional control of the construction characteristics of the assembly is carried
out, which must conform with the project documentation (see reference documents) and to the
applicable internal regulations (see reference documents).

3.1

VISUAL & DIMENSIONAL TEST

Panel and associated equipments, shall be visually checked to verify that the construction was
made according to the following drawings:
- U.C.S. Construction Drawing & Equipment List (see 2.3).
The following checks in particular have to be carried out:

Checking the correct manufacture and the conformity of the finishing and the
dimensions of the parts which make up the system to the specifications;
Checking that the labels present on the system structures and on the connecting
cables allow the item to be identified easily;
Checking that the front panel labels and the warning labels on each door (in English
language) are present;
Checking that all installed components correspond in types and quantities to the
referenced drawings;
Checking that installation of components and wiring correspond to requirements.

This activity has the aim of checking that the construction and the various mechanical
assemblies have been carried out correctly. The following is also checked:

The absence of evident assembly and cabling errors

The painting is conformity to painting specification

This phase is considered to be passed unless there are deficiencies noted in the abovementioned points.

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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3.2

INSULATION AND DIELECTRIC TEST

This test will be carried out in accordance with the N.P: standard document ITN 04240/A.
The aim of the test is to verify the insulation of all the active parts that have no ground
reference and to measure the insulation resistance. No dielectric strength test is repeated
because it is already carried out in the internal inspection phases on the applicable parts.
Moreover, if it is repeated more than once it can have a damaging effect on the system.
Insulation tests are carried out on the applicable parts that havent ground reference. To carry
out the above-mentioned test, the panel must not be connected to power supply and all the
subsystems must be disconnected. The relevant test certificate will be included in each UCS
test report.
Dielectric Test, in order to verify the withstand strength of power supply circuits, shall be carried
out for 60 sec. and with the following voltages:
- circuits with operating voltage Ui 12V : 280 VRMS 50Hz
- circuits with operating voltage 12V Ui 60V : 500 VRMS 50Hz
- circuits with operating voltage Ui > 60V : 2xUi + 1000 VRMS (min. 1500 VRMS) 50Hz

Measuring is carried out by using a MegaOhm measuring instrument set to 500Vdc.

This phase is considered to be passed if the insulation resistance is not less than 10Mohm for
one minute.

3.3 EARTHING CHECK

1.

This test shall be carried out using a Multimeter or Ohm-meter to confirm the continuity of the
following:
a. P.E. Protection earth
To verify continuity between the earth and all part of the cabinet including instrument
chassis.
b. F.E. Functional Earth
To verify continuity between the instrument earth bar connection and instrument cable
screen terminals.
c. I.S.E. Intrinsically Safe Earth
To verify continuity of the I.S.E. earth bar system connection between each other.

2.

Also using a Multimeter or Ohm-meter the P.E., F.E. and I.S.E. bars are to be confirmed
100% isolated from each other. F.E. and I.S.E. earths must be isolated from the cabinet.

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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4. POINT TO POINT WIRING TEST

With panel powered off, just perform a continuity check with Ohm-meter.
This test will be carried out following the drawings:
- U.C.S. Wiring Diagram (see 2.3)
The relevant test certificate will be included in UCS test report

NOTE: All tests present in this document have been performed internally by supplier at 100%,
the test to be witnessed by Customer for 100%.
5. UCS POWER DISTRIBUTION CHECK.
5.1 110VDC FROM DCP FEEDER 1 (10H) - POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 110Vdc.
Control that all conductors and wire-ways are safely and properly fixed in the control panel.
POWER ON test for sockets.
Verify that all devices are functioning properly.
Functionality of each single DC load shall be checked.
EQUIPMENT
MARK VIe
MARK VIeS
DC/AC Inverter 110Vdc/110Vac G#1A
DC/DC Module 110Vdc/24Vdc G#2B
Bently Nevada Temperature Monitor (Line B)

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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5.2 110VDC FROM DCP FEEDER 2 (30 MIN) - POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 110Vdc.
Control that all conductors and wireways are safely and properly fixed in the control panel.
Functionality of each single DC load shall be checked.

EQUIPMENT
DC/AC Inverter 110Vdc/110Vac G#1B
DC/DC Module 110Vdc/24Vdc G#3B
Bently Nevada Vibration Monitor (Line B)

5.3 110VDC FROM DCP FEEDER 3 (10H) - POWER SUPPLY DISTRIBUTION (FOR FF
SECTION PANEL)

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 110Vdc.
Control that all conductors and wireways are safely and properly fixed in the control panel.
Verify that all devices are functioning properly.
Functionality of each single DC load shall be checked.

EQUIPMENT
DC/DC Module 110Vdc/24Vdc G#4A (FF SECTION)

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

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5.4 230VAC-50HZ FROM MAIN - POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 230Vac.
Control that all conductors and wireways are safely and properly fixed in the control panel.
POWER ON test for lights, heaters, and sockets.
Verify that all devices are functioning properly.
Functionality of each single AC load shall be checked.
EQUIPMENT
MARK VIe DACA-1
MARK VIeS DACA-2
Bently Nevada Vibration Monitor (Line A)
Bently Nevada Temperature Monitor (Line A)
AC/DC Module 230Vac/24Vdc G#2A
AC/DC Module 230Vac/24Vdc G#3A
Service Socket XS1
Internal Lights EL1EL8
Ventilation Fans V1V8
Anticondensation Heaters EH1EH8
AC/DC Module 230Vac/24Vdc G#4B (FF SECTION)

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

SOM6629519

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5.5 110VAC INTERNALLY GENERATED POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 110VAC.
Control that all conductors and wireways are safely and properly fixed in the control panel.
Verify that all devices are functioning properly.
Functionality of each single AC load shall be checked.

EQUIPMENT (from G#1A & G#1B)

CCC Load Sharing Controller
CCC Master Controller
HMI Printer
Ethernet Switch #1
Ethernet Switch #2
Bently Nevada Switch

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

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5.6 24VDC INTERNALLY GENERATED POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 24VDC.
Control that all conductors and wireways are safely and properly fixed in the control panel.
Verify that all devices are functioning properly.
Functionality of each single DC load shall be checked.

EQUIPMENT (from G#2A & G#2B)

Solenoid Valves
Safety Relays
Mark VIe & Mark VIeS Wetting Voltage

EQUIPMENT (from G#3A & G#3B)

Communication Gateway #1
Communication Gateway #2
Hart Multiplexer
Galvanic Isolators
HMI Panel PC

EQUIPMENT (from G#4A & G#4B)

FF Monitor
FF Field Instruments
Solenoid Valves

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

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6. TRAIN VIEW SERVER PANEL POWER DISTRIBUTION CHECK.

6.1

110VDC FROM DCP FEEDER 4 (10H) - POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 110Vdc.
Control that all conductors and wireways are safely and properly fixed in the control panel.
Functionality of each single DC load shall be checked
EQUIPMENT
DC/AC Inverter 110Vdc/110Vac G#2B

6.2

230VAC-50HZ FROM MAINS - POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 230Vac.
Control that all conductors and wireways are safely and properly fixed in the control panel.
POWER ON test for lights, heaters, and sockets.
Verify that all devices are functioning properly.
Functionality of each single AC load shall be checked.
EQUIPMENT
AC/AC Module 230Vac/110Vac G#2A

TITLE:

DOCUMENT CODE

UCS FACTORY ACCEPTANCE TEST PROCEDURE

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6.3

230VAC-50HZ FROM MAIN - POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 230Vac.
Control that all conductors and wireways are safely and properly fixed in the control panel.
POWER ON test for lights, heaters, and sockets.
Verify that all devices are functioning properly.
Functionality of each single AC load shall be checked.
EQUIPMENT
Service Socket XS-CCC
Internal Light EL1
Ventilation Fan V1
Anticondensation Heater EH1

6.4

110VAC INTERNALLY GENERATED POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 110VAC.
Control that all conductors and wireways are safely and properly fixed in the control panel.
Verify that all devices are functioning properly.
Functionality of each single AC load shall be checked.

EQUIPMENT (from G#1A & G#1B)

CCC KVM Switch line B
CCC Trainview Server A line B
CCC Trainview Server B line B
CCC TFT Monitor line B

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6.5 110VAC INTERNALLY GENERATED POWER SUPPLY DISTRIBUTION

With reference to the pages of Wiring Diagram power supply pages only (see 2.3) verify the
following points:
Correct cross section and type of cables.
Correct size, type and rating of fuses and breakers.
Correct connection of power distribution with all devices supplied at 110VAC.
Control that all conductors and wireways are safely and properly fixed in the control panel.
Verify that all devices are functioning properly.
Functionality of each single AC load shall be checked.
EQUIPMENT (from G#1A & G#1B)
CCC KVM Switch line A
CCC Trainview Server A line A
CCC Trainview Server B line A
CCC TFT Monitor line A
7. SIMULATOR PANEL DESCRIPTION
Dynamic simulation of gas turbine will not be possible during FAT.
A static simulator panel will be used for the functional test; this will be connected directly to the
UCS field input/outputs terminal strips.
The static simulator panel is provided with:
on/off selectors for simulation of digital inputs from field;
LEDs to visualize the state of digital outputs from UCS.
multiturn potentiometers 100200 ohm to simulate RTD;
current modulators 2,525 mA for 4 20 mA input signals.
mA meter for 4-20 mA output signals
Separate simulator:
Frequency generator for speed and vibration simulation.
Thermocouple single channel simulator
NOTES:
1. It is not possible to simulate the following signals during the FAT:
LVDTs
Servovalves
UV flame detectors
These are standard gas turbine systems pre-engineered. These instruments will also be
exercised during string test.

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8. MARK VIe SYSTEM TEST

The Mark VIe is the main item in this control system..
The Supplier shall verify and demonstrate that all components/ items for the completion of
Mark VIe system have been successfully installed and functioning.
The procedure to verify the system functionality:
1.
2.
3.
4.
5.
6.
7.
8.

Verify the software configuration, the power supply, tagging and labeling.
Connect the HMI computer to the Mark VIe Ethernet switch via Ethernet cable.
Start the execution of the development software for Mark VIe.
Download the application program from HMI to the Mark VIe. Verify that download has
been performed with success.
Ensure that HMI Monitor and graphics are functioning properly.
Observe for any error message that might come out on the monitor.
Override diagnostic alarms due to absence of the Gas Turbine.
Verify if the Mark VIe functions works properly or not.

Any non-conforming items / problem found shall be indicated in the proper area of the UCS
Wiring Diagram by drawing a cloud around it and recorded in the punch list.
9. MARK VIeS SYSTEM TEST
The Mark VIeS is the main item in this control system..
The Supplier shall verify and demonstrate that all components/ items for the completion of
Mark VIeS system have been successfully installed and functioning.
The procedure to verify the system functionality:
1. Verify the software configuration, the power supply, tagging and labeling.
2. Connect the HMI computer to the Mark VIeS Ethernet switch via Ethernet cable.
3. Start the execution of the development software for Mark VIeS.
4. Download the application program from HMI to the Mark VIeS. Verify that download has
been performed with success.
5. Ensure that HMI Monitor and graphics are functioning properly.
6. Observe for any error message that might come out on the monitor.
7. Override diagnostic alarms due to absence of the Gas Turbine.
8. Verify if the Mark VIeS functions works properly or not
Any non-conforming items / problem found shall be indicated in the proper area of the UCS
Wiring Diagram by drawing a cloud around it and recorded in the punch list.

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10.

CHECK I/O SIGNAL

All tests present in this document have been performed internally by supplier at 100%, The
test to be witnessed by Customer for 100%.
1. All input/ output signals corresponding to each tag number inside I/O List shall be
tested.
For each I/O signal, verify the unit and range set inside Mark VIe, Mark VIeS and FF
System against the unit and range specified for the signal in the Field Instrument List
document (ref. to para 2.3).
2. For every I/O signal having alarm function, check the following:
a. Alarm status inside HMI graphic corresponding to the signal.
b. Verify consistency between alarm settings inside Mark VIe, Mark VIeS and FF
System against the alarm setting specified in the Field Instrument List document
(ref. to para 2.3).
c. Verify the consistency of tag number and service description in printer output for
the signal (if any).
With reference to the UCS I/O List and UCS Wiring Diagram, verify the correct acquisition (with
the appropriate simulator, see point 2.1) for the signals of following common types.
For each I/O signal, a base range set inside Mark VIe, Mark VIeS and FF system is used.
Observe and verify consistency of tag number for each I/O signal inside software environment
and inside Mark VIe, Mark VIeS graphic.
Confirm the accuracy of the analog input / output signal is within acceptable limit of (0.1-0.3) %
(Deviation with respect to base range).
<3>
Verify the 2 out of 3 logic of the redundant instruments.

Digital input Test Procedure

> To be checked using jumper or switch on the simulator panel.
> Test is passed when the digital status displayed is coherent with simulator status.

420 mA analog input Test Procedure

> To be checked using potentiometer or resistance on the simulator panel.
> Test is passed when the value in engineering unit is correctly displayed on all destination
points.

Thermocouple input Test Procedure

> To be checked using millivolts generator
> Test is passed when the value in engineering unit in correctly displayed on all destination
points.

Frequency input Test Procedure

> To be checked using function generator
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> Test is passed when the value in engineering unit in correctly displayed on all destination
points.

Digital output Test Procedure

> To be checked using lamp or relay or tester
> Test is passed when the lamp or relay status or tester is coherent with command issue.

Analog output Test Procedure

> To be checked using a ammeter
> Test is passed when the ammeter value is coherent with command issue.

RTD Input Test Procedure

> To be checked using a potentiometer or resistance on the simulator panel
> Test is passed when the value in engineering unit is correctly displayed on all destination
points.

Vibration Monitoring Signals Test Procedure

> To be checked using a function generator
> Test is passed when the value in engineering unit is correctly displayed on all destination
points.

LVDT Signals Test Procedure

> It is not possible to simulate this instrument during the FAT. These are standard gas
turbine systems pre-engineered
Servo-valve Command Test Procedure
> It is not possible to simulate this instrument during the FAT. These are standard gas
turbine systems pre-engineered
Flame Detector Signals Test Procedure
> It is not possible to simulate this instrument during the FAT. These are standard gas
turbine systems pre-engineered

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11.

AUXILIARY SUBSYSTEM

11.1

FIRE FIGHTING DETECTION SYSTEM

The FF subsystem test provides functional testing of the cards making the system.
This test will be carried out by subsystem specialist and will be followed from UCS
packager for interfacing of this subsystem with others UCS subsystem.
Control:
Correct input signal acquisition
Correct output signal management
Correct operation and signalling in case of faults
Correct signals visualization on HMI

11.2

ANTISURGE CONTROLLER (CCC SERIES 5)

The CCC subsystem test provides functional testing of the cards making the system.
This test will be carried out by subsystem specialist and will be followed from UCS
packager for interfacing of this subsystem with others UCS subsystem.

Control:
Correct input signal acquisition
Correct output signal management
Correct operation and signalling in case of faults
Correct signals visualization on HMI

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11.3

BENTLY NEVADA VIBRATION AND TEMPERATURE SYSTEM TEST

The Bently Nevada system test provides for the functional test of the cards making up the
system.
The procedure to verify the system functionality:
1
2
3
4
5

6
7

Verify the hardware configuration, the power supply, tagging and labeling.
Configuration of the individual cards (acquisition method and scale and alarm and trip
threshold level)
Diagnostics at power-on.
Communication Mark VIe/Mark VIeS <-> Bently Nevada 3500
Acquisition of axial displacement and radial vibration signals, by means of the whole
terminal/interconnecting cable/card connection, of 0% - 50% - 100% of the field and of
some values included in the range; control of axial displacement proximitors open
circuit management alarms; control of the alarm and trip thresholds; control of the card
status summary signal.
Verify the acquisition of the monitor rack on local HMI (Bargraph, Trend) screen.
Observe for any error message that might come out on the display.

Any non-conforming items / problem found shall be indicated in the proper area of the UCS
Wiring Diagram by drawing a cloud around it and recorded in the punch list.

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12.

ESD PUSH BUTTON TEST

Confirm functioning of the front panel emergency shutdown push button.

13.

UCS SUBSYSTEMS INTEGRATION TEST

This test verifies the correct connection between subsystems. The input signals are simulated,
with the aid of appropriate simulators, on origin subsystem and the outputs checked on target
subsystem.

Control:
Correct signal updating on target subsystem.:
FF <-> Mark VIe (Hardware)
Bently Nevada <-> Mark Vie/Mark VIeS (Hardware)
CCC <-> Mark VIe/Mark VIeS (Hardware)
It shall be demonstrated that the systems communicates each other.

14. LCP INTEGRATION TEST

This test shall be conducted at the end of the FAT connecting the UCS and the Local Control
Panel on the network as per control system schematic.
This test verifies also the following communication links:
Ethernet Switch 1A LCP
Ethernet Switch 1B LCP
CCC Trainview Server Panel LCP
The test is carried out only with the purpose to check the correct configuration of the systems
and the correct communication link.

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15. SOFTWARE FUNCTIONAL TEST

The software source files and licenses are installed in the HMI.
In accordance with document Functional Description and Software Check List the following
main sequences will be checked:
TURBINE AUXILIARES SEQUENCES
START-UP SEQUENCE (UP TO COMPLETE SEQUENCE)
NORMAL STOP SEQUENCE
EMERGENCY SHUT-DOWN SEQUENCE
LOAD AUXILIARES SEQUENCES
At the same time, it will be checked the graphic pages in the HMI.
The results shall be recorded in the Software Check List.

16.

HEAT SOAK TEST

Following test will be done by panel supplier internally, test report will be checked.
For this test the UCS is placed in a climatic room. UCS Internal/external temperatures are
measured and recorded by an external device. A selection of Boolean and 4-20 mA I/O' s is
chosen and the associated status is continuously recorded by means of trend displays.
The temperature of the climatic room is raised up to 45 C; heaters are then turned off until
ambient temperature is detected, when they are turned on again .
Test duration is 48 Hours.
During this period no any hardware failure shall be observed, and the status of the selected
I/O shall be verified to be not changed.

17.

BURN IN TEST

Following test will be done by panel supplier internally, test report will be checked.
This test consists in a continuous power up of the UCS, at ambient temperature.
Test duration is 120 Hours.
During this period hardware failure shall not be observed.

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18.

CERTIFICATION CHECK

Applicable conformity declaration/certificates (CE / UL/ CSA etc.) will be verified as per project
requirements.
GE-NP shall provide:

Inspection Certificate / Report according to EN 10204

Certificate of Compliance with the Order according to EN 10204
Calibration check test measurement test
CE Conformity Certification
List of software used and relevant licenses (LOG BOOK)

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19. PUNCH LIST FORMAT

CLIENTE:

g GE Oil & Gas

Nuovo Pignone

N. ORDINE .

CUSTOMER

ORDER No.

COMMESSA N.P.
N.P. JOB

PROCEDURA DI TEST
TEST PROCEDURE

Pag.

Tipo di pannello:
Type of panel:
No. di serie:
Serial No.:

Q.t
Q.ty

PUNCH LIST
Description

Collaudatore/
Operator:

Data/
Date:

Approvato/
Approved:

To be solved within

Data/Date:

Checked

Approvazione Cliente/
Customerss

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