Emerson Doc. No.

XXXXX-A-32, Rev-0
QAP, FAT & ITP Documents
Date 07.08.2023

TABLE OF CONTENT

ITEM NO TITLEs Emerson Doc. No.

1 Quality Assurance Plan for Hardware and software XXXXX-A-31, Rev-0
2 Factory Acceptance Test Procedure -Hardware and software XXXXX-A-06 REV-00
3 ITP Documents XXXXX/IR-01

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project
Consultant -
Project Name BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
 Doc No. XXXXX-A-31, Rev-0
Emerson Automation Solutions Intelligent Platforms Pvt. Ltd.
Velankani Tech Park, Ground Floor, Building No.8,
QUALITY ASSURANCE PLAN for Hardware 07-Aug-23
Date
No.43, Electronics City, Bangalore-560100, Karnataka, India and software Page No Refer Below

Type of Quantum Reference Format Agency

SN Component Characteristics Acceptence Crieteria Remarks
Check of check Document of Record P R/W
INCOMING MATERIALS
1 Physical Veification Visual No physical damages to the components Rejected Products are
1. PO on Vendor identified with
1 PLC Modules 2 Model, Part No. & qty. Physical 100% Model no. make & qty. as per PO NA P1 NA
2. Invoice of Vendor "Rejected" sticker on
3 Accessories Visual All necessary accessories supplied product
1 Dimensions Physical Dimensions as per drawings
Painting free from scales, unevenness, peelings,
2 Painting Visual
Enclosures, Control 1. PO on Vendor correct shade
desks, PC 3 Cutouts Visual 2. Test Report of vendor Cutouts as per the drawings
QA/FORM/
2 Consoles, Table 4 Lifting Hooks Visual 100% 3. Drawings Lifting hooks as per drawings P1 NA
IR-ENCL
tops and Fabricated 4. Incoming Inspection
items 5 Locking Arrangements Physical Procedure Locking arrangement as per drawings
6 Certificate Visual Protection Class Certificates if applicable
7 Accessories Visual All necessary accessories supplied
Convertors, 1 Physical Verification Visual 1. PO on vendor No physical damage to the Product
As per
Transducers, 2 Dimensions Physical 2. Product Literature Dimensions as per specification
Sampling Seal & Sign
3 Isolators/barriers, 3. Vendor TC/Cal. Report P1 NA
3 Accessories Visual Inspection All necessary accessories supplied on PO
Ethernet Switches, 4. Incoming Inspection
Plan
SPD, FFU, Sensors 4 Inspection Visual Procedure TC/Calibration report of the vendor as applicable
In case of any
1 Physical Veification Visual No physical damage to the Product
deviations the same is
2 Dimensions Physical As per 1. PO on vendor Dimensions should be as per Drawing informed to vendor to
Relays,
Sampling 2. Product Literature Seal & Sign
4 Relay Boards, 3 Accessories Visual All necessary accessories supplied P1 NA rectify the defect
Inspection 3. Incoming Inspection on PO
Interface Boards,
4 Physical Verification Visual Plan Procedure Product should be as per PO
5 Inspection Visual Vendor TC
1 Physical Veification Visual 1. PO on vendor No physical damage to the Product
Power Supplies, 2 Accessories Visual 2. Product Literature All necessary accessories supplied Seal & Sign
5 UPS, Transformers, 100% 3. Vendor TC P1 NA
3 Input/Out put Rating Visual Input & Output ratings as per rating on PO
Meters 4. Incoming Inspection
4 Inspection Visual Procedure Vendor TC
As per
1. PO on vendor
Cables and Sampling Seal & Sign
6 1 Physical Verification Visual 2. Incoming Inspection Product as per PO P1 NA
Accssories Inspection on PO
Procedure
Plan
1. PO on vendor
GPS Master clock Seal & Sign
7 1 Physical Verification Visual 100% 2. Incoming Inspection Product should be as per P.O. P1 NA
System on PO
Procedure

Page 1 of 4
 Doc No. XXXXX-A-31, Rev-0
Emerson Automation Solutions Intelligent Platforms Pvt. Ltd.
Velankani Tech Park, Ground Floor, Building No.8,
QUALITY ASSURANCE PLAN for Hardware 07-Aug-23
Date
No.43, Electronics City, Bangalore-560100, Karnataka, India and software Page No Refer Below

Type of Quantum Reference Format Agency

SN Component Characteristics Acceptence Crieteria Remarks
Check of check Document of Record P R/W
INCOMING MATERIALS
1 Physical Verification Visual 1. PO on vendor No physical damage to the Product
Computers/Laptops
2. Installation Report Seal & Sign
8 & Software, Printers, 2 Accessories Visual 100% All necessary accessories supplied P1 NA
3. Incoming Inspection on PO
Monitors, LVS
3 Installation for Computers Functional Procedure Installation report from the vendor
MCB, PB, IL
As per
Annunciators, TB, 1. PO on Vendor
Sampling Seal & Sign
9 Fans, Switches, 1 Physical Verification Physical 2. Incoming Inspection All Materials to be as per PO P1 NA
Inspection on PO
Hooters, Diode Procedure
Plan
Modules In case of defect / not
1 BOM Check Visual All Materials to be as per BOM meeting requirement,
2 Dimensions Physical Dimensions should be as per drawing will be returned to
1. BOM
Painting should be free from scales, unevenness, vendor
3 Painting Visual 2. PO on vendor P1/
Assembled & Pre- peelings, correct shade QA/FORM/
10 100% 3. Vendor Test report P2/ NA
wired panels IR-ENCL
4 Physical Verification Visual 4. Incoming Inspection No physical damage to the Product P3
Procedure
5 Accessories Visual All necessary accessories supplied
6 Cutouts Visual Cutouts should as per the drawings
1. PO on Vendor
Seal & Sign
11 Furnitures 1 Physical Verification Physical 100% 2. Incoming Inspection All Material should be as per PO P1 NA
on PO
Procedure

Page 2 of 4
 Doc No. XXXXX-A-31, Rev-0
Emerson Automation Solutions Intelligent Platforms Pvt. Ltd.
Velankani Tech Park, Ground Floor, Building No.8,
QUALITY ASSURANCE PLAN for Hardware 07-Aug-23
Date
No.43, Electronics City, Bangalore-560100, Karnataka, India and software Page No Refer Below

Type of Quantum Reference Format Agency

SN Component Characteristics Acceptence Crieteria Remarks
Check of check Document of Record P R/W
IN-PROCESS
Assembled & pre- 1. Vendor Test report In case of any
QA/FORM/
1 wired panels/ 1 Functionally Functional 100% 2. BOM Functionally working
IR-ENCL malfunction, vendor
systems 3. Work Intructions will be informed to
Vendor sourced BOM All Materials to be as per BOM & TC wherever rectify the defect
2 1 Physical Verification Physical 100% NA
Items applicable
1 Mechanical Completion Visual System should be complete as per requirement
2 Mounting of Equipments Visual Mounting of equipments as per drawing
3 Labeling of Equipments Visual 1. GA drawings Labelling are correct & complete
4 Fixing of Cable Ducts Physical 2. BOM Cable troughs fixed firmly
3. Work Insturctions
5 Checking of H/Ws used Visual Use of correct H/W as per drawing
Comments &
6 Fixing of busbars Physical Busbars should be fixed firmly Observations are
QA/FORM/
100% recorded in the
7 BOM Check Physical Use of Materials as per BOM IR-MECH
Process/Inspection
Point To Point Wiring
8
Check
Visual Wiring and Continuity between the ends of wires P1/ R1/ Tag
9 Checking of Wire sizes Visual Wire size as per requirement P2/ R2/ Deviations in Layout
1, Wiring Diagrams P3 R3 are recorded and
10 Checking of Wire colours Visual Wire Colour as per requirement corresponding
3 Internal Inspection drawings revised
11 Checking of ferrules Visual All Ferruling as per requirements
Deviations due to use
12 Checking of Crimping Physical No Loose crimps and Correct size of lugs used of wrong equipment
1. Schematic Diagrams All equipments are powered ON are recorded &
Power Up Tests & Power QA/FORM/
13 Functional 100% 2. BOM All indications as per the requirements rectified
Distribution Test IR-PD Deviations in
3. Inspection Procedure Voltages as per distribution diagram
Input/Output Tests before 1. Schematic Diagrams All Input & Outputs are energised as per the QA/FORM/ Ferruling/ crimping/
14 Functional 100%
Burn-in Test 2. Inspection Procedure Simulation IR-IO termination are
Materials are kept under continuous energised QA/FORM/ recorded & rectified
15 Burn-in Test Functional 100% Inspection Procedure
condition for 48 hours . IR-BIT
Input/Output Tests after 1. Schematic Diagrams All Input & Outputs are energised as per the QA/FORM/
16 Functional 100%
Burn-in Test 2. Inspection Procedure Simulation IR-IO
Configuration & Software Control Writeup/BLD/as System is working as per test logic / Customer
17 Functional 100%
Test per customer inputs requirements QA/FORM/
P&ID/SLD/Flow Screen layout as per Ref Documents and Tags are IR-CFGSW
18 HMI/SCADA Screens Visual 100%
Diagram//Cust inputs configured as per system requirements

Page 3 of 4
 Doc No. XXXXX-A-31, Rev-0
Emerson Automation Solutions Intelligent Platforms Pvt. Ltd.
Velankani Tech Park, Ground Floor, Building No.8,
QUALITY ASSURANCE PLAN for Hardware 07-Aug-23
Date
No.43, Electronics City, Bangalore-560100, Karnataka, India and software Page No Refer Below

Type of Quantum Reference Format Agency

SN Component Characteristics Acceptence Crieteria Remarks
Check of check Document of Record P R/W
FACTORY ACCEPTANCE TEST (FAT)
1 Mechanical Completion Visual System should be complete as per requirement Comments &
2 Mounting of Equipments Visual Mounting of equipments as per drawing Observations are
recorded in FAT
3 Labeling of Equipments Visual 1. GA drawings Labelling are correct & complete
Report
4 Fixing of Cable Ducts Physical 100% 2. BOM Cable troughs fixed firmly Deviations in Layout
5 are recorded &
Checking of H/Ws used Visual Use of correct H/W as per drawing
corresponding
6 Fixing of busbars Physical Busbars should be fixed firmly drawings revised
7 BOM Check Physical Use of Materials as per BOM Deviations due to use
of wrong equipment
Point To Point Wiring
8 Visual Wiring and Continuity between the ends of wires are recorded &
Check FAT Report/ W1
P1/ rectified
9 Checking of Wire sizes Visual Wire size as per requirement Customer /W
1 Customer Inspection P2/ Deviations in
100% 1, Wiring Diagrams Formats 2/
10 Checking of Wire colours Visual Wire Colour as per requirement P3 Ferruling/ crimping/
if any W3
termination are
11 Checking of ferrules Visual All Ferruling as per requirements
recorded & rectified
12 Checking of Crimping Physical No Loose crimps and Correct size of lugs used System Accepted
1. Schematic Diagrams All equipments are powered ON based on working of
Power Up Tests & Power
13 Functional 100% 2. BOM All indications as per the requirements test logic / logic as per
Distribution Test
3. Inspection Procedure Voltages as per distribution diagram Customer
1. Schematic Diagrams All Input & Outputs are energised as per the requirements
14 Input/Output Test Functional 100%
2. Inspection Procedure Simulation Screens accepted
Configuration & Software Control Writeup/ System is working as per test logic / Customer upon comparision of
15 Functional 100%
Test BLD/Customer inputs requirements customer
P&ID/SLD/Flow Screen layout as per Ref Documents and Tags are requirements & actual.
16 HMI/SCADA Screens Visual 100%
Diagram//Cust inputs configured as per system requirements
P = Performer R = Reviewer W = Witness
1 Emerson Automation Solutions Intelligent Platforms Pvt. Ltd., 1 Customer 1 Customer
2 Sub-contractor of Emerson Automation Solutions Intelligent Platforms Pvt. Ltd., 2 Consultant 2 Consultant
3 Vendor of Emerson Automation Solutions Intelligent Platforms Pvt. Ltd., 3 Inspection Agency 3 Inspection Agency
Prepared by Approved by
Projects Quality

Page 4 of 4
 Emerson Doc. No. XXXXX-A-06 REV-00
PLC FAT PROCEDURE
Client Doc. No. ---

Factory Acceptance Test Procedure -Hardware and software

Project BMS SCADA for Elevated Station

Document Title Factory Acceptance Test Procedure

Revision Date 07.08.2023

Revision 0
Originator Revanna
Checked By Revanna
Approved for issue by Ravi Kumar Ronanki

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 1 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

Reference Documents:
Rev. Category of
S.NO Document Description Doc No.
No Approval
1 PLC SYSTEM CONFIGURATION DRAWING
2 PLC GA & POWER DISTRIBUTION DRAWING
3 PLC I/O MODULE WIRING DRAWING
4 PLC BILL OF MATERIALS
5 PLC DATA SHEET
6 QUALITY PLAN

Revision History:
Revision Revision Date Author Change Description
0 07.08.2023 Revanna Initial submission

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 2 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

Contents
1. Introduction ......................................................................................................................... 4
2. Nominated Persons ............................................................................................................ 6
3. Review of Tools .................................................................................................................. 7
4. Bill of Materials Check ........................................................................................................ 7
5. Cabinet / Console Visual Check ......................................................................................... 8
6. Panel Power Distribution Check ......................................................................................... 8
7. Panel Earthing Check ......................................................................................................... 9
8. I/O Operation Check ......................................................................................................... 10
9. Redundancy Check........................................................................................................... 11
10. HMI Graphics & Software Functionality Check ................................................................. 14
11. Third Party Connectivity Check ........................................................................................ 15
12. Power Fail and Restart Check .......................................................................................... 16
13. PLC System Boot up procedure check ............................................................................. 17

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 3 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

1. Introduction

Purpose
The purpose of this document is to set forth the objectives, methodology, and documentation verification and test
activities necessary to complete the Factory Acceptance Test for SCADA system for Project.

Objectives
The objectives of the Factory Acceptance Test are to establish that the control system can be expected to be
commissioned at site within a reasonable time and that it will perform as defined in the contract specification and
approved documents. The Complete system will be tested during the FAT. Internal FAT will be conducted as per
approved FAT Procedure.

FAT Phase and Schedule

Daily schedule will be between 0930 hours to 1730 hours with last one hour reserved for daily review meeting.

Location: Bangalore - India.

Address: Emerson Automation Solutions Intelligent Platforms
Velankani Tech Park
Bldg 8, Ground Floor, 43
Electronics City Phase-II
Hosur Road, Bangalore-560100
Phone: 080-42515300-04
Fax: 080-42515305-06

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 4 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

Abbreviations
General abbreviations and technical words used for protocol development and execution and data sheet collection
include the following:
Term Definition
AC Alternating Current
AI Analog Input
AO Analog Output
BOM Bill of Materials
CPU Central Processing Unit
DC Direct Current
DI Discrete Input
DO Discrete Output
EWS Engineering Workstation
OWS Operator Workstation
FAT Factory Acceptance Test
FB Function Block
Hz Hertz (Frequency)
I/O Inputs / Outputs
LAN Local Area Network
mA milli-amperes
N/A Not Applicable
N/AV Not Available
N/S Not Specified
OI Operator Interface
P & ID Piping and Instrumentation Diagram
PID Proportional, Integral, Derivative Control Algorithm
PRN Printer
PSU Power Supply Unit
PV Process Value
RAM Random Access Memory
SAT Site Acceptance Test
SFC Sequential Function Chart
SP Set point
TP Twisted Pair
UPS Uninterruptible Power Supply
V Volts
VAC Voltage – Alternating Current
VDC Voltage – Direct Current

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 5 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

2. Nominated Persons

Name Name of the Organisation Signature Date

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 6 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

3. Review of Tools

Purpose:
To verify that the measuring equipment used for testing or inspection are calibrated:
Multimeter, Analog Input Simulator

Procedures:
Check that all the tools used for testing and intended to be used for inspection have a valid calibration report.

Acceptance Criteria:
The calibration certificate of each tool is present, and the calibration due date is later than the first day of inspection.

Observation:
Acceptance Criteria Met: ❑ Yes ❑ No

4. Bill of Materials Check

Purpose:

The purpose of this verification is to ensure that the all the item quantity and makes listed in the bill of materials are as
per the BOM document.

Procedure:
Verify that each item listed in the provided “Bill of Material” are available.

Acceptance Criteria:
All items included in the “Bill of Material” document must be available.

Observation:
Acceptance Criteria Met: ❑ Yes ❑ No

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 7 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

5. Cabinet / Console Visual Check

Purpose:
The purpose of this verification is to ensure that the appearance of the cabinets/consoles are as per approved GA/IGA
Diagrams and specifications.

Procedure:
i. Verify Cabinet/Console dimensions.
ii. Verify appearance of Cabinets/Consoles per approved GA/IGA.
iii. Verify installed items as per GA/IGA.
iv. Verify the wire size and colours as per the drawings.

Acceptance Criteria:
i. All the panel/console dimensions are as per the drawings.
ii. All items installed as per the drawings.
iii. All the wire colour and size are as per the drawing.

Observation:
Acceptance Criteria Met: ❑ Yes ❑ No

6. Panel Power Distribution Check

Purpose:
i. The purpose of this test is to verify the Power distribution are as per approved drawing.
ii. To verify the AC/DC voltages are distributed correctly as per requirement.

Procedure:
i. Check the voltage level of the incoming TB/MCB’s.
ii. Check the voltages of 24VDC bulk power supply output.
iii. Check the Voltage level at each MCB output as per the power distribution drawing.

Acceptance Criteria:
i. Wiring is done as per approved Power distribution & wiring drawing.
ii. The measured Voltage ranges are as per the power distribution drawing.

Observation:
Acceptance Criteria Met: ❑ Yes ❑ No

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 8 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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7. Panel Earthing Check

Purpose:
To ensure that each equipment connected to the corresponding earth bars as per the panel power distribution drawings.

Procedure:
i. Visually check the cable connection between the earth bar and equipment’s.
ii. Check the continuity between the equipment earth terminal and earth bar.

Acceptance Criteria:
The Multimeter shows continuity between equipment earth point and earth bus bar.

Observation:
Acceptance Criteria Met: ❑ Yes ❑ No

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 9 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

8. I/O Operation Check

Purpose:
To ensure that all the IO’s are configured as per the configuration drawing and functioning.

Procedure:
Digital Inputs:
i. Short the Field terminal end using short link.
ii. Observe LED indication on corresponding Digital Input modules.
iii. Observe corresponding input status change in the Workstation for the assigned address.
Digital Outputs:
i. Force the Output memory I/O address in Workstation.
ii. Observe LED Indication in the corresponding Digital output module.
iii. Wet contacts: Check the voltage level at Field terminals across Power and return using Multi meter and read
the value as per approved Wiring drawing.
iv. Pot Free contacts: Check the continuity at Field terminals across Power and return using Multi meter and
observe the buzzer sound.
Analog Inputs:
i. For 4-20 mA inputs, connect “Current source” to the Field terminals as per the wiring drawing.
ii. Change the values between 4-20mA and read the corresponding values in the Workstation.
iii. The values should be within the tolerance level specified in the document.
Analog Outputs (Current / Voltage):
i. Enter the Analogue counts for the assigned I/O address in Workstation.
ii. Connect the “Current source” at the Field terminals as per wiring drawing and read the corresponding value.
iii. The values should be within the tolerance level specified in the document.

Acceptance Criteria:
Digital Input
Module wiring is as per the wiring drawing, LED’s are functioning, IO addresses are configured as per the IO list.
Digital Output
Module wiring is as per the wiring drawing, LED’s are functioning, IO addresses are configured as per the IO list.
Analog Input
Module wiring is as per the wiring drawing, IO addresses are configured as per the IO list and measured values are
within the accuracy limits.
Analog Output
Module wiring is as per the wiring drawing, IO addresses are configured as per the IO list and measured values are
within the accuracy limits.
Observation:
Acceptance Criteria Met: ❑ Yes ❑ No

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 10 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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9. Redundancy Check

Purpose:
To Ensure the redundancy levels are functioning as per the configuration drawing.

Procedure:
Check the procedures as per the below tables:

10.1 PLC Controller

Controller Redundancy Check

Pass/Fail Performed
Procedure Expected Result
(Error Log #) By/Date
Open the system diagnostic screen and
observe that both the PLC controller are
heathy, and PLCA is Master and PLCB  Pass
Everything Healthy. All Outputs are ON.
is standby.  Fail
Short a Digital Input & energize all the
Digital O/P’s from that.
Verify that the status is changed in the
Diagnostics screen. The PLC-B controller
has become Master and PLC-A Off.
 Pass
Switch OFF the PLCA Switch over is bump less
 Fail
All I/O cards function Normally, no loss of
I/O signal during switchover.
Operator interface function normally.
Verify that the status is changed in the
Diagnostics screen. The PLCB controller
is Master and PLC-A becomes the
 Pass
Switch ON the PLCA Standby.
 Fail
All I/O cards function Normally, no loss of
I/O signal during switchover.
Operator interface function normally.
Verify that the status is changed in the
Diagnostics screen. The PLC-A controller
has become Master and PLC-B Off.
 Pass
Switch OFF the PLCB Switch over is bump less
 Fail
All I/O cards function Normally, no loss of
I/O signal during switchover.
Operator interface function normally.

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 11 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

Controller Redundancy Check

Pass/Fail Performed
Procedure Expected Result
(Error Log #) By/Date
Verify that the status is changed in the
Diagnostics screen. The PLC-A controller
is Master and PLC-B becomes the
 Pass
Switch ON the PLCB Standby.
 Fail
All I/O cards function Normally, no loss of
I/O signal during switchover.
Operator interface function normally.
Comments/Observations:

10.3 I/O Communication

I/O Network Redundancy

Pass/Fail (Error
Procedure Expected Result Performed By/Date
Log #)
Verify that LAN-A failure status in
Diagnostics screen. Verify that
Remove the Connector of LAN A from  Pass
All the IO Status are unaffected,
the I/O Rack.  Fail
and the I/O’s are functioning
Normally.
Verify that the status is changed
Reconnect the Connector of LAN A & to healthy in the Diagnostics
 Pass
Remove the Connector of LANB from screen. Verify that All the IO
 Fail
the I/O Rack. Status are unaffected, and the
I/O’s are functioning Normally.
All the I/O’s Status gets
Remove the Connector of LAN A & LAN dropped/affected.  Pass
B from the I/O Rack.  Fail

Comments/Observations:

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 12 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

10.4 24VDC Power Supply

AC/DC Power Supply Redundancy Check-24VDC

Pass/Fail (Error
Procedure Expected Result Performed By/Date
Log #)
Switch OFF one of the power  Pass
System functions smoothly
supply  Fail
Switch On the power supply &
 Pass
Switch Off the second Power System functions smoothly
 Fail
Supply
Switch Off both the Power System connected to this Power  Pass
Supplies Supply will fail  Fail

Comments/Observations:

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 13 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

10. HMI Graphics & Software Functionality Check

Purpose:
The purpose of this verification is to ensure that the HMI Graphics & Software is developed as per Customer inputs and
requirements (P&ID, Control Philosophy etc.)

HMI Graphics Check

Procedure:
i. Verify the Graphics Background colour, Equipment & object colours.
ii. Verify Equipment Tags/Labels, Graphics heading, Arrow text, & other static text.
iii. Verify Dynamic properties of Digital inputs, Motor, Pumps, Valves, Level bar, Push buttons, etc.
iv. Verify all the graphics operation features, Faceplate, History View, Real time Trend, Pop-up display & Alarm
list etc.
v. Verify the graphics links like graphics Navigation arrow links, Next/Previous graphics.

Software functionality Check

i. After I/O tests & tag database check, interlock & sequence will be tested as per Logic diagrams / Control
Write-up.
ii. All input conditions of interlocks will be simulated through on-line Soft Screens & output will be checked for
each interlock condition.

Observation:
Acceptance Criteria Met: ❑ Yes ❑ No

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 14 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
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Client Doc. No. ---

11. Third Party Connectivity Check

Purpose:
To Check Modbus RTU/Modbus TCP/IP functionality for third party data exchanges.

Modbus RTU / TCP/IP

Procedure:
i. Modbus Simulator / Modbus Slave Setup Software will be installed on a PC and configure the simulator as
slave/ master device based on the configuration requirement. Connect Communication cable between PC &
Modbus Device. Configure few MODBUS I/O Register in slave/Master Simulator and verify the same in PLC.
ii. Connect the Communication cable between PC and PLC System.
iii. Interface parameters like Baud Rate, Parity and Data Bits, Time out, IP address, Slave ID are configured in
the Modbus Simulator.
iv. Same Parameters will be configured in the PLC System.
v. Configure the available Modbus RTU master/slave and/or Modbus TCP/IP Server/client as per the system
configuration.
vi. Establish the communication with the Modbus simulator.
vii. Simulate the Modbus read/write data exchanges between the controller and Modbus simulator.
viii. The Data received from the serial device can be viewed in the PLC Programmer.

Acceptance Criteria:
The data exchange between PLC and Third-party device is achieved.

Observation:
Acceptance Criteria Met: ❑ Yes ❑ No

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 15 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
PLC FAT PROCEDURE
Client Doc. No. ---

12. Power Fail and Restart Check

Power Fail & Restart Check

Pass/Fail (Error
Procedure Expected Result Performed By/Date
Log #)
HMI application functioning
Verify system operation and properly and there is no major  Pass
healthiness. error in system Diagnostic  Fail
screen.

Switch OFF mains AC supply from Main The cabinet & console power is  Pass
Incoming supply from the MCB. in OFF state.  Fail

All cabinets should restart by

itself without human intervention.
Switch ON the mains AC supply from All the workstation should restart  Pass
Main Incoming supply from the MCB after pressing power button, and  Fail
Windows logon should appear
on the screen.
Comments/Observations:

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 16 of 17
 Emerson Doc. No. XXXXX-A-06 REV-00
PLC FAT PROCEDURE
Client Doc. No. ---

13. PLC System Boot up procedure check

Complete PLC System Boot up Procedure Check

Pass/Fail (Error
Procedure Expected Result Performed By/Date
Log #)
All the workstations are in OFF  Pass
Switch OFF all the workstations.
state.  Fail

All the controllers, I/O cards,

 Pass
Switch OFF all the DC power supply. Relays, & Barriers are in OFF
 Fail
state.
The Workstation should restart
after pressing power button and  Pass
Switch ON Workstation
Windows logon should appear  Fail
on the screen.
The Controller should initialize
and Boot up Normally, all the I/O
cards showing healthy.
 Pass
Switch ON all the DC power supply. Verify operation functionality in
 Fail
Operator Interface and check the
integrity in system Diagnostic
screen.
Comments/Observations:

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project

Project BMS SCADA for Elevated Station

This Document is property of Emerson, it is supplied in confidence and may not be copied or used without
consent of Emerson
. Page 17 of 17
 IR No. XXXXX/IR-01
INSPECTION REPORT
Project No. XXXXX
INDEX
Page No. 1

Sl.No. Description Date Page No. Remarks

1 Mechanical completion and wiring test

2 Power up and Power distribution test

3 Input / Output test

4 Configuration and Software test

5 Burn-in test

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project
Consultant -----
Project BMS SCADA for Elevated Station

Inspected by Approved by

FORMAT No.: QA/FORM/IR-INDEX R1 DT. 20-MAy-2019

 IR No. XXXXX/IR-01
INSPECTION REPORT
Project No. XXXXX
MECHANICAL, BOM & WIRING CHECK
Page No. 2

Type of Check Result Remarks

Physical Check
BOM Check
Panel dimension
Plinth & Anti vibration pad
Fixing of Cable Ducts
Fixing of busbars

Visual Check
Panel Paint shade : External
Panel Paint shade : Internal
Mouning plate colour
Paint Thickness
Panel Name plate
PLC Modules
Panel Legend
Component Tags
Service Tags
Cable Troughs
Bulk Power supplies
Terminal Blocks
Interrogation/Earth Bus bars
Fans
Breakers
Ethernet Switches
Converters
Relays / Relay boards
Barriers / Repeaters
Wire Sizes
Wire Colours
Terminal Fuses
Mechanical Completion
Mounting of Components as per GA drawing
Labeling of the Equipments
Checking of H/Ws used

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project
Consultant -----
Project BMS SCADA for Elevated Station

Inspected by Approved by

FORMAT No.: QA/FORM/IR-MECH R2 DT. 20-MAy-2019

 IR No. XXXXX/IR-01
INSPECTION REPORT
Project No. XXXXX
POWER UP & POWER DISTRIBUTION CHECK
Page No. 3

Pre-requisite

All connections have to be properly terminated to its designated Terminals Power supply connections to the various
devices are at correct potential. The Power Distribution scheme in line with the Power Distribution Diagram the test
configuration as shown in the PLC configuration diagram & the same will be prepared for FAT.

Procedure
Measure the Input voltage to the device. Record its Readings.
Switch ON the device. Measure the Output voltage of the device. Record its readings.
Results
Record the results of the readings done & Sign off this sheet after the tests are completed

Tag Reading Tag Reading Tag Reading Tag Reading

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project
Consultant -----
Project BMS SCADA for Elevated Station

Inspected by Approved by

FORMAT No.: QA/FORM/IR-PD R1 DT. 20-MAy-2019

 IR No. XXXXX/IR-01
INSPECTION REPORT
Project No. XXXXX
INPUT / OUTPUT TEST
Page No. 4
This test is conducted to ascertain the following:-
Termination of the Wiring in its designated Terminal Block/Bus bar.
Checking of the Configuration with respect to Configuration Diagram.
Checking of Communication between PLC and PC.
Working of the Input Output Points before and after the burn-in test
Procedure
All I/O Points are checked 100% for its operation prior to burn in test .
Random checks are conducted for the operation of I/O Points after Burn in Tests.
Digital Inputs
Connect the Potential to the terminal as per details in the reference document’ Read the corresponding signal in the
Programmer Package on the PC for Inputs.
Acceptance
Observe the change of state in the programmer for all inputs. Also observe the status change of the indications in
the discrete input modules on application of the required potential at the terminals.
Digital Outputs
Force a particular point in the Programmer Package on the PC for Outputs
Verify the Output as per the details in the Reference Document
Acceptance
Check Relay Operation (if applicable) and check the potential (24VDC) between contacts assigned for particular output
Observe LED Indication in the corresponding digital output termination module
Analog Inputs
Connect “current source” to the termination block as per the wiring drawing.
Observe corresponding values with respect to Input address through programming terminal.
Acceptance
Value read is within the tolerance given by the data sheet.
Analog Outputs
Feed the “current source” in the form of PLC counts through programming terminal.
Connect to the respective termination block as per the wiring drawing
Observe corresponding values with respect to PLC counts through programming terminal.
Acceptance
Value read is within the tolerance given in the product data sheet.
RTD / TC Inputs
Connect “RTD / TC source” to the termination block as per the wiring drawing.
Observe corresponding values with respect to Input address through programming terminal.
Acceptance
Value read in the PLC is in the correct I/O memory location
Value read is within the tolerance given in the product data sheet.
Module type Catalogue No. Acceptance Criteria (As per Product Data sheet)

Digital Input ----- -----

Digital Output ----- -----
Digital Output ----- -----
Analog Output ----- -----
Analog RTD/TC Input ----- -----

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project
Consultant -----
Project BMS SCADA for Elevated Station

Inspected by Approved by
FORMAT No.: QA/FORM/IR-IO R1 DT. 20-MAy-2019
 IR No. XXXXX/IR-01
INSPECTION REPORT
Project No. XXXXX
INPUT / OUTPUT TEST
Page No. 5

Module No. Result Module No. Result Module No. Result Module No. Result

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project
Consultant -----
Project BMS SCADA for Elevated Station

Inspected by Approved by

FORMAT No.: QA/FORM/IR-IO R1 DT. 20-MAy-2019

 IR No. XXXXX/IR-01
INSPECTION REPORT
Project No. XXXXX
CONFIGURATION & SOFTWARE TESTS
Page No. 6

Procedure:
Configuration: The connected configuration is checked up with respect to the system configuration drg.
Communication: The communication between various devices checked for proper functioning of read/write
commands. Communication between Third party devices shall be carried with Soft simulator.
Bulk Power Supplies Redundancy: Redundancy is checked by switching off one of the Power Supplies at a time
and checking for the System status for drop-out.
PLC System Redundancy: Redundancy is checked by switching off one of the PLC System at a time and checking
for the System status for drop-out of Outputs.

Bus / LAN Redundancy: Redundancy is checked by disconnecting one of the LAN Cables and checking for loss of
Outputs.
Logic & SCADA: HMI Screens & Software functionality check shall be carried out with respect to the BLD/Control
write, I/O list and P&ID provided by Client

Type of check Result Remarks

Communication check
Communication Between PC and PLC
Communication Between PLC and I/O Nodes
Communication Between Third Party Devices

Redundancy check
Bulk Power Supplies redundancy
CPU redundancy
Communication Redundancy
Bus/LAN Redundancy

Programming Logic
Application Logic

HMI / Scada
HMI/SCADA Screens
Operator Interface / Screens Dynamics
Taging philosophy
Screen Layout
Navigation
Alarm Logging & Printout
Report Generation
Trending

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project
Consultant -----
Project BMS SCADA for Elevated Station

Inspected by Approved by

FORMAT No.: QA/FORM/IR-CFGSW R1 DT. 20-MAy-2019

 IR No. XXXXX/IR-01
INSPECTION REPORT
Project No. XXXXX
BURN-IN TEST
Page No. 7

Pre-requisite:
This test is conducted after completion of the Input/Output Tests
Procedure

The System and all other equipments are kept under continuously energised condition for a period of 48 Hours.

Acceptance
The System is observed for any abnormal heating of failure of the various components. The system is accepted if
the temperature raise inside the panel is not above 10degC

Panel Serial Burn-in Start Temp. (Deg C) Burn-in End Temp. (Deg C)
Result
No. Date & Time Ambient Inside Date & Time Ambient Inside

Customer M/s. URC Construction (P) Ltd

End User M/s. Bhopal Metro Rail Project
Consultant -----
Project BMS SCADA for Elevated Station

Inspected by Approved by

FORMAT No.: QA/FORM/IR-BIT R1 DT. 20-MAy-2019