Factory Acceptance Test Explained - Part 1 | Power the Control Panel

[@saurabhbhardwaj9667]

Control system FAT usually comprises of Hardware and Software FAT. Before starting with FAT, it is important that all the documents required for performing FAT are available: system configuration, P&IDs, I/O list, Functional design specifications, HMI design specification, Alarm and trip setting list, Logic diagrams, Control loop diagrams, HMI screen, Specification of Control system hardware, panel GAD and wiring diagram, Bill of material, list of signal exchange with third party interface ( hardwired and soft signals) and FAT procedure as a minimum. All these documents should be approved by your customer before you can take a panel into manufacturing and start with system development. A FAT procedure lists the detailed procedure for testing of hardware, I/Os, program, HMI interface and third party interface as much as practicable.

[@realpars]

Saurabh, thank you for the extended explanation of many of the components (hardware, software, documentation, drawings, etc.) that are included in the FAT process. Your comments will certainly help our viewers to better understand the scope of the FAT test!

[@saurabhbhardwaj9667]

RealPars Team, you are most welcome. Understanding the documentation requirement and the purpose of each type of document at each stage of FAT is a pre-requisite to a successful FAT. In my experience, I have seen that FAT procedures are not so well written by control system vendors and end up widening a gap between one's expectations and what is offered by the vendor. Hope my feedback serves as a value addition to your team responsible for developing content for KZbin channel.

[@prabhakaran20ten]

@@realpars Great❤️

[@JC-xc8rx]

@@saurabhbhardwaj9667 thank you so much for sharing your knowledge and experience. Much respect.

[@CommercialGasEngineerVideos]

These vids are helpful as there aren't many in the UK. Thanks

[@realpars]

Glad you like them!

[@godtermand]

In developing a new plant, we also use the FAT to test SCADA checking TAGs, units, scalings, texts, alarm areas etc. We also let the operators get a hands on experience by navigating in a safe environment and let them give their inputs before the functionality and software is locked for site testing.

[@realpars]

Thanks for sharing your experience with us!

[@alexandernorman5337]

In my experience, the secret to a good FAT is to identify and test all functionality. It's usually not possible to reproduce all the inputs, outputs, and interfaces of the destination plant. But identify every type and test a representative sample, and scale your system so that it can handle the full requirement.

[@realpars]

Alexander, this is a great observation! In small FAT tests of a single panel, it may practical to test every point and I/O terminal. However, in very large systems, a representative sample, perhaps one point from every I/O card, or verification of power at the "endpoints" per the panel drawings, will give a high probability of suitability for installation in the field. Again, the client has the final say in the scope of the FAT, since they are "footing the bill" for the time it takes to complete the testing.

[@muzammilsyed6225]

Very basic but very important. Wonderfully explained. Thx

[@realpars]

Glad it was helpful!

[@mufti1312]

I have started my career in automation last year.. Your every presentation is very useful.

[@realpars]

Glad to hear that! Best of luck!

[@ghanshamshirbhate1034]

thanks.....Explained Very Nicely.....Really Helpful...…..Keep it up...…Waiting for the Video on SAT (Site Acceptance Test)

[@realpars]

Happy to hear that!

[@marlonzapata8240]

It's an important video, i like to learn by watching all your videos. A step that i used to do before turn on the main braker is to check with the multimeter with continuity, the possibles shorts circuits between lines that helps tolo correct the conections and saves the elementd of the control panel.

[@realpars]

Thanks for your kind support, Marlon!

[@behroozma9946]

Thank you Realpars team🙏

[@realpars]

You're very welcome, Behrooz!

[@paulrinehart5557]

I would like to see a video on incorporating a battery backup into the PLC. Nice job on the FAT.

[@realpars]

Hi Paul! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

[@emmanuelsanusi1389]

Thank you Realpars team!!

[@realpars]

Our pleasure, Emmanuel!

[@aminokamad1681]

Can't wait part 2 video

[@realpars]

Glad to hear your anticipation, Amin!

[@jagdeepminhas7669]

Valuable for me to level up my knowledge

[@adekolasulaiman2549]

Nice and good job. Thanks for sharing.

[@realpars]

Our pleasure, happy learning!

[@TheSikandarNawaz]

I believe first step is to check the integrity of wiring and if proper grounding is in place. I have had bad experience of wrong wiring where short circuit happened just after panel is powered on. Also in one instance the grounding was not properly fixed and one of the PLC card burnt because of electrostatic discharge.

[@realpars]

Thanks for adding that, Sikandar!

[@odeaore1316]

I have already done this kind of task for automotive industry in France, and they asked to check the tension too, and in the end you must sign.

[@MohamedSoliman-rm6mt]

Very Valuable Information Thank you, RealPars

[@realpars]

Glad it was helpful, Mohamed!

[@dharunnarayanankasi2564]

Very useful 👍

[@realpars]

Thanks a lot!

[@karimsh4281]

Nice one. would you kindly make a vedio about PLC software based PC

[@realpars]

Hi Karim! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

[@preetamsagarsahu]

Thanks for introducing FAT to me

[@realpars]

Our pleasure, Preetam!

[@bitebonumbere1426]

Thank you RealPars

[@realpars]

Our pleasure, Bitebo! Happy learning.

[@nallamanish155]

Hello Realpars. If it's possible kindly make a video for ground bond test. Insulation resistance test. HV test, Megger test, Earthing leakage relay test. Thank you.

[@realpars]

Hi Nalla! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

[@KevIn-tu4fv]

Make sure to do a point-to-point test before turning on the main power. Somestimes the connections made during the building of the panel can be wrong.

[@realpars]

Thank you, Kevin!

[@navnitpatel8487]

Nice. Would like to see more videos .

[@realpars]

More to come!

[@hamzamohamed7935]

I like this vedio because i found it sooo useful

[@realpars]

That's great to hear, Hamza!

[@judetochukwuogbozor6355]

Wonderfully explained. #first_to_comment

[@realpars]

Thanks for your support!

[@aminokamad1681]

Awesome video 🔥 🔥 🔥

[@realpars]

Thank you, Amin!

[@basilrasool]

very good

[@realpars]

Thank you!

[@mizanurrahman-jk1gy]

Nice

[@Anil.Varanasi]

Hai, What is Configuration Acceptance Test for PLC?

[@realpars]

SA Configuration Acceptance Test for a PLC is a systematic test and/or verification that the configurable parameters in the PLC (IP address, port baud rates, connected device node numbers, etc., meet the values contained in the hardware or configuration specification document.

[@SandeepKumar-ng2bq]

Nice 👍👍👍👍👍👍👍👍

[@realpars]

Thank you!

[@tamilselvans7117]

Hi can anyone tell me how to check pull test (any device available) of the the Connected wire in Terminal block , MCB, PSU, ,,,

[@realpars]

If I understand your question correctly, you want to verify that the wires are securely terminated. The "pull test" is actually a very good test to perform, since many times, a panel builder will not tighten the wires per spec. To do a pull test, make sure the power is disconnected from the panel. Then gently tug each wire (small amount force) to see if the wire comes loose from the terminal. If so, reinsert and tighten. If wires do not make good solid contact with the terminals, they could arc, or simply not make contact such that the device wiring prevents proper operation.

[@tamilselvans7117]

@@realpars yeah thanks for the info.i am asking about any device or instruments are there to check pull test.with the equipment not with hands.

[@ominence5573]

Full point to point wire test should be at least undertaken before power up, this will minimize short circuit faults etc.

[@mehulpatel9579]

👍🏻

[@ahmednor5806]

🙏🌹🌹