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BSI 23/30426460 DC 2023

BSI 23/30426460 DC 2023

$13.70

BS EN IEC 62381. Automation systems in the process industry. Factory acceptance test (FAT); site acceptance test (SAT); and site integration test (SIT)

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BSI 2023 41
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PDF Catalog

PDF Pages PDF Title
7 FOREWORD
9 INTRODUCTION
10 1 Scope
1.1 General applicability
1.2 Exclusions
1.2.1 Prior and post activities
1.2.2 Regulated industries
1.2.3 Safety Instrumented Systems
1.2.4 Manufacturing Execution Systems
1.2.5 Advanced Process Control
1.2.6 Security for industrial automation and control systems
11 2 Normative References
3 Terms, definitions, abbreviated terms and acronyms
3.1 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
• ISO Online browsing platform: available at https://www.iso.org/obp
• IEC Electropedia: available at https://www.electropedia.org.
3.1.1
3.1.2
3.1.3
12 3.1.4
3.1.5
control system
3.1.6
detailed design specification
3.1.7
3.1.8
3.1.9
3.1.10
3.1.11
13 3.1.12
3.1.13
3.1.14
3.1.15
3.1.16
3.1.17
3.1.18
14 3.1.19
3.1.20
3.1.21
3.2 Abbreviated terms
4 Overview of automation system testing
4.1 General
An automation system is to be tested at various stages in its development and implementation. Each new automation system shall be subjected to three tests to demonstrate proper operation in accordance with project-specific requirements: Factory Accept…
15 4.2 Methods of test performance
4.3 Project Design Changes
4.4 Adapted procedures in case of modifications to existing systems
5 Factory Acceptance Test (FAT)
5.1 General
This clause provides the activities that are precursors to, conducted during, and provided after the FAT. The purpose of the FAT is to demonstrate that the automation system, subsystem, or component is in accordance with the URS and FRS and to verify …
5.2 Performance
5.3 Pre-FAT activities
5.3.1 General
Prior to commencing the FAT, the following activities shall be completed:
16 5.3.2 Vendor tests
The vendor shall conduct all vendor standard and any necessary custom tests of the system. Reports documenting the tests shall be available for buyer inspection.
5.3.3 Documentation
5.3.4 Test plan
17 5.3.5 Test schedule
5.4 FAT punch list
5.4.1 General
With respect to the test specification, any incomplete work or non-conformances detected during the FAT shall be recorded on a punch list for correction of same by the party agreed upon by the vendor and the buyer. Punch list items shall be categorize…
5.4.2 Correction
18 5.4.3 Corrections after FAT
5.5 Documentation of FAT
5.5.1 General
The results of the FAT shall be completely documented, including:
5.5.2 FAT report
5.5.3 FAT final documentation
5.6 FAT completion
19 6 Factory Integration Test (FIT)
6.1 General
This clause provides the activities that are precursors to, conducted during, and provided after the FIT. The FIT is an optional test that can be conducted after or in conjunction with the FAT at the factory before shipment of the system. The purpose …
6.2 Performance
6.3 Pre-FIT activities
6.3.1 General
Prior to commencing the FIT, the following activities shall be completed:
6.3.2 Test plan
20 6.3.3 Test schedule
6.4 FIT punch list
6.4.1 General
With respect to the test specification, any incomplete work or non-conformances detected during the FIT shall be recorded on a punch list for correction of same by the appropriate party. Punch list items shall be categorized as follows:
6.4.2 Correction
6.4.3 Correction after FIT
21 6.5 Documentation of FIT
6.5.1 General
The results of the FIT shall be completely documented, including:
6.5.2 FIT report
6.5.3 FIT final documentation
6.6 FIT Completion
7 Site Acceptance Test (SAT)
7.1 Performance
22 7.2 Pre-SAT activities
7.2.1 General
Prior to conducting the SAT, the relevant hardware/software components shall be delivered to the site and properly installed. The following items shall be completed during the installation of the automation system/subsystem/components before the SAT c…
7.2.2 Test plan
7.2.3 Test schedule
23 7.3 SAT punch list
7.3.1 General
With respect to the test specification, any incomplete work or non-conformances detected during the SAT shall be recorded on a punch list for correction of same by the appropriate party. Punch list items shall be categorized as follows:
7.3.2 Correction
7.3.3 Correction after SAT
7.4 Documentation of SAT
7.4.1 General
The results of the SAT shall be completely documented, including:
24 7.4.2 SAT report
7.4.3 SAT final documentation
7.5 SAT completion
8 Site Integration Test (SIT)
8.1 Performance
25 8.2 Pre-SIT activities
8.2.1 General
Prior to conducting the SIT, the relevant hardware/software components of all systems and sub-systems to be involved in the SIT shall have satisfactorily completed their respective SAT. Installation of all communications and interconnections (e.g. dir…
8.2.2 Test plan
8.2.3 Test schedule
8.3 SIT punch list
8.3.1 General
With respect to the test specification, any incomplete work or non-conformances detected during the SIT shall be recorded on a punch list for correction of same by the appropriate party. Punch list items shall be categorized as follows:
26 8.3.2 Correction
8.3.3 Correction after SIT
8.4 Documentation of SIT
8.4.1 General
The results of the SIT shall be completely documented, including:
8.4.2 SIT report
8.4.3 SIT final documentation
27 8.5 SIT completion
29 Annex A (informative) Factory Acceptance Testing Checklist
A.1 Assemble Documentation
Assemble all documentation applicable to the project prior to the FAT. Documentation can include:
A.1.1 User requirements specification:
A.1.2 Functional requirements specification:
30 A.1.3 Information to vendor
A.1.4 Vendor documentation
A.2 Develop a written test plan and specification.
A.2.1 Documentation:
A.2.2 Hardware/software inventory:
31 A.2.3 Mechanical inspection:
A.2.4 Wiring and termination inspection:
A.2.5 Start-up, shut-down and re-start test and general system functions:
A.2.6 System alarm test :
32 A.2.7 Hardware redundancy and diagnostics (including fail and changeover of redundant units):
A.2.8 Operator interface
Prior to any loop-oriented or I/O-oriented test, the static parts of the HMI displays (if applicable) should be verified. The following display functionality (static and dynamic) should be verified, using the applicable P&ID or display requirements sk…
A.2.9 Engineering workstation functionality:
A.2.10 User management:
33 A.2.11 Network and system security-
Examples of test points are listed below. For overall network and system security requirements refer to IEC 62443.
A.2.12 Test I/O to the operator display:
Each I/O point in the system should be tested as follows:
A.2.13 Complete I/O tests
All I/O should be tested for proper operation to the fullest extent possible, including verification of individual I/O ranges and engineering units.
34 A.2.14 Bus interfaces
A generic test should be conducted for each specified type of field or external device bus interface which is compliant to the relevant standard. This test should cover the interoperability of the automation system and the device, including:
A.2.15 Intelligent field devices
The configuration of intelligent field devices, if already established at this point, should be tested during FAT (Refer to IEC TR 63082).
A.2.16 FAT open item
Any portions of the system hardware not fully tested during the FAT (e.g. marshalling terminals) should be fully tested as part of the SAT and any issues resolved at that time.
A.2.17 Check of complex functionality and interlocks
The test of complex functionality and interlocks should be carried out after the I/O tests. The tests to be performed should be as outlined in the FAT document and include:
A.2.18 Test of communication links to subsystems
Whenever possible, every connection to an external system should be tested. If the actual connection to the external system cannot be made during the FAT, the test should be performed by means of a subsystem simulation device. Actual signal type/level…
35 A.2.19 Check of other system functions
In addition to the application-related test, other systems should be tested, including:
A.3 Develop a test schedule
A.4 FAT certificate
If a formal certificate is required, the form can be provided by the buyer or the vendor.
36 Annex B (Informative) Site Acceptance Testing Checklist
B.1 Develop a written test plan and specification
B.1.1 Documentation:
All necessary documentation should be available and current. Reference documentation for the SAT includes:
B.1.2 Hardware/software inventory:
B.1.3 Mechanical inspection:
B.1.4 Wiring and terminal inspection:
B.1.5 System energization:
37 B.1.6 Hardware redundancy and diagnostics:
This process is the re-verification of proper operation after field installation, including :
B.1.7 Operator interface:
B.1.8 Network and system security:
B.1.9 I/O test:
B.1.10 Bus interfaces:
B.1.11 Intelligent field devices:
B.1.12 Check of complex functionality and interlocks
38 B.2 Develop a test schedule
B.3 SAT Certificate
39 Annex C (Informative) Site Integration Testing Checklist
C.1 Develop a written test plan and specification
The following provides typical tests for various aspects of integration of the automation system with other systems or sub-systems that should be included in the test plan. A test plan should be developed for each system that tests and verifies the sy…
C.1.1 Documentation
For each system, or sub-system to be checked:
C.1.2 Visual inspection:
C.1.3 Communications:
C.1.4 Operator interface:
C.1.5 Hardwired I/O:
C.1.6 Functionality:
40 C.2 Develop a test schedule
C.3 SIT Certificate
If a formal certificate is required, the form can be provided by the buyer or the vendor.

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