ICSS testing shall consist of three distinct phases:
• Factory Acceptance Test (FAT)
• Software Factory Acceptance Test (SFAT)
• Site Acceptance Test (SAT)
The Purchaser shall issue specifications for each of these tests.
8.1
SUPPLIER PRE-FAT TESTING AND PREPARATION
The supplier shall carry out works tests prior to the FAT in accordance with the project FAT Specification and his quality assurance procedures. All aspects of the system to be tested in the FAT shall be pre-tested prior to the start of the FAT. The Purchaser will attend the Supplier’s premises to verify that this pre-testing and other preparation is complete.
Preparation and pre-tests required will be defined in the project FAT Specification, and shall include (but not be limited to) the requirements of the following sections.
8.1.1
Hardware and Staging Completion
The system shall be considered ready for FAT when the following are complete:
• Hardware build complete
• System staging including inter-panel wiring, fibre optics, networks complete
• All hardwired relay simulations, and other test simulations required by the Purchaser shall be installed
• Calibration certificates shall be available for the test equipment.
• All certifications shall be complete
8.1.2
Electrical Tests
Prior to the power up of each panel, comprehensive electrical earth fault tests shall be executed and recorded.
A 100% I/O test shall be completed and recorded, proving the wiring from terminals to I/O cards, and the correction functioning of all channels on all cards. This test must be completed for all configured and spare I/O channels.
8.1.3
System Hardware Pre-tests
Hardware and system performance pre-testing in line with the Purchaser’s FAT procedure shall be completed before the FAT. This shall include a black start pre-test. If any failures occur, these shall be rectified prior to the FAT.
All hardware testing and associated records must be completed by the supplier and be available for inspection prior to any factory hardware acceptance tests by the Purchaser proceeding.
8.1.4
Application Software Pre-tests
The supplier shall carry out a full check on the “frozen” software design to prove its conformance with design documentation.
All cause and effects application software shall be comprehensively pre-tested, with all test scripts available for checking by the Purchaser. These tests should be completed from input terminal to output terminal using the relay simulations.
All graphics shall be 100% complete as per the issued project documentation. Cause and Effect graphics and Process Graphics shall be complete for the testing of safety logic. All other graphics as specified in the project documentation shall be complete, with all
symbols or dynamic components healthy.
All PCS Control Narratives issued before the agreed project freeze date shall be pre-tested with test documentation available to the Purchaser.
All HMI system configuration, historian configuration and other system configuration should also be complete for the FAT.
8.2
FACTORY HARDWARE AND SAFETY LOGIC ACCEPTANCE TEST (FAT)
The acceptance tests shall be in accordance with the Purchaser’s FAT specification.
A full day-by-day plan of FAT activities and required resources from both the Supplier and Purchaser shall be submitted by the Supplier no less than 6 weeks prior to the FAT.
The acceptance tests shall be led by the Supplier with assistance as required from the Purchaser and be checked for compliance.
The primary purposes of the FAT are as follows:
• Hardware inspection
• System Integrity and Performance tests
• Safety Cause and Effects implementation test
• Class Approval of Safety Cause and Effects implementation
• System configuration and application software inspections
• Process Control logic testing
8.2.1
Hardware Inspection
The purpose of the hardware inspection is to:
• To demonstrate that the hardware build is of the required level of quality.
• To demonstrate that the hardware fully complies with the design documentation such as the project ICSS Specification and required Corporate Standards.
• Checking that all equipment specified and recorded in the Bill of Materials is present and installed in the correct location.
As such detailed panel inspections are broken into the following categories:
• Mechanical inspection
• Electrical inspection
• Hazardous area protection / compliance
• Environmental protection inspection
8.2.2
System Performance and Integrity Tests
The purpose of these tests is to demonstrate the hardware performance is as required.
This includes its correct configuration, failure modes, recovery, redundancy and diagnostics. As such system performance tests shall cover:
• I/O Module performance, diagnostics and redundancy (where applied)
• I/O bus performance, diagnostics and redundancy
• Processor performance, diagnostics and redundancy
• Power supply redundancy
• Control level network communications performance, diagnostics and redundancy
• Packages network performance
• Server performance, diagnostics and redundancy
• HMI level network communications performance, diagnostics and redundancy
• HMI client performance
• System black start
8.2.3
Safety Cause and Effects Implementation Test
The safety logic acceptance test shall consist of:• A full input terminal to output terminal test of safety logic, not relying on software simulations. In order to make this test regime more efficient, hardwired
simulations of plant objects shall be used. For example a relay shall be wired into the ICSS terminals to simulate every shutdown valve, with relay contacts wired into digital inputs to simulate the position feedback for the valve.
• The simulation of every cause and the observation of every associated effect
• Checking of safety logic voting functionality
• Checking of maintenance and operational override functionality
• To demonstrate that all safety I/O, range, alarm, trip and units have been correctly implemented to design documentation.
8.2.4
Class Approval of Safety Cause and Effects Implementation
The supplier shall demonstrate all safety cause and effects logic to the nominated class society, obtaining the required system sign-off.
8.2.5
System Configuration and Application Software Inspections
The purpose of these tests is to confirm that the following system configuration and performance requirements are met:
• Graphics – all graphics shall be 100% complete up to the agreed revisions of P&IDs or Fire and Gas layout drawings. This is to include all special graphics, as required in the purchaser’s documentation. All HMI objects shall show good quality, i.e. shall be correctly tagged to the function blocks running in the processors.
• HMI system configuration shall be complete – including the correct configuration of alarms, security, logins
• Historian configuration shall be witnessed
• System performance tests and inspections shall be performed – including response time and system loading
• Software quality inspections shall be performed – covering an inspection of the software quality, software library implementation, and system structure.
8.2.6
Process Control Logic Testing
These tests will consist of:• Process control narratives issued to the supplier before the agreed software freeze date shall be tested.
• All Modbus or profibus serial links shall be tested
• Intelligent device connectivity type tests (as per project requirements) shall be performed.
• OPC connectivity tests for Package Unit system interfaces may be required.
8.3
SOFTWARE FACTORY ACCEPTANCE TEST (SFAT)
The Software acceptance tests shall be in accordance with the Purchaser’s software acceptance test specification. The purpose is to verify completion of all Supplier work scope. The Software FAT (SFAT) testing shall include, but not be limited to:
• To demonstrate that the process control application software correctly fulfils the design intent of submitted Process Control Narratives and other design
documentation
• To confirm that all graphics have been built to the Purchaser’s requirements, that all FAT comments have been included, and that all required style, structure, ergonomic and project-specific requirements have been met. Graphics missing at the FAT shall be inspected; this may include Package Unit interface graphics.
• All overrides – including maintenance overrides (MOS) and operational overrides (OOS) shall be tested.
• Additional Range, alarm and trip values issued after the FAT software freeze date shall be tested.
• To confirm that all HMI system configuration has been completed, to the
Purchaser’s design documentation and written requirements. This shall include logins and security, alarm management, graphics framework functionality, system start-up and other requirements.
• To demonstrate that the historian is configured to record all required variables, to transfer data correctly to the historian server and that required trend displays are produced.
• To demonstrate that the required reports have been configured.
• Spot checks of software quality shall be completed. OWL items relating to software quality shall be retested.
• To prove serial links, intelligent device connectivity tests and other interface tests not completed at FAT.
• All FAT Outstanding Work List (OWL) items shall be completed.
• To confirm that all software simulations are removed prior to acceptance.
In addition to the above, the SFAT is likely to include the testing of “Work packs”
consisting of the implementation of revised Cause and Effects, I/O maps and P&IDs.
8.3.1
Test Platform
The testing of processor application software may be completed on either a simulation platform, or processor held back from the post-FAT system shipment. Similarly, HMI configuration and graphics shall be witnessed on project clients and servers, or on a duplicate platform.
8.4
SITE ACCEPTANCE TEST (SAT)
Following installation on site the Purchaser and Supplier shall perform the Site
Acceptance Test (SAT). The purpose of the SAT is to demonstrate that the installation work has been carried out correctly and that the ICSS meets the requirements of this Functional specification under operational conditions. The Purchaser shall invite the classification society to witness the C&E logic testing during the SAT.
The Site Acceptance Test is designed to:
• Verify that system installation is complete, and complies to design documentation and standards required by the project
• Verify that all aspects of system configuration are complete
• Test system integrity, redundancy or performance tests for key system components (e.g. processor redundancy)
• Test system integrity for ICSS sub-systems that have been reconnected in the construction yard (e.g. networks)
• Verify that safety system mandatory safety parameters and modes are enabled.
• Test all safety Cause and Effects logic which shall be witnessed by the certifying authority (e.g. ABS, DNV)
• Test all process control logic (this will largely be completed offshore when the process itself is commissioned)
• Confirm that all OWL items from the FAT and SFAT have been cleared
The intent is to execute the SAT immediately prior to sail away from the construction yard.
It is accepted that some items, for example process control commissioning, cannot be completed by this stage. As such, a final Outstanding Work List will be produced, the completion of which signals the acceptance of the ICSS.
8.4.1
Cause and Effects Testing
SAT cause and effects testing shall comply with the following:
• Every cause and every effect shall be tested by a competent engineer, and signed off on the master Cause and Effects documents.
• All outputs shall be tested to the actual operation of the actual device (e.g.
shutdown valve closing). Where this is not possible for individual effects (e.g. a unit cannot be tripped, so tested to panel terminals only), these shall be listed in the OWL as not complete, and shall not be signed off on the master C&E script.
• All trip levels and ranges shall be verified as part of the testing against the final revision of the alarm and trip schedule.
8.4.2
Independent Cause and Effect implementation review
An independent review of the application software implementation of cause and effects logic shall be completed prior to the handover of the Production Unit to the operating company. The purpose of this review is to visually check that Cause and Effects logic is correctly implemented. This additional “offline” check is intended to supplement the complete SAT cause and effects test completed on the Production Unit.