Thursday, July 1, 2021



Over PLC Panel (Programmable Logic Controller Panel) all system configuration checks:

A. Visual Inspection Checks

  1. Check the suitability of the testing area (staging area)
  2. Degree of Mechanical Protection
  3. The type test Certificate (as per IDS) including the electromagnetic
  4. Compatibility, topicalization etc.
  5. Check of instrument calibration (certificate for the instruments that will be used for the test)
  6. Cabinet type
  7. Check terminal strips functional separation
  8. check fusing and fuse rating
  9. check of the wiring separation of various voltages
  10. check the filling ducts
  11. check of the space of future expansion
  12. safety grounding circuit check as per EN 61010‐1 check of the safety ground insulation test
  13. Verify the control and signal cables
  14. Paintwork free from scratches, blemishes, deformities
  15. Eye bolts fitted
  16. All mechanical connections are secure and fit properly
  17. Doors and Lock/Keys are fitted securely
  18. Nuts / bolts / screws / fasteners are tight
  19. All Exterior cabinet nameplates are correctly located and squared to front and rear of cabinet for easy viewing
  20. All hazardous labels are fitted (voltage > 50 V)
  21. All device labels are fitted
  22. All MCB labels are fitted
  23. All terminal block labels are fitted
  24. All earth bar labels are fitted
  25. All rack interconnect I/O bus cables are labeled
  26. Randomly check crimped ends and screw connections
  27. All IO modules are in correct Rack / Slot
  28. Check Location of each component against General Arrangement drawing

B. Electrical Checks

  1. All cabinet wiring shall be inspected prior to power‐up
  2. Control Cabinets:
  3. Random Cabinet power wiring visual or continuity checked against drawing
  4. Random ferrule tagging visual check, should be clear and readable
  5. Random Point to Point (resistance test)
  6. Random Point to Ground (resistance test)
  7. Earth bonding test shall not exceed 0.1 ohms between bonded item and appropriate earth bus bar, use megger to check earthing

C. Power Connection Checks

  1. The following test is to ensure proper power feed is connected to the system prior to power on. Note that main processor batteries should be removed prior to powering up. This means the system has power but it has no application code.
  2. Verify the correctness of the connection with the supply system, correct power connection to terminal strip, neutral and phase
  3. Check cabinets are connected to a suitable earthing point in the FAT premise
  4. Check a 230V AC (+ 5%), 50 Hz (+ 1%) supply to incoming UPS AC supply terminals
  5. Check a 230V AC (+ 5%), 50 Hz (+ 1%) supply to incoming Utility AC supply terminals
  6. Check all MCB's for the correct rating protection (refer to Electrical Power
  7. Distribution & Grounding Drawing)

D. System Power (230 V AC) Up

  1. Check 230 V AC available at terminal 1&2
  2. Switch 'ON' Circuit breaker 'MCB', check voltage on its output terminals.
  3. Check Voltage on its output terminals; ensure the respective output devices are 'ON' such as Fan unit, Panel Lamp and Field PS units. Ensure all control system modules are in 'ACTIVE'.

E. Field Output Power (24V DC) Up

  1. Check the 230 V AC power on the input terminals of 24V DC power supply unit.
  2. Switch 'ON' power supply and check voltage on their output terminals respectively. 
  3. Note: Using a test meter measure the power supply module (off load) and ensure that the measured output voltage is 24V DC + 5%. If the DC voltage is outside of the specified limit, adjust power supply output in accordance with the manufacturer's guide.
  4. Ensure System Healthiness as below:
  5. Ensure the main rack power supply does not show any alarm
  6. Ensure no alarm on the IO modules after power up of the 24V DC field power supply.

F. Power Consumption

  1. For each type of power feeds, measure voltage and total system current with with system "No‐Load" condition and record the results
  2. 230 V AC Input feed Voltage:   Current:
  3. 24V DC Power supply Voltage:  Current:

G. Signal Wiring Checks

  1. Randomly the signal wiring shall be inspected prior to loop checks and application program (Logic Simulation)
  2. Cabinet wiring visual or continuity checked against drawing
  3. Ferrule tagging visual check, should be clear and readable
  4. Point to Point (resistance test)
  5. Point to Ground (resistance test)
  6. Randomly check the wiring for proper crimping and termination (Tug Test)
  7. Note: Earth bonding test shall not exceed 0.1 ohms between bonded item and appropriate earth bus bar

H. System Configuration Checks

  1. Verify existence of control program
  2. Check the module configuration as per 'Rack Assignment & I/O Details'
  3. Check the I/O addressing for the hardware points 100%
  4. Check the I/O addressing for the software points 100%

I. Loop Checks

  1. This check will be done as per pre‐test before checking the application logic.

J. Analog Inputs

  1. Activate each of the analog inputs by varying the potentiometer on the simulation panel.
  2. Check the current at the field terminals using a multimeter.
  3. Check the correct system reference address is activated and the value in the register varies correctly.
  4. Check configured analog scaling and analog alarm/trip levels are correct
  5. Check configured Alarms for HMI
  6. Record results

K. Digital Inputs

  1. Activate each of the digital inputs by toggling the switches on the simulation panel
  2. Check the current Rack/Slot/Channel LED illuminates on input module and corresponding HMI display is changing the respective device color as specified in the FDS
  3. Check configured HMI alarm is correct
  4. Record results

L. Digital Outputs

  1. Using Engineering station force ON (energize) each output
  2. Confirm that correct Rack/Slot/Channel LED illuminates on output module
  3. Confirm that correct lamp on the simulation panel turns ON.
  4. Record results
  5. Note: Any discrepancy will be in the punch List and will be cleared before starting the Application Logic Test

M. Application Program Checks

  1. The purpose of this test is to verify the LCP Application Codes against the sequence of operation as specified in the Control Logic diagram/FDS. The simulation cabinets have been wired to allow all I/O groups to be operated without delay.
  2. All the changes in the logic shall be visualized by simulator panel

N. Field I/O Normal

  1. All the digital inputs into its normal position 'Open' or 'Close' as per normal process operating conditions
  2. All analog inputs into its normal position 'less than High set point' or 'more than Low set point' as per normal process operating conditions

O. Logic Test

  1. The logic sequence will be tested exactly as per the control logic diagram and normal plant operating conditions, with each step performed in sequence. Any corrections required will be done then or at the end of the test based on the correction required.

P. Redundancy Checks

  1. CPU Redundancy Check
  2. Check changeover between CPU A & CPU B and vice versa
  3. Power supply Redundancy Check
  4. Check changeover between PS A & PS B and vice versa
  5. Ethernet Switch Redundancy Check
  6. RIO Bus Redundancy Check

Q. Spare Capacity Checks

  1. Check digital input square quantity in %
  2. Check digital output square quantity in %
  3. Check analog input square quantity in %
  4. Check analog output square quantity in %
  5. System Shutdown/Reboot Functionality Checks
  6. End the runtime program, turn off power, for all enclosures‐ Observe Status
  7. Switch on power, for all enclosures‐ Observe Status

R. Check Test Certificates

  1. Check the test certificate as per document
  2. Calibration Test Certificates Internal test report if any Material Test Certificate
  3. Conformity Certificate

Download File

PLC Panel (Programmable Logic Controller Panel)

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