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Contents&SignCustom Process Equipment4727 NW Evangeline ThruwayDPSD DOCUMENT NO.FAT PROCEDURECarencro, LA 70520DPS-2010-1105-Q-KA-0005Tel : (337) 896-3815Abu Qir Thermal Power PlantSupplier: DPSClient PO:10-118-26ContentsManufacturer: CPE1Introduction1.1Objective1.2Supplier Reference Documents1.3Necessary Material2FAT Overall Planning3Procedures3.1Mechanical Checklist3.1.1Package General3.1.2Piping3.1.3Vessels3.1.4Access3.2Instrument Checklist3.2.1Level Gauges3.2.2Level Control Valves3.2.3Differential Pressure Transmitters3.2.4Pressure Indicators/Pressure Differential Indicator/Temperature Indicators/Flow Indicators3.2.5Pressure Relief Valves3.2.6Level Switches3.3Electrical Checklist3.3.1Junction Boxes3.3.2General Inspections3.3.3Documentation3.3.4Conformity3.3.5Cable Installation and Tests3.4Document Verification1Introduction1.1ObjectiveThe Objective of this document is to provide a detailed Factory Acceptance Test Plan for DPS purchase order PO-2010-1105-001, which consist of a Filter Separator and Drain Tank Skid Assembly. The major components of the package include the following:1. Filter Separator Skid Assemblya .Filter Separator Vessel 6-FG-MT001b. Filter Separator Vessel 7-FG-MT001c. Drain Tank 9-FG-MT-001The test procedures containted in Section 3 of this document will be utilized to determine the following:1. Product compliance with the purchase order document2. Product compliance with the purchase order specifications3. Acceptability of workmanship4. Integrity if components5. Verification of FunctionalityIt should be noted that process control is being performed in the Plant Control System. The instruments and valving associated with these functions will be checked for calibration and functionality using a hand held communicator.FAT will be considered complete when all items on the checklist have be brought into conformity.All Equipment from sub-vendors will have been tested and calibrated prior to delivery.1.2Supplier Reference DocumentsDPS Document No.Client Doc. No.Document TitleDPSD-2010-1105-I-LA-0001 Rev.HInstrument List Rev HDPS-2010-1105-TST-001Manufacturer's Hydrotest ReportsDPS-2010-1105-TST-002Manufacturer's NDE ReportsDPS-2010-1105-R-STD-003Manufacturer's Coating ReportsDPS-2010-1105-R-STD-006Material Test CertificatesDPS-2010-1105-402Cause & Effect Matrix / Logic FunctionDPS-2010-1105-500Pipe & Instrument Diagrams (P&ID)DPS-2010-1105-201Piping GA (Plans & Elevations)DPS-2010-1105-101Filter Separator GAt DrawingDPS-2010-1105-102Drain Tank GA DrawingDPS-2010-1105-201Skid Assembly Drawing2010-D-1105-202Structural Skid Drawing2010-D-1105-203Filter Separator Platform DrawingDSP-2010-1105-400Electrical / Wiring DrawingsDSP-2010-1105-401Junction Box Layout DrawingDPS-2010-1105-I-VD-0001Instrument Calibrations and CertificationClient Reference DocumentsPurchaser's Minimum Quality Surveillance Summary Data SheetClient Document NumberDocument Title7929-511-413-03-18Purchase Order NumberDPS-2010-1105-R-DS-00001Fuel Gas Filter Separator Data SheetDPS-2010-1105-R-DS-00002Drain Tank Data Sheet99999-9-3DS-P72-00001Design of Piping on skids10054-9-3PS-JQ07-00001Instrumentation & Electrical Requirements for packaged equipmentDPS-2010-1105-R-K-0002ITP Form99999-9-3SS-NX00-00003Surface Preparation and Painting1.3Necessary MaterialHART COMMUNICATOR FOR PDITMANOMETER PRESSURE SET FOR PDIT24VDC POWER SUPPLYFLUKE MULTIMETERWATER SOURCECOMPRESSED AIR SOURCE2FAT Overall PlanningThe FAT is intended to cover the following major areas:1. Documentation Review. A review of the project documentation will be conducted by Supplier personnel as well as the Client representative. The following are the major areas of review.a. Manufacturing data reviewb. Valve and instrument data reviewc. Miscellaneous Equipment data review2. Equipment Inspection and Testing. The checklists contained in Section 3 of this document will be used to verify their functionality and conformance with project requirements. Supplier personnel along with the customer representative will proceed through the lists and perform the necessary evaluation. The checklists are divided into the following major categories:a. Mechanicalb. Instrumentsc. Electrical3Procedures3.1Mechanical ChecklistChecklist3.1.1Package GeneralSIGNDATEVerify package completed to P&ID: DPS-2010-1105-500TS3/31/11All tagging to be checked in position and correct to P&ID for all items.TS3/31/11Verify package completed to all General Arrangement drawings.TS3/31/11Confirm all TP locations.TS3/31/11Check for any visible signs of damage.TS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming ________X_______ Non-Conforming _______________TS3/31/113.1.2PipingConfirm that all flanged joints are made up correctly.TS3/31/11Confirm pipe routing, supporting and painting are in accordance to Project Specifications.TS3/31/11Confirm all paintwork is undamaged.TS3/31/11Confirm piping color banding and identification is correct (if applicable).TS3/31/11Review project documentation.TS3/31/11Check for any required actions: Conforming _________X_________ Non-Conforming _______________TS3/31/113.1.3VesselsConfirm all hold down bolts are correctly fitted.TS3/31/11Confirm vessel nameplates are correct and securely fittedTS3/31/11Confirm vessel hand hole bolts and gaskets are correctly fitted.TS3/31/11Confirm all paintwork is undamaged.TS3/31/11Review project documentation.TS3/31/11Check for any required actions: Conforming ________X_______ Non-Conforming _______________TS3/31/113.1.4AccessConfirm access for operation and maintenance of all valves,and instruments.TS3/31/11Review project documentation.TS3/31/11Check for any required actions: Conforming ________X_______ Non-Conforming _______________TS3/31/11Checklist3.2Instrument ChecklistSIGNDATE3.2.1Level GaugesCheck mechanical mounting is correct and firm.TS3/31/11Check instrument for any visible sign of damage.TS3/31/11Verify material certification available with instrumentTS3/31/11Verify nameplate is correct and securely fitted.TS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming _______X________ Non-Conforming _______________TS3/31/113.2.2Level Control ValvesCheck valve failure mode for loss of air supply.TS3/31/11Check wiring termination cable tag is correct and securely fastenedTS3/31/11Check mechanical mounting is correct and firm.TS3/31/11Confirm that instrument is installed in correct positionTS3/31/11Test with increasing and decreasing signal 0%, 25%, 50%, 75%, 100%, 75%, 50%, 25%, 0%TS3/31/11Check instrument for any visible sign of damage.TS3/31/11Verify material certification availableTS3/31/11Verify nameplate is correct and securely fitted.TS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming _______X_______ Non-Conforming _______________TS3/31/113.2.3Differential Pressure TransmittersWill be powered and checked at ambient pressure.TS3/31/11Check wiring termination cable tag is correct and securely fastenedTS3/31/11Confirm that instrument is installed in correct postionTS3/31/11Check wiring termination cable tag is correct and securely fastenedTS3/31/11Confirm that instrument is installed in correct postionTS3/31/11Check mechanical mounting is correct and firm.TS3/31/11Check instrument installed in correct position.TS3/31/11Check instrument for any visible sign of damage.TS3/31/11Verify nameplate is correct and securely fitted.TS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming _______X________ Non-Conforming _______________TS3/31/113.2.4Pressure Indicators/Pressure Differential Indicator/Temperature Indicators/Flow IndicatorsCheck mechanical mounting is correct and firm.TS3/31/11Check instrument installed in correct position.TS3/31/11Check indicator is reading correct ambient conditions.TS3/31/11Check instrument for any visible sign of damage.TS3/31/11Verify that instrument is installed with correct accessoriesTS3/31/11Verify nameplate is correct and securely fitted.TS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming ________X_______ Non-Conforming _______________TS3/31/113.2.5Pressure Relief ValvesCheck mechanical mounting is correct and firm.TS3/31/11Check instrument installed in correct position.TS3/31/11Check for any visible sign of damage.TS3/31/11Verify nameplate is correct and securely fitted.TS3/31/11Review manufacturers set pressure certification.TS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming ________X_______ Non-Conforming _______________TS3/31/113.2.6Level SwitchesCheck mechanical mounting is correct and firm.TS3/31/11Check instrument installed in correct position.TS3/31/11Check for any visible sign of damage.TS3/31/11Verify nameplate is correct and securely fitted.TS3/31/11Review manufacturers set pressure certification.TS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming _______X________ Non-Conforming _______________TS3/31/11Checklist3.3Electrical ChecklistSIGNDATE3.3.1Junction Box Installation and TestsConfirm junction box and wiring installation is complete and in accordance with project approved documents and contract specifications.TS3/31/11Confirm all junction boxes are adequately supported and the installation does not foul operators access.TS3/31/11Verify junction box is tagged as per the cable schedule.TS3/31/11Confirm all items are correctly earth bonded.TS3/31/11Confirm all electrical equipment is certified for the hazardous environment and that correct certification is available for review.TS3/31/11Confirm that all spare entries are plugged with certified plugsTS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming ______X_________ Non-Conforming _______________TS3/31/113.3.2General InspectionsVerify materials agree with Bill of MaterialTS3/31/11Verify dimensions agree with AssemblyTS3/31/11Verify component layout agrees with AssemblyTS3/31/11Verify fuses are installed and ratingsTS3/31/11Verify equipment grounding connections to chassis and instrument ground bussesTS3/31/113.3.3DocumentationJunction Box Layout drawing number DSP-2010-1105-401TS3/31/11Junction Box Wiring drawing number DSP-2010-1105-402TS3/31/113.3.4ConformityCheck for any required actions: Conforming _______X________ Non-Conforming _______________TS3/31/113.3.5Cable Installation and TestsConfirm the instrument wiring installation is complete and in accordance with project approved documents and contract specifications.TS3/31/11Confirm all cable and cable tray is adequately supported and the installation does not foul operators access.TS3/31/11Confirm all cable tray edges are smooth and protected.TS3/31/11Verify all cables are tagged as per the cable schedule.TS3/31/11Confirm all items are correctly earth bonded.TS3/31/11Confirm all electrical equipment is certified for the hazardous environment and that correct certification is available for review.TS3/31/11Review project documentattion.TS3/31/11Check for any required actions: Conforming ________X_______ Non-Conforming _______________TS3/31/11Checklist3.4Documentation VerificationSIGNDATEVerify completion of hydrotest record and stamp from customer inspector.DD3/31/11Verify completion of NDE record and stamp from customer inspector..DD3/31/11Verify completion of coating record and stamp from customer inspector..DD3/31/11Verify availability of Material Test Record and stamp from customer inspector..DD3/31/11Verify availability of instrument calibrations and verification, and stamp from customer inspector..DD3/31/11Verify all instruments' data against the instrument list.TS3/31/11Verify Cause & Effect is approved with no customer comments.TS3/31/11Verify P&ID is approved with no customer comments.TS3/31/11Verify Junction Box Diagram is approved with no customer comments.TS3/31/11Verify Instrument Calibrations and Certification is approved with no customer comments.TS3/31/11Verify on-skid cable routing and earthing is approved with no customer comments.TS3/31/11CPE Representative:Date:Client Representative:Date: