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R-0 For approval

Rev No. Issue Date Description Remarks

SITE ACCEPTANCE TEST

Client Name Bayer

Vendor’s Name Exergy LLC / Hydropure Systems

Project Name Bayer Shawnee R&D

PO No 140524-P-100

Document Name

Site Acceptance Test

Document No HPS-PR 247-SAT Rev 0

Reference Drawing No

02922 Rev B

02923 Rev B

Issue Date October 31, 2014

Client Name Bayer Project POINT OF USE COOLER

Document Name Site Acceptance Test ( SAT )

Document No. HPS-PR 247-SAT Rev No - 0

Issue Date October 31, 2014 of 23

TABLE OF CONTENT

1.0 APPROVAL .......................................................................................................... 4

2.0 SAT PLAN ............................................................................................................ 5

2.1 INTRODUCTION .................................................................................................. 5

2.2 ABBREVIATIONS ................................................................................................. 5

2.3 REFERENCE DOCUMENTS .................................................................................. 5

2.4 PURPOSE OF THE TESTS ..................................................................................... 5

2.5 OBJECT DESCRIPTION ........................................................................................ 6

2.6 SAT PERFORMANCE ........................................................................................... 6

2.6.1 RESPONSIBILITIES ............................................................................................... 6

2.6.2 GOOD TESTING PRACTICE .................................................................................. 6

2.6.3 HOW TO FILL IN THE TESTS / INSPECTIONS ....................................................... 7

2.6.4 DEVIATION HANDLING....................................................................................... 8

2.7 ACCEPTANCE CRITERIA ...................................................................................... 8

2.8 SAT RESULT ........................................................................................................ 8

3.0 TESTS .................................................................................................................. 9

3.1 MECHANICAL & DOCUMENTATION INSPECTIONS .......................................... 10

3.1.1 FAT CLOSURE .................................................................................................. 10

3.1.2 VERIFICATION OF COMPONENTS AS PER P & ID ............................................. 11

3.1.3 VERIFICATION OF ELECTRICALS ....................................................................... 12

3.1.4 VERIFICATION OF COMPONENT SPECIFICATIONS ........................................... 13

3.1.5 REVIEW OF TEST CERTIFICATES & TEST REPORTS ........................................... 14

3.1.6 CHECK FOR AVAILABILITY OF MANUAL & DATA .............................................. 15

3.2 SYSTEM ACCEPTANCE TEST ............................................................................. 16

3.2.1 TO CHECK FUNCTIONAL LOGIC & ALARM ....................................................... 16

3.2.2 TO CHECK THE I/O ........................................................................................... 17

3.3 OPERATION TEST ............................................................................................. 18

3.3.1 LEAK TEST ......................................................................................................... 18

3.3.2 CHECK FOR SYSTEM OPERATING PARAMETERS………………………………….……….19

4.0 SAT REPORT ..................................................................................................... 20

4.1 PURPOSE OF THE REPORT ............................................................................... 20

4.2 DEVIATIONS ..................................................................................................... 20





4.3 RETESTS ............................................................................................................ 22

4.4 FINAL APPROVAL ............................................................................................. 23





1.0 APPROVAL

Signatures on this page indicate that this document has been reviewed, checked and

approved by the concerned persons. It shall be signed and dated as shown below.

Department Name Designation Signature Date

Exergy, LLC

Project Engineer

Project Manager

Bayer

Engineering

Validation

QA





2.0 SAT Plan

2.1 Introduction

Point of Use cooler is specially designed for cooling of PW/WFI water in loop at required temperature. It contains Sanitary Type Double Tube Sheet Heat Exchangers, which reduces PW Water temperature from 65 Deg. C to 30 Deg. C at maximum flow rate of 5 GPM. Chilled Water at the inlet of Heat Exchanger is required at Temperature of 5.5 Deg. C at a flow rate of 8.6 GPM. The SAT shall show that the Point of Use Cooler is manufactured and operates in accordance with the design specifications, functional logics and operating Instructions. The SAT is divided into three test sections:

Mechanical & Documentation Inspections

Hardware Acceptance Test

Operation Test

2.2 Abbreviations

SAT Site Acceptance Test MOC Material of Construction TC Tri Clover Ra Average Roughness NLT Not Less Than

2.3 Reference Documents

1. P & ID 2. Design Qualification 3. Test Certificates 4. Manuals & data sheet check 5. GA Drawings 6. Control Wiring Diagram

7. FAT Report

2.4 Purpose of the Tests

The purpose of the SAT is to test, inspect and show that the Point of Use Cooler is installed correctly according to mechanical and electrical specifications, that components are marked and located according to the valid P & ID and that the system works according to the Functional Logics.





2.5 Object description

Product : Point of Use Cooler Function : for cooling product water in loop Manufacturer : Exergy LLC / Hydropure Systems Project number : Year of manufacture :

2.6 SAT Performance

The tester shall first read this SAT Plan section, then perform the tests and finally fill in the Report in the end of this document. The performance of the specific Factory Acceptance Tests is described for each test in the test sheets.

2.6.1 Responsibilities

The person who performs the tests (Tester) is responsible for the execution of the tests. The tester confirms with his/her initials that the test is performed correctly. A second person, (Witness) checks if the test was correctly performed and that the result was in accordance with the acceptance criteria and if not, that a deviation report is filled in.

2.6.2 Good Testing Practice

A (archive resistance) blue pen shall be used for the SAT tests, for approvals and for the corrections in the attached design documents (such as Tank Drawing). Correction fluid and other correction techniques that obscure the original entry shall not be used. Spelling mistakes and other changes shall be corrected as follows:

Ex: Installation 20/01/04 Initials

Deviations are recorded and traceable. Fields in a test, which is not filled out, shall be clearly marked as N/A (not applicable) Attachments such as Drawing and MOC check lists shall be marked with the name of the SAT test and date and initials of the tester. This shall be written on all attached page

Ex) Attachment to test FAT 2.1.1 Components 20/01/04 Initials

When the SAT is performed and completed, all documents associated with the SAT shall be reviewed for correctness and completeness before the SAT Report section is filled in.

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Cross-Out

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Inserted Text

The Exergy Site Representative will review with the Exergy Project Manager all relevant Site Acceptance Testing (SAT)documentations prior to start-up and have a complete understanding of the procedures for start-up. SAT will reflect, as closely as possible, parameters and testing in the Factory Acceptance Tests (FAT).

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Inserted Text

The Exergy Site Representative will be responsible for observing the results and recording of the step-by-step SAT with the customer representatives. All results, deviations and notes will be recorded in the Operation Test.





2.6.3 How to fill in the tests / inspections

Name of Test

Test procedure

Required document(s) / equipment

Acceptance criteria

1)

Pass /Fail + Deviation no

2)

Comment

3)

Tester, Date / Initials

4)

Witness, Date /initials

5)

For a description of the different sections of each test script please see below: 1) The acceptance criteria are specified in this square and if values are to be recorded there

will also be an “Actual value” result table provided. The tester shall Fill in the actual value observed and then indicate a “Pass” or “Fail”. in the square provided.

Description Required value Actual value Result (Pass /Fail)

Ex) Temperature at TT270.6.3

> 80°C

2) If the acceptance criteria are fulfilled, “Pass” is written in the square. If not, “Fail” and

deviation number(s) are written, and a deviation report is filled in. (See deviation Report) 3) Comment: This field is used to provide additional information on how the test was

executed, any anomalies identified, additional explanatory information and additional details if required to explain what occurred in a particular deviation, the tester should include the Date of the execution of the test / inspection and initials of the tester.

4) The witness should include the date of the execution of the test /inspection and initials of

witness.





2.6.4 Deviation handling

A Deviation report regarding SAT is filled in, if the result of a test is not according to the acceptance criteria. It could be necessary, to write more than one deviation report per test. In this case all deviation numbers have to be filled in the test sheet.

2.7 Acceptance criteria

The acceptance criteria for each Site Acceptance Test are specified in the test sheets.

2.8 SAT Result

The result of the SAT will be concluded in the SAT Report section.





3.0 Tests

Company Name Initials

XXXXXXXXX

XXXXXXXXX

Exergy LLC

Exergy LLC

Attachments to this Site acceptance test (To be filled in on the day for SAT start)

P & ID No. And Revision No.

Components List, Revision No.

Control Panel Wiring Diagram, Revision No.





3.1 Mechanical & Documentation Inspections

Name of test

3.1.1 FAT Closure

Test procedure

Check if the retests specified in the FAT Report are performed, and signed in the FAT test sheets. If not, perform those tests now and write “Pass” or “Fail” for the corresponding test in the FAT document. All the deviations should be closed before start of SAT.


The FAT Report.

Acceptance criteria

All the Factory Acceptance Tests shall have been executed.

Pass / Fail + Deviation no’s

Comment


Witness, Date / Initials

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Sticky Note

The mechanical (mounting, piping of water and air, leak detection), electrical (incoming power and control wiring, grounding) inspections should be in a single test document - PRE-OPERATION CHECK OUT. This is the first step in the start-up.





Name of test

3.1.2 Verification of components as per P & ID

Test procedure

Check that the Point of Use Cooler is built according to the P & ID and that all equipment/components are marked with the correct Tag Numbers as shown on the P & ID. Write, “Pass” at the valve /instrument /component on the P & ID if both criteria are fulfilled. If not write “Fail” and the deviation number on the drawing. Corrections shall be written with an archive safe pen on the P & ID. The tester, witness shall Sign & date the P & ID marked up for this test. Attach the marked up P & ID to this document.


P & ID

Acceptance criteria

All valves, instruments and components shall be located according to the P & ID and be marked with the correct Tag Number.


Comment



dhodge

Sticky Note

This section is not required and should be covered in the submittal process. Hydropure needs to manufacture to the submittal.

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Sticky Note

This will be marked on the final drawing. Tags locations could be part of the list of the PRE-OPERATION CHECK OUT.





Name of test

3.1.3 Verification of Electricals

Test procedure

Check that the Control panel is built according to the circuit diagram and that the items are marked with the correct ferrule / tag numbers. Write “Pass” at the valve/instrument /component on the circuit diagrams if both criteria are fulfilled. If not, write “Fail” and the deviation number in the drawing. Sign & date the circuit diagram. Attach the circuit diagram used to verify the actual system (Electrical connections, Wiring) showing the verification results to his document.


Circuit Diagram

Acceptance criteria

All the items shall be located according to the circuit and be marked with the correct Ferrule/Tag numbers.


Comment



dhodge

Sticky Note

Part of submittals. Not part of the start-up





Name of test

3.1.4 Verification of Component specifications

Test procedure

Check that Valves, Instruments and Components installed are in accordance with their description and specification as mentioned in the List /design qualification. Write, “Pass” at the Valve /Instrument /Component in the list, if the item is in compliance with the specifications. If not write “Fail” and the deviation number in the list. Corrections shall be written with an archive safe pen in the component list. The Tester, Witness shall Sign & date in the bottom of each page of the marked up component list. Attach the marked up Component List to this document.


Component List /Design Qualification

Acceptance criteria

All Valves, Instruments and Components shall be in the accordance with their description and specifications in the Component List /Design Qualification.


Comment



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Sticky Note

Part of the submittal. Not required for startup





Name of test

3.1.5 Review of Test Certificates & Test Reports

Test procedure

Check that test certificates / Test Reports for components/ piping /fittings, and other Inspection /test Reports are available as per the component list. Write, “Pass” at the Valve /Instrument /Component in the list, if the required certificate is present. If not write “Fail” and the deviation number. Sign & date in the bottom of each page. Attach the used component list to this document.

Needed document(s) / equipment

Certificates and the Component List.

Acceptance criteria

Certificates shall be present according to specifications in the Component list.


Comment



dhodge

Sticky Note

Part of submittal. Not required for startup





Name of test

3.1.6 Check for availability of Manuals / Data

Test procedure

Check that Instruments/Component manual are present for instruments from the supplier as per the component list. Write, “Pass” at the Instrument /Component in the list, if the required certificate is present. If not write “Fail” and the deviation number. Sign & date in the bottom of each page. Attach the used component list to this document.


Manual and the Component List.

Acceptance criteria

Certificates shall be present according to specifications in the Component list.


Comment



dhodge

Sticky Note

Manuals should be provided at startup. Number of copies should be determined during submittal process. FAT results should be available for comparison.





3.2 System Acceptance Test

Name of test

3.2.1 To Check Functional Logic & Alarm

Test procedure

Test Procedure should be as per the Interlock and Alarm list of Design qualification, to challenge each & every alarm provided in the system. All the alarm will be checked during SAT.


Interlock and Alarm list

Acceptance criteria

All alarm shall be performed as per Interlock and Alarm list.


Comment



dhodge

Sticky Note

List of alrams and interlocks should be listed, tested and intialed.





Name of test

3.2.2 To Check I/O ‘s

Test procedure

Test Procedure should be to check each & every Digital & Analogue Input & Output of PLC, as per the I/O List mentioned in design qualification.


I/O List

Acceptance criteria

All Inputs & Outputs shall be performed as per I/O List.


Comment



dhodge

Sticky Note

Part of submittal process and final documentation. No required in startup.





3.3 Operation Test

Name of test

3.3.1 Leak Test

Test procedure

Put the Point of Use Cooler into “Operation mode” by drawing product water from any one user

point. During operation, the operating pressure is maintained for product water circuit as well as cooling water circuit.

Let the Point of Use Cooler run for 15 mins.

Check the tri-clover connections and components for leak test by visual inspection.

If leakage is found, mark the leaking connection and/or components position on P&ID & rectify the leak.


N/A

Acceptance criteria

No leaks shall be observed in the Point of Use Cooler.


Comment



dhodge

Sticky Note

Want to run this test in PRE-OPERATION CHECK OUT.





Name of test

3.3.2 Check for System Operating parameters

Test procedure

Operate the Point of Use Cooler by drawing water from any sampling point.

Fill in the log sheet and note the flow & temperature of product water exiting from sampling point.


Design Qualification

Acceptance criteria

Flow and temperature of product water exiting from sampling point shall meet the required parameters mentioned in design qualification.


Comment



dhodge

Sticky Note

This description should include a sequence of events to show what normal operation will be. 1. start water flow - check HMI shows XX 2. etc.





4.0 SAT Report

4.1 Purpose of the Report

To conclude the performed Site Acceptance Test of Point of use Cooler.

4.2 Deviations

The deviations shall be measured until the time for SAT.

Deviation summary

Total amount of attached deviations:





Deviation list:

Deviation No. Description

Noted by: (Date / Sign)

Completed by ( Date / Sign)

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Sticky Note

This form should be included in the final SAT with each point of testing.





4.3 Retests

All tests that for some reason were not executed shall be performed after completion.

Test No. Test Name Test

completed

(Yes / No)

Mechanical & Documentation Inspections

3.1.1 FAT Closure

3.1.2 Verification of components as per P&ID

3.1.3 Verification of Electricals

3.1.4 Verification of Component specifications

3.1.5 Review of Test Certificates and Test Reports

3.1.6 Check for availability of Manuals & data

System Acceptance tests

3.2.1 TO check functional logic and alarm

3.2.2 TO check I / O list

Operation Tests

3.3.1 Leak Tests

3.3.2 Check for System Operating parameters.





4.4 Final approval

To be signed by the SAT participants. If the customer has chosen not to attend the SAT, HYDROPURE SYSTEMS will decide about the project handover.

POINT OF USE COOLER is validated and handed over to client

Name & Designation

Company

Sign & Date

EXERGY LLC

EXERGY LLC

CUSTOMER

CUSTOMER