ISA 62381-2011 Automation Systems in the Process Industry C Factory Acceptance Test (FAT) Site Acceptance Test (SAT) and Site Integration Test (SIT).pdf

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1、 AMERICAN NATIONAL STANDARD ANSI/ISA-62381-2011 (IEC 62381 Modified) Automation Systems in the Process Industry Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT) Approved 31 January 2012 ANSI/ISA-62381-2011 (IEC 62381 Modified) Automation Systems in the Proce

2、ss Industry Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT) ISBN: 978-1-937560-22-5 Copyright 2011 by IEC and ISA. All rights reserved. Not for resale. Printed in the United States of America. No part of this publication may be reproduced, stored in a retri

3、eval system, or transmitted in any form or by any means (electronic mechanical, photocopying, recording, or otherwise), without the prior written permission of the Publisher. ISA 67 Alexander Drive P.O. Box 12277 Research Triangle Park, North Carolina 27709 USA - 3 - ANSI/ISA-62381-2011 (IEC 62381 M

4、odified) Preface This preface, as well as all footnotes and annexes, is included for inf ormation purposes and is not part of ANSI/ISA-62381-2011 (IEC 62381 Modified). This document has been prepared as part of the service of ISA toward a goal of uniformity in the field of instrumentation. To be of

5、real value, this document should not be sta tic but should be subject to periodic review. Toward this end, the Society welcomes all comments and criticisms and asks that they be addressed to the Secretary, Standards and Practices Board; ISA; 67 Alexander Drive; P. O. Box 12277; Research Triangle Par

6、k, NC 27709; Telephone (919) 549-8411; Fax (919) 549-8288; E-mail: standardsisa.org. The ISA Standards and Practices Department is aware of the growing need for attention to the metric system of units in general, and the International System of Units (SI) in particular, in the preparation of instrum

7、entation standards. The Department is further aware of the benefits to USA users of ISA standards of incorporating suitable references to the SI (and the metric syste m) in their business and professional dealings with other countries. Toward this end, this Department will endeavor to introduce SI-a

8、cceptable metric units in all new and revised standards, recommended practices, and technical reports to the greatest extent possible. Standard for Use of the International System of Units (SI): The Modern Metric System, published by the American Society for Testing any IEC National Committee intere

9、sted in the subject dealt with may participate in this preparatory work. International, governmental and non-governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely with the International Org anization for Standardization (ISO) in accordance wi

10、th conditions determined by agreement between the two organizations. 2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international consensus of opinion on the relevant subjects since each technical committee has representation from all interested

11、IEC National Committees. 3) IEC Publications have the form of recommendations for international use and are accepted by IEC National Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC Publications is accurate, IEC cannot be held responsible fo

12、r the way in which they are used or for any misinterpretation by any end user. 4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications transparently to the maximum extent possible in their national and regional publications. Any divergence between

13、 any IEC Publication and the corresponding national or regional publication shall be clearly indicated in the latter. 5) IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any equipment declared to be in conformity with an IEC Publication. 6) All users

14、should ensure that they have the latest edition of this publication. 7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and members of its technical committees and IEC National Committees for any personal injury, property damage or other

15、damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC Publications. 8) Attention is drawn to the Normative references cited in this publication. Use

16、 of the referenced publications is indispensable for the correct application of this publication. 9) Attention is drawn to the possibility that some of the elements of this IEC Publication may b e the subject of patent rights. IEC shall not be held responsible for identifying any or all such patent

17、rights. International Standard IEC 62381 has been prepared by IEC technical committee 65: Industrial-process measurement and control. This standard cancels and replaces IEC/PAS 62381 published in 2004. This first edition constitutes a technical revision. The text of this standard is based on the fol

18、lowing documents: FDIS Report on voting 65/385/FDIS 65/394/RVD Full information on the voting for the approval of this standard can be found in the report on voting indicated in the above table. This publication has been drafted in accordance with the ISO/IEC Directives, Part 2. The committee has de

19、cided that the contents of this publication will remain unch anged until the maintenance result date indicated on the IEC web site under “http:/webstore.iec.ch“ in the data related to the specific publication. At this date, the publication will be reconfirmed, withdrawn, ANSI/ISA-62381-2011 (IEC 623

20、81 Modified) - 8 - replaced by a revised edition, or amended. A bilingual version of this publication may be issued at a later date. - 9 - ANSI/ISA-62381-2011 (IEC 62381 Modified) CONTENTS 1 Scope . 11 1.1 General applicability 11 1.2 Exclusions . 11 1.2.1 Prior and post activities . 11 1.2.2 Regula

21、ted industries 11 1.2.3 Safety Instrumented Systems 11 1.2.4 Manufacturing Execution Systems . 11 2 Normative references . 11 3 Definitions of Terms and Abbreviations . 12 3.2 Abbreviations for terms not otherwise defined 14 4 Testing of automation systems . 15 5 Factory Acceptance Test (FAT) 18 5.1

22、 Performance 18 5.2 Pre-FAT activities 18 5.2.1 Vendor tests 18 5.2.2 Documentation 18 5.2.3 Test plan . 18 5.2.4 Test schedule 19 5.3 FAT Punch List 19 5.3.1 Correction 20 5.3.2 Correction after FAT 20 5.4 Documentation of FAT . 20 5.4.1 FAT report . 20 5.4.2 FAT documentation . 20 5.5 FAT completi

23、on . 21 6 Site Acceptance Test (SAT) 21 6.1 Performance 21 6.2 Pre-SAT activities 21 6.2.1 Test Plan . 21 6.2.2 Test schedule 22 6.3 SAT Punch List 22 6.3.1 Correction 23 6.3.2 Correction after SAT 23 6.4 Documentation of the SAT . 23 6.4.1 SAT report . 23 6.4.2 6.4.2 SAT Documentation 23 6.5 SAT Co

24、mpletion 24 7 Site Integration Test (SIT) 24 7.1 Performance 24 7.2 Pre-SIT activities . 24 7.2.1 Test Plan . 24 7.2.2 Test schedule 25 7.3 SIT Punch list 25 ANSI/ISA-62381-2011 (IEC 62381 Modified) - 10 - 7.3.1 Correction 25 7.3.2 Correction after SIT . 25 7.4 Documentation of the SIT 26 7.4.1 SIT

25、report 26 7.4.2 SIT Documentation 26 7.5 SIT Completion 26 Annex A Factory Acceptance Testing Checklist . 27 Annex B Site Acceptance Testing Checklist 33 Annex C Site Integration Testing Checklist . 35 FIGURES Figure 1 Diagram depicting typical sequence of events for FAT, SAT and SIT with respect to

26、 the project milestones. 15 Figure 2 Diagram depicting the relationship for the SAT and SIT between the BPCS and subsystems . 16 Figure 3 Diagram depicting the relationship between the FAT, SAT and SIT with the relevant plant levels 17 - 11 - ANSI/ISA-62381-2011 (IEC 62381 Modified) AUTOMATION SYSTE

27、MS IN THE PROCESS INDUSTRY FACTORY ACCEPTANCE TEST (FAT), SITE ACCEPTANCE TEST (SAT), AND SITE INTEGRATION TEST (SIT) 1 Scope 1.1 General applicability This standard defines procedures and specifications for the Factory Acceptance Test (FAT), the Site Acceptance Test (SAT), and the Site Integration

28、Test (SIT) of an industrial automation system. These tests are carried out to prove that the automation system meets the requirements of the specification. The annexes of this standard contain forms which may be used in the development of specific test procedures for a specific automation system. 1.

29、2 Exclusions 1.2.1 Prior and post activities Engineering and manufacturing activities prior to or subsequent to the FAT, SAT and SIT, such as loop checks and commissioning, are not covered by this standard. The intent of this standard is to provide a means for all parties, including the owner, the c

30、ontractor and the vendor, to clearly establish and agree on the scope of activities and responsibilities involved in performing these tests in order to achieve a timely delivery and acceptance of the automation system. The activities described in this standard can be taken as a guideline and adapted

31、 to the specific requirements of the process/plant/equipment. 1.2.2 Regulated industries For applications in the pharmaceutical or other highly specialized industries, additional gui delines (for example, Good Automated Manufacturing Practice (GAMP), definitions and stipulations should apply in acco

32、rdance with existing standards, for example, for GMP Compliance 21 CFR (FDA) and the Standard Operating Procedure of the European Medicines Agency (SOP/INSP/2003). 1.2.3 Safety Instrumented Systems For additional guidance on specific requirements on the installation, commissioning, start-up, and val

33、idation of safety instrumented systems, refer to ANSI/ISA84.00.012004 (IEC 61511 Mod) Part 1 Functional Safety: Safety Instrumented Systems for the Process Industry Sector Part 1: Framework, Definitions, System, Hardware and Software Requirements. 1.2.4 Manufacturing Execution Systems Testing and ve

34、rification of manufacturing execution systems (MES) is not covered by this standard. 2 Normative references The following referenced documents are useful for the application of this standard. For dated references, only the edition cited applies. For undated references, the latest edition of the refe

35、renced document (including any amendments) applies. ANSI/ISA-62381-2011 (IEC 62381 Modified) - 12 - ANSI/ISA84.00.012004 (IEC 61511 Mod) Part 1 Functional Safety: Safety Instrumented Systems for the Process Industry Sector Part 1: Framework, Definitions, System, Hardware and Software Requirements AN

36、SI/ISA-5.06.01-2007, Functional Requirements Documentation for Control Software Applications 3 Definitions of terms and abbreviations 3.1 Definitions The common abbreviation is shown in parenthesis after the term. 3.1.1 automation system general term referring to the complete system for the monitori

37、ng and control of production facilities. An automation system would include a BPCS and may also include an SIS and control sub-systems. 3.1.2 Basic Process Control System (BPCS) system which responds to input signals from the process, its associated equipment, other programmable systems and/or an op

38、erator and generates output signals causing the process and its associated equipment to operate in the desired manner but which does not perform any safety instrumented functions with a claimed SIL 1 3.1.3 buyer company which is functionally responsible for the automation system purchased from vendo

39、r, i.e. either the owner or the contractor 3.1.4 contractor organization or person(s) given a written order to provide a service or undertake specified work NOTE The function of contractor can be fulfilled by the owner. 3.1.5 control system a system that responds to input signals from the equipment

40、under control and/or from an operator and generates output signals that cause the equipment under control to operate in the desired manner 3.1.6 Factory Acceptance Test (FAT) activity, including inspection and testing, to demonstrate that the automation system, subsystem, or component is in accordan

41、ce with the specification and is typically conducted at the vendors facility - 13 - ANSI/ISA-62381-2011 (IEC 62381 Modified) 3.1.7 Functional Design Specification (FDS) document that contains the complete description of all functional requirements for realization of the users requirements for the au

42、tomation system 3.1.8 owner company that owns the production facilities where the automation system will be installed 3.1.9 process industry industry that has a continuous or batch flow and uses chemical reactions, separations, or mixing techniques in order to create new products, modify existing pr

43、oducts or treat was te and includes the following types of industries: chemical, petrochemical, water and wastewater treatment, paper, cement, microprocessor, etc. It does not include such industries as equipment/machine manufacturing or other similar industries. It does not include industries which

44、 are subject to regulations which have specialized validation requirements. 3.1.10 punch list list of all problems found, the corrective action to be taken, person responsible and date completed. Other classifications can be added as required. 3.1.11 Safety Instrumented Function (SIF) safety functio

45、n with a specified safety integrity level which is necessary to achieve functional safety and which can be either a safety instrumented protection function or a safety instrumented control function 3.1.12 Safety Instrumented System (SIS) instrumented system used to implement one or more safety instr

46、umented functions. An SIS is composed of any combination of sensor (s), logic solver (s), and final element (s) 3.1.13 Safety Integrity Level (SIL) discrete level (one out of four) for specifying the safety integrity requirements of the safety instrumented functions to be allocated to the safety ins

47、trumented systems. Safety integrity level 4 has the highest level of safety integrity; safety integrity level 1 has the low est. 3.1.14 Safety Requirements Specification (SRS) specification that contains all the requirements of the safety instrumented functions that have to be performed by the safet

48、y instrumented systems 3.1.15 Site Acceptance Test (SAT) activity, including inspection and testing, conducted at the site of the installation, to demonstrate that the installation of the automation system, any subsystem, or any component is in accordance with the applicable standards, codes, specif

49、ications and installation instructions ANSI/ISA-62381-2011 (IEC 62381 Modified) - 14 - 3.1.16 Site Integration Test (SIT) activity, including inspection and testing, conducted at the site of the installation, to demonstrate that the merging of the various subsystems and components into one overall automation system is completed and that all components work together as specified 3.1.17 tag unique identifier assigned to a process measurement, calculation, or device within the automation system 3.1.18 User Requirements Specification (URS) document that defin