Tests are needed at different stages of each automation project in order to ensure¬†success.
The¬†two¬†most significant tests in¬†automation projects are:
- Workshop tests (FAT).
- On-site tests (SAT).
These tests take place when¬†the control system equipment is¬†in Zeus Control workshop before being sent¬†to its¬†final destination in the industrial production plant.
These tests, known as FAT (Factory Acceptance Test), are particularly relevant because they¬†ensure¬†hardware and software¬†delivered¬†complies¬†with customer requirements. These tests are¬†associated with¬†formal acceptance by the customer.
After¬†assembling the control system hardware, configuring¬†and loading the software,¬†the whole system goes through¬†tests with¬†previously established protocols and approved by the client.¬†First,¬†the hardware is tested, essentially mechanical and electrical aspects, and then the control functionality, which depends directly on software, is tested.
Typically performed tests in Zeus Control workshops are:
General and electrical tests
- Each component is the one established in the engineering documentation.
- The location of each component in the cabinet is the one established in engineering documention.
- Components‚Äô marking.
- Continuity between points connected by wire. All wiring in cabinet.
- Continuity on safety wires.
- Galvanic isolation between pairs of¬†busbars and with reference to earth.
- Dielectric strength tests.
- Electrical functionality tests.
Checking internal communications in the¬†control system:
- Acquisition of wired signals.
- Generation of wired signals.
- Checking redundancies in power supplies and controllers.
- Checking programming:¬†control loops, process logic, presented values¬†on screen displays,¬†alarms, events, etc.
Once the control system equipment has been installed in the plant, tests are conducted¬†to ensure¬†the system is fully prepared to control the production process.
On-site tests are focused on verifying installation and functionality.¬†Not duplicating the previously carried out¬†workshop tests.
On-site tests¬†usually verify:
- Wiring between electrical cabinets and consumers.
- Wiring between¬†control cabinets,¬†sensor transmitters¬†and actuators was¬†carried out properly.
- Control system does not present any abnormality when¬†fed¬†electrically for the first time on-site.
- Communications between¬†control system components.
- Every wired input signal is¬†properly received in the¬†control system.
- Every wired output signal is¬†properly received by¬†actuators and/or consumers.