IEC PAS 62381:2004

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IEC
AVAILABLE
PAS 62381
SPECIFICATION
First edition
Pre-Standard
2004-01
Activities during the factory acceptance
test (FAT), site acceptance test (SAT),
and site integration test (SIT)
for automation systems
in the process industry
Reference number
IEC/PAS 62381:2004(E)
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PUBLICLY
IEC
AVAILABLE
PAS 62381
SPECIFICATION
First edition
Pre-Standard
2004-01
Activities during the factory acceptance
test (FAT), site acceptance test (SAT),
and site integration test (SIT)
for automation systems
in the process industry
© IEC 2004 ⎯ Copyright - all rights reserved
No part of this publication may be reproduced or utilized in any form or by any means, electronic or
mechanical, including photocopying and microfilm, without permission in writing from the publisher.
International Electrotechnical Commission, 3, rue de Varembé, PO Box 131, CH-1211 Geneva 20, Switzerland
Telephone: +41 22 919 02 11 Telefax: +41 22 919 03 00 E-mail: inmail@iec.ch Web: www.iec.ch
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International Electrotechnical Commission
МеждународнаяЭлектротехническаяКомиссия
For price, see current catalogue

– 2 – PAS 62381 © IEC:2004 (E)

CONTENTS
FOREWORD .3

INTRODUCTION.3

1 Scope .5

2 Definitions.8

3 Abbreviations.9

4 General preparation before conducting the FAT.10

4.1 Documents typically prepared by the OWNER/CONTRACTOR .10

4.2 Documents typically prepared by the VENDOR .10
5 Factory acceptance test .10
5.1 General.10
5.2 Test schedule .11
5.3 Test procedure .11
5.4 FAT rework.14
5.5 Documentation of FAT in accordance with Annex A.14
6 Site acceptance test.14
6.1 General.14
6.2 Test schedule .15
7 Site integration test.15
7.1 General.15
7.2 Test schedule .15
Annex A (informative) FAT checklists .16
A.1 Documentation check.16
A.2 HW and SW inventory check .16
A.3 Mechanical inspection.17
A.4 Wiring and termination inspection .18
A.5 Start-up text and general system functions.19
A.6 System alarm test.20
A.7 Hardware redundancy and diagnostic check .21
A.8 Visualization/operation .22
A.9 Test of functionality against FBD, FUP, etc. .23
A.10 Complex functionality and operation modes .25

A.11 Integration of subsystems .26
Annex B (informative) SAT checklist.27
Annex C (informative) SIT checklist .28
Annex D (informative) Factory acceptance test certificate.29
Annex E (informative) Site acceptance test certificate.30
Annex F (informative) Site integration test certificate.31
Annex G (informative) Automation system acceptance certificate.32
Annex H (informative) FAT punch list.33
Annex I (informative) SAT punch list .34
Annex J (informative) SIT punch list.35

PAS 62381 © IEC:2004 (E) – 3 –

INTERNATIONAL ELECTROTECHNICAL COMMISSION

____________
ACTIVITIES DURING THE FACTORY ACCEPTANCE TEST (FAT),

SITE ACCEPTANCE TEST (SAT), AND SITE INTEGRATION TEST (SIT)

FOR AUTOMATION SYSTEMS IN THE PROCESS INDUSTRY

FOREWORD
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A PAS is a technical specification not fulfilling the requirements for a standard but made available to
the public.
IEC-PAS 62381 has been processed by IEC technical committee 65: Industrial-process measurement
and control.
The text of this PAS is based on the This PAS was approved for publication
following document: by the P-members of the committee
concerned as indicated in the following
document
Draft PAS Report on voting
65/309/PAS 65/322/RVD
Following publication of this PAS, which is a pre-standard publication, the technical committee or
subcommittee concerned will transform it into an International Standard.

– 4 – PAS 62381 © IEC:2004 (E)

INTRODUCTION
There is an increasing trend in the process industry to shorten the time period for project execution. At

the same time, the complexity of automation systems is being increased due to the number of

connected systems and the use of new technologies, for example, fieldbus systems.

Experience has shown that the owner, the contractor and the vendor have long and extensive

discussions to unambiguously lay down the scope of activities and responsibilities in order to achieve
a timely delivery and acceptance of automation systems.

This document should lead to an improvement and acceleration of the negotiation phase and to a

mutual understanding about the scope of activities of each party.

This document does not reflect the additional interests of industries which are subject to special
requirements such as validation.
The annexes of this standard contain forms which may be used in the test procedures. They are
attached to this publication in Excel format. Buyers of this publication may copy these forms for their
own purposes only in the required amount.
The IEC sells read-only PDF files as a general rule. In the present instance, and quite exceptionally,
to enable the user to fill in the forms, a revisable file is included in a pocket affixed to the back cover of
this publication. Please use the zip/unzip function.
This file can also be downloaded from the Web as a PDF file.

PAS 62381 © IEC:2004 (E) – 5 –

ACTIVITIES DURING THE FACTORY ACCEPTANCE TEST (FAT),

SITE ACCEPTANCE TEST (SAT), AND SITE INTEGRATION TEST (SIT)

FOR AUTOMATION SYSTEMS IN THE PROCESS INDUSTRY

1 Scope
This document defines procedures and specifications for the factory acceptance test (FAT), site

acceptance test (SAT), and site integration test (SIT). These tests are carried out to prove that the

automation system is in accordance with the specification.

Engineering and manufacturing activities prior to these tests are not covered by this document.

The description of activities described in this document can be taken as a guideline and adapted to the
specific requirements of the process/plant/equipment. A typical sequence of activities and events is
shown in Figure 1, their relationship in Figures 2 and 3.

– 6 – PAS 62381 © IEC:2004 (E
Construction Pre-commissioning  Commissioning

Mechanical Completion
Start up
Loop check * Cold commissioning Hot commissioning

Process control system completion
ESD ESD
ESD/DCS
DCS DCS
FAT SAT SIT
Prerequisite for FAT Prerequisite for SAT Prerequisite for SIT

- SW complete - Shipment of system to site - Systems properly connected
- System hooked up - SAT complete
- Proper Installation
- Vendor in-house test
- System start up
*The loop check can actually be started during the construction phase once the required infrastructure has been installed.
Figure 1 – Diagram depicting a typical sequence of events for FAT, SAT and SIT
with respect to the project milestones

PAS 62381 © IEC:2004 (E) – 7 –

Figure 2 – Diagram depicting the relationship for the SAT and the SIT
between the DCS and subsystems

– 8 – PAS 62381 © IEC:2004 (E)

Typical DCS
Operator level
Process level
Operator level
Field device
Hart, etc
Loop check
Loop check
Loop check
Figure 3 – Diagram depicting the relationship between the FAT, the SAT and the SIT
with the relevant plant levels
2 Definitions
For the purposes of this document the following definitions apply.
2.1
automation system
DCS- or PLC- based system for the monitoring and controlling of production facilities in the process
industry, including control systems based on fieldbus technologies
2.2
tag
an unambiguous alphanumerical descriptor which identifies a sensor or actuator
2.3
factory acceptance test
activity to demonstrate that the vendor system and additional supplied systems are in accordance with
the specification
2.4
site acceptance test
activity to demonstrate that the installation of the various vendor systems are in accordance with the
applicable specifications and installation instructions
2.5
site integration test
activity to demonstrate that the merging of the various systems to one overall system is completed and
that all components work together as specified

PAS 62381 © IEC:2004 (E) – 9 –

2.6
buyer
company which is functionally responsible for the automation system purchased from the vendor, i.e.

either the owner or the contractor

2.7
owner
company that hired a contractor to build a chemical plant, petrochemical plant, etc.

2.8
contractor
company which is hired by the owner to design and build a chemical plant, petrochemical plant, etc.

NOTE The function of contractor can be fulfilled by the owner.
2.9
vendor
manufacturer or distributor of the automation system
2.10
process Industry
industry that uses chemical reactions, separations, or mixing techniques in order to create new
products, modify existing products or treat waste and includes the following types of industries:
chemical, petrochemical, waste treatment, paper, cement, etc. It does not include such industries as
equipment/machine manufacturing or other similar industries. Industries which are subject to special
requirements and or validation, etc., are also not included
2.11
project design specification (PDS)
document that defines detailed information needed to implement the functionality described in the PFS
2.12
project functional specification (PFS)
document that contains the vendor`s response to the requirements the buyer made prior to starting the
project with the vendor
3 Abbreviations
C&E Cause and Effect Diagram
DCS Distributed control system
ESD Emergency shut down system
FAT Factory acceptance testing
FBD Functional block diagram
FUP Function plan
HMI Human machine interface
HW Hardware
MC Mechanical completion
PDS Project design specifications
PFS Project functional specification
PLC Programmable logic controller
SAT Site acceptance test
SIT Site integration test
SW Software
– 10 – PAS 62381 © IEC:2004 (E)

4 General preparation before conducting the FAT

Prior to commencing FAT, the VENDOR shall complete full in-house testing. Test reports shall be

available for inspection.
All relevant documents shall be prepared for use during the FAT. The following list shows documents

typically used. The list should be adapted to be specific to the project.

4.1 Documents typically prepared by the OWNER/CONTRACTOR

– Specifications
– Preceding agreement(s)
– Function plans
– Cause and effect diagrams
– Sequential functional charts
– Sketches of operator displays and relevant text
– Control narratives
– Instrument index, for example TAG - Service text – I/O type - Scaling - Units
– Alarm message list, for example TAG - Type of alarm - Sorting criteria (priority, plant area)
– Setpoint, control, effect and safety directions
– Interlock list, for example interlocks assigned to each sensor/acuator, software (DCS) and
hardware (ESD)
4.2 Documents typically prepared by the VENDOR
– System documentation
– Manuals, system data sheets, certificates
– System layout
– Hardware layout
– Description of interfaces
– I/O list
– Graphic printouts
– Configuration printout
– In-house test reports
– List of deliveries (hardware, software, application, and licenses)

5 Factory acceptance test
5.1 General
The FAT shall be performed by the VENDOR. The BUYER should witness the test activities.
The FAT shall comprise the following areas
– project relevant scope of supply;
– application-related functions of automation system from I/O to HMI;
– system related functions;
– adequate infrastructure shall be provided by the VENDOR.
The FAT shall be conducted using the Annex A checklists.

PAS 62381 © IEC:2004 (E) – 11 –

With respect to the specification, any incomplete work or non-conformances detected during the FAT

shall be recorded on a punch list (Annex H).

Punch items will be categorized as follows:

• to be cleared on the spot, FAT to continue after rectification;

• ongoing rectification during FAT;

• FAT to be repeated;
• modifications to be made after FAT, before the system is shipped to the site;

• remaining work to be rectified, i.e. at site.

The FAT shall be considered complete when the vendor has successfully proven all necessary

functions according FAT procedures and specifications, with the exception of to the mutually agreed
remaining punch list items.
Upon successful completion of the FAT, authorized representatives of the BUYER and the VENDOR
shall sign the factory acceptance test certificate (see Annex D).
5.2 Test schedule
A test schedule (activities and time-schedule) shall be mutually agreed upon between the BUYER and
the VENDOR. The schedule shall include, but is not limited to the following activities:
Item Description
1 Start-up meeting (document review, schedule etc.)
2 Vendor documentation (including in-house test reports) check
3 HW and SW inventory check
4 Mechanical inspection
5 Wiring and termination inspection
6 Start-up test
7 General system functions inclunding Hardware redundancy and diagnostic check
8 Visualization/operation
9 Test of functionality against all documents mentioned in clause 4
10 Complex functionality and operation modes (for example batch, sequence control)
11 Subsystem interface test
12 FAT rework, punch list for onsite (SAT) work
13 FAT close out meeting
5.3 Test procedure
5.3.1 Test set-up
5.3.1.1 Rack/Remote I/O
According to one or more of the following typical scenarios, a complete test shall be carried out:
The following scenario is customary:
• forcing of Rack/Remote I/O by means of simulation devices hooked up at I/O modules
The scenarios listed below depend upon contract/specification requirements
• forcing of I/O by means of SW simulation on processor level;
• forcing of I/O by means of SW simulation on the I/O modules;
• forcing of I/O by means of simulation devices hooked up at field terminals (thus test inclusive
marshalling, process interface (Ex), cross-wiring, system cabling and I/O modules).

– 12 – PAS 62381 © IEC:2004 (E)

5.3.1.2 Bus interfaces
A generic test shall be carried out for each specified type of field device which is compliant to the

relevant standard. This test shall cover the interoperability of the automation system and the device.

• One segment shall be built up and tested with all associated devices linked to it. Selection of the

segment shall be mutually agreed upon.

• In case of distributed control functionality, all concerned segments shall be tested.

• Signals related to segments which are not built up shall be simulated.

• All relevant documents, data sheets, figures (load, cycle time, architecture) shall be reviewed for

all segments.
5.3.1.3 Subsystem connection
The following scenario is customary:
Test of the link itself and selected loops should be performed by means of a subsystem simulation
device. The value of the signal is forced/monitored in the simulation device/automation system. The
specified architecture, for example redundancy, medium of link (glass fibre or copper cable
connection, etc.) should be provided as far as practicable.
Other scenarios such as listed below depend upon contract/specification requirements
• Subsystem is emulated in the automation system, signals are forced/monitored in the automation
system
• Complete subsystem, link devices and automation system are available, forcing/monitoring of I/O
at the subsystem/automation system.
The method of testing has to be defined for each subsystem individually and after consideration of the
project requirements.
5.3.2 Conducting of test
The test activities can be divided into check of system features, project related scope of supply and
application. For check lists, refer to Annex A.
5.3.2.1 Checklists for the test of system features
– Start-up test
– General system functions including hardware redundancy and diagnostic check
5.3.2.2 Checklists for project related scope of supply
– Documentation check
– HW and SW inventory check
– Mechanical inspection
– Wiring and termination inspection
5.3.2.3 Reference documents
The documents listed below shall serve as the basis for the functionality test. Completed tags shall be
marked and the resulting documents shall be considered as FAT record.
– P&ID
– Function plan
– Control narrative
– Cause and effects, interlock lists

PAS 62381 © IEC:2004 (E) – 13 –

– Function logic diagrams
– Complex control schemes
– Interface documents
5.3.3 Application check procedures

5.3.3.1 Check of HMI displays
Prior to the loop-oriented test, the static parts of the HMI displays shall be tested.

Verify the following display functionality (static):

– symbols for vessels, process lines, valves, transmitters, motors, pumps, etc.;
– colors for static items, for ex
...