How do you develop and execute comprehensive DCS FAT and SAT procedures?
Answer
FAT (Factory Acceptance Test) development: define test scope (all configured hardware and software), create test procedures (I/O point verification, control strategy testing, HMI navigation, alarm testing, historian functionality, communication interfaces, failover testing), establish acceptance criteria (quantitative pass/fail), plan test duration and resources, simulate field conditions where possible, and document results systematically. SAT (Site Acceptance Test) additions: actual field wiring verification, real I/O testing, network connectivity to other systems, and performance under actual conditions. Execution: follow procedures without deviation (document any exceptions), capture test evidence (screenshots, logs), track deficiencies for resolution, and obtain formal sign-off. FAT reduces commissioning time and catches issues early. SAT confirms real-world functionality.
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