Site Acceptance Test Protocol

# Site Acceptance Test Protocol
## {{PROJECT_NAME}}

| | |
|---|---|
| **Document title** | Site Acceptance Test Protocol (SAT) |
| **Document number** | {{DOC_NO}} |
| **Revision** | {{REV}} |
| **Date** | {{DATE}} |
| **Project** | {{PROJECT_NAME}} |
| **Client** | {{CLIENT}} |
| **Prepared by** | {{AUTHOR}}, {{COMPANY}} |

### Revision history

| Rev | Date | Description | Author | Approved |
|---|---|---|---|---|
| 0 | {{DATE}} | First issue | {{AUTHOR}} | |
| | | | | |

### Approval

| Role | Name | Signature | Date |
|---|---|---|---|
| Author | {{AUTHOR}} | | |
| Reviewer (engineering) | | | |
| Approver ({{COMPANY}}) | | | |
| Approver ({{CLIENT}}) | | | |

---

## 1. Scope

Acceptance testing of the control system for {{PROJECT_NAME}} installed at {{CLIENT}}, on real
plant with real field devices.

### 1.1 Relationship to the FAT
Tests passed and witnessed at FAT are not repeated in full. What must be repeated is anything
that depends on the physical installation: every loop check, every safety function, and every
test whose FAT result relied on simulation.

| FAT reference | Date | Result | Punch items outstanding |
|---|---|---|---|
| | | | |

---

## 2. Entry criteria

| # | Criterion | Met | Initial |
|---|---|---|---|
| 1 | Installation complete, cables landed and glanded | | |
| 2 | Cable tests complete, results available | | |
| 3 | Field devices installed and accessible | | |
| 4 | Power available and stable | | |
| 5 | Compressed air and utilities available | | |
| 6 | Mechanical completion signed off | | |
| 7 | FAT punch list Category A items closed | | |
| 8 | Permit to work arrangements in place | | |
| 9 | Plant available for testing, and isolated where required | | |
| 10 | Operations staff available for training | | |

---

## 3. Installation inspection

| # | Check | Result | Initial |
|---|---|---|---|
| 3.1 | Panel installed level, secure, accessible | | |
| 3.2 | Cable entries correct, glands tight, IP maintained | | |
| 3.3 | Earthing installed per drawing, continuity verified | | |
| 3.4 | Screens earthed at one end only, per cable schedule | | |
| 3.5 | Segregation maintained in tray and trunking | | |
| 3.6 | Field devices installed per manufacturer instructions | | |
| 3.7 | Instrument installation correct: impulse lines, orientation, isolation | | |
| 3.8 | Labels fitted at both ends of every cable | | |
| 3.9 | Panel free from site debris | | |

---

## 4. Loop checks

The core of the SAT. Every signal is proved from the field device to the operator screen. A
loop check that stops at the panel terminal is a terminal check.

**Method, discrete.** Operate the device in the field. Confirm the state changes at the
controller and on the HMI, with correct description.

**Method, analog.** Apply a known input at the device, or use the device's own simulation.
Confirm the value at the controller and on the HMI at 0, 50 and 100 percent.

| Tag | Description | Field operated | Controller reads | HMI shows | Correct description | Pass | Tester | Date |
|---|---|---|---|---|---|---|---|---|
| XV-101-ZSO | Inlet valve open limit | | | | | | | |
| FT-101 | Feed flow | | | | | | | |
| MTR-101-RUN | Feed pump run | | | | | | | |
| FCV-101 | Feed control valve | | | | | | | |

### 4.1 Valve and actuator strokes
| Tag | Command | Observed travel | Time to stroke | Limit switches | Fail position verified | Pass |
|---|---|---|---|---|---|---|
| FCV-101 | 0, 50, 100% | | | | Air removed, valve closes | |
| XV-101 | Open / close | | | | | |

---

## 5. Field device calibration

| Tag | Type | As found | As left | Tolerance | Cert no | Calibrated by | Date |
|---|---|---|---|---|---|---|---|
| FT-101 | Flow | | | ± [%] | | | |
| LT-101 | Level | | | | | | |
| TT-101 | Temperature | | | | | | |

Record as found values before adjusting. An instrument that was out of tolerance on arrival is
information the site needs.

---

## 6. Functional tests on plant

| Test ref | FDS ref | Description | Expected | Actual | Pass | Initial |
|---|---|---|---|---|---|---|
| SAT-FN-001 | 3 | Mode selection on plant | | | | |
| SAT-FN-002 | 4.1 | Full start sequence with real equipment | | | | |
| SAT-FN-003 | 4.2 | Steady state running for [duration] | | | | |
| SAT-FN-004 | 4.3 | Controlled stop | | | | |
| SAT-FN-005 | 4.4 | Emergency stop, real | | | | |
| SAT-FN-006 | 4.5 | Restart after power interruption | | | | |
| SAT-FN-007 | 9 | Recipe download and execution | | | | |

---

## 7. Safety validation

Every safety function is validated on the installed system. This is not a repeat of the FAT: it
proves the real device, the real wiring and the real stopping performance.

| # | Safety function | Test | Expected | Actual | Pass | Witness |
|---|---|---|---|---|---|---|
| 7.1 | E-stop station 1 | Press | Category [0/1] stop, all motion ceases | | | |
| 7.2 | E-stop station 2 | Press | As above | | | |
| 7.3 | Guard interlock | Open during motion | Motion stops within [ms] | | | |
| 7.4 | Guard interlock | Attempt start with guard open | Start refused | | | |
| 7.5 | Reset | Reset with hazard present | Reset refused | | | |
| 7.6 | Stopping time measurement | Measure with instrument | Within calculated safety distance | | | |
| 7.7 | Muting / bypass (if fitted) | Verify conditions and annunciation | Per design | | | |

**Stopping time.** Measure it, do not assume it. The safety distance calculation to ISO 13855
depends on the real stopping time of the real machine with its real load.

---

## 8. Performance and capacity

| # | Measure | Target | Achieved | Pass |
|---|---|---|---|---|
| 8.1 | Throughput | [units/h] | | |
| 8.2 | Cycle time | [s] | | |
| 8.3 | Controller scan time | < [ms] | | |
| 8.4 | Controller memory used | < [%] | | |
| 8.5 | Spare I/O available | > 20% | | |
| 8.6 | Network utilisation | < [%] | | |
| 8.7 | Alarm rate, average per hour | < 6 | | |
| 8.8 | HMI screen call up time | < [s] | | |

---

## 9. Training

| Course | Attendees | Duration | Delivered by | Date | Materials issued |
|---|---|---|---|---|---|
| Operation | | | | | |
| Alarm response | | | | | |
| Maintenance and fault finding | | | | | |
| Engineering, program access | | | | | |

| Name | Role | Signature | Date |
|---|---|---|---|
| | | | |

---

## 10. Punch list

| # | Category | Description | Raised by | Owner | Target | Closed | Verified |
|---|---|---|---|---|---|---|---|
| 1 | A / B | | | | | | |

---

## 11. Handover and acceptance

### 11.1 Deliverables received

| # | Item | Received | Initial |
|---|---|---|---|
| 1 | As-built schematics | | |
| 2 | Final I/O list | | |
| 3 | Program source and backup | | |
| 4 | HMI application backup | | |
| 5 | Software version record | | |
| 6 | O&M manual | | |
| 7 | Spare parts | | |
| 8 | Calibration certificates | | |
| 9 | Declaration of conformity | | |
| 10 | Training records | | |

### 11.2 Acceptance

- [ ] **Accepted.** System taken over by {{CLIENT}} on the date below.
- [ ] **Accepted with punch list.** Items listed in section 10, owners and dates agreed.
- [ ] **Not accepted.** Reason: ______________________________

### 11.3 Signatures

| Role | Name | Company | Signature | Date |
|---|---|---|---|---|
| Commissioning engineer | | {{COMPANY}} | | |
| Project manager | | {{COMPANY}} | | |
| Client engineering | | {{CLIENT}} | | |
| Client operations | | {{CLIENT}} | | |

### 11.4 Warranty
Warranty period begins on the acceptance date above and runs for [period]. Scope and exclusions
per contract clause [ref].