Process Analyzer Systems Levels of Acceptance Testing

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Process Analyzer SystemsLevels of Acceptance
Testing

• David Lewko - SNC Lavalin Inc.
• Michael Chaney - Equistar Chemical
• Bac Vu - Exxon Mobil Chemical

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Introduction

• Factors that play a key role in selecting the
  correct level of acceptance testing include
• Complexity of the Process Analyzers.
• Complexity of the Sample Conditioning Systems.
• Existing company procedures.
• Applications that involve Process Analyzers that
  have been used in the process facility.

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Purpose for Acceptance Testing

• Verify the analyzer system and documentation is
  in accordance with material requisition
• Ensure the analyzer system is fully operational
  and meets the project requirements.
• Ensures that all deficiencies are identified and
  correction actions are in place prior to
  shipment.

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Types of Tests

• A Hardware Acceptance Test (HAT) is designed to
  verify the construction and maintainability of
  the system. As a general rule the equipment will
  not be started up during a HAT.
• A Factory Acceptance Test is designed to verify
  the functional operation of the Process
  Analyzers. Certified standards will be used to
  verify the performance of the analyzers over a
  specified period of time.

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Types of Tests (contd)

• A Site Acceptance Test is designed to verify the
  functional operation of the Process Analyzers
  after installation at site. Certified standards
  will be used to verify the performance of the
  analyzers over a specified period of time and the
  results will be trended in the plant wide DCS
  System.

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Test Documentation.

• A formal test record should be produced
  regardless of the testing level that has been
  identified. The test record defines the level of
  testing and will be signed by all parties.
• ISA-RP76.0.01-1998 - Analyzer System Inspection
  and Acceptance can be used as a test document in
  cases when a project specific test form has not
  been generated.

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Test Documentation (contd)

• The most current revision of the following
  documents shall kept on hand for reference during
  the test phase of the project
• Vendor Prints
• PIDs
• ILDs
• Instrument Data Sheets
• Installation Details
• Discrepancy Log

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Conclusion

• An acceptance test of complex systems such as
  process analyzer systems is a valuable tool to
  ensure that the final system meets all of the
  project requirements.
• The level of acceptance testing is usually
  determined by the complexity of the process
  analyzer system.

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Conclusion (contd)

• As a general rule, acceptance testing is usually
  reserved for complex analyzer systems, such as
  Gas Chromatograph networks or fully integrated
  analyzer shelters.
• Acceptance testing is a valuable tool in special
  cases such as new process analyzers or in unusual
  situations such as equipment that potentially
  subject to damage prior to final mechanical
  completion.