CONTROL SYSTEM FACTORY ACCEPTANCE

TEST
PEN-XXXXXX-1-A-REPT-001

XXXXXX, XXXXXXX
End-of-Life Plastic Chemical Recycling Plant

REV DESCRIPTION PREPARED REVIEWED APPROVED DATE

V0.0 Issued for Review

Plastic Energy Ltd

65 Carter Lane
London,
EC4V 5DY
T: +44 203 146 4967

Plastic Energy Ltd.

This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This
information is confidential, legally privileged and protected in law. Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited
without the consent of Plastic Energy Ltd. If you have received this communication in error, please contact us immediately.
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Purpose & Scope - Test Folder

TABLE OF CONTENTS
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Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

1 Purpose & Scope ...............................................................................................................................4

1.1 Purpose ........................................................................................................................................................................ 4
1.2 Scope ............................................................................................................................................................................. 4
1.3 General Method ........................................................................................................................................................ 4
1.4 Terms and abbreviations ..................................................................................................................................... 5
2 Referenced Documentation ..............................................................................................................7
2.1 Plastic Energy Documentation ........................................................................................................................... 7
3 Test Method ......................................................................................................................................8
3.1 General GUIDELINES .............................................................................................................................................. 8
3.2 Mistakes....................................................................................................................................................................... 8
3.3 Replying to tests....................................................................................................................................................... 8
3.4 Comments/Deviations........................................................................................................................................... 8
3.4.1 Test Folder....................................................................................................................................................................................8
4 Test Prerequisites..............................................................................................................................9
4.1 Prerequisites Checklist.......................................................................................................................................... 9
4.3 Attendance Record................................................................................................................................................ 10
Plastic Energy Ltd.

5 Testing ............................................................................................................................................ 11
5.1 Objectives.................................................................................................................................................................. 11
5.2 Procedure ................................................................................................................................................................. 11
5.3 Hardware Configuration ..................................................................................................................................... 11
5.4 Instantiation ............................................................................................................................................................ 15
5.4.1.1 DI Monitoring ................................................................................................................................................................ 15
5.4.1.2 AI Monitoring ................................................................................................................................................................ 17
5.4.1.3 Digital Valves (VlvL) ................................................................................................................................................... 20
5.4.1.4 Control VLV AI ............................................................................................................................................................... 22
5.4.1.5 Motors ............................................................................................................................................................................... 24
5.4.1.6 OpDi ..................................................................................................................... Error! Bookmark not defined.
5.4.1.7 OpAn .................................................................................................................... Error! Bookmark not defined.
5.4.1.8 PID Controllers ............................................................................................................................................................. 26
5.4.1.9 Totalizers ......................................................................................................................................................................... 29
5.5 Automated Functions Testing .......................................................................................................................... 30
5.5.1 Module 0 ..................................................................................................................................................................................... 31
5.5.1.1 X-0003 Auto mode ...................................................................................................................................................... 31
5.5.1.2 X-0004 Auto mode ...................................................................................................................................................... 33
5.5.1.3 XY-0004Ω Paddles Control ...................................................................................................................................... 35
5.5.1.4 T-A010: Walking Floor Control ............................................................................................................................. 36
5.5.1.5 X-Ω010 Conveyor control ........................................................................................................................................ 37

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CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Purpose & Scope - Test Folder

5.5.1.6 X-Ω011 Conveyor Control ........................................................................................................................................ 38

This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

5.5.1.7 Melt Feed Line Program ........................................................................................................................................... 39

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5.5.2 Core Module .............................................................................................................................................................................. 46

5.5.2.1 Temperature Control ................................................................................................................................................. 46
5.5.2.2 Vapours Route Selection .......................................................................................................................................... 51
5.5.2.3 Flush Program ............................................................................................................................................................... 55
5.5.2.4 Agitator Control Program ........................................................................................................................................ 57
5.6 Interlocks Testing .................................................................................................................................................. 72
5.7 Graphics Testing .................................................................................................................................................... 74
5.8 Alarm Testing .......................................................................................................................................................... 76
5.9 Communications with 3rd Parties / INTERFACES .................................................................................... 78
5.10 Other Tests ............................................................................................................................................................... 80
6 Unstructered Test............................................................................................................................ 82
7 Appendicies ..................................................................................................................................... 85
7.1 Project Query Form .............................................................................................................................................. 86
7.2 Notes ........................................................................................................................................................................... 87

Table 1: Abbreviations ...........................................................................................................................................................................................6

Plastic Energy Ltd.

Table 2: PE Documentation Reference ............................................................................................................................................................7

Table 3: Prerequisites Checklist ...........................................................................................................................................................................9
Table 4: Witnessed By ............................................................................................................................................................................................9
Table 5: Attendance Record .............................................................................................................................................................................. 10
Table 6: Monitoring DI....................................................................................................................................................................................... 16
Table 7: Valves Digital ........................................................................................................................................................................................ 21
Table 8: Control Module Valve AI .................................................................................................................................................................. 23
Table 9: Control Module Motor DI ................................................................................................................................................................ 25
Table 10: Control Module Operator DI .......................................................................................... Error! Bookmark not defined.
Table 11: Control Module Operator AN ......................................................................................... Error! Bookmark not defined.
Table 12: Control Module PID ........................................................................................................................................................................ 27
Table 13: Control Module Totalizer ................................................................................................................................................................ 29
Table 14: Unstructured Testing ........................................................................................................................................................................ 83
Table 15: Project Query Form .......................................................................................................................................................................... 86

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 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Purpose & Scope - Test Folder

1 PURPOSE & SCOPE

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1.1 PURPOSE
This document defines the Factory Acceptance Testing procedure and testing for the Distributed
Control System for this project including validation procedures and test cases.

1.2 SCOPE
This Factory Acceptance Test includes testing to ensure that the software configuration matches
Plastic Energy’s requirements.

1.3 GENERAL METHOD

This document details the structured approach to testing.
The test steps listed in this document shall be verified and signed off by Plastic Energy personnel. Any
queries raised shall be entered using the Project Query (PQ) database and actioned as per Plastic
Energy standards and PQ system requirements.
Plastic Energy Ltd.

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CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Purpose & Scope - Test Folder

1.4 TERMS AND ABBREVIATIONS

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PE Plastic Energy
CM Control Module
EM Equipment Module
PID Proportional–Integral–Derivative controller
DI Digital Input
DO Digital Output
AI Analog Input
AO Analog Output
P&ID Piping and Instrumentation Diagram
FAT Factory Acceptance Test
PQ Project Query
PLC Programmable Logic Controller
I/O Input/Output
RIO Remote Input/Output
MCC Motor Control Centre
SCADA Supervisory Control and Data Acquisition
FDS Functional Design and Specification
PCS7 Process Control System 7 (Siemans)
Plastic Energy Ltd.

OS Operator Station
ES Engineering Station
AS Automation System
CPU Central Processing Unit
UPS Uninterupted Power Supply
HMI Human Machine Interface
SAT Site Acceptance Test
MONDI Monitoring Digital Input
MONAI Monitoring Analog Input
URV Upper Range Value
LRV Lower Range Value
PV Process Value
MV Manipulated Variable
CUR Current Upper Range
CLR Current Lower Range
VLVDI Valve Digital Input
VLVAI Valve Analog Input
OPDI Operator Digital Input
OPAN Operator Analog
SP Setpoint
FUR Feedback Upper Range
FLR Feedback Lower Range

Page 5 of 88
 Plastic Energy Ltd.
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FP
LO
KE
RD
OH

DCS
LRV

FBK
TOT
URV

CMT
PEN-XXXXXX-1-A-REPT-001

Totalizer

Light Oil

Faceplate
Kerosene

Feedback
Overheads
Raw Diesel
Upper Range Value
Lower Range Value

Control Module Type

Distributed Control System

Table 1: Abbreviations
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Purpose & Scope - Test Folder

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 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Referenced Documentation - Test Folder

2 REFERENCED DOCUMENTATION
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The following documents were referenced for the writing of this document.

2.1 PLASTIC ENERGY DOCUMENTATION

Document Reference Version
PEN-004GLN-01-P-PIDS-A000_V2.0 (Superseded)_FAT.pdf V2.0
Plant P&ID’s PEN-004GLN-01-P-PIDS-0002_FAT.pdf V1.0
PEN-004GLN-01-P-PIDS-A102_V3.0_FAT.pdf V3.0
List of Alarms PEN-004GLN-01-P-LIST-0020_V3.0-Module 00 Alarms.xlsx V3.0
Electrical Schematics Not available on 2022/05/23
URS PEN-004GLN-01-P-URS-0001_V3.0-Chapter 3 Module 00.pdf V3.0
Signals List PEN-004GLN-01-A-LIST-001-V2.7 List Of Signals_FAT.xlsx V2.7
Interlocks List PEN-004GLN-01-P-LIST-000_V3.0-Module 00-D0 Interlocks_FAT.pdf V3.0
ADD ALL INTERLOCK MATRIX DOCUMENTS
Electrical Devices
Not available on 2022/05/23
Configuration List

Table 2: PE Documentation Reference

Plastic Energy Ltd.

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CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Test Method - Test Folder

3 TEST METHOD
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3.1 GENERAL GUIDELINES

These guidelines aim to ensure that the testing is performed consistently and accurately and that all
results are recorded in the correct manor.
The Project Query list will be used to log and manage queries raised at each stage of testing. A PQ list
is attached to this procedure

3.2 MISTAKES
• Mistakes will highlighted in red in the PDF or applicable digital file (.xlsx, etc) and identified
with a PQ number

3.3 REPLYING TO TESTS

All tests which require a response of ‘PASS’ / ‘PQ’, must be responded to by writing the response, not
by ticking or crossing.
• All tests which require a fuller response must be detailed enough to be meaningful to others;
• All test responses should be filled in, even if it is non-applicable (N/A). If a test is
N/A, fill out a comment and PQ Form explaining why;
• As each section/item is tested successfully, the Test Engineer shall enter their initials and the date
Plastic Energy Ltd.

in the appropriate column of the Test Record sheet to signify completion of that test.

3.4 COMMENTS/DEVIATIONS
• A comment or deviation is a statement of clarification or deviation from the protocol, i.e. ‘a
fault cannot be rectified and is acceptable’ or ‘a test could not be done for some reason’;
• These deviations must be recorded on a PQ.
3.4.1 Test Folder
A specific Test Folder shall be kept for Testing. The Test Folder shall contain:
• A copy of the Test specification.
• A copy of the referenced documentation – refer to section 2.1– Plastic Energy Documentation.
• Screenshots Operator graphics, as needed.
• PQ List
The Test Folder records shall be updated as specified as each point is checked.
Comments shall be brief and concise. Successful checks shall be recorded as well as any problems.

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 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Test Prerequisites - Test Folder

4 TEST PREREQUISITES
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4.1 PREREQUISITES CHECKLIST

Prerequisites Checklist
Item Action/Observation Pass/PQ N° Initials Signed
Documentation Audit: Test Document
1 Confirm that this Test Specification has been
reviewed and approved by PE personnel
Attendance Record:
2 Complete the Attendance Record. Refer to
Section 4.2 Attendance Record.
ES:
3 Confirm that the ES is ready and connected
to the simulation tool. See section 5.2
OS:
4 Confirm the OS has been downloaded and is
connected to the simulation tool. See section
5.2
Test Folder:
Confirm that Test Folder contains all relevant
5 documentation as described in Section 3.4.1.
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Verify Revision number for documentation is

up to date.
Table 3: Prerequisites Checklist

Witnessed By
Name Position Signature Date

Table 4: Witnessed By

Page 9 of 88
 Plastic Energy Ltd.
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Representative
Plastic Energy E&A

(name & signature)

PEN-XXXXXX-1-A-REPT-001

4.3 ATTENDANCE RECORD

Plastic Energy

Representative
Commissioning

(name & signature)

Table 5: Attendance Record

Notes
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Test Prerequisites - Test Folder

Page 10 of 88
Date
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

5 TESTING
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Items will be tested and proven to the ES and/or OS

5.1 OBJECTIVES
Testing will be carried out to verify that the software configuration matches the Plastic Energy
Documentation as detailed in section 2.1. This includes:-
• Verifying that the I/O hardware allocation matches the PE documentation.
• Further tests are included as detailed below.

5.2 PROCEDURE
Each section of the Test Record Sheet shall be completed in full. ES and/or the OS will be used to
verify the state of the software tags and will allow the ‘simulating’ of the relevant signals/variables to
simulate I/O’s
The items will be viewed from the relevant faceplate/graphic on the OS
Siemens PLCSIM will be used as a simulator in order to run the software. Both ES and OS will be
connected to simulator which is equivalent to the PLC CPU for testing purposes.

5.3 HARDWARE CONFIGURATION

•
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Verify the correct profibus has been assigned

• Verify the number and type of cards are correct
• Verify the basic parameters of the motor management and control devices (simocode)
• Verify the basic parameters of the VFD’s

Item Initial Date Pass/PQ N°

CP-PLC-1A
CP-PLC-1B
RIO-00-01
RIO-06-01
RIO-07-02A
RIO-07-02B
RIO-07-03A
RIO-07-03B
RIO-07-04
RIO-07-05
RIO-08-01
RIO-09-01
RIO-09-02
RIO-10-01

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CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Item Initial Date Pass/PQ N°

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RIO-11-01
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RIO-13-01
RIO-18-01
RIO-A1-01
RIO-A1-02
RIO-A2-01
RIO-A2-02
RIO-A3-01
RIO-A3-02
RIO-B1-01
RIO-B1-02
RIO-B2-01
RIO-B2-02
RIO-B3-01
RIO-B3-02
RIO-C1-01
RIO-C1-02
RIO-C2-01
Plastic Energy Ltd.

RIO-C2-02
RIO-C3-01
RIO-C3-02
RIO-D1-01
RIO-D1-02
RIO-D2-01
RIO-D2-02
RIO-D3-01
RIO-D3-02
CP-DIST-0A
CP-DIST-0B
CP-DIST-0C
CP-DIST-0D
CP-FLR-A1-01
CP-FLR-A2-01
CP-FLR-A3-01
CP-FLR-B1-01
CP-FLR-B2-01
CP-FLR-B3-01
CP-FLR-C1-01

Page 12 of 88
 Plastic Energy Ltd.
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Item
PEN-XXXXXX-1-A-REPT-001

CP-DIST-10
CP-DIST-07
CP-DIST-06
CP-DIST-05
CP-DIST-04
CP-DIST-03
CP-DIST-02
CP-FLR-C3-01
CP-FLR-C2-01

CP-FLR-D3-01
CP-FLR-D2-01
CP-FLR-D1-01

RIO-MCC-01 x11
Motor drivers will be added

Notes
Initial
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Date
Pass/PQ N°

Page 13 of 88
 Plastic Energy Ltd.
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Name
Item
PEN-XXXXXX-1-A-REPT-001

Position
Initial

Witnessed By
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Date

Signature
Pass/PQ N°

Date

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 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

5.4 INSTANTIATION
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For the development of the project, the Siemens APL has been used. This implies that the objects that
represent sensors, actuators and other software components such as selectors are already validated by
Siemens. Therefore, the instantiation testing consists on ensuring that all APL objects used are correctly
configured. In other words, the internal execution of the APL blocks is not required to be tested.
Those specific blocks developed by PE shall have a specific testing procedure which will include not
only the configuration of the block but also the internal execution of the block as well as its associated
graphics/faceplate
5.4.1.1 DI Monitoring

• You will need your Test folder. Refer to section 3.4.1

• Archiving
• Verify each instance enumerated in the Object Instantiation List:
o Description is meaningful. Highlight the description in the object instantiation list
o Verify against the P&ID’s the Instrumentation ‘Block Icon’ on the OS is in correct
position and correct symbol. Highlight in the P&ID the item
o The right input channel has been assigned
• Once verified the list of instances, ensure that all the items in the P&ID has been covered as
well as in the signal list.
• Verify against the Instrumentation List that the descriptions and Tag numbers are correct.
• On ES ‘Simulate’ a digital 1 and 0 and confirm that the ‘Text’ and colours matches the
specification on the Instrumentation list and the FDS.
•
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Verify that the alarm delays have been configured correctly

• Verify alarm appears in the alarm bar, faceplate, and alarm summary if applicable and the
description is correct.
• Record results in the signal list file and highlight the signal in the P&IDs.
• Record Out Delay Time Coming
• Record Out Delay Time Going

Note: Those digital inputs that belong to other devices such as valves (feedbacks) shall be tested in their appropriate
section

Item Initial Date Pass/PQ N°

Module 0
Module Core
Module 6
Module 7
Module 8
Module 9
Module 10
Module 11
Module 12
Module 13
Module 14

Page 15 of 88
 Plastic Energy Ltd.
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Item
PEN-XXXXXX-1-A-REPT-001

Module 16
Module 15

Module 19
Module 18
Module 17

Notes
Initial

Table 6: Monitoring DI
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Date
Pass/PQ N°

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 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Notes
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Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Witnessed By
Name Position Signature Date

5.4.1.2 AI Monitoring

• You will need your Test folder. Refer to section 3.4.1

• See section Error! Reference source not found. onwards for documentation locations
• Verify the Instrumentation is connected to the appropriate input channel as per signal list on
‘ES’.
• Verify against the P&ID’s the Instrumentation ‘Block Icon’ on the OS is in correct position
and correct symbol.
• For calculated tags, ensure the bad quality is connected to the CSF input
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• Verify against the ‘Instrumentation List’ that the descriptions and Tag numbers are correct.
• Verify in ‘ES’ that the ‘URV’ and ‘LRV’ are specified correctly
• Verify the ‘Unit of PV’ is in accordance with the signal list.
• Verify trends displays correct values
• Verify that the gradient configuration in the ‘ES’ matches the Instrumentation specification.
• Record results in the signal list file.
• Verify any Signal/Calculated Variables e.g for PDI or Totalisers
Item Initial Date Pass/PQ N°
Module 0
Module Core
Module 6
Module 7
Module 8
Module 9
Module 10
Module 11
Module 12
Module 13
Module 14
Module 15
Module 16

Page 17 of 88
 Plastic Energy Ltd.
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Item
PEN-XXXXXX-1-A-REPT-001

Module 19
Module 18
Module 17

Notes:
Initial
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Date
Pass/PQ N°

Page 18 of 88
 Plastic Energy Ltd.
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Name
PEN-XXXXXX-1-A-REPT-001

Position
Witnessed By
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Signature
Date

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 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

5.4.1.3 Digital Valves (VlvL)

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• You will need your Test folder. Refer to section 3.4.1

Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

• Verify that the valve exists in the object instantiation list

• Verify against the P&ID’s the Valve ‘Block Icon’ on the OS is in correct position and
correct symbol.
• Verify using ES that the Valve FBK is connected to the appropriate input channel and that
the Valve open/close command is connected to the appropriate output channel as per the
signal list. Ensure that the signal list tags match the tags defined in the object instantiation list
• Verify against the Object Instantiation List that the configuration of the valve is
correct:
o Safe position
o Time to open (monitoring)
• Verify against the Instrumentation List that the descriptions and Tag numbers are correct.
• Valve commands:
o Put Valve Face plate into Simulation Mode
o Make all applicable interlocks ‘healthy’
o Open valve from ‘FP’ and verify in ‘ES’ correct hardware signal is sent
o Close valve from ‘FP’ and verify in ‘ES’ correct hardware signal is sent
• Valve Feedbacks
o On ES put Open/Closed FBK signal processing blocks into simulation
o On ES put Open/Closed Command signal processing blocks into simulation
o Set closed command on FP
o On ES simulate FBK open as de-energised and FBK closed as energised
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o Verify on OS the FP and block icon indicate closed position

o Set open command on FP
o On ES simulate FBK open as Energised and FBK closed as De-Energised
o Verify on OS the FP and block icon indicates open position

Note:
• The Valve ‘Safe Position’ will be covered in the ‘Interlock’ section.
• Valve Errors will be covered in the Alarms section of this document

Item Initial Date Pass/PQ N°

Module 0
Module Core
Module 6
Module 7
Module 8
Module 9
Module 10
Module 11
Module 12
Module 13
Module 14
Module 15
Module 16
Page 20 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Item
PEN-XXXXXX-1-A-REPT-001

Module 19
Module 18
Module 17

Notes:
Initial

Table 7: Valves Digital

CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Date
Pass/PQ N°

Page 21 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Witnessed By
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name Position Signature Date

5.4.1.4 Control VLV AI

• You will need your Test folder. Refer to section 3.4.1

• See section Error! Reference source not found. onwards for documentation locations.
• Verify using ES that the CM FBK (If Applicable) is connected to the appropriate input and
the CM analog command is connected to the appropriate output channel as per the signal
list.
• Verify against the P&ID’s the CM ‘Block Icon’ on the OS is in correct position and correct
symbol.
• Verify against the CM List that the descriptions and Tag numbers are correct.
• Verify using ‘OS’ the Engineering unit MV is specified as per the ‘CM List’
• Verify in ‘ES’ that the ‘RUV’ and ‘RLV’ are specified correctly
• Valve Command
Plastic Energy Ltd.

o By-Pass all interlocks affecting the valve and its controller

o On ES set the command output processing block in simulation
o Change MV to 0%,50% and 100% from PID Controller/ valve FP verify processing
block on ES shows correct value
• Valve FBK
o If applicable, put ‘AN’ ‘FBK’ processing block into simulation and set the simulated
value to 0%-50% and 100% on ES and verify the FP shows the correct position on
the OS.
• Verify using the ‘ES’ the fully open and closed positions are as per ‘CM List’
• Record results below.

Note:
• The Valve ‘Safe Position’ will be covered in the ‘Interlock’ section.
• Valve errors will be covered in the Alarm section of this document

Item Initial Date Pass/PQ N°

Module 0
Module Core
Module 6
Module 7 AF Pass
Module 8
Module 9
Module 10

Page 22 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Item
PEN-XXXXXX-1-A-REPT-001

Module 16
Module 15
Module 14
Module 13
Module 12
Module 11

Module 19
Module 18
Module 17

Notes:
Initial
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Table 8: Control Module Valve AI

Date
Pass/PQ N°

Page 23 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Notes:
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Witnessed By
Name Position Signature Date
Plastic Energy Ltd.

5.4.1.5 Motors

• You will need your Test folder. Refer to section 3.4.1

• See section ….. onwards for documentation locations.
• Verify against the P&ID’s the CM ‘Block Icon’ on the OS is in correct position and correct
symbol.
• Verify against the electrical schematics that the signals connected to the Simocode (E-
Stop/Circuit Breaker/Contactor) are transferred to the appropriate block and displayed in
the faceplate
• Verify against the CM List that the descriptions and Tag numbers are correct.
• Motor Command
o Put CM into simulation mode on OS.
o Set current to healthy value on faceplate
o Start the motor from FP and verify on ES the processing block receives the correct
signal
o Stop the motor from FP and verify on ES the processing block receives the correct
signal
o Restart the motor and set current to low trip value and verify the motor trips
accordingly and verify the reset command.
• Verify in ‘ES’ that the ‘CUR’ and ‘CLR’ are specified correctly
• Verify using ‘ES’ the engineering units of current as per ‘CM List’
• Record results below.

Page 24 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Notes:

Item
PEN-XXXXXX-1-A-REPT-001

Module 0

Module 9
Module 8
Module 7
Module 6

Module 16
Module 15
Module 14
Module 13
Module 12
Module 11
Module 10

Module 19
Module 18
Module 17
Module Core

Notes:
Initial
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Table 9: Control Module Motor DI

Date
• This CM type will be tested further and more in-depth during SAT

Pass/PQ N°

Page 25 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Notes:
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Witnessed By
Plastic Energy Ltd.

Name Position Signature Date

5.4.1.6 PID Controllers

• General Checks:
o Verify that the description of the PID controller matches the instantiation list
• Ranges and units:
o Verify that the PV range and unit matches the instantiation list along with the signal list
o Verify that the MV range and unit matches the instantiation list as well as the URS
o Verify that the SP range and default SP matches the instantiation list and the URS.
• Faults:
o Verify that the PV bad quality sends the controller to safe state (interlock)
▪ In case the PV is a differential PV, ensure that either AI bad quality trips the controller
interlock
▪ In case the PV comes from a selection between 2 Ais, ensure that the bad quality trips the
controller interlock only for the selected PV.
o Verify that when the actuator linked to the PID controller is interlocked, the PID is also interlocked.
• Modes:
o Ensure that when the linked PV or Actuator are out of service, the controller is automatically set as
out of service too
o Ensure that the operator cannot modify the setpoint to “External” when required (no higher level
controllers exist)

Page 26 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

• Control action
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

o Verify that when the PID is set to manual, the MV can be modified directly from the PID. Ensure the
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

correct actuator is linked to the PID.

o Verify the right control direction (NegGain) of the controller by means of setting the controller to
auto and simulating the PV. Update Instantiation list if needed.
• Others:
o Ensure that in case of E-Stop, the controller is set to manual. The operator must reenable the auto
mode after the E-Stop has been cleared.
o Ensure that after PLC startup, the controller starts in manual mode.
• Record results by highlighting green in the Instantiation List and logging them into the table
below. Create a PQ where required.

Item Initial Date Pass/PQ N°

Module 0
Module Core
Module 6
Module 7
Module 8
Module 9
Module 10
Module 11
Module 12
Plastic Energy Ltd.

Module 13
Module 14
Module 15
Module 16
Module 17
Module 18
Module 19
Table 10: PID Controllers

Notes:

PID parameters such as Proportional gain, Integral time, Differential time (derivative time), Gain
of differentiator will all be completed after commissioning. (Auto Mode)

Page 27 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name
PEN-XXXXXX-1-A-REPT-001

Position
Notes:

Witnessed By
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Signature
Date

Page 28 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

5.4.1.7 Totalizers
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

• You will need your Test folder. Refer to section 3.4.1

Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

• See section Error! Reference source not found. onwards for documentation locations.
• Verify against the P&ID’s the CM ‘Block Icon’ on the OS is in correct position and correct
symbol.
• Verify against the CM List that the descriptions and Tag numbers are correct.
• Verify Totalizer is Configuered as FDS
• Verify using ‘ES’ the ‘ PV LRV’ and ‘ PV URV’ are specified correctly
• Verify the ‘PV’ unit is correctly specified as per the ‘CM List’ and ‘ES’
• Verify the unit of ‘TOT’ output is as specified in the ‘CM List’ and ‘ES’
• Confirm that ‘PV to be TOT’ on the ‘OS’ is specified as per the ‘CM List’
• Record results below.

Item Initial Date Pass/PQ N°

Module 0
Module Core
Module 6
Module 7
Module 8
Module 9
Plastic Energy Ltd.

Module 10
Module 11
Module 12
Module 13
Module 14
Module 15
Module 16
Module 17
Module 18
Module 19
Table 11: Control Module Totalizer

Notes:

Page 29 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Test Folder

Notes:
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Witnessed By
Name Position Signature Date

5.5 AUTOMATED FUNCTIONS TESTING

Specific test cases has been developed for each of the automatic functions available. Typically the target is to
Plastic Energy Ltd.

test:
• Permissives to start the function
• Interlocks that stop/disable the function (note that these are not interlocks defined in the C&E matrix
that sets the protection of all devices in the plant)
• Actual sequence or program execution of the function
• Generation of messages such as prompts and warnings.

Page 30 of 88
 5.5.1 Module 0
5.5.1.1 X-0003 Auto mode
Instance Name: Designed By JSP Witnessed By CS,PD,CA
Test Id:
Description Tested By JSP Tested Date 14/09/2022
Function Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
X-0003 is in auto X-0003 starts Pass
1.0
X-0004 is running
Combine with of the following events individually:
• XY-0004A is open and Silo A is “Filling Authorized”
OR “Filling”
• XY-0004B is open and Silo A is “Filling Authorized”
OR “Filling”
• XY-0004C is open and Silo A is “Filling Authorized”
OR “Filling”
• XY-0004D is open and Silo A is “Filling Authorized”
OR “Filling”
X-0003 is in auto X-0003 stops Pass
1.0
X-0004 is not running
Combine with of the following events individually:
• XY-0004A is open and Silo A is “Filling Authorized”
OR “Filling”
• XY-0004B is open and Silo A is “Filling Authorized”
OR “Filling”
• XY-0004C is open and Silo A is “Filling Authorized”
OR “Filling”
• XY-0004D is open and Silo A is “Filling Authorized”
OR “Filling”

Plastic Energy Ltd.

This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd. If you have received this communication in error, please contact us immediately.
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

Instance Name: Designed By JSP Witnessed By CS,PD,CA

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
Description Tested By JSP Tested Date 14/09/2022
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Function Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
X-0003 is in auto X-0003 stops Pass
1.0
X-0004 is running
Combine with of the following events individually:
• XY-0004A is not open OR Silo A is not “Filling
Authorized” and not “Filling”
• XY-0004B is not open OR Silo A is not “Filling
Authorized” and not “Filling”
• XY-0004C is not open OR Silo A is not “Filling
Authorized” and not “Filling”
• XY-0004D is not open OR Silo A is not “Filling
Authorized” and not “Filling”
Estop Total X-0003 switches to PQ250
Estop TAC manual
PreProcess
X-0003 in auto After PLC restart: Pass
PLC restart X-0003 is stop
X-0003 is in manual
Plastic Energy Ltd.

Page 32 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

5.5.1.2 X-0004 Auto mode

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Instance Name: Designed By JSP Witnessed By CA, PD, CS

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Description Tested By JSP Tested Date 14/09/2022

Function Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
X-0004 is in auto X-0004 starts Pass
1.0
Combine with of the following events individually:
• XY-0004A is open and Silo A is “Filling
Authorized” OR “Filling”
• XY-0004B is open and Silo A is “Filling
Authorized” OR “Filling”
• XY-0004C is open and Silo A is “Filling
Authorized” OR “Filling”
• XY-0004D is open and Silo A is “Filling
Authorized” OR “Filling”
X-0004 is in auto X-0004 stops after 120 Pass
1.0
Combine with of the following events individually: seconds
• XY-0004A is open and Silo A is “Filling
Authorized” OR “Filling”
• XY-0004B is open and Silo A is “Filling
Authorized” OR “Filling”
• XY-0004C is open and Silo A is “Filling
Authorized” OR “Filling”
• XY-0004D is open and Silo A is “Filling
Plastic Energy Ltd.

Authorized” OR “Filling”

Page 33 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

Instance Name: Designed By JSP Witnessed By CA, PD, CS

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
Description Tested By JSP Tested Date 14/09/2022
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Function Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
X-0004 is in auto X-0004 Stops Pass
Combine with of the following events individually:
• XY-0004A is not open OR Silo A is not “Filling
Authorized” and not “Filling”
• XY-0004B is not open OR Silo A is not “Filling
Authorized” and not “Filling”
• XY-0004C is not open OR Silo A is not “Filling
Authorized” and not “Filling”
• XY-0004D is not open OR Silo A is not “Filling
Authorized” and not “Filling”
Estop Total X-0004 switches to manual PQ250
Estop TAC
PreProcess
X-0004 in auto After PLC restart: Pass
PLC restart X-0004 is stop
X-0004 is in manual
Plastic Energy Ltd.

Page 34 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

5.5.1.3 XY-0004Ω Paddles Control

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Instance Name: Designed By JSP Witnessed By CA,PD,CS

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Description Tested By JSP Tested Date 14/09/2022

Function Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
XY-0004Ω in auto XY-0004A opens Pass
1.0
Silo Ω “Filling Authorized” OR “Filling”
XY-0004Ω in auto XY-0004A closes Pass
1.0
Silo Ω in either of the following:
• Shutdown
• Filling Wait
• Filling Interrupted
• Discharge Wait
• Discharge Authorized
• Discharging
• Discharge Completed
• Unknown
XY-0004Ω in auto XY-0004Ω closes (due to interlocks) PQ250
1.0
Individually trigger: XY-0004Ω is set to manual
• XY-0004Ω in error
• E-Stop Total
• E-Stop TAC
• E-Stop Preprocess
X-0004Ω in auto After PLC restart: PQ252
Plastic Energy Ltd.

PLC restart X-0004Ω is stop

X-0004Ω is in manual

Notes:

PQ248 and PQ249 related to paddles to be considered

Page 35 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

5.5.1.4 T-A010: Walking Floor Control

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Instance Name: Designed By JSP Witnessed By CS, CA, PD

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Description Tested By JSP Tested Date 14/09/2022

Function Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Interlocks to Silo T-Ω010 ok T-Ω010 Runs Reverse Pass
1.0
Silo in “Fill Authorized”
XY-0004Ω is open
Interlocks to Silo T-Ω010 ok T-Ω010 Runs Forward Pass
1.0
Silo Ω state is “Discharge Authorized”
Extruder Ω Hopper returns “Release”
X-Ω010 is running forward for at least 10 seconds
X-Ω011 is running forward for at least 10 seconds
Conditions for Run Revers and Run Forward not met T-Ω010 stops Pass
1.0
1.0
1.0
•
1.0
Plastic Energy Ltd.

Page 36 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

5.5.1.5 X-Ω010 Conveyor control

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Instance Name: Designed By JSP Witnessed By

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Description Tested By JSP Tested Date

Function Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
No
X- Ω010 in auto X-Ω010 runs forward Pass
1.0
Silo T-Ω010 Discharge Authorized
X- Ω011 conveyor running for at least 10 seconds
X- Ω010 in auto X-Ω010 stops Pass
1.0
Start conditions not met
X- Ω010 in auto X- Ω010 is set to manual PQ250
1.0
Individually trigger:
• X- Ω010 in error
• E-Stop Total
• E-Stop TAC
• E-Stop Preprocess
X- Ω010 in auto After PLC restart: Pass
1.0
PLC restart X- Ω010 is stop
X- Ω010 is in manual
Plastic Energy Ltd.

Page 37 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

5.5.1.6 X-Ω011 Conveyor Control

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Instance Name: Designed By Witnessed By

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Description Tested By Tested Date

Function Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
No
Silo T-Ω010 Discharging started X-Ω011 conveyor will run Pass
1.0
Release signal of Extruder allows feed forward

Silo T-Ω010 Discharging completed or stopped X-Ω010 conveyor will stop Pass Timer is set to 0
1.0
X- Ω010 conveyor stopped (no need to
Delay 30s empty the
conveyor)

1.0
1.0
Plastic Energy Ltd.

Page 38 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

5.5.1.7 Melt Feed Line Program

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

MFL_A Instance Name: ReactorsLineA/MFLRou Designed JSP Witnessed CS,PD,CA

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Melt Feed Line Description Test the melt feed line route selection Tested JSP Tested 14/09/2022
Function
Program By Date
Name:
Tests
Expected Result Actual Result Pass/PQ Notes
No Description

Extruder not stopped Melt feed line Reactor 1,2,3 and close not allowed Pass
1.0
(permissive)
Extruder not ready Melt feed line route to reactors not allowed Pass
1.0
(permissive)
Extruder comms in error Melt feed line Reactor 1,2,3 and Close not allowed PQ255
1.0
(permissive)
Reactor Feed batch completed Reactor that was fed cannot be refed Pass
1.0
Silo is refilled
XV-Ω010 in error (permissive) Melt feed line route to Reactors and Close not allowed Pass
1.0
XV-Ω020 in error (permissive) Melt feed line route to Reactors and Close not allowed Pass
1.0
XV-Ω030 in error (permissive) Melt feed line route to Reactors and Close not allowed Pass
1.0
XV-Ω040 in error (permissive) Melt feed line route to Reactors and Close not allowed Pass
1.0
XV-Ω010 not closed Melt feed line route to Reactors not allowed Pass
1.0
(permissive)
XV-Ω020 not closed Melt feed line route to Reactors not allowed Pass
1.0
Plastic Energy Ltd.

(permissive)
XV-Ω030 not closed Melt feed line route to Reactors not allowed Pass
1.0
(permissive)
XV-Ω040 not closed Melt feed line route to Reactors not allowed Pass
1.0
(permissive)
Permissives to Reactor 1 ok XV-A020 closes (already closed) Pass
1.0
Interlocks to Reactor 1 ok XV-A030 closed (already closed)
Select Reactor V-A100 XV-A040 opens
XV-A010 opens
Valves are left back to manual

Page 39 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

MFL_A Instance Name: ReactorsLineA/MFLRou Designed JSP Witnessed CS,PD,CA

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Melt Feed Line Description Test the melt feed line route selection Tested JSP Tested 14/09/2022
Function
Program By Date
Name:
Tests
Expected Result Actual Result Pass/PQ Notes
No Description

Permissives to Reactor 2 ok XV-A010 closes (already closed) Pass

1.0
Interlocks to Reactor 2 ok XV-A030 closed (already closed)
Select Reactor V-A200 XV-A040 opens
XV-A020 opens
Valves are left back to manual
Permissives to Reactor 3 ok XV-A010 closes (already closed) Pass
1.0
Interlocks to Reactor 3 ok XV-A020 closed (already closed)
Select Reactor V-A300 XV-A040 opens
XV-A030 opens
Valves are left back to manual
Permissives Close ok XV-A010 closes PAss
1.0
Interlocks Close ok XV-A040 closes
Currently Routed to Reactor 1 XV-A020 remains closed
Select Close melt feed line XV-A030 remains closed
Permissives Close ok XV-A020 closes Pass
1.0
Interlocks Close ok XV-A040 closes
Currently Routed to Reactor 2 XV-A010 remains closed
Select Close melt feed line XV-A030 remains closed
Permissives Close ok XV-A030 closes PAss
Plastic Energy Ltd.

1.0
Interlocks Close ok XV-A010 remains closed
Currently Routed to Reactor 3 XV-A020 remains closed
Select Close melt feed line XV-A040 remains closed

Page 40 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

MFL_A Instance Name: ReactorsLineA/MFLRou Designed JSP Witnessed CS,PD,CA

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Melt Feed Line Description Test the melt feed line route selection Tested JSP Tested 14/09/2022
Function
Program By Date
Name:
Tests
Expected Result Actual Result Pass/PQ Notes
No Description

Function not in execution Prompt “Select route” is displayed Pass

1.0
Permissives ok
Interlocks Ok
Silo discharge authorized
Extruder Ready
XV-A010 is open Function displays “Routed to Reactor 1” Pass
1.0
XV-A040 is open
XV-A020 is closed
XV-A030 is closed
XV-A020 is open Function displays “Routed to Reactor 2” Pass
1.0
XV-A040 is open
XV-A010 is closed
XV-A030 is closed
XV-A030 is open Function displays “Routed to Reactor 3” Pass
1.0
XV-A010 is closed
XV-A020 is closed
XV-A040 is closed
XV-A010 is closed Function displays “Route closed” Pass
1.0
XV-A020 is closed
Plastic Energy Ltd.

XV-A030 is closed
XV-A040 is closed or open
Any combination of valves Function displays “Route Fault” Pass
1.0
positions not considered in
previous monitoring tests
Function routing to Reactor 1 Generate message “Failted to switch to Route 1” PAss Adjust delay on
1.0
but not completed within 1 commissioning
minute

Page 41 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

MFL_A Instance Name: ReactorsLineA/MFLRou Designed JSP Witnessed CS,PD,CA

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Melt Feed Line Description Test the melt feed line route selection Tested JSP Tested 14/09/2022
Function
Program By Date
Name:
Tests
Expected Result Actual Result Pass/PQ Notes
No Description

Function routing to Reactor 2 Generate message “Failted to switch to Route 2” Pass Adjust delay on
1.0
but not completed within 1 commissioning
minute
Function routing to Reactor 3 Generate message “Failted to switch to Route 3” Pass Adjust delay on
1.0
but not completed within 1 commissioning
minute
Function closing melt feed line Generate message “Failted to switch to close melt feed line” Pass Adjust delay on
1.0
but not completed within 1 commissioning
minute
Silo Discharge is authorized Generate prompt “Recommended to select route” PQ265
1.0
Extruder is off
Extruder is ready
Reactor 1 is “Idle”
Silo Discharge is authorized Generate prompt “Recommended to select route” PQ265
1.0
Extruder is off
Extruder is ready
Reactor 2 is “Idle”
Silo Discharge is authorized Generate prompt “Recommended to select route” PQ265
1.0
Extruder is off
Plastic Energy Ltd.

Extruder is ready
Reactor 3 is “Idle”
PLC restart Valves go to fail position due to PLC restart PQ266
1.0
Routing to Reactor 1 executing Function does not continue execution
PLC restart Valves go to fail position due to PLC restart PQ266
1.0
Routing to Reactor 2 executing Function does not continue execution
PLC restart Valves go to fail position due to PLC restart PQ266
1.0
Routing to Reactor 3 executing Function does not continue execution

Page 42 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

MFL_A Instance Name: ReactorsLineA/MFLRou Designed JSP Witnessed CS,PD,CA

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Melt Feed Line Description Test the melt feed line route selection Tested JSP Tested 14/09/2022
Function
Program By Date
Name:
Tests
Expected Result Actual Result Pass/PQ Notes
No Description

PLC restart Closing executing Valves go to fail position due to PLC restart PQ266
1.0
Function does not continue execution

Notes:
Plastic Energy Ltd.

Page 43 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

5.5.1.8 Silo Monitoring

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

MFL_A Instance Name: ReactorsLineA/MFLRou Designed JSP Witnessed

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Melt Feed Line Description Test the melt feed line route selection Tested By JSP Tested Date
Function
Program
Name:
Tests
Expected Result Actual Result Pass/PQ Notes
No Description

Set to auto X-010 is set to auto Pass

1.0
X-011 is set to auto
XY-0004 is set to auto
Set to manual X-010 is set to manual Pass
1.0
X-011 is set to manual
XY-0004 is set to manual
Silo in auto Silo is set to manual Pass
1.0
E-Stop Total
Silo in auto Silo is set to manual Pass
1.0
E-Stop Preprocess
Silo in auto Silo is set to manual
E-Stop TAC
Silo in auto Silo is set to manual
Power Loss
Silo is filling Plastic Available = WI-A010
1.0
Plastic Filled = WI-A010
Silo is discharging Plastic Discharged = Plastic Filled – Plastic Available
1.0
Plastic Energy Ltd.

Plastic Available = WI-A010

1.0
1.0
1.0
1.0
1.0
1.0

Page 44 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 0

MFL_A Instance Name: ReactorsLineA/MFLRou Designed JSP Witnessed

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Melt Feed Line Description Test the melt feed line route selection Tested By JSP Tested Date
Function
Program
Name:
Tests
Expected Result Actual Result Pass/PQ Notes
No Description

1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0

Notes:
Plastic Energy Ltd.

Page 45 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

5.5.2 Core Module: Reactor

blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

5.5.2.1 Temperature Control

ReaTempCtl_A-100 Instance Name: Reactors/Reactor A-100/TempCtl Designed JSP Witnessed
Test Id:
By By
Reactor Temperature Control Description Test the Reactor temperature control Tested By JSP Tested Date
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Trigger individually: Temperature control is not allowed to be As expected Pass
1.0
TI-Ωα00 < 350 degC (permissive) enabled
Reactor state Unknown (permissive)
Reactor state Shutdown (permissive)
Trigger individually: Temperature control is disabled
1.0
Reactor state Shutdown (interlock) Temperature control is not allowed to be
TI-Ωα00 signal error (interlock) enabled
TI-Ωα03 signal error (interlock)
KΩα02 error
TIC-Ωα00 SP – PV > 0 TIC-Ωα00 increases setpoint to furnace
1.0
TIC-Ωα03 SP – PV < 0 TIC-Ωα03 increases fan speed
1.0
TIC-Ωα06 SP – PV > 0 TIC-Ωα06 increases setpoint to furnace
1.0
Reactor state is Idle TIC-Ωα00 auto. SP= Pyrolysis
1.0
Plastic Energy Ltd.

TIC-Ωα03 auto
TIC-Ωα06 disabled
Reactor state is Feeding Preparation TIC-Ωα00 auto. SP= Pyrolysis
1.0
TIC-Ωα03 auto
TIC-Ωα06 disabled
Reactor State is Feeding TIC-Ωα00 auto
1.0
TI-Ωα06 < 200 degC or TI-Ωα01 > 400 degC TIC-Ωα00 setpoint = Pyrolysis
TIC-Ωα06 disabled

Page 46 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

ReaTempCtl_A-100 Instance Name: Reactors/Reactor A-100/TempCtl Designed JSP Witnessed

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Reactor Temperature Control Description Test the Reactor temperature control Tested By JSP Tested Date
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Reactor State is Feeding TIC-Ωα00 auto
1.0
TI-Ωα06 >= 220 degC TIC-Ωα00 setpoint = Pyrolysis
TI-Ωα01 <= 400 degC TIC-Ωα06 disabled
Plastic Energy Ltd.

Page 47 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

ReaTempCtl_A-100 Instance Name: Reactors/Reactor A-100/TempCtl Designed JSP Witnessed

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Reactor Temperature Control Description Test the Reactor temperature control Tested By JSP Tested Date
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Reactor State is Feeding Interruption TIC-Ωα00 auto. SP = Pyrolysis
1.0
TI-A106 < 220 degC or TI-Ωα01 > 400 degC TIC-Ωα03 auto
TIC-Ωα06 disabled
Reactor State is Feeding Interruption TIC-Ωα00 disabled
1.0
TI-A106 >= 220 degC TIC-Ωα03 auto
TI-Ωα01 <= 400 degC TIC-Ωα06 auto
Reactor State is Cooking (Pre-Peak) TIC-Ωα00 auto. SP = Pyrolysis
1.0
TI-A106 < 220 degC or TI-Ωα01 > 400 degC TIC-Ωα03 auto
TIC-Ωα06 disabled
Reactor State is Cooking (Pre-Peak) TIC-Ωα00 disabled
1.0
TI-A106 >= 220 degC TIC-Ωα03 auto
TI-Ωα01 <= 405 degC TIC-Ωα06 auto
Reactor State is Cooking (Peaking) TIC-Ωα00 auto. SP = Dry
1.0
TI-A106 < 220 degC TIC-Ωα03 auto
TIC-Ωα06 disabled
Reactor State is Cooking (Peaking) TIC-Ωα00 disabled
1.0
TI-A106 >= 220 degC TIC-Ωα03 auto
TIC-Ωα06 auto
Reactor State is Cooking (Peak-End) TIC-Ωα00 auto. SP = Dry
1.0
Plastic Energy Ltd.

TI-A106 < 220 degC TIC-Ωα03 auto

TIC-Ωα06 disabled
Reactor State is Cooking (Peak-End) TIC-Ωα00 disabled
1.0
TI-A106 >= 220 degC TIC-Ωα03 auto
TIC-Ωα06 auto
Reactor State is Cooking (Ready to Dry) TIC-Ωα00 auto. SP = Dry
1.0
TIC-Ωα03 auto
TIC-Ωα06 disabled

Page 48 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

ReaTempCtl_A-100 Instance Name: Reactors/Reactor A-100/TempCtl Designed JSP Witnessed

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Reactor Temperature Control Description Test the Reactor temperature control Tested By JSP Tested Date
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Reactor State is Drying TIC-Ωα00 auto. SP= Dry
1.0
TIC-Ωα03 auto
TIC-Ωα06 disabled
Reactor State is Dried TIC-Ωα00 enabled
1.0
TIC-Ωα00 setpoint ramped down = Pyro
TIC-Ωα06 disabled
Reactor State is Flushing TIC-Ωα00 enabled
1.0
TIC-Ωα00 setpoint = Pyrolysis
TIC-Ωα06 disabled
Reactor State is Flushing (Venting) TIC-Ωα00 enabled
1.0
TIC-Ωα00 setpoint = Pyrolysis
TIC-Ωα06 disabled
Reactor State is Flushing (Completed) TIC-Ωα00 enabled
1.0
TIC-Ωα00 setpoint = Pyrolysis
TIC-Ωα06 disabled
Reactor State is Flushed TIC-Ωα00 enabled
1.0
TIC-Ωα00 setpoint = Pyrolysis
TIC-Ωα06 disabled
Reactor State is Char Removal TIC-Ωα00 enabled
1.0
Plastic Energy Ltd.

TIC-Ωα00 setpoint = Pyrolysis

TIC-Ωα06 disabled

Notes:

Page 49 of 88
 Plastic Energy Ltd.
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.
PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

Notes:

Page 50 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

5.5.2.2 Vapours Route Selection

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

VapRou_V-A100 Instance Name: Reactors/Reactor A-100/VapRou Designed JSP Witnessed CS, PD, CA
Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Reactor Vapours Route Selector Description Test the Reactor Vapours Route Tested JSP Tested 09/09/2022
Function
By Date
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
PDIC-A107 in error (permissive) Route to column not allowed Pass
1.0
Route to scrubber not allowed
PDIC-A102 in error (permissive) Route to column not allowed Pass
1.0
Route to scrubber not allowed
XV-A106 in error (permissive) Route to column not allowed Pass
1.0
Route to scrubber not allowed
XV-A108 in error (permissive) Route to column not allowed Pass
1.0
Route to scrubber not allowed
BV-A113 in error (permissive) Route to column not allowed Pass
1.0
BV-A113 not open (permissive) Route to column not allowed Pass
1.0
Reactor State: Route to scrubber not allowed PQ209 Update URS
1.0
- Feeding (any)
- Cooking (any)
XV-A208 Not Closed (only one reactor per Route to Scrubber not allowed Pass
1.0
line allowed to route to scrubber)
XV-A308 Not closed (only one reactor per Route to Scrubber not allowed Pass
1.0
line allowed to route to scrubber)
Plastic Energy Ltd.

Permissives to Column Ok XV-A106 opens PQ207 Update URS

1.0
Start program to Column PDIC-A102 to auto
PDIC-A107 closes
XV-A108 closes
Permissives to Scrubber Ok XV-A108 opens PQ207 Update URS
1.0
Start program to Scrubber PDIC-A107 to auto
PDIC-A102 closes
XV-A106 closes

Page 51 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

VapRou_V-A100 Instance Name: Reactors/Reactor A-100/VapRou Designed JSP Witnessed CS, PD, CA
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Reactor Vapours Route Selector Description Test the Reactor Vapours Route Tested JSP Tested 09/09/2022
Function
By Date
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Program is being executed to Column The program does not restart after PLC restart Pass
1.0
Stop PLC
Restart PLC
Program is being executed to Scrubber The program does not restart after PLC restart Pass
1.0
Stop PLC
Restart PLC
Function not in execution Display “Routed to column” regardless on whether the Pass
1.0
XV-A106 open valves were set to position manually or automatically
XV-A108 closed
PDIC-A102 in auto
PDIC-A107 closed
Function not in execution Display “Routed to Scrubber” regardless on whether the Pass
1.0
XV-A106 closed valves were set to position manually or automatically
XV-A108 open
PDIC-A102 closed
PDIC-A107 in auto
XV-A106 closed Display “Closed” Pass
1.0
XV-A108 closed
PDIC-A102 closed or not closed
Plastic Energy Ltd.

PDIC-A107 closed or not closed

Page 52 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

VapRou_V-A100 Instance Name: Reactors/Reactor A-100/VapRou Designed JSP Witnessed CS, PD, CA
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Reactor Vapours Route Selector Description Test the Reactor Vapours Route Tested JSP Tested 09/09/2022
Function
By Date
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Function switching to Column Display “Column” Pass
1.0
Function switching to Scrubber Display “Scrubber” Pass
1.0
Function not in execution Display “Unknown”
1.0
“Routed to column” not detected
“Routed to Scrubber” not detected
“Closed” not detected
Permissives to Column Ok Generate message “Failed to switch to column” PQ211
1.0
Start program to Column Route Back to Scrubber
XV-A106 error
Permissives to Column Ok Generate message “A device fault was detected” PQ212
1.0
Start program to Column Continue to column
XV-A108 error
Permissives to Column Ok Generate message “A device fault was detected” PQ212
1.0
Start program to Column Continue to column
PDIC-A107 error
Permissives to Column Ok Generate message “Failed to switch to column” PQ213
1.0
Start program to Column Route Back to Scrubber
PDIC-A102 error
Plastic Energy Ltd.

Permissives to Column Ok Generate message “Failed to switch to column” PQ214

1.0
Start program to Column Route Back to Scrubber
BV-A113 error or not open
Permissives to Scrubber Ok Generate message “A device fault was detected” PQ212
1.0
Start program to Scrubber Continue to scrubber
XV-A106 error
Permissives to Scrubber Ok Generate message “Failed to switch to scrubber” Pass
1.0
Start program to Scrubber Route Back to Column
XV-A108 error

Page 53 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

VapRou_V-A100 Instance Name: Reactors/Reactor A-100/VapRou Designed JSP Witnessed CS, PD, CA
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Reactor Vapours Route Selector Description Test the Reactor Vapours Route Tested JSP Tested 09/09/2022
Function
By Date
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Permissives to Scrubber Ok Generate message “Failed to switch to scrubber” Pass
1.0
Start program to Scrubber Route Back to Column
PDIC-A107 error
Permissives to Scrubber Ok Generate message “A device fault was detected” PQ212
1.0
Start program to Scrubber Continue to Scrubber
PDIC-A102 error

Notes:

PDIC error includes the PDCV error

Plastic Energy Ltd.

Page 54 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

5.5.2.3 Flush Program

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Flush_A-100 Instance Reactors/Reactor A-100/Flush Designed JSP Witnessed PD, CA

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name: By By
Reactor Flush Program Description Test the Reactor Flush Program Tested By JSP Tested Date 09/09/2022
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Trigger the following events individually: Flush is not allowed to be started PQ216 Text of permissives
1.0
XV- A150 in error (permissive) to be checked
FCV- A150 in error (permissive) during graphics
XV-A100 in error (permissive) testing
FI- A150 in error (permissive)
XV-A200 not closed (permissive)
XV-A300 not closed (permissive)
Reactor not in “Dried” (permissive)
Line through V-0901 is open (permissive)
Program in execution Flush program execution is stopped
1.0
Trigger individually the following events XV-50 to manual
Estop Total (interlock) FIC-50 to manual
Estop TAC (interlock) XV-00 to manual
PowerLoss (interlock) (Devices to fail position due to interlock)
Flush is not allowed to be started
Program in execution Flush program execution is paused. PQ217
1.0
Trigger individually the following events XV-50 closes PQ218
No route through V-0901 is open (pause interlock) FIC-50 closes PQ219
Plastic Energy Ltd.

LSHH-0901 high level (pause interlock) XV-00 closes PQ220

High reactor pressure (pause interlock) FQI maintained
PDIC-07 not controlling
PDCV-07 position not ok
PDCV-07 at 100% for 30 seconds
FCV-50 at max position for 30 seconds
Permissives ok Flush sequence executed as per URS Pass
1.0
Flush is started by operator
Flush paused Flush is allowed to be resumed by operator Pass
1.0
Pause interlocks Ok

Page 55 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

Flush_A-100 Instance Reactors/Reactor A-100/Flush Designed JSP Witnessed PD, CA

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
Name: By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Reactor Flush Program Description Test the Reactor Flush Program Tested By JSP Tested Date 09/09/2022
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Flush paused Flush sequence executed as per URS (ignoring Pass
1.0
Pause interlocks Ok the FQI-50 reset)
Operator select “Resume”
Flush running XV-00 closes Pass
1.0
Operator selects “Stop” FIC-50 closes
XV-50 closes
All to manual
Flushing Flush does not restart PQ223
1.0
PLC Restart Ensure that totalizer starts at 0

Notes:
Plastic Energy Ltd.

Page 56 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Reactor

5.5.2.4 Agitator Control Program

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

AgiCtl_A-100 Instance Reactors/Reactor A- Designed JSP Witnessed CA,CS,PD

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name: 100/AgiCtl By By
Reactor Agitator Control Description Test the Agitator control Tested JSP Tested 09/09/2022
Function
By Date
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
No
Reactor not Flushed and not in Char Removal (permissive) Speed Control is not allowed Pass
V1.0
to be started
Trigger individually the following events: Char Removal is stopped PQ226
V1.0
E-Stop Total active (interlock) Agitator is stopped due to
E-Stop TAC active (interlock) interlock
Power Loss active (interlock) Agitator is set back to manual
A-A100 Error (interlock) Char Removal is not allowed
to be started
Speed Control is disabled
Permissives ok Execute sequence as per URS
V1.0
Interlocks Ok
Char Removal is started by operator

Notes:
Plastic Energy Ltd.

Page 57 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

5.5.3 Core Module: Char Receivers

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

5.5.3.1 PIC-A109: Auto Purge

blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

ReaTempCtl_A-100 Instance Name: Char Receivers/V-A101/PIC-A109 Designed JSP Witnessed CS, CA, PD
Test Id:
By By
Automatic Purge Controller Description Test the Reactor temperature control Tested By JSP Tested 14/09/2022
Function
Date
Name:
Tests
Description Expected Result Actual Result Pass/P Notes
V
Q
Estop-Total The controller is disabled (devices set to Pass
1.0
E-Stop TAC manual)
XS-A102 not purged AND XV-A109 opens PQ235
1.0
XS-A103 empty AND
X-A100 not running AND
XV-A107 closed
XS-A102 purged OR XV-A109 closes PQ235
1.0
X-A100 running OR
XS-A103 empty OR
XV-A107 not closed
Function enabled Function disabled on restart Pass
1.0
PLC restart

Notes:
Plastic Energy Ltd.

Page 58 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

5.5.3.2 PIC-A111: Auto Vent

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

ReaTempCtl_A-100 Instance Name: Char Receivers/V-A101/PIC-A111 Designed JSP Witnessed CS, CA, PD
Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Automatic Vent Controller Description Test the Reactor temperature control Tested By JSP Tested 14/09/2022
Function
Date
Name:
Tests
Description Expected Result Actual Result Pass/P Notes
V
Q
Estop-Total The controller is disabled (devices set to Pass
1.0
E-Stop TAC manual)
PI-A101 > SP XV-A109 opens Pass
1.0
PI-A101 < SP - Hyst XV-A109 closes Pass
1.0
Function enabled Function disabled on restart Pass
1.0
PLC restart
1.0
1.0
1.0
1.0
1.0
1.0
1.0
Plastic Energy Ltd.

Notes:

Page 59 of 88
 Plastic Energy Ltd.
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.
PEN-XXXXXX-1-A-REPT-001

Notes:
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

Page 60 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

5.5.3.3 HIC-A100: Auto Discharge

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

ReaTempCtl_A-100 Instance Name: Char Receivers/V-A101/HIC-A100 Designed JSP Witnessed CS, CA, PD
Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Automatic Discharge Controller Description Test the Reactor temperature control Tested By JSP Tested 14/09/2022
Function
Date
Name:
Tests
Description Expected Result Actual Result Pass/P Notes
V
Q
Estop-Total The controller is disabled (devices set to Pass
1.0
E-Stop TAC manual)
HIC-A100 enabled X-A100 starts PQ236
1.0
XV-112 closed XV-A103 opens PQ237
XS-A103 indicates loaded XV-A107 opens
HIC-A100 enabled X-A100 stops PQ236
1.0
XV-112 open XV-A103 closes PQ237
XV-A107 closes
HIC-A100 enabled X-A100 stops PQ236
1.0
XS-A103 indicates “Not loaded” XV-A103 closes PQ237
XV-A107 closes
HIC-A100 disabled X-A100 in manual Pass
1.0
XV-A103 in manual
XV-A107 in manual
Function enabled Function disabled on restart Pass
1.0
PLC restart
Plastic Energy Ltd.

Notes:

Page 61 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

5.5.3.4 KIC-A113: Auto Knocker

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

ReaTempCtl_A-100 Instance Name: Char Receivers/V-A101/KIC-A113 Designed JSP Witnessed

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Automatic knocker control Description Tested By JSP Tested Date
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Estop-Total The controller is disabled (devices set to
1.0
E-Stop TAC manual)
KIC-A113 in auto XY-A113 opens and closes at the slow
1.0
X-A100 running frequency setpoint entered
WI-A101 > 50
KIC-A113 in auto XY-A113 opens and closes at the high
1.0
X-A100 running frequency setpoint entered
WI-A101 > 50
KIC-A113 in auto XY-A113 closes
1.0
X-A100 not running
1.0
Function enabled Function disabled on restart
1.0
PLC restart
1.0
1.0
1.0
Plastic Energy Ltd.

1.0
1.0

Notes:

Page 62 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Notes:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

5.5.3.5 XI-A102: Purged Flag

XI-A102 Instance Name: Char Receivers/V-A101/XI-A102 Designed JSP Witnessed CS, CA, PD
Test Id:
By By
Purged Flag Description Tested By JSP Tested 14/09/2022
Function
Date
Name:
Tests
Description Expected Result Actual Result Pass/P Notes
V
Q
Estop-Total The controller is disabled (devices set to
1.0
E-Stop TAC manual)
Pressure > SP Pass
1.0
PI-07 > 1bar
Receiver state is “purging”
Purge time is reset when purge is held for more PQ239
1.0
than 10 min
Function enabled Function disabled on restart
1.0
PLC restart
1.0
Plastic Energy Ltd.

1.0
1.0
1.0

Page 63 of 88
 Plastic Energy Ltd.
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.
PEN-XXXXXX-1-A-REPT-001

Notes:
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

Page 64 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

5.5.3.6 XI-A103: Loaded Flag

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

XI-A103 Instance Name: Char Receivers/V-A101/XI-A103 Designed JSP Witnessed CS, CA, PD
Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Loaded Flag Description Tested By JSP Tested 14/09/2022
Function
Date
Name:
Tests
Description Expected Result Actual Result Pass/P Notes
V
Q
WDI-A101 >20 kgr (5Kgr hyst) XI-A103 indicates “Loaded”
1.0
TI-A108 > 60 (1 degC hyst) XI-A103 indicates “Loaded” Pass
1.0
TI-A109 > 60 (1 degC hyst) XI-A103 indicates “Loaded” Pass
1.0
WDI-A101 <20 Kgr AND XI-A103 indicates “Not Loaded”
1.0
TI-A108 > 60 (1 degC hyst) AND
TI-A108 > 60 (1 degC hyst)

Notes:
Plastic Energy Ltd.

Page 65 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

5.5.3.7 XI-A104: Fire Flag

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

XI-A104 Instance Name: Char Receivers/V-A101/XI-A104 Designed JSP Witnessed CS, CA, PD
Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Fire Flag Description Tested By JSP Tested 14/09/2022
Function
Date
Name:
Tests
Description Expected Result Actual Result Pass/P Notes
V
Q
Estop-Total The controller is disabled (devices set to N/A
1.0
E-Stop TAC manual)
TI-A106 > 449 Fire Flag indicates “Fire” N/A
1.0
TI-A107 > 449 Fire Flag indicates “Fire” N/A
1.0
TI-A106 <= 449 AND N/A
1.0
TI-A107 <= 449
1.0
1.0
1.0
1.0
1.0
Plastic Energy Ltd.

Notes:

The fire flag is considered not required as the high temperature alarms of the char receivers is set at the same threshould

Page 66 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Core Module: Char Receivers

5.5.3.8 XI-A105: Vent Blockage Flag

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

XI-A105 Instance Name: Char Receivers/V-A101/XI-A105 Designed JSP Witnessed

Test Id:
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

By By
Purged Flag Description Tested By JSP Tested Date
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Estop-Total The controller is disabled (devices set to
1.0
E-Stop TAC manual)
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0

Notes:
Plastic Energy Ltd.

Page 67 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 07 08

5.5.4 Module 07 08
he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Instance Name: Designed By AF Witnessed By

blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Test Id:
Description Tested By AF Tested Date
Function
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V

5.5.5 Module 9
5.5.5.1 V-0901 Drain Sequence
Drain_V-901 Instance V901 Drain Sequence Designed MV Witnessed
Test Id:
Name: By By
V901 Drain Sequence Description Reactor Flush Knock Out Drum V- Tested By MV Tested Date
Function
0901 to the Wastewater
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Plastic Energy Ltd.

Sequence is started Pass

Wait for LS-0901 High Level activated Pass
Display Message “V-0901 High liquid level” Pass
Hold all reactor flushing sequences. Pass
Wait for the Reactor Flushing sequences to hold Pass
Display Message “V-0901 Draining” Pass

Page 68 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Drain_V-901 Instance V901 Drain Sequence Designed MV Witnessed

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
Name: By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

V901 Drain Sequence Description Reactor Flush Knock Out Drum V- Tested By MV Tested Date
Function
0901 to the Wastewater
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Close XV-0919A/B and record which is the duty valve/heat Pass
exchanger
Wait for XV-0919A/B to be closed Pass
Close XV-0905/XV-0920 (Pending HS-0905/20 selection) Pass
Wait for XV-0905/XV-0920 to be closed Pass
Open XV-0916 Pass
Wait for XV-0916 to be open Pass
Open XV-0907 Pass
Pass
Wait for LS-0901 AND LS-0902 to not be in alarm OR 120
seconds.
If alarm does not clear within 120 seconds activate prompt
“V-0901 failed to Drain, Operator to Investigate and hold
Reactor flushing Sequence”
Pass
Close XV-0907
Plastic Energy Ltd.

Pass
Close XV-0916
Pass
Wait for XV-0916 to be closed
Pass
Open duty XV-0919A/B
Pass
Wait for XV-0919A/B to be open
Pass
Open XV-0905/XV-0920 (Pending HS-0905/20 selection)

Page 69 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Drain_V-901 Instance V901 Drain Sequence Designed MV Witnessed

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
Name: By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

V901 Drain Sequence Description Reactor Flush Knock Out Drum V- Tested By MV Tested Date
Function
0901 to the Wastewater
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Pass
Wait for XV-0905/XV-0920 to be open
Pass
Remove Display Message on HMI “V-0901 Draining”
Pass
Release hold on reactor flushing sequences.
Pass
Return to Step 2

5.5.5.2 V-0911 Drain Sequence

Drain_V-911 Instance V911 Drain Sequence Designed MV Witnessed
Test Id:
Name: By By
Mist Eliminator Vessel V-0911 to the Description Mist Eliminator Vessel V-0911 to Tested By MV Tested Date
Function
wastewater sump T-1300 the wastewater sump T-1300
Name:
Plastic Energy Ltd.

Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Sequence is started
Wait for LS-0911 High Level activated
Display Message “V-0911 High liquid level”
Open XV-0915

Page 70 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Drain_V-911 Instance V911 Drain Sequence Designed MV Witnessed

he person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.

Test Id:
Name: By By
blication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Mist Eliminator Vessel V-0911 to the Description Mist Eliminator Vessel V-0911 to Tested By MV Tested Date
Function
wastewater sump T-1300 the wastewater sump T-1300
Name:
Tests
Description Expected Result Actual Result Pass/PQ Notes
V
Wait for XV-0915 to be open
Open XV-0921
Wait for XV-0921 to be open
Display Message “V-0911 Draining”

Wait for LS-0911 AND LS-0912 to not be in alarm OR

60seconds
If alarm does not clear within 60 seconds activate prompt
“V-0911 failed to Drain- Operator to Investigate”
Close XV-0915 AND XV-0921
Wait for XV-0915 AND XV-0921 to be closed
Remove Display Message “V-0911 Draining”

Return to Step 2
Plastic Energy Ltd.

5.5.6 Module 9

Page 71 of 88
 5.6 INTERLOCKS TESTING
• You will need your Test folder. Refer to section 3.4.1
• Verify per module that the appropriate icon for interlocks has been placed.
• Using the ‘OS’ and in some cases ‘ES’ verify all interlocks by triggering each cause of
interlock and checking every ‘Effect’ occurs when a cause trips as specified in the
‘Interlocks List’
• When interlocks are checked highlight in green on Interlocks List
• Should the interlock not pass, highlight in red and identify the interlock with a PQ number
describing the issue.
• Ensure interlocks coded comply with the notes defined in the interlock matrices
• Grouping by effects, records the results below:
Module Initial Date Pass/PQ N°
Module 0
Module Core
Module 6
Module 7
Module 8
Module 9
Module 10
Module 11
Module 12
Module 13
Module 14
Module 15
Module 16
Module 17
Module 18
Module 19

Notes:

Plastic Energy Ltd.

This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This
information is confidential, legally privileged and protected in law. Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited
without the consent of Plastic Energy Ltd. If you have received this communication in error, please contact us immediately.
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name
PEN-XXXXXX-1-A-REPT-001

Position
Notes:

Witnessed By
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Signature
Date

Page 73 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

5.7 GRAPHICS TESTING

This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

• You will need your Test folder. Refer to section 3.4.1

• See section Error! Reference source not found. onwards for documentation locations
• General look at each graphic on ‘SCADA’ and make sure it is as to the ‘P&ID’ and FDS.
• Verify that the vessels are tagged as the P&IDs.
• Ensure that the pipes connecting vessels and other devices are displayed as per the
P&ID
• Ensure that the HMI pipes colours follow the colour convention based on products
carried by the pipes
• Ensure that the navigation links work between the screens. Highlight in green if the link
works correctly.
Screen Module Initials Result
Module 0
Module Core
Module 6
Module 7
Module 8
Module 9
Module 10
Plastic Energy Ltd.

Module 11
Module 12
Module 13
Module 14
Module 15
Module 16
Module 17
Module 18
Module 19

Notes:

Page 74 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name
PEN-XXXXXX-1-A-REPT-001

Position
Notes:

Witnessed By
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Signature
Date

Page 75 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

5.8 ALARM TESTING

This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

• You will need your Test folder. Refer to section 3.4.1.

• See section Error! Reference source not found. onwards for documentation locations.
• Using the ‘ES’ trigger each alarm making sure it is the correct description, type and alarm
as specified in the ‘Alarms List’
• When test completed highlight alarm on ‘Alarms List’

Module Initial Date Pass/PQ N°

Module 0
Module Core
Module 6
Module 7
Module 8
Module 9
Module 10
Module 11
Module 12
Module 13
Module 14
Plastic Energy Ltd.

Module 15
Module 16
Module 17
Module 18
Module 19

Notes:

Page 76 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name
PEN-XXXXXX-1-A-REPT-001

Position
Notes:

Witnessed By
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Signature
Date

Page 77 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

5.9 COMMUNICATIONS WITH 3RD PARTIES / INTERFACES

This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

• You will need your Test folder. Refer to section 3.4.1.

• Vendor packages
• See section Error! Reference source not found. onwards for documentation locations.
• Verify that the assigned addresses match the addresses specified by the signal list provided
for the 3rd Party system. (Data blocks structures and its descriptions match)
• Verify that the communicated signals are connected to the right I/O
• Highlight the block icon / widget in the screens to those signals to be displayed as per
P&ID
• When test completed highlight signal on 3rd party list.
Item Instances Initial Date Pass/PQ N°
Walking Floor 4
Load Cells 19
Plastic Energy Ltd.

Notes:

Page 78 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name
PEN-XXXXXX-1-A-REPT-001

Position
Notes:

Witnessed By
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Signature
Date

Page 79 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

5.10 OTHER TESTS

tags
Item
PEN-XXXXXX-1-A-REPT-001

PLC indication
General Shutdown due to power loss
Communications Faliure Between OS &

Aquasition cycle and hysterisis for archive

Notes:
Initial
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Date
Pass/PQ N°

Page 80 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name
PEN-XXXXXX-1-A-REPT-001

Position
Notes:

Witnessed By
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Testing - Module 9

Signature
Date

Page 81 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

•
•

ID
PEN-XXXXXX-1-A-REPT-001

Record your results below.

6 UNSTRUCTERED TEST

covered in this test specification.

Test Description
Unstructured Tests

Date
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Unstructered Test - Module 9

Initials
Pass/PQ N°

Page 82 of 88
All tests performed that have not been covered in the previous tests procedures will be
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

ID
PEN-XXXXXX-1-A-REPT-001

Test Description

Table 12: Unstructured Testing

Unstructured Tests

Date
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Unstructered Test - Module 9

Initials
Pass/PQ N°

Page 83 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

Name
PEN-XXXXXX-1-A-REPT-001

Position
Notes:

Witnessed By
Signature
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Unstructered Test - Module 9

Date

Page 84 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.
PEN-XXXXXX-1-A-REPT-001

7 APPENDICIES
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Appendicies - Module 9

Page 85 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

PQ N°

NOTES
REQUIRED

PREPARED BY

APPROVED BY
REVIEWED BY
PROJECT CODE

PQ DESCRIPTION

QUERY RESPONSE
DOCUMENTATION
PEN-XXXXXX-1-A-REPT-001

7.1 PROJECT QUERY FORM

SIGNATURE:
SIGNATURE:

NAME
PROJECT QUERY FORM

Table 13: Project Query Form

DATE
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Appendicies - Module 9

SIGN
DATE:
DATE :

DATE

Page 86 of 88
 PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Appendicies - Module 9

7.2 NOTES
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.

• Record any optional Notes/Comments below.

Notes/Comments
1- Several alarm limits have been detected at the max and min range of the instrument. It is
preferred to avoid this.
2- It is required to discuss whether to introduce a general requirement to set all control loops
to manual mode when the Estop Total is tripped (or other applicable estops)
For SAT procedure, it is important to include the plc power off event in order to ensure that the
retentive variables are kept such as peak detected, kilos fed, etc.
Timeout of melt feed lines is to be adjusted during commissioning
Plastic Energy Ltd.

Page 87 of 88
 Plastic Energy Ltd.
This communication and the information herein is intended for the person(s) or organisations(s) named above and for no other person(s) or organisation(s). This information is confidential, legally privileged and protected in law.
Disclosure to unauthorised individuals or dissemination, publication or copying is prohibited without the consent of Plastic Energy Ltd.. If you have received this communication in error, please contact us immediately.
PEN-XXXXXX-1-A-REPT-001
CONTROL SYSTEM FACTORY ACCEPTANCE TEST: Appendicies - Module 9

Page 88 of 88