The Factory Acceptance Test is a quality check done by equipment manufacturers before product delivery. During the test, the manufacturer verifies that the equipment functions correctly and meets the agreed-upon specifications. This is done in a controlled factory environment. Experts from both the manufacturer and the customer witness the tests, ensuring the equipment functions as intended. Any issues found are fixed before delivery. helps guarantee that the equipment is ready for use, reducing the risk of problems later. It's an important step to ensure product quality and customer satisfaction.
When a piece of new equipment is manufactured, it has the potential for countless errors. The error potential also increases with an increase in the machine's complexity. It is, therefore, necessary to test the equipment to ensure it is functioning as intended without errors. This test is known as the factory acceptance test, which is popularly by its acronym "FAT". In this article, we will explore more about FAT, its definition, purpose, steps, examples, checklist, and differences with the site acceptance tests (SAT).
When a piece of new equipment is manufactured, it has the potential for countless errors. The error potential also increases with an increase in the machine's complexity. It is, therefore, necessary to test the equipment to ensure it is functioning as intended without errors. This test is known as the factory acceptance test, which is popularly by its acronym "FAT". In this article, we will explore more about FAT, its definition, purpose, steps, examples, checklist, and differences with the site acceptance tests (SAT).
A Factory Acceptance Test is performed before the equipment is delivered. On the other hand, A Site Acceptance Test or SAT is conducted once the equipment is installed at the site. So, the SAT is performed after FAT, along with all interfaces and peripherals in the working environment of the equipment. The major differences between a Factory acceptance test and a Site acceptance test are provided in Table 1 below:
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Factory Acceptance Test |
Site Acceptance Test |
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The factory Acceptance test is performed at the factory workshop. |
The site acceptance test is performed at the construction site. |
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A factory Acceptance test is performed before the equipment is shipped from the manufacturer. |
A site acceptance test is performed once the equipment is installed at the site. |
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The duration of FAT is short. |
SAT is usually longer. |
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Testing in the factory acceptance test is done only to check the equipment. |
The site acceptance test is done with all interfaces connected. So, it ensures the actual working in the site conditions. |
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As the factory acceptance test is performed inside the manufacturing facility, the environment is not extreme. |
The site environment during the test may be different from the FAT environment. |
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Detailed documentation is prepared for the factory acceptance test. |
The documentation is not detailed in the case of the site acceptance test. |
Steps for Factory Acceptance Test
Factory acceptance testing is usually performed following the steps:
Planning :
The first step is the proper planning for the FAT. All details mentioned in the customer's order specification should be studied thoroughly. All applicable standards and drawings need to be checked to find out the FAT scope. All related reference documents must be kept ready. Some such documents are:
Customer scope and specifications.
Applicable Codes / References.
Relevant drawings like GA, P&ID, etc.
Equipment or component datasheets.
ITP (Inspection Test Plan).
FAT Checklists and Procedures.
Calibrations and Certifications as required by contract.
Testing:
During the factory acceptance testing, various parameters are inspected and ensured. Usually, the following things are addressed during a FAT:
Comprehensive inspection: In this stage, a range of conformity checks and verifications are performed. Any job-specific requirements as stated in the customer specifications are also ensured.
Contract Audit: To ascertain that all contractual obligations are taken care of.
Raw data is taken, recorded, and submitted to the customer to prove the functionality.
Along with the customer representative, various drawings like GA, P&ID, and electrical drawings are reviewed to verify their correctness.
NDE, Coating, Transportation, or Storage Procedures are reviewed.
Factory Acceptance Test Result
All the findings from the test are documented. If any deviation is found during the FAT from the expected working condition, the same is studied and corrected. The reason for the deviation and what corrective actions are taken are also documented. If there is any deviation from the client's requirements, the same is also documented and informed to the client for their approval. Once all the modifications are corrected, the equipment is retested to find compliance with the requirements.
Who should participate in the FAT?
As the factory acceptance test is performed at the manufacturer's workshop, all the key engineers should participate in the testing. Sometimes, the client is also invited to take part in the test. There could be a requirement for third-party approval for the test. So, overall, the following professionals should participate in the FAT:
Manufacturer engineers and managers.
Client representatives (Plant engineers, maintenance personnel, etc).
3rd party inspectors.
Having more participants during testing increases efficiency. Also, in case of any problem, the same can be discussed mutually to arrive at a quick resolution.
Who is responsible for the Factory Acceptance Test?
Performing a factory acceptance test is the responsibility of the equipment manufacturer. However, the requirement of FAT shall be specified in the scope document. Once the factory acceptance test is included in the project scope, there is no extra cost for the test.
Factory Acceptance Test Checklist
A factory acceptance test checklist is an important tool to ensure that all important components are inspected during the FAT. A factory acceptance test checklist reduces costly project delays by ensuring all details are taken care of during the FAT. Even though the actual FAT checklist varies from equipment to equipment, in general, the following checkpoints are included:
Scope of the FAT indicating the specific tests required.
Applicable codes and standards: These ensure that the exact code and standard requirements are followed for the FAT.
Reference documents: It verifies if all the relevant documents are available and referred to.
Testing equipment: Additional instruments like gauges, speedometers, etc, are available during the test.
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