Getting through the FAT is another milestone in the project, as the software has been proven in design. The next step is to place the equipment in the field and verify everything again using the real world inputs and outputs. The planning presents a set op of the appropriate tests to be carried out and who is responsible for developing the test cases. Appropriate levels of competence and independence of assessors are required. The realization of tests shall be described as well as the personnel responsible to carry out the test.

Performing FATs involves risk and hazards due to dealing with high-pressure fluid that could cause mechanical failure of the valves and actuators. Therefore strict safety consideration and implementation based on company risk procedures and regulations are essential. Extreme caution should be applied during the testing of both valves and actuators to prevent injury. Wearing safety glasses, a safety hat, and safety shoes in some areas of the factory are essential practices. It should be noted that the high-pressure gas test requires an especially high level of safety; the valve should be tested in a pit at a sufficient distance from personnel, and the pit should be equipped with gas detector alarms.

Benefits of  Factory Acceptance Testing

A Factory Acceptance Test (FAT) is a crucial procedure involved in the manufacturing process, designed to verify that newly manufactured equipment functions as expected before it’s delivered to your site. The objective is to provide confidence that the developed product meets both the functional and non-functional requirements. The Factory Acceptance Test (FAT) is a test of subsea equipment before installation, which is always performed on newly manufactured equipment, to check whether the equipment satisfy the performance and function requirements or not. Extended Factory Acceptance Test (EFAT) may be only applicable for several equipment or subsea structures, e.g., subsea trees with sub-assemblies. The System Integrity Test (SIT) is performed to verify the whole system no matter from one supplier only or different suppliers, which shall interface with each other acceptably. The main difference between a Factory Acceptance Test (FAT) and a Site Acceptance Test (SAT) is the place and time of execution.

The FAT is the time to discover failures or issues, determine reliability, verify efficiencies, and explore how the machine should handle failures. The test plan should be prepared up front and submitted to the supplier as part of the Request for Quote (RFQ). The machine will not perform as expected if the criteria aren’t specified; neither will performance be competently assessed.

The Purpose of Factory Acceptance Test

Many projects require a Factory Acceptance Test (FAT) prior to going on site. This testing phase involves demonstrating to the consultant and to the customer that the specified design has been properly implemented in the software. Since the software documents have been kept up to date, these same documents can be used to verify the operations of the software.

You connect it to the circuit breaker only for testing and once you are done and want to ship the cabinet, you simply disconnect the wires from the topside of the circuit breaker. Now that you have a good idea about the concept and feel comfortable with it, let’s explore FAT a bit further through a practical example. This is actually an acceptance test, done by you, on your computer before the document is sent. Verify that each individual assembly interfaces and operates properly with other components and assemblies of the system. All instrumentation used for test validation must be calibrated prior to and following test activities.

Before you want to connect the cable to the main circuit breaker inside the panel make sure that you have disconnected the power using this switch. Factory Acceptance Tests (FATs) are performed at the site of manufacture of a piece of equipment before it is shipped to the customer. Like with the testing procedure, the reports should be written in a standard format to allow efficient reviews and ensure that the relevant information is contained. Read to understand about quality compliance and the steps for a successful project completion.

These platforms also foster enhanced collaboration and communication by providing a central hub for all FAT-related activities. This feature ensures that everyone involved in the process, from the equipment manufacturers to the purchasing company representatives, has instant access to the same accurate, real-time information. This transparency reduces miscommunications and aligns expectations. Factory Acceptance Testing (FAT) provides essential benefits that justify the time, effort, and resources invested into executing it. Employing a robust FAT process can deliver substantial advantages, ranging from quality assurance to cost savings.

Step Switch on all the devices in the control panel

Once all the modifications are corrected, the equipment is retested to find compliance with the requirements. A Site Acceptance Test (SAT) is the qualification stage followed by the FAT and it includes a series of testing done on equipment, carried out at the owner representative site. The SAT provides documented evidence that the equipment/system has been delivered in good condition and has not been affected by the transportation. Lastly, discrepancies in documentation can cause significant obstacles in the FAT process.

• Wouldn’t it be nice to get some reassurance prior to receiving your equipment?
• Now you may ask, what If I don’t have an HMI installed with my panel?
• According to the customer’s user requirements specification, both stages are used to configure the equipment/system correctly and check that everything is working properly.
• During the FAT, faults and problems can be identified and rectified before handover to the customer takes place.
• FAT helps reduce the risk of equipment failure at the operational site.

Create and follow a detailed “failure script.” 

Make an inventory of the type of failures that you’ve experienced or might experience in production, as well as expected outcomes. Use this checklist to fully assess machine performance during the FAT. Machines have a natural backup curve that is all about early failures. Running, even dry running, is very critical; you can find leakage, electronic failures, and more, and then make sensible engineering changes. You can’t reap the benefits of testing if you don’t do the testing. Changes made at the FAT stage are the least-expensive ones; many times you don’t even pay for them.

The Factory Acceptance Test is performed at the manufacturer’s site before the respective plant or machine is delivered to the customer. The purpose of the FAT is to ensure that the customer’s requirements are met. https://www.globalcloudteam.com/ The Site Acceptance Test is performed directly at the customer’s site after a successful Factory Acceptance Test. It is used to ensure that the plant or machine has been properly installed and is operational.

By prioritizing and conducting diligent FAT procedures, businesses can ensure the consistent production of high-quality products, thereby boosting their market competitiveness. Low-code platforms can automate much of the tedious documentation involved in FAT. They can automatically generate detailed test reports, non-conformance reports, and other documentation, reducing the chances of human error and saving valuable time. This automatic documentation also ensures that all findings, decisions, and corrective actions are accurately recorded. You can repeat the same process for all of the other inputs as well. To check if the pump turns on in the output, you just need to know to which digital output the pump will be connected to and then you can see if the relay or the contactor will be energized as you change the input current.

This simplification can significantly reduce the time and effort required to conduct a FAT, speeding up the overall testing process. FAT isn’t just a test—it guarantees that each piece of equipment will fulfill its intended role within your operational framework, ensuring the seamless continuity of your production processes. This article will delve deeper into what a FAT is and how to go about conducting one successfully. The acceptance test suite is run using predefined acceptance test procedures to direct the testers which data to use, the step-by-step processes to follow and the expected result following execution. The actual results are retained for comparison with the expected results.[8] If the actual results match the expected results for each test case, the test case is said to pass. If the quantity of non-passing test cases does not breach the project’s predetermined threshold, the test suite is said to pass.

Focus on the personnel who will ultimately be responsible for running the machines, those who “own the line.” Sending engineers isn’t sufficient; the operators will see what makes the most sense on the line. The people who will run the equipment daily are uniquely qualified to make observations beyond the specifications and recognize issues or flaws prior to delivery. Additionally, the ownership aspect is invaluable, as the best technology going into a plant is not going to work if the operators are not comfortable with it, or have no faith in it. Engaging the production team early in the process is one of the most important aspects of new equipment design. If training is provided as part of the FAT, make sure the people being trained are those who will run the line, not the engineers.

In many cases it is difficult to predict the correct operation of the safety instrumented system or consequences due to failures in some parts of the safety instrumented system. For that reason the FAT is a valuable check of the safety issues. The safety of your employees is always a top concern so the quality assurance gives you the peace of mind that all components of your system are functioning the way they should, and within the full range of operating specifications. Factory Acceptance Testing occurs at the vendor’s test facility before the completed equipment proceeds to the customer site.