The main objective of the FAT is to test the instrumented safety system . The tests are normally carried out during the final part of the design and engineering phase before the final installation in the plant. The FAT is a customized procedure to verify the instrumented safety system and the instrumented safety functions according to the specification of safety requirements. Documentation and Logging The platform allows for digital documentation and logging of the entire factory acceptance testing process.

Through operational testing and assessment, any deviations from acceptance criteria are identified and resolved, ensuring that the equipment functions optimally in its intended setting. The testing included in a FAT procedure should be largely derived from the performance criteria defined in the Functional Requirements Document , which is created by the project team early in the project planning process. The FRD should be the focal point for discussions when interviewing potential system integrators and should be included in the contract/purchase order package. These requirements should, therefore, be well known and understood well before time to develop the actual FAT protocol.

Site Acceptance Test (SAT)

It is, therefore, required to test the equipment to find out if the equipment is working as needed without errors. This test is known as the factory acceptance test which is popular 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 . Ajay Pazhayattil is a pharmaceutical management consultant leading technical operations, quality assurance, and regulatory compliance risk mitigation/remediation projects.

The FAT reveals weaknesses in the design and engineering phase or in the safety requirement specification phase these phases have to be modified according to the result of the FAT. In order to check the modifications the safety instrumented system has to be re- tested. The ISPE’s GAMP 5 guidance tells us that in a given project, there may be some pre-delivery testing that can include Factory Acceptance Testing. This testing requires that all system components be assembled and tested to show that the system functions as expected. Several topics need to be considered when determining the contents of the SAT.

Definition in English: Site Acceptance Testing

In addition, factory acceptance helps to strengthen the customer’s confidence in the quality and reliability of the machine. Factory Acceptance Testing and Site Acceptance Testing are two crucial processes that ensure the quality and functionality of industrial equipment and systems. In this article, we will delve into the details of both FAT and SAT, exploring their purposes, procedures, and significance in ensuring successful project implementation. The factory Acceptance testing or FAT guarantees that the equipment is complying with all the requirements and are ready to be commissioned without any problem. This test is performed at the factory and is beneficial for both the end users and the manufacturer. Any functional issues are identified before the equipment leaves the factory premise and can easily be rectified by the manufacturer.

• SAT allows for the customization and fine-tuning of equipment to ensure optimal performance within the client’s unique operational environment.
• The most important part of the FAT addresses the specification of test cases, that is, a clear description of test cases, well-structured test procedures and relevant test cases.
• Execution of factory acceptance testing and site acceptance testing is a business-critical activity when it comes to commissioning of a new system or equipment.
• While FATs can use simulations to demonstrate how the equipment will function in its future operating environment, it may be difficult to mimic the actual operating conditions.
• Factory Acceptance Testing and Site Acceptance Testing play pivotal roles in ensuring the successful implementation of industrial projects.
• Increasingly, customers are simply looking for a video testimonial that the machine actually runs before it leaves the supplier’s facility, in lieu of a FAT.

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. Of the valves is normally done after assembling and before painting, mainly to make sure that the leakage rate from the body and the seats of the valve are within the accepted limits. This chapter provides practical examples of FAT on different types of valves. The focus is to consider FAT is more than a pressure test on the valves so a checklist has been provided for activities which should be done during FAT.

Testing

All relevant information, such as checklists, inspection reports, photos, or videos, can be captured and stored directly within the platform. The tests are conducted under simulated operating conditions in the factory premises. The equipment is thoroughly inspected, and various functional tests are performed to ensure its compliance with design specifications. In today’s fast-paced, ever-changing manufacturing world, it is important to execute the activities of a project that ensure no stone was left unturned. Site acceptance testing provides a well-documented way to ensure that the scope of a project was met.

For custom and modular systems, SAT can be much more complex, as you would need to verify that each component was built according to the specifications before accepting them from the vendor. Factory Acceptance Training is not performed for a Vaisala monitoring system because its components are separate, off-the-shelf products, and they are neither new nor complex. Also, we can’t assemble your monitoring system at our factory, so there is really nothing to test.

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Test of the equipment per the dealer’s approved procedure; these should include functionality testing and regulatory testing. Ad hoc testing may be required to define any major non-conformities revealed by testing. Create and follow a detailed “failure script.” Make an inventory of the type of failures you might experience in production, as well as expected outcomes. FAT is typically conducted in order to assess any discrepancies and non-conformities, as well as develop a process for how they are to be handled. Deviations or abnormalities observed during testing are documented in a problem report and corrected prior to shipment. The factory acceptance test duration varies based on the type of plant and equipment.

The formal FAT would then be essentially a repeat of what was already done, but would be witnessed by and signed off by the customer and the consultant. It is important to get the FAT officially signed off since this represents a major milestone in the overall project. The successful completion of the FAT serves as a benchmark https://globalcloudteam.com/ for the system during site commissioning. 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.

Process

Any necessary calibrations and adjustments are made during this phase. The equipment manufacturer prepares a detailed test plan outlining the specific tests to be performed during the FAT process. This plan serves as a roadmap for conducting comprehensive evaluations. In the FAT, use the materials that will be put in operation during actual production. Performing a factory acceptance test is the responsibility of the equipment manufacturer. However, the requirement of FAT shall be specified in the scope document.

Utility capacity, automation, interface, and control issues/gaps usually are highlighted during this stage. Therefore, additional test cases to verify the potential failure modes need to be integrated into the SAT protocol. Rectifying manufacturing issues while the system is still with the manufacturer helps control aspects of the project, such as timeline and budget.

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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. Conducted at the contractor’s facility; such a test consists site acceptance testing meaning of the contractor, or the system programmer in particular, demonstrating that the program logic works correctly. With the PCLDs and PPC points lists in hand, the various processes of the design are simulated and the operations are verified. The test is usually performed with the completed panel, with the PPC and all terminations.