The headache of dealing with troubles when equipment is manufactured and operated for the first time might be a significant burden if you are in charge of installation and start-up. Wouldn’t it be good to have some confidence before receiving your equipment? That is what Factory Acceptance Tests,means. These tests, performed at the manufacturer’s site prior to delivery and installation, aid in identifying and correcting any defects before shipping. The factory test is tailored to contain a combination of manufacturer-mandated ‘standard’ tests, as well as special client or designer criteria, which were chosen to demonstrate the full functionality of the systems. This allows operators to confirm that the equipment is performing as expected and offers them confidence that their high-quality equipment will function effectively from the start.
What is a Factory Acceptance Test (FAT)?
A factory acceptance test (also known as factory approval testing or simply FAT) is a series of functioning checks performed on industrial equipment by a manufacturer prior to shipment to the end-user. This test is typically performed in the presence of an independent inspector and a client and/or end-user representative.
What does a Factory Acceptance Test entail?
The factory acceptance testing, or FAT, ensures that the equipment meets all standards and is ready to be commissioned without issue. This test is carried out at the factory and benefits both the end-users and the producer. Any functional flaws are recognised before the equipment leaves production, and the manufacturer may quickly correct them. As a result, FAT aids in project timetables and cost control.
Importance of Factory Acceptance Test in UAE
FATs benefit not just the consumer and end-users, but also the producer. Both parties may be confident that the equipment satisfies all contractual criteria, and any flaws can be resolved before the equipment arrives at the customer’s location. Rectifying faults while the system is still in the manufacturer’s ownership helps to keep the project on track and under budget. FATs almost always save time and money over field repairs.
Because the safety of your personnel is always a top priority, quality assurance provides you with the peace of mind that all components of your system are performing properly and within the entire range of operating requirements. Furthermore, FATs aid in determining who is to blame for the problems that have been detected. Sometimes the problems are the manufacturer’s fault, such as when an instrument fails to function properly, and other times they are the customer’s fault (for example, if a customer decides after seeing the physical layout they want to reconfigure the design, the manufacturer can move things around prior to shipping it to the site).
Basics of a factory acceptance test
Given the importance of factory acceptance testing, selecting a manufacturer who offers FAT is a critical initial step in the design/build process. Connecting the skid to utilities to perform functional activities, comparing the assembly to the as-built drawings, and verifying construction to applicable standards such as ASME-BPE, 3-A Sanitary, or other client specifications are all part of the FAT execution process.
A basic FAT checklist comprises the testing of a number of critical components and services. Because testing is usually tailored to the needs of the customer, the following things are typical on most checklists but are not mandatory:
- Connections are tested to confirm that they meet type, size, and placement requirements.
- Installation and positioning of the control panel
- Drain connections, size, type and location
- Overall dimensions
- Workmanship
- Documentation: datasheets, drawings, supplier documentation, and certifications.
- Major equipment and materials of construction
- Verification of welds and weld documentation
- Report verification and pressure testing
- Examine the Quality Control documentation.
What are the advantages of FAT?
For both parties involved, there are various benefits to undertaking a Factory Acceptance Test.
The vendor can assure that the system is working, which aids the project in remaining on track to be completed on time. According to the order specifications, the buyer can qualify the equipment against the contractual agreement.
Here’s the problem about new systems, especially given the level of sophistication found in CPI equipment: it’s very uncommon for tiny faults to occur the first time they’re powered on. The advantage of performing a FAT is that the manufacturer may address common first-run difficulties, often even before the customer arrives.
Who should be present during a FAT?
While there are no hard and fast rules on who should witness a FAT, they must have enough prior knowledge about the equipment they would be evaluating. In most cases, factory approval testing necessitates the presence of the following individuals:
- Project supervisors
- Machinery operators
- Site engineers
- Maintenance workers
- Independent third-party inspectors
To wrap things up, the FAT ensures that the new purchase has been evaluated against a set of scenarios based on the design specifications.