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The Factory Acceptance Test (FAT) is a process that evaluates the equipment during and after
the assembly process by verifying that it is built and operating in accordance with design
specifications. FAT ensures that the components and controls are working properly according to
the functionality of the equipment itself. As the name suggests, this testing is performed at the
factory.
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 FAT is a customized testing procedure for different types of systems and the tests are
executed before the final installation at the plant. The FAT is not a requirement but recommended
to be carried out, according to the standard IEC 61511, if the application software of the logic
solver is fairly complex or if the architecture of the safety instrumented system is using redundant
arrangements.
FAT must be conducted in a thorough and forthright manner. A poor or rushed FAT can lead to
missed non conformities, which can only then be corrected after the equipment is installed—which
in turn can wreak havoc on a project schedule.
FATs are beneficial not just for the buyer and end users but for the manufacturer as well. Both
parties can be assured that the equipment meets all the contractual specifications and any issues
can be addressed before arriving at the customer’s site. Rectifying issues while the system is still
in the possession of the manufacturer helps to keep the project on track and within budget. FATs
almost always save time and money over fixing issues in the field.
Our broad factory acceptance test is the most lucrative way to ensure that your equipment or
plant operates correctly. As a highly qualified, independent third-party, we have the trusted skills
and resources to perform steadfast testing. Alternatively, we can witness appropriate testing on
your behalf. 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.
Achieve independent proof of functionality, quality and integrity with our comprehensive checking
process
Verify all important documents, such as manuals, instructions, plans, drawings, piping and
instrumentation diagrams (P&IDs)
Ensure that your equipment or plant performs as expected under the testable range of likely
conditions, including mishandling and error
The main objective of the FAT is to test the safety instrumented system (logic solver and
associated software together). The tests are normally executed during the final part of the design
and engineering phase before the final installation at the plant. The FAT is a customized
procedure of checking the safety instrumented system and the safety instrumented functions
according to the safety requirements specification.
The FAT includes appropriate general testing procedures for verification of the correct operation
of the safety instrumented system. Since the testing activities are general methods the FAT is
applicable to programmable or non-programmable safety instrumented systems. The most
important part of the FAT addresses specification of the test cases i.e. clear description of the test
cases, well-structured test procedures and relevant test cases.
It’s important to note here that there are varying levels of an FAT. They can be performed at a
very basic level, such as setting up the main pieces of the system with temporary wiring and
making sure everything moves as it is supposed to, or a more complete FAT can be conducted
where the manufacturer physically builds the whole system in their shop to test it fully. In the latter
example, the system is then taken apart, moved to the customer’s site, and put back together
again.
The FAT is normally performed at the manufacturer work shop. The manufacturer checks that the
safety instrumented system works as intended and according to the requirements stated in the
safety system works as intended and according to the requirements the safety requirements
specification, NRN. During the FAT the manufacturer checks:
The used equipment are mending to the specification eg, compatible HW and SW versions
The used equipment are installed according to manufacturer’s specification
The input and the outputs are connected according to the drawings
The calibration of the equipment are correct
The trip points operate according to the requirements in the SRS.
The associated software operate according to the requirements in the SRS the outputs and their
actions behave according to the SRS
The reset functions operate according to the SRS
The alarms operate according to the SRS
The operator functions operate according to the SRS
The bypass functions operate according to the SRS
The manual shutdown functions operate according to the SRS
The diagnostic alarm functions operate according to the SRS
The outputs from the safety instrumented function are examined during different test cases e.g.
simulation of inputs in order to verity that the safety instrumented functions meet the requirements
in the safety requirements specification.
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.
Preparation is key to getting the most out of a FAT. Here are a few of the tips you can use to set
your stretch wrapper FAT up to deliver the greatest benefit.
1. Use the right materials. In the FAT, use the materials that will be put in operation during actual
production. Not using them may compromise test validity. With stretch wrappers, specifically,
providing the film that will be used in production is also a key component as the gauge & quality
of the film has a significant impact on how the machine is set up and its overall performance.
2. Engage the operators and technicians. 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.
3. Be smart about training. 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. Train and educate the right people.
4. 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. Use this checklist to fully assess
machine performance during the FAT.
5. Check safety with a keen eye. Complete a review of the equipment from a safety perspective.
Look for poorly guarded areas and pinch points.
There are several components that make up FAT. The product must be assembled, prepared,
and connected to utilities for testing. Documentation such as drawings, ASME certificates, and
test procedures must be gathered. And finally, testing must be conducted in the factory that
follows specific test procedures.
Before the FAT begins, the manufacturer should present the FAT procedure to the client for review
and approval. The procedure should include testing of as much functionality as is practical in the
factory and, where possible, should show pass/fail criteria or desired results for each item tested.
Once the procedure is approved, the manufacturer should test the equipment before the FAT
begins. Keep in mind that some clients like to visit the factory during FAT, so this “pre-test” will
confirm that the sterilizer is set up with the correct options, ensure a smoother FAT process and
minimize down-time during the FAT.
A pre-planning is necessary for an efficient FAT. 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. The test protocol is developed
during the planning and furthermore who is responsible to attest the test protocol.
The procedures to carry out the FAT shall be well defined and documented in a proper way. Each
test procedure shall be described in a logical sequence i.e. How to test the application software
and hardware. The needed competence for involved test personnel is described during the
planning. It is recommended that personnel with experience suitable for the intended process
application and safety instrumented system deals with the FAT planning.
The testing included in a FAT procedure should be largely derived from the performance criteria
defined in the Functional Requirements Document (FRD), 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.
The system integrator/dealer should prepare and submit a FAT procedure well in advance of the
FAT. This procedure should be reviewed and approved by the system owner/project manager. It
should attempt to include testing of as much functionality as is practical in the factory, and check
of all interfaces among equipment and systems. Where possible the procedure should show
pass/fail criteria or desired results for each item.
The dealer should also provide a schedule for the FAT showing all timing and sequence of testing.
Prior to FAT all design approvals should be complete. This is to remove technical ambiguity from
the FAT and prevent disputes over work that continues after FAT.
The dealer should prepare a test facility that can be effectively used to conduct the FAT testing,
including calibrated test equipment and any special test equipment.
The dealer should compile a document set that can support the testing and serve as a reference
for the test results, including:
o Contract specifications and copies of all references called out in the specification.
o All drawings for the project, including drawings received from other vendors that describe
interfaces.
o Detailed testing check list, including pass/fail criteria.
The dealer is to pretest the system before FAT. Failure to do this can result in wasted time during
FAT, and potentially a prolonged extension of FAT while fixes are effected.
If the system in question is large enough to impact the system owner’s facilities, laboratory layout
or utilities or if there are any questions regarding moving the system into the owner’s facility, it is
highly recommended that a person responsible for the owner’s physical plant/facility be invited to
attend FAT.
Review the specification line by line while checking the equipment or drawings for compliance
with the specification, including any change orders.
Inspect for workmanship
Inspect for problems that can occur during installation or use of the equipment, for example, lifting
points and safe access to components for maintenance, etc.
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.
Note the software and firmware versions in the equipment being tested.
All the test cases of the FAT shall be explained in the documentation and furthermore if the
objectives and criteria of the tests have been met or not. Exposed failures during the test are
documented and the causes for the failures are also documented supported by essential actions
to correct the failures. If there are modifications of the safety instrumented system it is necessary
to carry out a safety analysis in order to determine if the safety is affected and if re-testing is
necessary.
Step 3: Processes done after Factory Acceptance Testing
Check of documentation
Confirm vendor’s/dealer’s schedule for completing all documentation.
Customers can “touch and feel” the equipment while it is in operational mode before it ships.
The manufacturer can provide some initial hands on training to the customer, giving operating
personnel more confidence when running the machinery for the first time in real-world settings.
Key project people from both sides are together, making it an ideal time to review the bill of
materials, discuss required and recommended spare parts (for start-up and first year of operation)
and review maintenance procedures and equipment limitations.
The thorough FAT documentation can be used as a template for the Installation Qualification
portion of the validated process/installation.
Based on the results of the FAT, both parties can create a punch list of additional items that need
to be addressed prior to shipment.