Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Fundamentals of Factory Acceptance Testing (FAT)

• Understand the purpose and importance of FAT in industrial projects.
• Differentiate between FAT, Site Acceptance Test (SAT), and Commissioning.
• Identify industries where FAT is critical (e.g., manufacturing, oil & gas, power, pharmaceutical, automation).

2. FAT Planning and Preparation

• Define FAT requirements based on project specifications.
• Develop a detailed FAT checklist and test procedures.
• Identify key stakeholders involved in FAT (vendors, customers, inspectors).
• Ensure compliance with industry standards (ISO, IEC, API, ASTM, ASME, GMP, etc.).

3. FAT Execution: Testing and Inspection Procedures

• Perform various FAT procedures, including:
• Visual inspection (material quality, workmanship, labeling)
• Dimensional checks (using precision measuring tools)
• Functional and performance testing (motor operation, control system response)
• Safety interlocks and fail-safe tests
• Electrical testing (continuity, insulation resistance, power-up sequence)
• Pressure and leak testing (for fluid systems)
• Software and automation validation (PLC, SCADA, HMI)
• Ensure proper data recording and result validation.

4. FAT Troubleshooting and Problem Resolution

• Identify common issues encountered during FAT.
• Develop strategies for real-time problem-solving.
• Work with vendors and engineers to resolve discrepancies.
• Implement root cause analysis and corrective actions.

5. Documentation and Reporting

• Develop a comprehensive FAT report, including:
• Test results and compliance verification
• Non-conformance reports (NCR) and corrective actions
• Client sign-off procedures
• Certificates of compliance
• Ensure proper documentation aligns with contractual and regulatory requirements.

6. Safety and Compliance During FAT

• Follow FAT safety protocols (hazard assessment, PPE, emergency response).
• Ensure compliance with workplace safety regulations (OSHA, ISO 45001, NFPA, etc.).
• Address environmental considerations for FAT testing.

7. FAT Approval, Acceptance, and Next Steps

• Define criteria for FAT acceptance and final approval.
• Establish post-FAT modifications and retesting procedures.
• Develop a transition plan for equipment shipment, installation, and Site Acceptance Test (SAT).

8. Case Studies and Practical Applications

• Review real-world FAT examples and best practices.
• Participate in hands-on exercises for FAT checklist creation and execution.
• Analyze previous FAT failures and lessons learned.

Target Audience

• Quality assurance and testing engineers
• Project managers and procurement specialists
• Electrical, mechanical, and automation engineers
• Maintenance and reliability engineers
• Operations and commissioning teams