Image: Factory Acceptance Test at Powder Systems Ltd
It requires thorough functional, performance, and safety tests of intricate systems. These may comprise many components and interdependencies. Challenging though it may be, these must be systematically assessed before they’re put into operation. This approach is broadly known as acceptance testing.
There are many forms of acceptance testing. Two closely related approaches that often come in for confusion are Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT). Both are critical stages in the verification and validation of equipment and systems within industrial and manufacturing contexts. However, they differ significantly in terms of location, timing, purpose, scope, participants, outcomes, and testing environment. Let’s explore in more depth.
1. Location
Factory acceptance testing is conducted at the vendor’s facility or equipment manufacturing site. This setting allows the vendor to utilise their controlled environment and specialised tools to test the equipment before it leaves the factory. In contrast, site acceptance testing occurs at the customer’s site once the equipment is delivered and installed. The shift in location is crucial as it allows for the evaluation of the equipment in its actual operating environment, which includes integration with other systems and site-specific conditions.
2. Timing
Another key difference is timing. Factory acceptance testing occurs before the equipment is shipped to the customer. This early testing phase is designed to catch any issues that can be resolved before the equipment leaves the vendor’s control. On the other hand, site acceptance testing is conducted after the equipment has been delivered and installed at the customer’s site but before it goes into full production. This sequence ensures any issues related to installation and site-specific operation are identified and addressed.
3. Purpose
The purposes are distinct yet complementary. Factory acceptance testing aims to verify the equipment’s functionality, performance, and compliance with specified requirements before shipment. This phase includes comprehensive tests to ensure that all components meet the necessary standards. Conversely, the goal of site acceptance testing is to confirm that the system works as expected in the customer’s environment. It also ensures that it meets all user requirements. This involves checking the system’s performance within the actual operating conditions it will face during regular use.
4. Scope
Factory acceptance testing typically involves a more rigorous and comprehensive testing process. This testing procedure includes the detailed verification of system components to ensure they function correctly and meet design specifications. In contrast, site acceptance testing focuses on operational performance over a time period, such as 1-2 weeks. It does this to identify any issues that may arise in the actual operating environment. The testing period helps ensure the system integrates well with existing operations and performs reliably under real-world conditions.
5. Participants
There are differences between the type of testing in relation to their participants. Factory acceptance testing is usually conducted by the vendor, with customer representatives present to witness and verify the tests. Taking a collaborative approach ensures both parties agree on the equipment’s functionality before it is shipped. In contrast, site acceptance testing involves the customer’s team more extensively, including operators and on-site engineers. This hands-on involvement is critical for ensuring the equipment meets the expectations of the customer’s operational team.
6. Outcomes
The outcomes are designed to address different aspects of equipment validation. Factory acceptance testing helps identify and resolve any issues before shipment. As a result, it can help reduce the time and costs associated with on-site fixes. By ensuring the equipment functions correctly before leaving the factory, factory acceptance testing minimises the risk of significant problems arising during installation and operation. Site acceptance testing, on the other hand, provides confirmation that the system is ready for full-scale operation and acceptance by the customer. This final step ensures that the equipment meets technical specifications and performs as required in its intended operational context.
7. Testing Environment
Finally, testing environments are fundamentally different. Factory acceptance testing is performed in a controlled factory setting. Performing the testing in this area allows for precise testing conditions and the use of specialised equipment. The controlled environment helps ensure that the equipment meets all technical specifications. Site acceptance testing, however, tests the equipment in its actual operating environment. It takes into account site-specific factors and integration with existing systems. Undertaking this real-world testing can show that the equipment performs reliably under the conditions it will encounter during normal operation.
Acceptance Testing Processes
Factory acceptance testing and site acceptance testing do vary, but each contains important processes. Both are essential for ensuring equipment and systems meet required specifications and function properly. Factory acceptance testing focuses on verifying core functionality and compliance in a controlled environment. However, site acceptance testing ensures the system performs as expected in the customer’s specific environment and confirms that it meets all user requirements. Understanding and executing these tests correctly can significantly enhance the reliability and performance of industrial equipment, leading to smoother operations and greater customer satisfaction.
At Powder Systems, factory acceptance testing is a mandatory step that strengthens our quality procedures and plans. PSL implement a wide range of checks on instruments to ensure they work well, from operational checks, like the vacuum leak test and pressure hold test, to checks for automation.
