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Factory Acceptance & Testing

At TKMS, Factory Acceptance Testing (FAT) is a process that evaluates our equipment and Systems 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 in our 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.
 

Each FAT is a customized testing procedure for different types of Modular Systems and the tests are executed before the final installation at the client's facility. A poorly executed or rushed FAT can lead to missed non-conformities, which can only then be corrected after the equipment is installed—which in turn can bring havoc on a project schedule.

Benefits of a Factory Acceptance Test at TKMS:

  • Achieves independent proof of functionality, quality, and integrity with our comprehensive checking process

  • Verification of all important documents, including component manuals, instructions, electrical plans, drawings, piping, and instrumentation diagrams (P&IDs)

  • Ensures that your modular system performs as expected under the testable conditions

 

At Turnkey Modular Systems, we check that the instrumentation system functions as intended in accordance with the requirements stated in the Design Specifications.

 

During the FAT we check for the following:

  • The components used are to the specifications issued by our clients

  • All equipment is installed according to manufacturer’s and owners specifications

  • The control system input and the outputs are connected according to the drawings

  • The calibration of the equipment is correct (where possible)

  • The software (when provided by TKMS) operates according to the system requirements and the outputs and their actions operate according to the design

 

At TKMS we provide the following upon acceptance of a FAT:

  • A full Documentation and Turn-over package, including a completed FAT Protocol

  • Maintenance and users’ manuals

  • Certificates of compliance

  • As-built technical drawings (electrical, mechanical, pneumatic, & process)

  • Materials certificates and data sheets

  • Main equipment data sheets

  • Instruments calibration certificates

  • Welding processes qualifications

  • Weld Logs and Maps including full QA documentation of each welder

How do we conduct a Factory Acceptance Test?

How TKMS Conducts a Factory Acceptance Testing?

There are several components that makeup 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, we issue our FAT procedure to the client for review and approval. The procedure include testing of as much functionality as is practical in the factory and, where possible, shows pass/fail criteria or desired results for each item tested. Once the procedure is approved, we test the equipment before the FAT begins. Sometimes our clients prefer to visit our factory during FAT, so this “pre-test” will confirm that the modular systems are set up with the correct options, ensure a smoother FAT process and minimize down-time during the FAT.

A successful FAT in our facility includes pressure hold tests, Riboflavin testing, CIP and SIP routing, line sloping. dead leg inspection, correct component installation, proper placement of components, correct finish on stainless steel materials and proper authority inspection. 

Benefits of TKMS Factory Acceptance Testing

  • While our customers are in our facility they can “touch and feel” the equipment while it is in operational mode before it ships.

  • We 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.

  • The 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, a punch list of additional items is prepared that becomes the task list of things to be completed prior to shipment.

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Headquarters & Factory

2590 Sheridan Garden Drive,

Oakville, Ontario Canada. L6J 7R2

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Telephone: 1-905-608-8006

Fax: 1-905-608-8007