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 client design specifications. FAT ensures that the components and controls are working in accordance with the functionality of the equipment itself. As the name suggests, this testing is performed in our factory.
FAT is conducted to determine discrepancies and non-conformities, as well as developing a process for how they are to be corrected. Discrepancies observed during testing are documented in a problem report and corrected prior to shipment.
Benefits of a Factory Acceptance Test at TKMS:
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Achieves independent proof of functionality, quality, and integrity with our comprehensive checking process
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Verifies of all important documents, including component manuals, instructions, electrical plans, drawings and piping and instrumentation diagrams (P&IDs).
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Ensures that client's modular system performs as expected under the testable conditions.
During the FAT we check for the following:
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The components used meet the specifications issued by our clients
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All equipment is installed according to manufacturer’s and owners specifications
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The control system inputs and outputs are connected according to the drawings
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The calibration of the equipment is correct (where possible)
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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:
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A full documentation and turn-over package, including a completed FAT Protocol
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Maintenance and users’ manuals
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Certificates of Compliance
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As-built technical drawings (Electrical, Mechanical, Pneumatic, & Process)
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Materials certificates and data sheets
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Main equipment data sheets
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Instruments calibration certificates
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Welding processes qualifications
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Weld logs and maps including full QA documentation of each welder
How do we conduct a Factory Acceptance Test?
How TKMS Conducts Factory Acceptance Testing?
There are several components that makeup a 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. Finally, testing must be conducted in the factory following specific test procedures.
Before the FAT begins, we issue our FAT procedure to the client for review and approval. The procedure includes testing of as much functionality as is practical in the factory and, when possible, show 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. This “Pre-Test” will confirm that the modular systems are established with the correct options to 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.
