To do a FAT you need to test each of the PLC inputs and outputs one by one and make sure everything works properly based on the PLC logic. The PLC power supply could be installed on the same rack as the PLC or somewhere else on the panel. We may have one, two, or three power supplies on our panel depending on how many devices we need to power on in the control panel. Now that you have connected the power cable to the control panel and switched on the circuit breaker, you also need to switch on any other breakers or fuses that you may have on the way to power the PLC and the other devices.

• Other mechanical and visual tests also take place in order to affirm the conformance to wiring and safety standards.
• Making such changes at the installation site is impractical; hence, FAT is a must-do step versus nice to do, for critical systems.
• There are often changes identified during the FAT after seeing how the system functions in a simulated manner.
• Problems may still show up on site during the commissioning, but at this FAT stage, much of the logic can be checked out and demonstrated.
• The planning presents a set op of the appropriate tests to be carried out and who is responsible for developing the test cases.

Not all (or many) machinery suppliers have factories set up to perform a well-rounded FAT for customers. Some will build or mock up complete systems, but duplicating a customer’s process can be very difficult and expensive. Suppliers may be able to prove to the end user that their machine can perform in the manner desired during pre-sales (or pre-PO) product-testing procedures. Once customers are satisfied that equipment can do what they want it to do, POs are issued. Increasingly, customers are simply looking for a video testimonial that the machine actually runs before it leaves the supplier’s facility, in lieu of a FAT.

Factory Acceptance Testing

The document itself does not necessarily have to be lengthy or too detailed; usually the key operating characteristics must be listed with some details of their respective operations. Typically both the consultant and the customer are present definition of factory acceptance testing for the testing, so that both parties are satisfied that the system has been implemented correctly. Problems may still show up on site during the commissioning, but at this FAT stage, much of the logic can be checked out and demonstrated.

Although this seems a very simple process so far, there are two important points that you need to consider when trying to power on your control panel. Consequently, you will have to spend countless hours at the client’s site solving issues that you could have easily taken care of before shipping the control panel. In the world of industrial automation, a Factory Acceptance Test or FAT is simply a test for a newly manufactured control system that takes place at your factory or your workshop before you ship the control panel to the customer. 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.

Extended-run factory acceptance testing

Both parties can be confident that the equipment meets all contractual specifications, and that any issues can be resolved before the equipment arrives at the customer’s location. Rectifying issues while the system is still in the manufacturer’s possession helps to keep the project on track and within budget. Having a detailed test plan will help ensure that you don’t short-change the FAT. By testing the equipment or components before they are received by the customer, DXP can increase the odds that new installations will perform as expected.

The Site Acceptance Test is performed directly at the customer’s site after a successful Factory Acceptance Test. It is used to ensure that the plant or machine has been properly installed and is operational. Create and follow a detailed “failure script.” 

Make an inventory of the type of failures that you’ve experienced or might experience in production, as well as expected outcomes. While manufacturers typically don’t charge for testing, customers do incur costs for travel and stays for factory testing.

This article will discuss what a FAT is and how to make a factory acceptance test checklist. Ok, so this is pretty much what you need to know to be able to perform a Factory Acceptance Test for your control panel. To test this input we first need to know how the transmitters are connected to the card. For example, let’s say that the first digital output that we have here is connected to a motor via a contactor. The PLC program logic, says when the level switch 1 and level switch 2 are both active, we need to have the motor connected to this output turned on.

The cost of an EFAT, when needed, is normally negotiated between the vendor and the operator. All instrumentation used for test validation must be calibrated prior to and following test activities. If the pump turns on it means that everything works fine for this input and the logic. If the oil pump does not turn on, I need to look into the wiring or my PLC logic. To test the output, all you need to do is to activate the inputs using simulated signals and see if the contactor on the output will be energized. However, if the device is active, you need to look at the wiring diagram and find the best way to simulate the signal coming from that active device.

The SAT provides documented evidence that the equipment/system has been delivered in good condition and has not been affected by the transportation. Ascertain that your electrical boards perform as expected under a testable range of likely conditions, such as mishandling and error as well as the required operating voltage. There are often changes identified during the FAT after seeing how the system functions in a simulated manner. These changes are again extra to the contract but must never the less be incorporated. The Process Operation Testing Checklist introduced in the last section could be used as a basis for the FAT. If all of the processes in the design have been included in these checklists, then these lists might serve the FAT very well.
The off-site FAT, on-site SAT, and commissioning activities need careful planning for flawless execution. Table 1 provides guidance on the checks and balances required when utilizing external services for commissioning. A responsibility matrix provides clarity and ensures ownership of activities, along with optimal utilization of internal and external subject matter experts. FAT’s benefit is not only to the customer and end users but also to the manufacturer.