Factory Acceptance Testing

Now I can play with the simulator, change the input values and observe the changes on the output based on the PLC logic. The final part of the logical testing includes testing megawatt control, behavior control, frequency control, power factor control, and reactive power control. At Nor-Cal, we have RTDS real-time simulator software that allows us to simulate the exact devices that will be out in the field. The control logic “thinks” it is connected to the device, but it’s actually connected to the simulator. This allows us to complete up to 96% of the controls testing prior to shipping the SCADA rack to the site, as opposed to about 90% without the simulator. For most projects, the SCADA rack will be housed in the plant substation.
factory acceptance testing
This is what a factory acceptance test (FAT) is for—to ensure that the equipment meets all of your expectations and functions as expected. The other way to check the wiring diagram for your card is the manual. For example, this is the wiring diagram for the analog input card that I have installed in my control panel. The main difference definition of factory acceptance testing between a Factory Acceptance Test (FAT) and a Site Acceptance Test (SAT) is the place and time of execution. The Factory Acceptance Test is performed at the manufacturer’s site before the respective plant or machine is delivered to the customer. The purpose of the FAT is to ensure that the customer’s requirements are met.

Acceptance testing

Since our SCADA systems are based on open architecture hardware and software, you’re not locked into one OEM, and you avoid proprietary data access fees and restrictive service contracts. Sending someone who is familiar with processing needs, specifications and tolerances helps ensure an efficient and cost-effective trip to the manufacturing center. While manufacturers will typically have personnel on hand to help with testing and to answer questions, you want to have your own experts on hand to run the tests and check the specifications that matter most. A FAT file is handed over to the customer on completion of the FAT procedures. Customers are increasingly looking for a video testimonial that the Distribution Board actually operates as it should before it leaves the factory.

They occur after all commissioning tasks for the equipment are completed but before installation. The product must be assembled, prepared, and connected to utilities for testing. Documentation such as drawings, ASME certificates, and test procedures must be gathered.

Factory Acceptance Testing vs. Site Acceptance Testing

Addressing the issues at the equipment manufacturer’s site has a plethora of advantages, such as ease of sourcing components, quality of equipment/instrument used to test and correct, cost, etc. These aspects primarily relate to functionality, safety, fitness to user requirements, compliance of the system to GMPs, and data integrity. It is common to find inconsistencies post fabrication since there are possibilities of misses during translation of all the user requirement specifications (URS) and purchase order commitments into design/fabrication. An example is the use of a typical coated surface instead of a stainless-steel finish for environmental chambers. The product impact could be minimal since it is strictly used for storage of the unit’s post-secondary packaging. However, there could be an impact on the cleaning procedure that might be applied on-site.

The tables below include items commonly recommended, but not required, for testing. The following is a list of supplementary tests which can be performed on MTU Onsite Energy engine-generator sets. The purpose of the SAT is to affirm that the machine runs your product to your specifications in its operating environment. Knowing the difference between a FAT and SAT can save you and the supplier time, money, and aggravation. In the FAT, use the materials that will be put in operation during actual production.

Practical Procedures for SCADA Software Development

To test this I can change the current and look at the HMI installed on the panel to see if the indicator for the oil pump turns on. Assuming that other ends of these terminals here are connected to terminals number 1 and 2, to test this input I can put the signal simulator on the 4-20mA current mode and then connect it to the other end of these terminals. All you need to know here is that if you want to wire a 2-wire transmitter to this card you simply need to connect the positive to terminal number 1 and the negative to the next terminal.
factory acceptance testing
Engaging the production team early in the process is one of the most important aspects of new equipment design. If training is provided as part of the FAT, make sure the people being trained are those who will run the line, not the engineers. The PLC’s (PPC) job is to control plant output to meet specified ISO/utility standards.

As a global safety science leader, UL Solutions helps companies to demonstrate safety, enhance sustainability, strengthen security, deliver quality, manage risk and achieve regulatory compliance. Ajay Pazhayattil is a pharmaceutical management consultant leading technical operations, quality assurance, and regulatory compliance risk mitigation/remediation projects. He has conceived and implemented novel methodologies applying sound pharmaceutical science principles. He is an industrial pharmacist with experience in solid dose, liquid, and parenteral dosage forms. Ensure equipment, material, and components arrive at the right place, at the right time and function properly.

  • Additionally, the ownership aspect is invaluable, as the best technology going into a plant is not going to work if the operators are not comfortable with it, or have no faith in it.
  • It is up to the customer if they want to review the FAT in person or virtually.
  • It ensures that all equipment meets the design specifications and functions properly, both individually and as a whole system.
  • Since the testing activities are general methods the FAT is applicable to programmable or non-programmable safety instrumented systems.
  • Bode plots represent the actual signature (rotor response) of a rotor for a given condition of unbalance, support stiffness, and unbalance.

Applying the insights discussed in this article can add value and greatly reduce potential downstream issues during a critical CQV project. Final inspection servicesWe conduct the final inspection according to the specifications you approved. This may include checking conformity of drawings and documents, inspecting nameplate data, general appearance and verifying the quality of painting and coating.

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