FACTORY ACCEPTANCE TESTING | Guideline, Agenda & Report

To ensure that any major/critical equipment on a project meets its intended operational requirements, a factory test will typically be conducted before delivery to the site. The test will evaluate the equipment’s operation against its approved manufactured and operational data, which can normally be found within its technical/material submission or the equipment datasheets.

Once the factory acceptance testing has been completed successfully, the associated equipment will be approved to be shipped and delivered to the site for installation.

🟩 What is the reason for completing a Factory Acceptance Test?

Factory Acceptance Testing is used to ensure that, before dispatch to the site/project, there is no manufacturing, build quality, or performance issues with the equipment based upon the approved documentation, such as:

• Manufacturers drawings
• Data Sheets
• Specifications
• Material/Technical Submissions
• Testing Method Statement

If the testing is not completed, and there are noted issues when delivered to the project, these could cause huge implications related to:

• Programme
• Owners Project Requirements
• Design
• Operation

🟩 What is the difference between Factory Acceptance Testing and Site Acceptance Testing?

The main difference between the two is how the testing is completed.

During a factory test for HVAC equipment especially, the testing is usually completed under stringent conditions within a chamber that is equipped with instrumentation to allow remote monitoring and reporting of data.

	Factory Testing	Site Testing
Location:	At Factory [another country]	On-Site
Programme Time Required:	Short	Usually Longer
The Extent of Testing:	Detailed specific to the equipment	Detailed to the equipment but also can include integration with other systems
Testing Environment:	Mainly completed by installing HVAC components/equipment into a purpose-built chamber so that ambient conditions can be controlled and simulation conducted.	Equipment installed onsite, infield testing, limited ability to change ambient conditions if needed.
Reporting:	Usually, due to how the equipment and systems are set up and connected to instrumentation, reports, documentation, and data can be very detailed.	Generally find less information can be provided at site testing. If combined with the Factory information, then it provides a good understanding of the equipment.

🟩 When is Factory Acceptance Testing required?

Not all Plant and Equipment on a project will need to be factory tested. It will depend on the requirements set out in the Owners Project Requirements [OPR] and Commissioning Plan/Specification.

Generally, the testing would be needed if it is a complex piece of equipment or something that would severely impact the completion of the facility’s project or operation if not manufactured or working correctly upon installation, commissioning, and handover/completion.

🟩 Factory Acceptance Test Duration

Testing duration will depend upon what type of plant and equipment is being reviewed. They can usually range from 1 day to 3 days.

🟩 Factory Acceptance Test Costs

As with the testing duration, costs will fully depend upon the following:

• Type of equipment [more complex the equipment = more $]
• Quantity of each type of equipment [more of each type = more $]
• Location of testing, some can be long distances/other countries [further away = more $]
• Quantity of people to attend at the factory [more people = more accommodation = more travel = more $]
• How many days will the testing take to complete [more days = more $]

🟩 Responsibilities for the FAT

There will be various team members involved with the testing at the different stages, below provides a general example of tasks and responsibilities:

Description	Responsible	Document
Select Equipment to be tested	Client Commissioning Consultant MEP Designer	Owners Project Requirements [OPR] Commissioning Spec Commissioning Plan
Specify Testing that should be completed as a minimum	Commissioning Consultant MEP Designer	Commissioning Spec Commissioning Plan
Specify who should be in attendance for the testing	Commissioning Consultant	Commissioning Spec Commissioning Plan
Costing schedule for testing [testing, instruments, documents, transport, accommodation, meals, local travel, etc]	Main Contractor General Contractor	Commissioning Spec Commissioning Plan
Format of documents [factory testing method statement, Reports]	Commissioning Consultant	Commissioning Spec Commissioning Plan Standard document format
Agreeing if FAT witnessing is to be conducted remotely or at the factory	Commissioning Consultant Main Contractor General Contractor	n/a
Ensure Factory has the resource and ability to conduct the required testing with all equipment and data reporting tools	Main Contractor General Contractor	n/a
Managing and Writing Testing Method Statement/Script	Main Contractor General Contractor	FAT Method Statement
Review and Approve Testing Method Statement/Script	Commissioning Consultant MEP Designer	Comment report
Coordinate relevant parties on the Dates, Location, Travel Arrangements, Accommodation, etc	Main Contractor General Contractor	Itinerary Document
7 days prior to FAT, confirm factory is ready and all equipment/instruments are available	Main Contractor General Contractor	Email
At Factory, manage and coordinate all testing between parties, obtain all Calibration Certificates	Main Contractor General Contractor	FAT Method Statement
Conduct all testing and monitoring/recording information	Main Contractor General Contractor Factory	Data Sheets
Write/update and manage the observation/defect list	Commissioning Consultant Main Contractor General Contractor	Issue Register
Once testing completed, agree and provide a certificate that the equipment has successfully passed the testing [subject to observations] and can be shipped	Commissioning Consultant	Able to ship certificate
Write FAT report in line with project requirements, including all data and certification etc.	Commissioning Consultant Main Contractor General Contractor	FAT Report
Review and approve Factory Test Report	Commissioning Consultant MEP Designer	Comment Report
Manage and closeout observations/defects	Commissioning Consultant MEP Designer Main Contractor General Contractor	Issue Register

🟩 How do you write a Factory Acceptance Test Method Statement?

Managed by the Main/General Contractor and generally written by the Manufacturer, the Factory Acceptance Method Statement should be created after the material/technical submission for the particular equipment and plant has been approved, by the design consultant.

As a commissioning engineer/manager the most efficient way to write and review documents is if they are all created in the same format.

The below details a format that can be used and specified in the commissioning plan/specification to ensure the whole project provides the required format.

Section	Details
Front Cover	Front Cover detailing project Information
Contents	Page of Contents
Revision	Revision History Page
1	Introduction for the testing
2	Reference information used to create the document [guides, codes, standards, regulations, drawings, etc.]
3	Dates, times, and location of the testing
4	List of equipment/instrumentation to be used during the test with Calibration details
5	Pre-Requisites
6	System testing information [pressures, times, tolerances, etc]
7	Drawings/images/plans/documentation of factory testing set up and instruments
8	Details of remote testing set up [computers, screens, cameras] including setup plan
9	Programme/sequence of Testing
10	Method of testing & any tables and information to be completed during testing reports from instruments
11	Calibration certificates of all equipment and instruments attached

🟩 Factory Acceptance Test Checklist

Checklists are always helpful, and the below checklist can be used to help plan and execute your test:

Ref	Description	Responsible
1	Select Equipment to be tested in Owners Project Requirements [OPR], Commissioning Spec, Commissioning Plan	Client / Commissioning Consultant
2	Specify Testing that should be completed as a minimum in the Commissioning Spec, and Commissioning Plan for tender documents and pricing.	Commissioning Consultant MEP Designer
3	Specify who should be in attendance for the testing in the Commissioning Spec, and Commissioning Plan for tender documents and pricing.	Commissioning Consultant
4	Specify Format of documents [factory testing method statement, Reports] in the Commissioning Spec/Commissioning Plan for tender documents and pricing	Commissioning Consultant
5	Costing schedule for testing [testing, instruments, documents, transport, accommodation, meals, local travel, etc], in the Commissioning Spec/Commissioning Plan for tender documents and pricing.	Main Contractor General Contractor
6	Agreeing if FAT witnessing is to be conducted remotely or at the factory	Commissioning Consultant Main Contractor General Contractor
7	Ensure Factory has the resource and ability to conduct the required testing with all equipment and data reporting tools	Main Contractor General Contractor
8	Managing and Writing Testing Method Statement/Script	Main Contractor General Contractor
9	Review and Approve Testing Method Statement/Script	Commissioning Consultant MEP Designer
10	Coordinate relevant parties on the Dates, Location, Travel Arrangements, Accommodation, etc and issue itinerary document	Main Contractor General Contractor
11	Send email 7 days prior to FAT, confirm factory is ready, all equipment/instruments are available and details of travel and accommodation to client and consultant team	Main Contractor General Contractor
12	At Factory, manage and coordinate all testing between parties, obtain all Calibration Certificates	Main Contractor General Contractor
13	Conduct all testing and monitoring/recording information	Main Contractor General Contractor Factory
14	Write/update and manage the observation/defect list	Commissioning Consultant
15	Provide 'able to ship' certificate confirming that testing was completed successfully, and can be shipped	Commissioning Consultant
16	Write FAT report in line with project requirements, including all data and certification, etc.	Commissioning Consultant Main Contractor General Contractor
17	Review and approve Factory Test Report	Commissioning Consultant MEP Designer
18	Manage and closeout observations/defects on issue register	Commissioning Consultant MEP Designer Main Contractor General Contractor

🟩 Factory Acceptance Test Agenda and Set-Up

To be organized means to be efficient so the agenda below can be used to help run the testing day: 

Ref	Description
1	Pick up from accommodation
2	Transport to factory
3	Sign in and security checks at the factory
4	Camera/Wifi/internet connection checks [if conducting remotely]
5	Briefing on testing for the day
6	Calibration certificate checks of all equipment and instruments
7	Pre-Requisite checks
8	Start morning testing
9	Lunch
10	Start afternoon testing
11	Finish testing for the day
12	Debrief and run through observations
13	Transport back to the accommodation
14	Dinner

🟩 Factory Acceptance Test Report Template

Like with the testing procedure, the reports should be written in a standard format to allow efficient reviews and ensure that the relevant information is contained.

The requirement of the format and information should be detailed within the following documents, to ensure a clear direction is provided to the contractors/manufacturers during the tender process:

• Commissioning Plan
• Commissioning Specification

Obviously, there is scope to be flexible, but the ultimate aim as noted is to be efficient and ensure that the project understands the correct information to be included.

Below is a format that can be used/modified to suit your requirements; it contains responsibilities from different parties to ultimately write and approve the document.

• Written and managed by Main/General Contractor
• Added to by Commissioning Consultant
• Approved by Commissioning Consultant & MEP Designer

Section	Description	Responsible
1	Executive Summary	Commissioning Consultant
2	Introduction	Main/General Contractor
3	List of Attendees	Main/General Contractor
4	Table of observations/outcomes	Main/General Contractor Commissioning Consultant MEP Designer
5	Main Report	Main/General Contractor Factory
6	Conclusion	Main/General Contractor Factory
App 1	Sign Off Certificate	Commissioning Consultant
App 2	Design Intent/Performace Specification/Approved Method Statement	Main/General Contractor Factory
App 3	Test Results/Data Tables	Main/General Contractor Factory
App 4	Calculations	Main/General Contractor Factory
App 5	Computer Printouts	Main/General Contractor Factory
App 6	Calibration Certificates	Main/General Contractor Factory
App 7	Drawings	Main/General Contractor Factory
App 8	Record Photographs	Main/General Contractor Factory

🟩 Remote Factory Testing Infographic

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