FACTORY ACCEPTANCE TESTING | Guideline, Agenda & Report

January 1, 2023 |

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 TestingSite Testing
Location:At Factory [another country]On-Site
Programme Time Required:ShortUsually Longer
The Extent of Testing:Detailed specific to the equipmentDetailed 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 Testing Report Template [MS Word]

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🟩 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:

DescriptionResponsibleDocument
Select Equipment to be testedClient Commissioning Consultant
MEP Designer
Owners Project Requirements [OPR]
Commissioning Spec
Commissioning Plan
Specify Testing that should be completed as a minimumCommissioning Consultant
MEP Designer
Commissioning Spec
Commissioning Plan
Specify who should be in attendance for the testingCommissioning ConsultantCommissioning 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 ConsultantCommissioning Spec
Commissioning Plan
Standard document format
Agreeing if FAT witnessing is to be conducted remotely or at the factoryCommissioning 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 toolsMain Contractor
General Contractor
n/a
Managing and Writing Testing Method Statement/ScriptMain Contractor
General Contractor
FAT Method Statement
Review and Approve Testing Method Statement/ScriptCommissioning Consultant
MEP Designer
Comment report
Coordinate relevant parties on the Dates, Location, Travel Arrangements, Accommodation, etcMain Contractor
General Contractor
Itinerary Document
7 days prior to FAT, confirm factory is ready and all equipment/instruments are availableMain Contractor
General Contractor
Email
At Factory, manage and coordinate all testing between parties, obtain all Calibration CertificatesMain Contractor
General Contractor
FAT Method Statement
Conduct all testing and monitoring/recording informationMain Contractor
General Contractor
Factory
Data Sheets
Write/update and manage the observation/defect listCommissioning 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 shippedCommissioning ConsultantAble 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 ReportCommissioning Consultant
MEP Designer
Comment Report
Manage and closeout observations/defectsCommissioning 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.

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

RefDescriptionResponsible
1Select Equipment to be tested in Owners Project Requirements [OPR], Commissioning Spec, Commissioning PlanClient / Commissioning Consultant
2Specify Testing that should be completed as a minimum in the Commissioning Spec, and Commissioning Plan for tender documents and pricing.Commissioning Consultant
MEP Designer
3Specify who should be in attendance for the testing in the Commissioning Spec, and Commissioning Plan for tender documents and pricing.Commissioning Consultant
4Specify Format of documents [factory testing method statement, Reports] in the Commissioning Spec/Commissioning Plan for tender documents and pricingCommissioning Consultant
5Costing 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
6Agreeing if FAT witnessing is to be conducted remotely or at the factoryCommissioning Consultant
Main Contractor
General Contractor
7Ensure Factory has the resource and ability to conduct the required testing with all equipment and data reporting toolsMain Contractor
General Contractor
8Managing and Writing Testing Method Statement/ScriptMain Contractor
General Contractor
9Review and Approve Testing Method Statement/ScriptCommissioning Consultant
MEP Designer
10Coordinate relevant parties on the Dates, Location, Travel Arrangements, Accommodation, etc and issue itinerary documentMain Contractor
General Contractor
11Send 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 teamMain Contractor
General Contractor
12At Factory, manage and coordinate all testing between parties, obtain all Calibration CertificatesMain Contractor
General Contractor
13Conduct all testing and monitoring/recording informationMain Contractor
General Contractor
Factory
14Write/update and manage the observation/defect listCommissioning Consultant
15Provide 'able to ship' certificate confirming that testing was completed successfully, and can be shippedCommissioning Consultant
16Write FAT report in line with project requirements, including all data and certification, etc.Commissioning Consultant
Main Contractor
General Contractor
17Review and approve Factory Test ReportCommissioning Consultant
MEP Designer
18Manage and closeout observations/defects on issue registerCommissioning Consultant
MEP Designer
Main Contractor
General Contractor
Commissioning Report Bundle [Various]

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🟩 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: 

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

🟩 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.

Factory Testing Report Template [MS Word]

To save any cutting and pasting, we have made available our Factory Testing Report, which can be downloaded in [MS WORD] for easy editing.

#CC: 024
Buy Here | $4.95

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
SectionDescriptionResponsible
1Executive SummaryCommissioning Consultant
2IntroductionMain/General Contractor
3List of AttendeesMain/General Contractor
4Table of observations/outcomesMain/General Contractor
Commissioning Consultant
MEP Designer
5Main ReportMain/General Contractor
Factory
6ConclusionMain/General Contractor
Factory
App 1Sign Off CertificateCommissioning Consultant
App 2Design Intent/Performace Specification/Approved Method StatementMain/General Contractor
Factory
App 3Test Results/Data TablesMain/General Contractor
Factory
App 4CalculationsMain/General Contractor
Factory
App 5Computer PrintoutsMain/General Contractor
Factory
App 6Calibration CertificatesMain/General Contractor
Factory
App 7DrawingsMain/General Contractor
Factory
App 8Record PhotographsMain/General Contractor
Factory

🟩 Remote Factory Testing Infographic

-END-


⬜ Factory Acceptance Testing Report Template [MS Word]

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Click the ‘Buy Here‘ button to purchase the fully editable copy of the document below, which can be used straight away.

You will direct to our shop page.

024-Cx-Factory-Testing-Report-PDF


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