Factory Acceptance Testing (FAT): Process, Procedure & Checklist
New equipment can be incredibly complex with countless opportunities for error. Fortunately, Original Equipment Manufacturers know better than to hope for the best – they plan for the best.
By testing the equipment or components before the customer receives them, DXP can increase the odds that new installations will perform as expected. Planning, documenting, and testing the equipment before delivery ensures the product consistently meets the customer’s expectations.
DXP makes this possible with Factory Acceptance Testing.
What is Factory Acceptance Testing?
Factory Acceptance Testing (FAT) is a process within the manufacturing and quality assurance phase of industrial equipment or systems. It involves a series of tests and inspections conducted by the manufacturer or supplier to ensure that the product meets the specified requirements, design criteria, and functionality before it is delivered to the customer.
Purpose of a Factory Acceptance Test
The Factory Acceptance Test is valuable for both end-users and manufacturers. It ensures the new equipment meets all agreed-upon specifications, preventing issues at the client’s site. Fixing manufacturing issues before the equipment leaves the manufacturer helps control the project’s timeline and budget. The FAT is a cost-effective solution, preferred over addressing issues after deployment.
The Cost of Skipping FAT Testing:
- Delays during installation
- Unexpected system failures
- Rework and added costs
- Safety concerns during startup
Factory Acceptance Test vs. Site Acceptance Test (SAT)
A factory acceptance test is completed before equipment is shipped. It verifies functionality, controls, and system performance in a controlled environment.
A site acceptance test (SAT) is performed after installation. It confirms that the system operates correctly under real operating conditions.
Both are required for full validation:
- FAT testing confirms build quality and function
- SAT confirms performance in the field
Factory Acceptance Test Procedure (3-Step FAT Testing Process)
Here are three FAT protocols that can be used to guide a successful test.
Step 1. FAT Planning
Objective: The first step in a Factory Acceptance Test is planning. This planning happens when the manufacturer or OEM outlines what the FAT will include during the bid phase of the customer’s order. The plan, which is put into writing, covers all customer specifications, standards, and drawings.
By defining the scope of the FAT, we ensure that the equipment provided is acceptable and credible. This plan is shared with the customer from the beginning to make sure it aligns with their expectations and requirements.
Step 2. Engineering and Materials Documentation
Objective: This step involves gathering and documenting all engineering and materials information related to the equipment or system being tested.
A complete set of reference documents will be assembled before the FAT testing. These documents will include, but not be limited to:
- Customer scope and specifications
- Drawings (GA, P&ID, etc.)
- Data Sheets
- ITP (Inspection Test Plan)
- Applicable Codes / References
- Checklists and Procedures specific to the FAT
- Calibrations and Certifications as required by the contract
Along with the documents listed above, other manufacturing documents are reviewed by the manufacturer / OEM to verify that the equipment supplied meets the design drawings and the customer’s requirements before the FAT. Any instrumentation used to record data during the test will be verified within the calibration date as required by the manufacturer or customer specifications before the test.
Step 3. Testing
Objective: The final step is the actual testing phase, where the equipment or system is subjected to various tests and inspections to verify its compliance with specified requirements.
During the Factory Acceptance Test, the following should be accomplished:
- Following and referencing the ITP and FAT Procedures listed above.
- Raw data will be taken, recorded, and submitted to the customer.
- GA, P&ID, and electrical drawings will be reviewed with the customer or their representative.
- Any NDE, Coating, Transportation, or Storage Procedures will be reviewed.
- Job-specific requirements as referenced in the customer specifications.
By following these three steps, the Factory Acceptance Test Protocol aims to systematically plan, document, and execute a comprehensive testing process to verify the quality and functionality of industrial equipment or systems before they are delivered to the customer.
FAT Checklist: Critical Verification Points
To ensure a thorough evaluation, the Factory Acceptance Test should be categorized into specific inspection points. Using a structured checklist prevents minor technical oversights from becoming major field delays.
| Category | Verification Item | Description |
| Physical & Visual | General Arrangement | Verify dimensions, orientation, and nozzle locations match approved drawings. |
| Materials & Finishes | Check for correct material grades, paint specs, and the absence of surface defects. | |
| Nameplates | Confirm all tags and data plates are accurate and securely attached. | |
| Mechanical | Hydrostatic/Pneumatic | Pressure test piping and vessels to ensure zero leaks at operating limits. |
| Rotating Equipment | Check motor rotation, vibration levels, and alignment of shafts/couplings. | |
| Fasteners | Confirm all bolts are torqued to specification and marked. | |
| Electrical & Control | Loop Testing | Verify that signals from instruments reach the PLC/HMI correctly. |
| E-Stops & Interlocks | Trigger every safety shutdown to confirm the system reaches a safe state. | |
| Alarms | Simulate fault conditions (e.g., low flow, high temp) to verify HMI alerts. | |
| Documentation | Certifications | Review material test reports (MTRs) and welder certifications. |
| Calibration | Ensure all test gauges and instruments have current calibration stickers. |
Remote Factory Acceptance Testing
Many manufacturers now support remote FAT testing. This allows stakeholders to participate without being onsite. Some features specific to remote FAT testing may include:
- Live video walkthroughs
- Real-time test observation
- Digital documentation review
- Remote approval and sign-off
This virtual approach reduces travel while maintaining visibility into the factory acceptance test process.
Start Your Factory Acceptance Testing Process with DXP
From pump systems and rotating equipment to control panels and automation, factory acceptance testing plays a role in confirming that each system is ready for installation and operation. That’s why DXP provides engineered systems and factory acceptance testing support for industrial operations.
Schedule a factory acceptance test with DXP or speak with an engineer to plan FAT testing for your system. Our team can also support broader needs, including MRO engineered solutions, industrial automation and control integration, and ongoing MRO supply services.
Call (936) 261-7736 for more information about our SmartSolutions and other supply chain services.
