Custom process skids are designed to simplify installation, improve consistency, and accelerate project timelines. By integrating pumps, valves, instrumentation, controls, piping, and other components into a pre-engineered assembly, process skids can reduce field labor while helping facilities bring new systems online faster.
However, because these systems combine multiple technologies into a single package, identifying issues after delivery can be costly and time-consuming. This is why Factory Acceptance Testing (FAT) plays such an important role in successful project execution.
A well-planned FAT allows manufacturers and end users to verify performance, identify deficiencies, and confirm system functionality before equipment leaves the fabrication facility.
What Is a Process Skid?
A process skid is a modular system that contains multiple process components mounted on a common structural frame. These systems are commonly used in industries such as:
- Food and beverage processing
- Dairy manufacturing
- Pharmaceutical production
- Biotechnology
- Chemical processing
- Water treatment
Rather than assembling individual components entirely in the field, skid-mounted systems arrive largely complete and ready for installation.
This approach can significantly reduce commissioning time while improving quality control.
Why Testing Before Shipment Matters
When equipment arrives on-site, installation schedules are often compressed. Contractors, operators, engineers, and project managers may all be working against tight deadlines.
Discovering a wiring issue, programming error, incorrect component, or fabrication problem during startup can create delays that impact the entire project.
Factory Acceptance Testing helps prevent these issues by verifying system performance in a controlled environment before shipment.
Problems identified during fabrication are typically faster and less expensive to correct than problems discovered after installation.
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Key Objectives of a FAT
A Factory Acceptance Test is designed to confirm that the skid has been built according to approved project requirements.
The specific scope varies by project, but most FAT programs focus on several key objectives.
Verifying Mechanical Construction
The physical build should match approved drawings and specifications.
Typical review items include:
- Equipment placement
- Piping configuration
- Valve orientation
- Materials of construction
- Weld quality
- Structural workmanship
- Connection locations
Verifying these details before shipment reduces the likelihood of installation conflicts.
Confirming Electrical Functionality
Electrical systems are often tested extensively during a FAT.
This may include:
- Control panel inspections
- Power distribution verification
- Instrument checks
- Sensor validation
- Alarm testing
- Motor functionality
Identifying electrical issues before equipment leaves the facility can prevent significant startup delays.
Evaluating Automation and Controls
Many modern process skids rely heavily on automated controls.
A FAT provides an opportunity to verify:
- PLC programming
- HMI operation
- Automated sequences
- Safety interlocks
- Alarm responses
- Communication protocols
Operators and maintenance personnel can often participate in these reviews to become familiar with system operation before delivery.
Reviewing Documentation
A complete documentation package is just as important as the equipment itself.
Project teams typically review:
- P&IDs
- Wiring diagrams
- Equipment manuals
- Material certifications
- Pressure test records
- Quality documentation
Ensuring all required documents are complete before shipment helps support installation and future maintenance activities.
Common Issues Found During FATs
Many equipment problems are identified during Factory Acceptance Testing that could have caused significant issues during startup.
Examples include:
- Incorrect instrument configuration
- Programming errors
- Missing components
- Improper valve orientation
- Wiring discrepancies
- Documentation inconsistencies
- Incomplete labeling
Finding these issues in the factory environment allows corrections to be made before the equipment reaches the job site.
Improving FAT Effectiveness
Not all Factory Acceptance Tests provide the same level of value.
The most successful FATs begin with careful planning and clearly defined expectations.
Project teams should establish acceptance criteria before testing begins and identify which personnel need to participate in the review process.
Creating detailed test procedures and inspection checklists helps ensure that important items are not overlooked.
Whenever possible, testing should simulate actual operating conditions to provide meaningful performance validation.
Organizations looking to improve the quality and effectiveness of their process skid FAT testing programs often find that preparation and documentation are just as important as the testing itself.
Reducing Risk Before Startup
Every project carries risk, but Factory Acceptance Testing provides one of the best opportunities to reduce uncertainty before equipment arrives on-site.
By validating construction quality, confirming functionality, reviewing documentation, and identifying deficiencies early, project teams can improve startup performance and avoid costly surprises during commissioning.
For custom process skids, a thorough FAT is not simply a quality control step—it is an investment in project success. Facilities that take testing seriously often experience smoother installations, faster startups, and greater confidence in the performance of their new equipment.
