A vacuum system running does not by itself demonstrate that it meets every production requirement. Target pressure, pump-down time, control functions, and utility connections should be verified under defined conditions. Factory and site acceptance tests provide assessments at different stages. Agreeing the scope, acceptance criteria, and responsibilities in advance makes delivery and commissioning results easier to evaluate. Each test plan should reflect the technical requirements of the particular project.
Contents
- What Does an Acceptance Test Establish?
- What Is Checked During Factory Acceptance?
- What Does Site Acceptance Verify?
- How Are Acceptance Criteria Defined?
- How Is Performance Testing Planned?
- How Are Controls and Alarms Tested?
- Why Should Site Conditions Be Recorded?
- What Should the Test Report Include?
- How Are Nonconformities Managed?
- Frequently Asked Questions
What Does an Acceptance Test Establish?
An acceptance test helps determine whether supplied equipment meets requirements agreed in advance. Equipment scope, operating behaviour, and control functions can be defined in the test plan. The aim is to obtain verifiable results against agreed items rather than simply demonstrate that the system runs.
The equipment covered and the test conditions should be clear. Testing an individual pump is not the same as assessing a complete vacuum package or production line. Test boundaries and matters outside the scope should be stated in the report.
What Is Checked During Factory Acceptance?
A factory acceptance test, commonly called FAT, is generally performed at the manufacturer's premises before shipment. Depending on the agreed scope, checks may cover equipment identity, assembly, connections, indicators, and operating functions. Performance measurements may also be included in the test plan.
The absence of the actual product or plant utilities can limit which conditions are represented. Any substitute test gas or temporary connection should be recorded. Factory results should not automatically be treated as verification of production conditions that were not represented.
What Does Site Acceptance Verify?
A site acceptance test, commonly called SAT, is performed after installation at the operating location. Actual pipework, utilities, discharge arrangements, and automation connections are assessed at this stage. These checks establish how the system operates together with the plant.
Empty-system and product-loaded trials may be planned as separate stages where required. For loaded testing, product quantity, temperature, and cycle conditions should be defined. A single short run may not represent every production load and operating scenario.
How Are Acceptance Criteria Defined?
Statements such as “adequate vacuum shall be provided” do not give a clear basis for assessment. Target absolute pressure, time to reach it, test load, and permitted pressure variation should be specified where relevant. The measurement location and the stage being evaluated should also be stated.
Each criterion should have an associated method and acceptance limit. The treatment of measurement uncertainty for results close to a limit should be agreed beforehand. Criteria should reflect the equipment's actual duty rather than being copied directly from another process.
How Is Performance Testing Planned?
The plan should state whether it assesses pump-down time, capacity at a specified pressure, or pressure maintenance during production. These are related but different measurements. For example, an empty vessel reaching its target pressure does not alone establish capacity under a continuous gas load.
Record the gas used, temperature, connected volume, and pump operating conditions. Stabilisation periods and the number of repetitions can be defined in the plan. Results should be compared with design or performance data based on equivalent reference conditions.
How Are Controls and Alarms Tested?
Functions such as starting, stopping, operating permissives, and standby pump changeover should be checked where included in the project. Sensor readings should be verified between local indicators and the control display. Settings and delays should be included in the test records.
An alarm message appearing is not sufficient by itself; the intended system response should also be verified. Fault conditions should be represented using approved methods that do not damage equipment. Temporary settings and disabled functions must be restored to their normal state after testing.
Why Should Site Conditions Be Recorded?
Electrical supply, cooling facilities, service liquid, and discharge pressure can influence operating conditions. Service liquid inlet temperature and flow are particularly relevant to liquid ring pumps. Without these details, differences between factory and site results can be difficult to interpret.
If site conditions differ from the design values, the deviation should be stated clearly in the report. Measurements taken under different conditions should not be treated as directly equivalent. Any correction or additional testing needed for assessment should be technically agreed.
What Should the Test Report Include?
The report should identify the equipment model, serial number, test date, method, and acceptance criteria. Instrument identity, suitability, and calibration details should also be recorded. Pressure units and whether values are absolute or gauge should be explicit.
Measured results should be presented alongside operating conditions and relevant observations. Pressure-time records and unfinished items should be attached where applicable. At final approval, it should be clear which tests have been completed and which actions remain open.
How Are Nonconformities Managed?
When a result does not meet its acceptance limit, first review the measurement conditions and data validity. Then investigate possible causes in the equipment, plant connections, or process. Criteria should not be changed informally simply to obtain a passing result.
Define the corrective action, responsible person, and retest scope. Consider whether the change affects other functions. Closure should depend not only on the intervention being completed but also on satisfactory results from the required repeat tests.
Frequently Asked Questions
Are FAT and SAT the Same Test?
No. FAT assesses agreed factory conditions before shipment, while SAT evaluates the installed system and plant interfaces. Their scope is defined for the project.
Does Factory Testing Replace Site Testing?
Not always. Pipework, utilities, and actual process loads that were not represented at the factory may require separate verification on site.
Does an Empty-Vessel Test Prove Loaded Performance?
Not by itself. Gas and vapour released by the product, temperature, and cycle conditions may create different production loads.
Are Acceptance Limits the Same for Every Project?
No. Criteria should reflect system duty, process requirements, and the agreed test conditions.
Is an Alarm Appearing on the Screen Enough?
No. The protective or control response defined in the project should also be verified using an appropriate method.
Can Test Scope Be Agreed with Gücüm Pompa?
Test scope can be discussed by sharing target pressure, capacity, cycle conditions, and plant information. Factory tests, site tests, and reporting should be clarified within the quotation and project scope.
