Appendix F - FAT SAT Guide PDF
Appendix F - FAT SAT Guide PDF
00
Doc, Code MWC-CPM-OGD-2016-03
Page 1 of 11
PY
CO
MANILAWATER
CA8E IN EVERYDBOP
D
LE
OL
No^part of this documert may bE reproduced without prior permission from the CPM Management Representative and/or CPU! Continuous
Manager orhis/her authorized representative. A printed copyofthisdocument isuncontrolled when unstamped.
Title FactoryAcceptanceTest (FAT)/ SiteAcceptanceTest (SAT)Guide Rev. 00
Doc. Code MWC-CPM-OGD-2016-03
Page 2 of 11
Table of Contents
INTRODUCTION
PY
DEFINITION OF TERMS.
POLICIES.
CO
ROLES, RESPONSIBILITIES ANDAUTHORITIES..................................................................... 9
PROCEDURE
10
REFERENCES.
11
ATTACHMENTS.
11
D
RECORDS.
11
LE
OL
N TR
CO
UN
J^part^ofthis document may be reproduced without prior permission from the CPM Management Representative and/or CPM S^SF
Manager orhis/her authorized representative. A printed copyofthisdocument isuncontrolled when unstamped.
Title FactoryAcceptanceTest (FAT)/ SiteAcceptanceTest (SAT)Guide Rev. 00
Doc. Code MWC-CPM-OGD-2016-03
Page 3 of 11
INTRODUCTION
The Factory Acceptance Test (FAT) is a major project milestone where all materials, equipment,
appurtenances, systems and technology (hereinafter referred to as equipment) directly purchased by
MANILAWATER or by MANILAWATER-accredited suppliers or vendors are tested to ensure compliance
to the defined "FAT required items" in the project contract documents. Generally, a substantial financial
PY
payment to the supplier/vendor is triggered by a successful FAT, therefore the FAT must be conducted
formally andbewitnessed bythe client/owner orhis/herrepresentatives and/or Project Manager, with a
formal record of discrepancies or non-conformities and how they are to be handled.
CO
EXCEPTIONS, DEVIATIONS AND CONFLICT
Where the best interests of Manila Water Company, Inc. (MWCI) are served, Corporate Project
Management (CPM) group may deviate from this procedure. Any such deviation shall be agreed in
advanceandauthorizedinwritingbytheCPM-QADHeadwithconcurrence oftheCPMGroup Director.
D
Any agreed deviation shall be for a single use and repeat deviation shall require the review of this
documentation for necessary updating/revision otherthan the set periodicreview ofall CPMdocumented
LE
policies/procedures,whichis everyyear.
No part of this document may be reproduced without prior permission from the CPM Management Representatiue and/or CPM Continuous
ImprouementManagerorhis/herauthorizedrepresentative.A printedcopyofthisdocumentisuncontrolledwhenunstamped.
Title Factory Acceptance Test (FAT) / Site Acceptance Test (SAT) Guide Rev. 00
Doc. Code MWC-CPM-OGD-2016-03
Page 4 of 11
PY
. to ensure that any deviation from specifications or performance is identified and appropriate action
is taken before the equipment is shipped from the factory.
. to avoid project delays and/or contractual disputes arising from non-compliant or improper
equipment being delivered to the site.
CO
SiteAcceptance Inspections/Testsareconductedfor non-FATequipment:
. to ensure compliance with the specifications prior to installation.
. to ensure compliance with performance requirements, whether tested for FATor not.
. to avoid project delays, close-out problems, and/orcontractual disputesarisingfrom non-compliant
equipment being installed for the project.
D
Thisguide aims to provide Manila Water and its subsidiaries the appropriate criteria to determine when
or whether a FAT is necessary. This also provides standards and procedures for the conduct and
LE
evaluation of Site Acceptance Test (SAT).
This does not cover the development of test procedures and methodology to be used in the actual
factory/site testing.
OL
N TR
CO
UN
No part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Continuous
Improvement Manager or his/herauthorized representatiue. A printed copyofthisdocument is uncontrolled when unstamped.
Title Factory Acceptance Test (FAT) / Site Acceptance Test (SAT> Guide Rev. 00
Doc. Code MWC-CPM-OGD-2016-03
Page 5 of 11
DEFINITION OF TERMS
Factory Acceptance Test (FAT) After the completion of the manufacturing stage, FAT is usually
conducted at the vendor's plant prior to shipment and delivery to the
clientto ensurecompliancewithrespectto designandperformancedata
as defined in the relevant contract documents. The test may involve
PY
physical and chemical tests, mechanical tests, performance tests, or a
combinationofthese. FATis conductedwiththe presenceofthe client's
representative/s.
CO
Inspection Test Request and A controlled document used for requesting and documenting the
Report (ITRR) inspection.
Site Delivery Inspection Upon delivery to the site, and prior to installation, the equipment is
inspected to verify compliance with specifications.
Site Acceptance Tests (SAT) These are tests conducted on the installed equipment to validate the
D
results ofthe FAT. It servesto confirm that the equipment comply with
the requirements of the contract.
LE
System A group of components (piping, instrumentation electro-mechanicaT
equipment, motors, vessels, etc. ) related to a single process or utility
service such as water, wastewater, process plants, etc. Where
OL
components of the same service are located in different locations, they
can be treated either as separate systems or as subsystems.
Technology May refer to new innovations, new systems, automations, computer
programs, digital equipment, material composition and machineries
TR
No part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Continuous
ImprovementManagerorhis/herauthorizedrepresentative.A printedcopyofthisdocumentisuncontrolledwhenunstamped.
Title
FactoryAcceptanceTest (FAT)/ SiteAcceptanceTest (SAT)Guide Rev. 00
Doc. Code MWC-CPM-OGD-2016-03
Page6 of 11
POLICIES
PY
a) Criticality in the process
b) Complexity of the equipment / system / technology
c) As a general rule, the following equipment shall undergo FAT:
. all valves and appurtenances sourced outside the Philippines that cannot be accommodated
CO
by accredited local test facilities;
. all pumps, blowers, and other rotating equipment;
. all generator sets, including Manual Transfer Switches (MTS), Automatic Transfer Switches
(ATS), synchronizing equipment;
. all electrical equipment (switchgear; transformer, Variable Frequency Drive (VFD),
softstarter, capacitor bank, etc. );
. new product brands/technology;
D
. existingaccreditedandpreferred brandwithnewordifferentmodelordesign;
. other critical equipment/system that need to undergo performance and or~precision
LE
testing (e. g. SCAOAsystem)
d) Equipmentclassifiedas "highlycritical" whereinnoneor incomplete testfacilitiesofthe full
range of requiredtests are available locally
Non-accreditedequipment, materialsortechnologyshall undergoFATwithparallel
accreditation. Accreditation shall notimpedetheuseoftheequipment, materials ortechnology
OL
which have passed the FAT requirement.
f) Quantity - Ifthe procurement isfor more than one piece ofequipment ofthe same
specifications, only one piece may be tested to represent the batch.
TR
'a, rL°Lt hld°cumi'n;, TV be. rePr°duced w'thou< P^r Permission from the CPM Management Representative and/or CPM Continuous
Improvement Managerorhis/herauthorized representati»e. A printedcopyofthisdocument isuncontrolled when'unaamped"
Title FactoryAcceptanceTest (FAT)/ SiteAcceptanceTest (SAT)Guide Rev. 00
Doc. Code MWC-CPM-OGD-2016-03
Page 7 of 11
MANILA WATER may decide to waive the requirement for FAT or opt not to send representatives to
thefactory testing activities. Inthiscase,QADHead, subject tofinalapproval ofCPMGroup Director
and/or Corporate Operations Group (COG) Director, as appropriate, may recommend waiver of FAT
requirement for any of the following:
PY
. the project consists of replacement of existing equipment with another of the same brand and
model number;
. small or off-the-shelf equipment, materials or technology, as confirmed by the
supplier/manufacturer;
CO
. equipment ofthesamebrandandspecifications whichhavejust undergone FAT(oneyearorless);
. equipment which are in common use in MANILA WATER facilities, and with no issues:
. special cases such as emergencies or projects with time constraints as recommended by the
Project Manager(PM)/Construction Manager(CM);
. equipment classifiedas "Not FATrequired" items asstipulated in the contract.
D
the Contractor submits the relevant factory test results and Certificate of Inspection and Quality
Compliance (CIQC) from the manufacturer. LE
If Manila Water decides to waive or does not require FAT, the Contractor still has the option to
conduct/witness FATon his own. All costs for this activity shall be to the Contractor's account and
shall not be charged to Manila Water, and therefore should have no implication to the project time
and cost.
OL
4.
The Contractor/Supplier shall be responsible for facilitating all necessary travel documents, in caseof
foreign FAT. Travel and accommodation for MANILAWATERrepresentative/s shall beto the account
of MANILA WATER.
TR
SAT is conducted after the equipment is delivered to the site. It should mimic the tests that are
N
conducted in the FAT, and the results should mirror the same. SATis even more critical for those
items which have not undergone FAT.
CO
As a rule, no equipment should be installed without first being inspected as part of the SAT. All
equipment should undergoSATas a pre-requisiteto project close-out.
No^part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Continuous
ImprovementManagerorhis/herauthorizedrepresentative.A printedcopyofthisdocumentisuncontrolledwhenunstamped.'
Title Factory Acceptance Test |FAT| / Site Acceptance Test (5AT| Guide Rev, 00
Doc. Code MWC-CPM-OGD-2016-03
Page 8 of 11
YES
0 Incomplete or no facility to conduct the full range of the required
Is it critical? Do not waive tests are available locally
NO
PY
Is it complex? YES
NO Do not waive
Is it mandatory^ Materials (valves etc) and equipment not yet included in the
Vendor s List or had not yet undergone evaluation/accreditation
CO
Accredited but cannot be accommodated by local test facilities
Rotating equipment above 7. 5kw
<> DoYESnot waive Generator sets including ATS, MTS
Electrical equipment (MCC including switchgear, VFD,
transformer, soft starter, capacitor bank etc.)
NO More than one piece of equipment of the same specification to
represent the batch
D
Othercritical equipment/systemthat needsto undergoprecision
and performance testing
LE
Issue decision to PM/CM
OL
N TR
CO
UN
No^part of this documentmay be reproduced without prior permissionfrom the CPM Management Representative and/or CPM Continuous
ImprovementManagerorhis/herauthorizedrepresentative.A printedcopyofthisdocumentisuncontrolledwhe^unstamped'.
Titfe : Factory Acceptance Test (FAT) / Site Acceptance Test (SAT) Guide Rev, 00
Doc. Code ; MWC-CPM-OGD-2016-03
Page 9 of 11
CONTRACTOR
. submits list of equipment for MANILAWATER'Sdecision whether to conduct or waive FAT
. providesall the necessarytest facilityand relevant equipment
. facilitates the acquisition of all the requirement and relevant documents
PY
. informs MANILA WATER that the equipment is ready for testing
. providesall thenecessarytools, instruments, equipment,facilitiesand manpowerfortesting
It isthe Contractor's responsibilityto inform MANILAWATERthatthe equipment hasbeendelivered and
CO
isreadyfor inspection. Duringtesting, heshould provide the necessary facilities, tools, instruments (with
current calibration) and skilled manpower for the efficient conduct of the tests.
D
TheFATRepresentative/s shall bedrawnfromthefollowing teams basedonthe required discipline and/or
number of attendees: LE
. Quality Assurance Department (QAD) Representatives
. Facility Owner/Operations/Maintenance Services
. Construction Manager/Project Manager
. Engineering
OL
For complete details of other list of equipment for FAT and the respective nominated MWC
representative/s please refer to Appendix A. The QAD Head will then make a recommendation on the
nominated representative/s, for final approval of the Corporate Project Management (CPM) Group
Directoror atthe decisionofthe MWCtop management priorto attendingthe FAT.
TR
COG DIRECTOR
. Recommends and approves representative from COG
. Consulted in the deviation of policy
N
QAD HEAD
UN
ENGINEERING DEPARTMENT
. Gatherall necessaryinformationontheelectro-mechanical equipment/material initiallyidentified
for FATduringthe designstage
No part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Continuous
Improvement Manager orhis/her authorized representative. A printed copyofthisdocument reuncontrolled when unstamped.
Title : Factory Acceptance Test (FAT) / Site Acceptance Test (SAT) Guide Rev. 00
Doc. Code : MWC-CPM-OGD-2016-03
Page 10 of 11
PROCEDURE
PY
01 Receive from Contractor the list of 0- --0-- <3 .
.
The Contractor's submission of the
equipment proposed for FAT and required list of equipment is usually
forward to QAD Head
discussed during the pre-
commencement meeting, as part of
the Project Quality Plan (PQP)
CO
submittal.
'The list shal! indicate the equipment
type, brand and model, country of
origin, focal supplier (if any), location
of the test facilities and tentative
dates of the tests.
' The Contractor shall likewise indicate
if the vendor is already accredited by
MWC or not.
D
02 Review the submitted list and decide
Refer to the specified criteria for
which equipment should undergo
FAT or SAT
LE conductmg/attending the FAT/SAT
under the policies section in this
procedure
03 Receive from Contractor the ITRR
. The Contractor shall also submit the
form for the particular equipment
to be tested, sign and forward to necessary approved technical
QAD Head documents prior to FAT and ensures
OL
that all test facilities are available and
that the tools/ instruments are
property calibrated.
by the Contractor/Supplier/
Manufacturerandprovide any
cornments/suggestions regarding
CO
No part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Continuous
ImprovementManagerorhis/herauthorizedrepresentative.A printedcopyofthisdocumentisuncontrolledwhenunstamped.
Title
FactoryAcceptanceTest(FAT)/ SiteAcceptanceTest (SAT)Guide Rev, 00
Doc. Code MWC-CPM-OGD-2016-03
Page 11 of 11
REFERENCES
1. ISO 9001:2008 7. 1 Planning of Product Realization
ISO9001:2008 7. 2. 1 Determination of Requirements Related to the Product
ISO 14001:2004 4. 4. 6 Operational Control
OHSAS 18001:2007 4. 4. 6 Operational Control
MWC-CPM-2014-SP-05 Control ofNon-Conformities andCorrective Preventive Action Reportinj
PY
MWC-CPM-PMO-2014-DP-03 Control of Project Documents
MWC-CPM-QAD-2014-DP-02Calibrationof Equipment
ATTACHMENTS
CO
1. MWC-CPM-OGD-2016-03 Appendix A-List of Equipment and Required Personnel for FAT/SAT
2. MWC-CPM-2014-SP-13-F-02 Inspection & Testing Request and Report (ITRR)
3. MWC-CPM-2014-SP-05-F-01 Corrective Preventive Action Report (CPAR)
RECORDS
1. ITRR
2. CPAR
D
3. Project Folder
LE
OL
N TR
CO
UN
No part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Continuous
ImprovementManagerorhis/herauthorizedrepresentative.A printedcopyofthisdocumentisuncontrolledwhenunstamped.
Title : Listof Equipment & Required Personnelfor FAT/SAT Rev. 00
Doc Code : MWC-CPM-OGD-2016-03-Appendix A
Page 1 of 7
25 APR 2017
I Rev No
Internal testing should beconducted and test methodologies must betransmitted to roles assigned prior
to FAT/SATto ensure shortest duration of test inspection.
PY
It isthe responsibility ofthe Project Manager (PM) to ensure that the FAT/SAT isconducted efficiently at
the shortest possible time with minimal disruption to business operations.
CO
The role/s who conducted FATshould submit a report seven (7) days after inspection, must be present
during SAT, and will be held liable for the acceptance of equipment.
D
(Low and High) Engineer with more than 3 Engineer with more than 3 due to volume of
years Electrical Works years Electrical Works inspection in switch gears
Experience LEExperience and to save time
QAD-CPMG
^ Design Engineer, Electrical
ENGINEERING-CPMG
UN
No part of this document may be reproduced without prior permission from the CPM Management Representatiue and/or CPM Continuous
Improvement Manager.A printed copyofthis document is uncontrolled whenunstamped.
Title : Listof Equipment& Required Personnel for FAT/SAT Rev, 00
Doc Code : MWC-CPM-OGD-2016-03-Appendix A
Page 2 of 7
Motor Control Requirement: Electrical Requirement: Electrical 2 Roles are required due
Center (MCC) Engineer with more than 3 Engineer with more than 3 to complexity and volume
years Electrical Works years Electrical Works of assessment.
Experience Experience
PY
Manager- Electrical Works,
QAD-CPMG
CO
Capacitor Banks Requirement: Electrical Requirement: Electrical If less than 2 will be
Engineer with more than Engineer with more than inspected, only 1 Role is
3years Electrical Works 3years Electrical Works required.
Experience Experience
If 3 or more equipment to
be inspected, 2 roles
D
must conduct FAT.
Suggested Role(s):
Manager-Electrical Works,
QAD-CPMG
OL
^ Design Engineer-Electrical,
Engineering-CPMG
VFD/Soft Starter/ New or For Replacement New or For Replacement 2 Roles are required to
TR
are required.
PY
Manager-Electrical Works,
QAD-CPMG
^ Design Engineer-Electrical,
Engmeering-CPMG
CO
Valves / SAVs/ Air Requirement: Mechanical Requirement: Has an Elecro- 1 Role is Required
Valves/PRVs/Sluice Engineer/ Material Engineer Mechanical Works Experience
Gates / Penstock with more than 3 years of more than 5 years or
Material Inspection Has a Mechanical Engineering
Experience Background with Valve
Operation experience of more
D
than 3 years
Suggested Role(s):
^ Engineering Standards
LE Suggested Role(s):
^ Senior Construction
UN
Manager, CMD-CPMG
No part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Continuous
Improvement Manager. A printed copy of this document is uncontrolled when unstamped.
Title : List of Equipment & Required Personnel for FAT/5AT Rev. 00
Doc Code : MWC-CPM-OGD-2016-03-Appendix A Page 5 of 7
PY
^ Senior Design Engineer, Role
^ Facility Manager of UW Engineer! ng-CPMG
Treatment Plant, UW-COG
^ Senior Construction
Manager, CMD-CPMG
CO
Dosing Pumps Requirement: Has Gas Requirement: Material 1 Role is required for
(Chlorine, Alum, etc.) Chlorine Operation Engineer with more than small pumps (Granules)
experience of more than 3 Syears Material Inspection
years Experience or has a Mechanical For Treatment Plants with
Engineering Background Gas Chlorine Pump, it is
recommended that 1
D
Suggested Role(s): Suggested Role(s): Role from Project
Proponent with expertise
^ Project Proponent-Plant ^ Engineering Standards in Gas Chlorine Operation
Manager, COG
LE Technical Manager must attend the FAT.
^ Senior Construction
Manager, CMD-CPMG
OL
Flow and Level Meter Requirement: Has Metering Requirement: Has metering 1 Role is required
(including Reed expertise for more than 3 expertise of more than 5 years
Switches) years
TR
Overhead gantry Requirement: Has Plant Requirement: Has an Electro- 2 Roles to attend
cranes and lifting Operation experience of more Mechanical Works Experience
equipment than 2 years of more than 5 years
CO
No part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Continuous
Improvement Manager. A printed copy of this document is uncontrolled when unstamped.
Title List of Equipment & Required Personnel for FAT/SAT Rev. 00
Doc Code MWC-CPM-OGO-2016-03-Appendix A
Page 6 of 7
PY
Suggested Rote(s): Suggested Role(s):
CO
^ Senior Construction
^ Engineering Standards Manager, CMD-CPMG
Technical Manager,
Engineer!ng-CPMG
Belt Press/ Bar Requirement; Has Plant Requirement: Experience in 1 Role is required
Screen/ Fine Screen Operation experience of more Process Design of more than 2
D
than 2 years years
Suggested Role(s):
.
^ Project Proponent - Plant
LE
Suggested Role(s):
Engineering- CPMG
Fire Detection and Requirement: Has Safety Requirement: Has Safety 1 Role is required
Alarm System (FDAS) experience of more than 2 experience of more than 2
years years
No part of this document may be reproduced without prior permission from the CPM Management Representative and/or CPM Co^^T
Improvement Manager.A printedcopyofthisdocument isuncontrolled whenunstamped.
Title : List of Equipment & Required Personnel for FAT/SAT Rev. 00
Doc Code : MWC. CPIVt-OGD-2016-03-Appendix A
Page 7 of 7
PY
.
^ Engineering Standards ^ Engineering Standards
Technical Head, Engineering- Technical Manager,
CPMG Engineer! ng-CPMG
CO
iCADA Requirement: Has Requirement: Electrical 2 Roles are required
Instrumentation/SCADA Engineer with more than
Installation experience of Syears Electrical Works
more than 3 years Experience
D
^ Project Proponent - COG
.
^ ^Testing and
Commissioning Manager -
v Instrumentation Manager,
MSD-COG
LEElectrical Works, QAD-CPMG
Lighting and Power Requirement: Electrical Requirement; Electrical Both roles are needed
System Engineer with more than Engineer with more than due to volume of
3years Electrical Works 3years Electrical Works inspection in switch gears
Experience Experience and to save time
N
^ ^ Testing and
Commissioning Manager -
Electrical Works, QAD-CPMG
UN
No part of this^document may be reproduced without prior permission from the CPM Management Representatiue and/or CPM Continuous
Improvement Manager. A printed copy ofthis document isuncontrolled when unstamped.