Revision 2.

0
Petroleum Development Oman LLC Effective: Nov-11

3.8.3 Factory Acceptance Tests

INTRODUCTION
Vendors are required to carry out performance and acceptance tests on their
equipment. These tests will be carried out in accordance with approved procedures
prepared prior to the tests. In order to be satisfied that test results conform to
equipment specifications, the tests shall be witnessed by the project and contractor’s
package engineer and / or inspection and commissioning / operations representatives.
Due to physical, process and equipment constraints, final testing may only be possible
later in the build when all contract equipment, controls and processes are available.
COMMISSIONING INVOLVEMENT
The integrated CSU Team should identify those items of equipment where their input is
required from the facility equipment list. It must be ensured that they are on the FAT
procedure review distribution and that the documentation requested, via purchase
orders, is sufficient to record all information and results necessary to verify the
equipment’s performance at the FAT. These procedures and documentation
requirements must be finalised prior to the actual tests and equipment acceptance.
PERFORMANCE TEST WITNESSING
To ensure that FAT’s are conducted correctly witness and performance test results
should be tied to milestone payments and it should also be specified in the purchase
order if regulatory bodies need to witness these types of tests. It is considered good
practice for representatives from the asset to be present at the tests in order to
familiarise themselves with the equipment and its operation and maintenance.
FAT PROCEDURES
For all such packages, vendors are normally required to submit their proposed FAT
procedure in advance of the scheduled activity (for example 8 weeks), along with the
acceptance criteria for each check, and test for later validation and comment. FAT’s
should begin with a listing of hardware checks and follow with systematic installation
and function tests of the software and component parts. In order not to unnecessarily
delay production, asset owner requirements for witness, inspection or review of
vendor’s work stages must be specified in advance, together with notification
procedures for the project / contractor to provide the required inspectors at the specified
hold or witness points.
Where possible all practical testing in the factory should be incorporated and all FAT
activity must be incorporated into one dynamic schedule, be maintained up to date, and
with commissioning resources allocated to attend the FAT’s.
All system-based (dynamic) testing during FAT’s should be incorporated into the
integrated commissioning and start-up plans.
EQUIPMENT RELEASE / PUNCH LISTS
Any deficiencies, punch list items and performance shortfalls must be recorded and
agreed with the vendor prior to shipment. The way ahead for any rectification or punch
list clearance agreed with the vendor should also be recorded and entered into the
CCMS against the relevant subsystem, for tracking as an action item. Costs associated
with clearance of punch list items by the vendor should be to the vendor’s account.
TRANSPORTATION AND SHIPMENT
After factory acceptance it is essential that cleaned and partially tested equipment does
not deteriorate during transport and initial storage. In the case of vendor supplied
equipment, whether a single item such as a vessel, or a complicated machinery
package, the scope of cleaning, testing and preservation for shipment and initial
storage at field destination must be clearly specified and implemented. Failure to
consider protection against corrosion, shock load and humidity during transport
(particularly in the desert) and initial lay down of equipment packages in field locations
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 Revision 2.0
Petroleum Development Oman LLC Effective: Nov-11

(often also in an aggressive desert environment) can have serious project cost and
schedule impact later. Equipment packages which are sensitive to damage by shock or
climatic extremes, e.g. Distributed Control System (DCS) equipment, justify special
consideration during all stages of transport.

3.8.4 Offsite Systems Integration and Testing

As an intermediate step it will often be strategically prudent to arrange equipment onto
skids or into modules prior to transportation, e.g. compression and power packages.
With commissioning support and input to layout and equipment orientation issues,
significant testing and commissioning can be performed at the assembly site / yard and
be a critical activity in the project implementation strategy.
For control, safeguarding and fire and gas systems supplied by one vendor, the FAT
should embrace the physical interconnection of all panels and monitors, where possible
with remote control stations.
Software should be downloaded in, as far as practical, its final development state such
that all field inputs can be simulated including alarm set points and loop tuning
parameters, and expected outputs validated. Additionally, graphics should be
standardised and have Operations personnel state their requirements which shall,
where appropriate, be included into design, layout and acceptance.
Where multiple vendors are engaged to supply the equipment and software, it may be
necessary for the prime or main supplier to set up a staged assembly area (controlled
environment) to achieve the above.
Software validation against cause and effect charts and control philosophy must be
systematic with all faults recorded for rectification and re-testing. Where design change
or design immaturity leads to the engineering of ‘modification packs’ then
implementation, testing and validation should be completed, if not during the offsite
integration test, then onsite but prior to the facility going live.
The implementation of ‘modification packs’ during commissioning or after start-up will
lead to downtime, planned and spurious, with repeated testing to validate the changes.

3.8.5 Offsite Testing Objective

It should be a project objective to conduct as much pre-commissioning, commissioning
and testing offsite prior to load-out or transportation to site. The project should identify
within the PEP what commissioning activities should be carried out prior to
transportation to site, and these activities should be included in a pre-delivery checklist.
This will minimise onsite testing to ‘travel well’ testing and incremental subsystem and
system testing once skids and components have been interconnected, pipelines laid
and final interfaces made.
Within the constraints of weight, size and transportation logistics, facilities should, as far
as practical, be laid out and packaged to facilitate subsystem testing at the fabrication /
integration site.
In some cases it will be possible to temporarily interconnect related skids to achieve
maximum functionality or integration testing, e.g. field auxiliary rooms to the equipment
they control. Interconnection should as far as practical be with the full contract
equipment, or when constraints exist with temporary systems.

3.8.6 Commissioning Temporary Systems

Where temporary systems such as power, air etc are to be used, these should be
engineered to appropriate project standards, risk assessed and HAZOP’ed as
necessary.

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