Page 47 - Subyek Teknik Mesin - Forsthoffers Best Practice Handbook for Rotating Machinery by William E Forsthoffer

Be st Practice 1 .14 Project Best Practices

Best Practice 1.14Practice 1.14Practice 1.14Practice 1.14
Best
Best
Best
Assure a FAT (Factory Acceptance Test) of maximum Failure to conduct an effective FAT, from the end user’s per-
effectiveness. spective, will expose the end user to future safety and reliability
Establish FAT test requirements in the job specifications and con- issues.
firm during the pre-award and coordination meetings. My company has been involved with numerous site machinery re-
Require the FAT agenda to be submitted for approval by the end liability issues that have resulted from ineffective FATs.
user a minimum of 2 months prior to the FAT date.
Require a pre-test meeting the day before the first FAT with each Benchmarks
vendor. The above approach has been used in critical equipment projects
Assure that the FAT team consists of experienced machinery, op- since the early 1990s, and has resulted in projects free of safety and
erations and maintenance personnel as a minimum. reliability issues, and without significant cost adders or schedule
Require a post-test meeting to determine final acceptance and delays.
confirm the format of the format test report.

Lessons Learned
The FAT is the last chance to ensure that the equipment
was designed correctly and operates with optimum safety
and reliability!

B.P. 1.14. Supporting Material phase. Yes, there certainly are many opportunities to ensure
equipment reliability during shop test, but there are also a lot of
potential lost opportunities if they are not justified to the project
Testing phase team early, during the pre-FEED phase of the project. The
potential lost shop test phase opportunities are noted in
The testing phase is the last phase in terms of vendor and sub- Figure 1.14.2.
supplier design and manufacturing involvement in the project;
and it is the last chance to ensure the optimum availability of the
finished product.
Remember that all of the equipment addressed in this
section is most likely custom designed, and no matter how The following opportunities will be lost if they are not justified at
much accrued design and manufacturing experience is present, project inception:
Possible full load test
the possibility of some abnormality, hopefully a minor one, is Unproven component tests
high. Therefore, it is imperative that this phase be carefully Attendance at test by plant personnel
observed and witnessed by the end user team. Figure 1.14.1 Use of special tools
lists some important facts surrounding this phase of the Vendor permission for pictures
project. Agreement that assigned vendor field service specialists will be
present for tests
Agreement that the instruction book is reviewed
Agreement for formal field construction meeting to clearly define
all vendor procedures from receipt of equipment on site to initial
The shop test is an opportunity to: run in of equipment
Confirm vendor proper design and manufacture
To match field conditions
Fig 1.14.2 Potential lost test opportunities
To witness assembly and disassembly using job special tools
To have plant personnel observe test, assembly, etc. and take
pictures for purposes of emergency field maintenance excellence
Review the instruction book The success of the shop test depends on a good test plan that
Have the assigned vendor field service engineer observe the
is reviewed by the end user and contractor and modified as
equipment he will install requested well in advance of the test. Figure 1.14.3 presents
Review all vendor field procedures
these facts.
I actually began my career in rotating equipment on the test
Fig 1.14.1 The shop test floor. I can still remember how we would see the witnesses
come in with the intention of participating completely in the
entire test, only to leave for a long ‘test lunch’ an hour or so later.
I have included a shop test checklist at the end of this section, Why did this occur? Usually because the concerned end user
which will be useful in planning and executing the shop test and contractor witnesses did not have the opportunity to review

20