Factory Acceptance Test (FAT) Procedure for Control Valve

Step 1: Purpose

The purpose of this procedure is to ensure the control valve’s functionality, performance, and compliance with specified requirements before it is dispatched from the factory. The FAT provides a thorough check to verify that the control valve meets all relevant standards and specifications.

Step 2: Scope

This procedure applies to all control valves manufactured and assembled in the factory. It is conducted in the presence of the client or a third-party inspector, ensuring transparency and accuracy in the testing process.

Step 3: References documents

• Project specifications
• Manufacturer’s data sheets
• Applicable international standards (e.g., ISA, IEC, ASME)
• Inspection and test plan (ITP)

Step 4 Safety Precautions

• Ensure all personnel are wearing appropriate personal protective equipment (PPE), including gloves, safety glasses, and hearing protection.
• Follow all safety protocols for high-pressure testing, including emergency procedures.
• Verify that the test area is clear of unnecessary personnel and that access is restricted during testing.
• Ensure that all test equipment is properly calibrated, maintained, and suitable for the test pressures and conditions.
• Conduct a safety briefing for all personnel involved in the FAT before testing begins.
• Establish communication protocols in case of emergencies or test interruptions.

Step 5: Equipment and Tools for Control valve FAT

• Pressure gauges
• Flow meters
• Calibration tools
• Multimeters
• Portable data logger
• Pneumatic or electric actuator testing equipment
• Leak detection equipment (e.g., soap solution, electronic leak detectors)
• Safety gear (helmets, face shields, protective clothing)
• Hydrostatic test pumps
• Flanges, connectors, tubing, and fittings

Step 6: Personnel Involved in the Control Valve FAT

• Quality Control Engineer
• Test Engineer
• Client/Third-party Inspector (if applicable)
• Safety Officer (for oversight during high-risk testing activities)

Step 7: Pre-Test Inspection

Control valve Documentation Review

Verify that all documentation, including design specifications, data sheets, inspection reports, and material certificates, are complete, correct, and up to date. Ensure that any changes or deviations from the original design are documented and approved.

Visual Inspection of Control Valve

Conduct a thorough visual inspection of the control valve to check for any physical damage, proper labeling, and correct assembly. Ensure that all components, including the actuator, positioner, and associated hardware, are securely mounted and free of defects.

Calibration Certificates Verifications

Ensure that all instrumentation and test equipment used for the FAT are calibrated and within their valid calibration period. Calibration certificates should be reviewed and attached to the FAT documentation.

Click here for Checklist for Conducting a Running Inspection of a Control Valve in a Process Area

Step 8: Orientation of Witness

• A small meeting will be conducted for all concerned representatives, including the client, third-party inspectors, and project management representatives.
• The operating principles of the control valve (CV) package will be explained, covering key aspects such as control logic, fail-safe positions, and response characteristics.
• The exact FAT schedule, including the sequence of tests, expected duration, and acceptance criteria, will be communicated during this orientation.
• This step ensures that all parties involved have a clear understanding of the process and are aligned on expectations before the actual testing begins.

Step 9: Test Procedure – Control valve FAT

Hydrostatic Pressure Test

Verify the integrity of the valve body and bonnet by pressurizing the valve with water.

1. Install the valve in the test rig, ensuring that all connections are secure and leak-free.
2. Fill the valve with water, ensuring that all air pockets are removed to prevent false readings.
3. Adjust regulator for supply pressure to the positioner.
4. Close ball valve in control valve outlet  to feed liquid into the test valve.
5. Fill valve inlet chamber with suitable liquid and pressurize according to the figure 
6. Gradually increase the pressure to the specified test pressure, typically 1.5 times the maximum working pressure, monitoring the pressure rise carefully.
7. Maintain the pressure for a specified duration (e.g., 15 minutes) and inspect all valve components for any signs of leakage or deformation.
8. Record the test results, including the applied pressure, test duration, and any observations made during the test.
9. Open ball valve in control valve outlet  to release pressure on the valve after testing.

Seat Leakage Test

Verify the sealing capability of the valve seat under pressure.

1. Ensure the valve is in the fully closed position.
2. Apply pressure to the inlet side of the valve using the specified test medium (e.g., air, nitrogen).
3. Measure the leakage through the valve seat using a calibrated flow meter or rotameter.
4. Compare the measured leakage against the acceptable limits defined in the project specifications or ANSI B16.104 standard.
5. Record the test results, noting the measured leakage, applied pressure, and any deviations from the specifications.
6. This test is important for assessing the effectiveness of a valve’s seal when it’s supposed to be completely shut, helping to determine its performance and compliance with industry standards.

Functional Test(Stroke Test)

Verify the proper operation of the control valve, including the actuator and positioner.

1. Connect the control valve to the appropriate power source (pneumatic, electric, or hydraulic) and ensure that all connections are secure.
2. Apply control signals (e.g., 4-20 mA) incrementally to the actuator, observing the valve’s response at each signal level.
3. Stroke Test: Perform a stroke test by moving the valve from fully open to fully closed positions, and vice versa, while monitoring the valve position, response time, and smoothness of operation. Record the stroke time and ensure it meets the specified requirements.
4. Check for smooth operation, accurate valve positioning, and correct response times at each signal level.
5. Test the fail-safe position (e.g., fail-close or fail-open) by simulating a loss of signal or power and observing the valve’s behavior.
6. Record the test results, including stroke times, valve positions at each signal level, and any observations related to valve performance.

Refer the below link for simple Stroke Checking of Control Valve in a process industries

Control Signal Calibration

Ensure the control valve accurately responds to input control signals.

1. Apply incremental control signals (e.g., 0%, 25%, 50%, 75%, and 100%) to the valve actuator.
2. Measure the valve position at each signal increment, ensuring it matches the expected position as per the control signal.
3. Adjust the positioner as necessary to achieve accurate calibration, ensuring that the valve responds precisely to each control signal.
4. Record the calibration results, including any adjustments made to the positioner.

Refer the below link for the Calibration procedure for Control Valve in a process Industries

Leakage Test (Pneumatic/Electric Actuators)

Verify that there is no leakage from pneumatic or electric actuators.

1. Pressurize the actuator with the specified supply pressure, using instrument air or the appropriate fluid for the actuator type.
2. Inspect all actuator components, connections, and seals for any signs of air or fluid leakage.
3. Record the test results, noting any detected leaks and the pressure at which they occurred.

Documentation Verification

Ensure that all relevant documentation is complete, correct, and properly organized.

1. Review all test reports, calibration certificates, and inspection records to ensure they are accurate and complete.
2. Compile the FAT report, including all test results, calibration records, and any deviations or non-conformances.
3. Submit the FAT report to the client for review and approval.

Click her for Trouble shooting of Control Valve

Step 10: Acceptance Criteria – Control valve FAT

• The control valve must pass all tests without any non-conformance or deviations from the specified requirements.
• Leakage must be within acceptable limits as defined by the project specifications and relevant standards.
• The valve must operate smoothly, respond accurately to control signals, and achieve the specified stroke times.

Step 11: Non-Conformance and Corrective Action

• Any non-conformance identified during the FAT must be documented in a non-conformance report (NCR).
• Corrective actions must be taken to resolve the issues before re-testing. The corrective actions should be documented, reviewed, and approved by the client or third-party inspector.
• Re-testing of the affected components or systems should be performed to verify that the corrective actions have successfully addressed the non-conformance.

Step 12: Punch List

• Any discrepancies or issues identified during the FAT will be noted in the punch list document.
• The punch list will include a description of each issue, the agreed corrective action, and the responsible party for resolving the issue.
• The punch list will be reviewed and signed off by all parties involved once all issues have been resolved and verified.

Step 13: Final Documentation

• The final FAT report will include all test results, calibration records, non-conformance reports, and the completed punch list.
• The report will be reviewed and approved by the client or third-party inspector, with signatures obtained as required.
• A copy of the final FAT report will be provided to the client for their records.

Factory Acceptance Test (FAT) Checklist for Control Valves – Downloadable

This checklist is designed to ensure that every step of the FAT procedure is thoroughly completed and documented, allowing for a comprehensive evaluation of the control valve before it leaves the factory.

The Factory Acceptance Test (FAT) Checklist for Control Valves is available for download. You can download it using the link below

What is the testing procedure of a control valve?

The procedure includes hydrostatic pressure tests, seat leakage tests, functional tests, control signal calibration, and actuator leakage tests to ensure valve integrity, operation, and compliance with specifications.

What is the FAT approval process?

FAT approval involves performing tests, reviewing results, documenting non-conformances, implementing corrective actions, re-testing if needed, and obtaining client or third-party inspector approval.

What is the process of a FAT test?

The process includes pre-test inspections, testing for pressure, leakage, and functionality, documenting results, addressing non-conformances, and compiling a final report for client approval.

What is the factory acceptance test (FAT) procedure?

The FAT procedure tests control valves for performance, leakage, and functionality, ensuring compliance with project specifications before delivery to the client.

What is the type acceptance test for valves?

A type acceptance test (TAT) for valves verifies that a specific valve design meets industry standards and specifications through standardized testing. It assesses the valve’s performance, durability, and reliability before mass production.

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