Motor-Operated Valve (MOV) Factory Acceptance Test (FAT) Procedure

The MOV FAT procedure ensures motor-operated valve performance, safety, and compliance through systematic testing, verification, and documentation, assuring reliable operation in line with project specifications.

Step 1: Safety Preparation and Initial Setup

• Conduct a safety orientation that corresponds to the FAT activities for each employee who is involved.
• Make sure that personal protective equipment (PPE), such as gloves, insulated shoes, safety glasses, and hearing protection, is available and used appropriately.
• Verify the availability of emergency equipment such as first aid kits, fire extinguishers, and emergency contact lists.
• To prevent unintentional energization during the FAT, disconnect or isolate any power supply that are not being used.
• Make sure all emergency stop mechanisms and safety interlocks are operational before starting the FAT.
• Make sure your work area is dry, clean, and free of any obstructions that can make it difficult to move around or pose a risk.
• Verify that all testing equipment, including multimeters, torque wrenches, and signal generators, is operational and calibrated.

Step 2:Review of MOV Documentation

• Verify that the actuator’s torque, speed, and duty cycle all follow to the design parameters.
• Verify that the actuator satisfies the project papers’ operational performance requirements.
• Examine the actuator’s physical specifications, including its electrical and mechanical connections, in comparison to the as-built drawings that are provided.
• Find and fix any discrepancies between the documented specifications and the installed configuration.
• Verify the authenticity and traceability of calibration certificates for critical parts, such as torque settings, limit switches, and feedback sensors, to established standards (such ISO or NIST).
• To prevent testing the wrong equipment, compare the actuator model and serial numbers with the FAT plan and project documentation.
• Verify that the tags and labeling on the installed actuator correspond to those in the project documentation.
• Throughout the FAT process, make sure that operation and maintenance documentation is accessible for reference.
• Utilize these documents to address inquiries during testing and verify operational procedures.

Step 3: Creation of a Test Plan

• Specify the parameters of every test, including compliance checks, functional testing, performance testing, and visual inspection.
• For each test, clearly define the pass/fail criteria to guarantee a balanced assessment.
• Give FAT employees positions and tasks, such as operators, observers, and customer representatives.
• Determine which crucial tasks, such torque calibration and emergency stop testing, call for witness sign-offs.
• Create a thorough test schedule that allots enough time for every task, including a buffer period for handling any retests or any problems.

Step 4: Detailed MOV Control Valve FAT Procedure

Visual Inspection

• Check to see whether the actuator housing has any cracks, dents, corrosion, or apparent problems.
• Verify that protective coatings, gaskets, and seals are intact and appropriate for the environment.
• Check actuator specifications, nameplates, and labels for accuracy and legibility in relation to design specifications.
• Verify the actuator and valve’s coupling alignment to ensure correct positioning and operation.
• To prevent mechanical failures, tighten all fasteners (bolts, nuts) in accordance with the recommended torque values.
• Verify that the terminal block wiring follows the as-built designs, making sure that the connections and wire labeling are correct.
• To avoid stray voltages or grounding problems, make sure the earthing connection is correct.
• Check conduits and cable glands for environmental protection and tight sealing.

Functional Testing

Set the selector to LOCAL Mode and test actuator operations:

• Verify that the actuator display shows OPEN and a red LED after fully opening the valve.
• Verify a green LED and CLOSE indicator on the actuator display after completely closing the valve.
• During both processes, press the STOP button to make sure the actuator stops moving immediately.

Switch to REMOTE Mode and send control signals from a simulated or actual control system:

• Open command: Confirm that the valve fully opens and that the control system receives data indicating the correct state.
• Close command: Verify that the valve closes all the way and that the control system receives data indicating the correct condition.

Test Manual Mode operation:

• To operate the actuator through its whole range (open to close), engage the handwheel mechanism.
• Verify that the manual process runs smoothly and that the direction corresponds with the actuator labeling.

Test the Emergency STOP function:

• Make sure the actuator stops working right away by pressing the STOP button in both the local and remote modes.

Calibration Checks

• Verify torque settings using the actuator’s built-in torque measurement system or external tools. Record torque values for both open and close operations to ensure compliance with design requirements.

Refer the below link for the Calibration Procedure for Motorized Control Valve

Calibrate limit switches for accurate feedback:

• Adjust open/close position switches using the actuator’s configuration tool.
• Test to confirm precise position feedback for each actuator state.

Simulate full actuator movement and verify:

• Feedback signal outputs (e.g., 4-20mA or discrete signals) align with actual valve positions.
• Control system and remote monitoring devices display accurate actuator states.

Validate and adjust actuator settings, such as cycle timing, intermediate locations, and over-torque alarm thresholds, using proprietary software tools (if appropriate).

Refer the below link to do loop checking of Motor operated valve?

Step 5: MOV Performance Testing

• To assess the actuator’s reliability and consistent manner of functioning, repeat open/close cycles while it is working under normal load circumstances.
• Throughout testing, keep an eye out for any indications of overheating, excessive vibration, or strange noises coming from the actuator, as these could be signals of mechanical or electrical problems.
• To make sure the actuator meets the timing requirements in the design specifications, measure and note how long it takes for full open and shut actions.
• Make sure the actuator sustains the necessary torque, speed, and positional accuracy throughout the test by simulating load situations that correspond to actual field operations.

Refer the below link for the Step By Step Troubleshooting Guide for Motorized Control Valve (MOV)

Step 6: MOV Post-FAT Activities

• Examine each test result carefully, looking for any irregularities or deviations.
• Keep a record of every observation you make and any corrective actions you take during the testing process.
• Confirm that the actuator complies with relevant industry standards, such as IEC 60079 for hazardous area equipment or ISO 5211 for actuator mounting.
• Ensure the design aligns with the project’s technical specifications and requirements.

MOV FAT Activities Documentation

• Compile a comprehensive report that includes detailed test results, compliance certificates, and verified as-built drawings.
• Ensure that torque settings, limit switches, and feedback sensors are all accompanied by traceable calibration certifications.
• For future use, note all actuator settings and parameters set during FAT.

Step 7: Final Sign-Off and Packaging

• Make that the final report is signed by test engineers, QA personnel, and client representatives, among other FAT participants.
• To record test acceptance and approval, use a specific approval form.
• Make that the actuator is clean, sealed, and appropriately labeled with storage and handling guidelines.
• To keep the actuator safe while in transit, use packing materials that are both shock-resistant and watertight.
• Cover the package with all necessary documentation, including calibration certifications, operation and maintenance manuals, and FAT reports.

Motor-Operated Valve (MOV) Factory Acceptance Test (FAT) activities Checklist  

Ensure thorough verification and testing of MOV systems with our detailed checklist designed to streamline FAT activities, improve reliability, and confirm compliance with project specifications.

Refer the below link to download the detailed checklist for Motor-Operated Valve (MOV) Factory Acceptance Test (FAT) activities checklist in Excel format

Refer the below link for the Motor-Operated Valve Actuator Installation Procedure with Checklist

Click here for 50+Collection of Essential Instrumentation and Automation Control System Checklists

Frequently Asked Questions (FAQ) on Factory Acceptance Test (FAT)

What is the Factory Acceptance Test (FAT)?

A Factory Acceptance Test (FAT) is a quality assurance process where the manufacturer tests a machine, system, or equipment before delivering it to the customer. The primary objective is to confirm that the product meets the customer’s requirements, specifications, and standards.

What is the FAT process for valves?

The Factory Acceptance Test (FAT) for valves involves testing components like valves and actuators after assembly to verify they are manufactured in accordance with the relevant standards and specifications. Common tests include:

1. Hydrostatic pressure testing: To ensure there are no leaks under pressure.
2. Operational testing: To verify the smooth opening and closing of the valve.
3. Seat leakage testing: To ensure the sealing surfaces provide a proper seal.
   This ensures that the valve and actuators are functional and meet the relevant industry standards before being shipped

Why is FAT Important?

• Ensures compliance with design and operational requirements.
• Identifies defects or issues before the product leaves the manufacturer’s facility.
• Provides customers with confidence in the quality and reliability of the product.

What is the IEC standard for Factory Acceptance Tests?

IEC 62381:2024 provides comprehensive requirements and checklists for Factory Acceptance Tests (FAT), Factory Integration Tests (FIT), Site Acceptance Tests (SAT), and Site Integration Tests (SIT). These tests demonstrate that the automation systems and equipment comply with applicable specifications and performance criteria.

What is the FAT process for motors?

The FAT for electric motors is an essential step in quality assurance. It ensures that motors meet the design specifications and operational standards before deployment. Key tests typically include:

1. Insulation resistance testing: To check for electrical insulation integrity.
2. Vibration and noise testing: To ensure smooth and quiet operation.
3. Performance testing: To measure speed, torque, and power output.
4. Temperature rise testing: To verify thermal performance under operational conditions.