What is Site Acceptance Testing (SAT)
Site Acceptance Testing (SAT) is a structured process performed after the installation of equipment at a manufacturing site. It validates that the equipment functions as specified, integrates with existing systems, and complies with regulatory requirements. Precision and reliability define manufacturing operations. Equipment must work seamlessly within production lines, ensuring uptime and meeting strict standards. Site Acceptance Testing forms just one part of the wider validation master plan, ensuring the performance, integration, and compliance of newly installed equipment in real-world conditions. Writing SAT documents as apart of a validation plan? Read our guide on the validation plan process here.
Definition and Purpose
- Definition: SAT tests equipment performance in real-world operational environments. It’s a formal testing process conducted post-installation to verify that equipment meets specifications in its operational environment.
- FAT vs SAT: Factory Acceptance Testing (FAT) occurs pre-installation at the vendor’s site. SAT happens at the manufacturing site. Read our article on FAT here.
- Purpose: To confirm functionality, integration, and compliance before full-scale production.
Importance of Site Acceptance Testing
SAT minimises risks associated with equipment failure and integration issues. It protects investments and ensures production readiness by verifying:
- Operational Compliance: Equipment performs as per agreed specifications.
- System Integration: Seamless functioning within production environments.
- Regulatory Adherence: Meets industry and safety standards.
Key Objectives of Site Acceptance Testing
- Verify Integration with Local Systems
- Ensure the equipment communicates effectively with existing site infrastructure, such as SCADA (Supervisory Control and Data Acquisition) or PLC (Programmable Logic Controller) systems.
- Test signal flow between the equipment and site systems to confirm accurate data exchange. For example:
- Inputs: Verify sensors, temperature probes, and flow meters transmit correct data.
- Outputs: Validate that actuators, valves, and motors respond appropriately to commands.
- Check compatibility with local communication protocols (e.g., MODBUS, Ethernet/IP, or PROFIBUS).
- Test Equipment Performance in Real Conditions
- Run equipment under normal operating conditions to confirm it functions as expected within the real production environment.
- Evaluate process parameters such as speed, pressure, temperature, and throughput.
- Confirm integration of auxiliary systems like HVAC or compressed air supplies.
Why This Matters
Inadequate SAT can lead to downtime, inefficiencies, and safety risks. Engineers, maintenance teams, and procurement professionals depend on SAT to deliver reliable performance and operational confidence.
Site Acceptance Testing ensures:
- Equipment operates reliably in real production conditions.
- Regulatory and safety standards are upheld.
- Integration within the production system is seamless.
This article explains SAT processes, highlights best practices, and provides guidance for writing SAT documentation. Read on to learn how SAT safeguards manufacturing operations.
Roles and Responsibilities in Site Acceptance Testing
Collaborative Success in Site Acceptance Testing (SAT)
Effective Site Acceptance Testing (SAT) relies on the clear definition of roles and responsibilities. Both the customer and vendor play crucial parts, working together to ensure equipment performs as expected and integrates seamlessly into production.
Customer Responsibilities
The customer provides the foundation for a successful SAT. They prepare the site and oversee the evaluation to confirm operational readiness. Key responsibilities include:
- Infrastructure Preparation: Ensures utilities such as power, water, and compressed air are available and functioning.
- Verification of Results: Reviews test outcomes to ensure alignment with agreed specifications.
- Technical Team Availability: Assigns skilled personnel to participate in training and support activities.
The customer’s role ensures the operational environment supports testing and that acceptance decisions are based on comprehensive reviews. Make sure to define the roles of each team member involved in the SAT process:
- Test Coordinator: Responsible for scheduling tests, overseeing the process, and managing deviations or issues.
- Engineering Team: Carries out the technical tests, ensures that all equipment meets operational standards, and resolves any issues.
- Safety Officer: Verifies that the equipment complies with all safety standards and regulations.
- System Integrator: Ensures that the equipment integrates seamlessly with the existing control and monitoring systems.
Vendor Responsibilities
The vendor drives the execution of the SAT plan. They implement testing procedures, address issues, and provide essential resources. Key responsibilities include:
- Test Execution: Conducts all tests as outlined in the SAT documentation.
- Issue Resolution: Identifies and rectifies problems uncovered during testing.
- Documentation and Training: Supplies operating manuals, technical documents, and staff training to support long-term use.
The vendor ensures the equipment is fully functional and the customer team is equipped for successful operation.
Collaboration Is Key
Both parties must communicate openly and address issues promptly. SAT succeeds when customers and vendors coordinate their efforts to achieve shared goals.
Next, explore how to document the SAT process effectively, covering essential sections such as Scope of Tests, Test Content, and Test Plans.
Key Components of SAT Documentation
Creating thorough, well-structured SAT documentation is crucial for ensuring a clear, standardised, and auditable process. Each section contributes to the document’s clarity and usability, guiding both vendors and customers through the testing process. Here’s how to write and organise each key section effectively. Make sure to include a Table of Contents section so your document can be easily navigated.
Review and Approvals
Why It Matters: This section establishes accountability by recording stakeholder approvals before testing begins. It ensures alignment among all parties involved.
How to Write It:
- Create a dedicated section for pre-approvals near the start of the document.
- Use a clear table format to capture essential details, including:
- Full names of reviewers.
- Their roles (e.g., Engineering Manager, QA Lead).
- Dates of approval.
- Signatures.
Example:
| Reviewer Name | Role | Date Approved | Signature |
|---|---|---|---|
| Jane Doe | Engineering Manager | 2024-11-27 | [Signature] |
| John Smith | QA Lead | 2024-11-27 | [Signature] |
Pro Tip: Add a brief statement before the table, such as:
“The following stakeholders have reviewed and approved the SAT plan to ensure its alignment with operational objectives.”
SAT: Introduction and Purpose
Why It Matters: A well-crafted introduction sets the tone for the document, while the purpose explains the goals of the SAT. Together, they help readers immediately understand what the document is about.
How to Write It:
- Introduction:
- Clearly state what equipment is being tested.
- Mention its operational context (e.g., production line, system integration).
- Purpose:
- Explain the objectives of the SAT, such as validating equipment functionality, performance, and compliance with specifications.
Example:
This SAT evaluates the performance of a high-speed pharmaceutical granulator designed to integrate with upstream mixing equipment and downstream packaging lines. The purpose of this test is to validate its operational performance, verify safety features, and ensure seamless integration with existing systems.
Pro Tip: Use concise, factual statements. Avoid jargon or overly technical terms in this section to make it accessible to a broad audience.
SAT: Documentation Reference
Why It Matters: Including reference documents ensures traceability and provides the necessary context for the SAT process.
How to Write It:
- List all relevant documents, such as:
- Factory Acceptance Test (FAT) results. Read our article on FAT here.
- Technical specifications.
- User manuals.
- Regulatory standards (e.g., ISO guidelines).
Example Statement:
Refer to FAT Report No. 2024-GRA-001 and User Manual v2.3 for baseline performance data and operational guidance.
Pro Tip: Create a dedicated subsection for document references and organise it in a bullet point format for easy readability.
SAT: Scope of Tests
Why It Matters: Defining the scope prevents misunderstandings and ensures focus on the key objectives of the SAT.
How to Write It:
- Specify the boundaries of the testing process, including:
- The equipment being tested.
- The operational conditions.
- Any excluded tests or scenarios.
Example Scope Statement:
The SAT will evaluate the granulator’s mechanical performance, control system integration, and safety features under low, medium, and maximum operational loads. Energy efficiency tests beyond 100% capacity are excluded.
Pro Tip: Use clear, precise language to avoid ambiguity and highlight key exclusions to manage expectations.
SAT: Test Content and Areas Tested
Why It Matters: This section ensures all critical features and performance metrics are evaluated during the SAT.
How to Write It:
- Create a list of areas being tested.
- Use bullet points or a table to make the information easier to digest.
- Provide examples to clarify what will be evaluated.
Some areas that may be included:
- Emergency Stops
- Test all emergency stop (E-stop) buttons to confirm they immediately and reliably stop the equipment.
- Validate compliance with BS EN ISO 13850:2015 for emergency stop systems, which specifies requirements for function and reliability.
- Ensure E-stops are accessible, clearly labelled, and reset correctly after activation.
- Machine Guards and Safety Barriers
- Inspect physical safety features, such as guards, covers, or interlocks, to ensure they prevent access to hazardous parts during operation.
- Confirm compliance with BS EN ISO 14120:2015, which mandates performance requirements for guards.
- Test interlock systems to ensure the equipment cannot operate if guards are removed or opened.
- Functional Safety of Control Systems
- Assess critical safety functions such as alarms, cut-offs, and pressure relief systems.
- Conduct risk reduction measures according to BS EN ISO 13849-1, which specifies safety standards for control systems.
- Electrical Safety Testing
- Verify compliance with PUWER 1998 (Provision and Use of Work Equipment Regulations) and BS 7671:2018 for electrical installations.
- Test grounding, insulation, and circuit protection.
- Environmental Safety
- Check ventilation and air handling systems to prevent overheating or accumulation of hazardous gases.
- Ensure dust collection or filtration systems are operational, especially in ATEX-regulated environments.
Example:
- Safety Systems:
- Emergency stop functionality.
- Overload protection mechanisms.
- Operational Controls:
- User interface responsiveness.
- System alarms.
- Performance Metrics:
- Granulation rate: Target 100 kg/hour ± 2%.
- Energy consumption: ≤15 kWh per 100 kg.
Tip: Group tests by category (e.g., safety, performance) to make the content more navigable.
SAT: Overview and Test Plan
Why It Matters: The test plan provides a roadmap for the SAT, ensuring all activities are well-coordinated.
How to Write It:
- Summarise the sequence of tests in a chronological order.
- Use timelines or Gantt charts to visually represent the schedule.
Example:
- Day 1: Installation and system verification.
- Day 2: Performance and safety testing.
- Day 3: Integration and final approval.
Pro Tip: Include estimated durations for each activity to help with time management.
SAT Overview and Test Plan: Test Philosophy
Why It Matters: Defining the testing approach ensures clarity on how results will be interpreted.
How to Write It:
- Specify the pass/fail criteria for each test.
- Mention tolerances and testing conditions.
Example:
All operational tests will be performed at 20°C ± 2°C. A granulation rate of 100 kg/hour ± 2% is required to pass.
Pro Tip: Align the testing philosophy with industry standards (e.g., ISO 9001) to ensure compliance.
SAT: Test Personnel Requirements
Why It Matters: Defining roles and skills ensures that qualified individuals handle critical testing tasks.
How to Write It:
- List the required team members and their responsibilities.
- Include any necessary qualifications or certifications.
Example:
- Vendor Technician: Responsible for troubleshooting and equipment adjustments.
- Customer QA Specialist: Verifies compliance with operational standards.
Pro Tip: Use a table to match roles with specific responsibilities for better clarity.
SAT: Specification of Individual Tests
Why It Matters: Clearly specifying individual tests ensures consistency and repeatability, making results reliable and auditable.
How to Write It:
- Use a step-by-step format for each test procedure.
- Include all necessary tools, settings, and conditions to replicate the test accurately.
- Provide detailed descriptions of test objectives, actions, and expected outcomes.
Example:
Test Name: Granulator Performance Test
- Objective: Verify granulation rate under standard operating conditions.
- Preparation:
- Connect equipment to power and air supply.
- Calibrate input feeder to dispense 10 kg/min ± 0.5 kg/min.
- Procedure:
- Start the granulator and feed material at the calibrated rate.
- Measure granulation rate using the inline scale for 10 minutes.
- Expected Outcome:
- Achieve a consistent granulation rate of 100 kg/hour ± 2%.
Example:
Test Name: Electrical Systems Check
- Objective: Verify the integration of the electrical system with the local power grid and control systems.
- Methodology:
- Confirm proper connection to the electrical supply and control systems.
- Test for electrical faults or wiring issues using multimeters and testing tools.
- Acceptance Criteria: Electrical systems must be fully operational with no faults detected and meet safety regulations (e.g., BS EN 60204-1 for electrical equipment of machines).
- Expected Outcome: The electrical system must function without issues, and all connections should be secure and within operational limits.
Tip: Use tables to list tools and settings required for each test, making preparation straightforward for personnel.
SAT: Data Collected
Why It Matters: Properly recording data ensures accurate evaluation of equipment performance and provides evidence for acceptance.
How to Write It:
- Design standardised templates for result recording to minimise errors.
- Specify the metrics to be measured and their units.
Example:
| Metric | Unit | Recorded Value | Target Value | Pass/Fail |
|---|---|---|---|---|
| Granulation Rate | kg/hour | 98.5 | 100 ± 2% | Pass |
| Energy Consumption | kWh/100 kg | 14.8 | ≤15 | Pass |
Pro Tip: Include a section for observations or anomalies that may impact results to provide additional context.
SAT Test Requirements
Equipment and Utility Requirements
Why It Matters: Detailed requirements ensure that all necessary resources are available, avoiding delays or incomplete testing.
How to Write It:
- List all equipment, consumables, and utilities needed for the tests.
- Include specific technical details such as voltage, capacity, or calibration requirements.
Example:
- Equipment:
- Granulator Model G-100.
- Inline scale (±0.1 kg accuracy).
- Utilities:
- Power supply: 230V, 50Hz, single-phase.
- Compressed air: 6 bar, filtered and dry.
Pro Tip: Group requirements by category (e.g., equipment, consumables, utilities) for better organisation.
Tests
When preparing for Site Acceptance Testing (SAT), clear and comprehensive test listings are crucial. They ensure that all necessary functions and performance criteria are evaluated systematically. Below is the structure for defining and organising the tests to be performed.
Test Listing
Test Listing Overview:
A test listing is a detailed inventory of all tests to be conducted during the SAT. It includes both functional and performance tests, covering all critical aspects of the equipment’s operation. It serves as the foundation for tracking progress and ensuring that all key features are assessed.
Test Listing Format:
- Test ID: A unique identifier for each test.
- Test Description: A brief summary of what the test is assessing (e.g., pressure test, safety system verification).
- Test Method: Detailed instructions on how the test should be conducted.
- Pass/Fail Criteria: Specific conditions under which the test will pass or fail.
- Test Results: Space to record the outcome of the test.
- Responsible Party: The person or team responsible for carrying out the test.
- Date/Time: When the test is to be conducted or has been conducted.
Example of a Test Listing:
| Test ID | Test Description | Test Method | Pass/Fail Criteria | Results | Responsible Party | Date/Time |
|---|---|---|---|---|---|---|
| T01 | Pressure Test | Apply pressure as per spec | Pressure must not exceed 150 psi | Pass | John Doe | 12/12/2024 |
| T02 | Safety Shutdown | Simulate emergency shutdown | System must shut down within 5 seconds | Fail | Jane Smith | 12/12/2024 |
SAT: Acceptance and Approval
Define the process for the formal acceptance of the equipment after SAT:
- Conditions for Acceptance: Specify the conditions under which the equipment will be accepted. For example, all tests must pass, and any minor deviations must be resolved within an agreed timeframe.
- Approval Process: Outline the procedure for formally accepting the equipment, including sign-offs from relevant stakeholders (e.g., operations, safety, engineering).
Example:
- Conditions for Acceptance: The equipment will be accepted if all operational and safety tests pass successfully. Any minor issues identified must be rectified within two weeks from the test date.
- Approval Process: Final approval of the equipment is contingent on the successful completion of all tests, including functional, safety, and performance criteria. The approval sign-off will be completed by the operations manager, safety officer, and lead engineer.
SAT: Signature Identification Page
Why It Matters: Signatures confirm agreement between vendor and customer, making the SAT process legally binding.
How to Write It:
- Provide space for the names, roles, and signatures of all parties.
- Include a date field for each signature.
Example:
| Name | Role | Signature | Date |
|---|---|---|---|
| Jane Doe | Customer QA Lead | [Signature] | 2024-11-27 |
| John Smith | Vendor Engineer | [Signature] | 2024-11-27 |
Pro Tip: Add a declaration above the table, such as:
“The undersigned certify that all tests have been conducted and verified as per the SAT document.”
Why It Matters: A glossary improves comprehension by clarifying technical terms and acronyms used throughout the document.
SAT: Test Procedure and Results Sheets
Generate Detailed Test Reports to record findings for every SAT step, including integration test results, safety checks, and performance validation. Additionally, attach supporting evidence such as photographs, calibration certificates, and technician signatures. Ensure Traceability by linkling SAT documentation to earlier validation stages like FAT, IQ, and OQ for a cohesive compliance record. Read our article on FAT here.
Why It Matters: Combining instructions with space for results ensures clarity during testing and reduces the risk of missing data.
How to Write It:
- Present test procedures with step-by-step instructions followed by a results table.
- Leave space for notes or additional observations.
Key documentation for SAT:
Test Logs: Document every test performed, including the test conditions, results, and whether the equipment passed or failed each test.
Deviation Reports: If any issues arise, they should be documented, along with any corrective actions and re-testing.
Final SAT Report: Provide a summary of all tests, the outcomes, and any corrective actions taken, including sign-off by the relevant parties.
Example Format:
Test Procedure:
- Start equipment and allow it to stabilise for 5 minutes.
- Measure operating temperature every 2 minutes for 10 minutes.
Results Sheet:
| Time (min) | Temperature (°C) | Observations |
|---|---|---|
| 0 | 25.5 | Initial temperature. |
| 2 | 27.0 |
Pro Tip: Include a checklist at the end of each test procedure to ensure all steps are completed.
SAT: Glossary
How to Write It:
- List terms alphabetically for easy reference.
- Include brief but precise definitions.
Example:
- Granulation Rate: The rate at which material is processed into granules,
SAT: Revision History
Why It Matters: A revision history ensures that any changes to the SAT document are well-documented, providing transparency and traceability. It allows stakeholders to track updates and modifications made during the testing process.
How to Write It:
- Record all changes made to the SAT document, including the date of change and the person responsible.
- Use a table format to clearly track revisions, providing a concise summary of each update.
Example Format:
| Revision No. | Date | Description of Changes | Responsible Party |
|---|---|---|---|
| 1 | 2024-11-27 | Initial version of SAT document. | Jane Doe |
| 2 | 2024-11-30 | Updated test procedure for granulation rate. | John Smith |
| 3 | 2024-12-05 | Added equipment requirements for new batch mixer. | Michael Johnson |
Pro Tip: Ensure that each change is clearly documented with enough detail to make future revisions easy to understand and implement.
SAT: Appendices and Further Actions
Why It Matters: Appendices and further actions provide extra information that might be needed during or after the SAT process, such as troubleshooting steps and follow-up plans. These details ensure the SAT document is comprehensive and easy to navigate.
How to Write It:
- Include troubleshooting steps that address common issues encountered during testing.
- Add follow-up plans for corrective actions or any unresolved issues.
- Provide additional diagrams or charts that may help clarify complex concepts or steps in the process.
- Rework or Modifications: If any tests fail, outline the process for addressing the issues and re-testing.
- Training and Handover: If the SAT is successful, training for operational staff may be required, and the equipment is handed over to the operational team.
- Preparation for Operation: Ensure that the equipment is fully ready for production, with all necessary configurations and adjustments completed.
Example Format:
Appendix A: Troubleshooting
- Issue: Granulation rate out of specification.
Solution:- Check the feeder calibration and adjust to the correct settings.
- Verify air supply pressure.
- Issue: Equipment not powering on.
Solution:- Inspect power supply connections.
- Check circuit breakers and fuses.
Appendix B: Follow-up Actions
- Action 1: Confirm recalibration of granulator after testing.
- Action 2: Schedule a follow-up meeting to discuss potential design improvements based on test results.
Pro Tip: Use diagrams or flowcharts where applicable, especially for troubleshooting steps, to make the process easier to follow.
These sections play a crucial role in ensuring the SAT document remains up to date and comprehensive. Including detailed revision history provides accountability, while appendices ensure that any additional details are readily available for reference. Together, they contribute to a clear, standardised, and auditable SAT process that is both practical and effective. A well-structured document not only streamlines the testing process but also minimises risks of errors or disputes. Pay careful attention to detail, maintain consistency in format, and ensure each section serves a distinct purpose. This approach will help you achieve a successful SAT outcome.
Site Acceptance Testing Challenges
During Site Acceptance Testing (SAT), several challenges can arise. These include issues like scope creep, incomplete data, and lack of proper communication. Addressing these challenges promptly ensures that the testing process remains efficient, effective, and on track.
Scope Creep
Challenge:
Scope creep occurs when the testing scope expands beyond its original boundaries. This can result from ambiguous test objectives or the introduction of new requirements during the testing process.
Solution:
- Clearly define the scope from the start and ensure all stakeholders agree on it.
- Use a detailed SAT document to outline the tests and equipment involved, including exclusions.
- Maintain regular communication between the customer, vendor, and testing teams to avoid misunderstandings or the addition of unnecessary tasks.
Tip: Establish a formal change management process to approve any scope changes before they are implemented.
Incomplete Data
Challenge:
Incomplete or inaccurate data can derail the testing process, leading to unreliable results and delays in decision-making.
Solution:
- Implement standardised templates for data collection, ensuring all necessary parameters are recorded.
- Train testing personnel to understand the importance of data completeness and accuracy.
- Ensure that backup systems or tools are in place for data retrieval in case of system failures.
Tip: Regularly review the collected data to identify any gaps or inconsistencies during the testing process, not after.
Miscommunication Between Stakeholders
Challenge:
Lack of clarity between all involved parties, such as vendors, customers, and testing teams, can lead to mistakes, missed requirements, and delays in approval.
Solution:
- Establish a clear communication plan that specifies the roles, responsibilities, and channels for updates.
- Hold regular check-in meetings with all stakeholders to align on progress and address any concerns.
- Create a centralised document repository where all parties can access updated test plans, results, and revisions in real time.
Tip: Ensure that the communication flow remains formal and well-documented to avoid confusion.
Delays in Equipment Availability
Challenge:
Delays in receiving the necessary equipment or utilities for the tests can cause significant setbacks in the testing schedule.
Solution:
- Pre-test preparation is crucial. Ensure all required equipment and utilities are available and tested in advance.
- Coordinate with vendors to confirm that all required equipment is ready before the SAT begins.
- Consider having backup equipment or temporary solutions available for critical tests.
Tip: A detailed equipment checklist should be included in the SAT documentation to track readiness.
Addressing these common challenges is essential to maintaining a smooth and efficient SAT process. Indeed, by implementing clear scope boundaries, ensuring complete data, and fostering open communication, testing teams can reduce the risk of delays and complications. Stay proactive and prepared to overcome these challenges to ensure the successful acceptance of your equipment. Continue reading to explore more aspects of SAT documentation and its importance.
Conclusion
In conclusion, Site Acceptance Testing (SAT) is a critical step in the validation and acceptance of equipment within manufacturing environments. It ensures that equipment operates according to its intended specifications, meets regulatory standards, and aligns with operational requirements. Throughout this article, key best practices and common challenges have been explored, providing valuable guidance for conducting SATs effectively.
Key Takeaways
- Clearly Define the Scope of Testing
A well-defined scope at the beginning of the SAT process helps to prevent scope creep and ensures that all parties are aligned on testing objectives and boundaries. Regular reviews and clear communication are essential to maintain this scope throughout the testing process. - Implement Standardised Documentation and Processes
Standardised templates for data collection, testing procedures, and data recording are crucial for consistency and accuracy throughout the SAT. This includes creating clear step-by-step procedures, defined testing conditions, and standardised forms for data recording. - Regular Communication Between Stakeholders
Open, consistent communication between the vendor, customer, and testing team is vital. Regular check-ins, well-defined roles and responsibilities, and centralised document management help prevent misunderstandings and delays in decision-making. - Address Incomplete Data and Miscommunication Early
Incomplete data or miscommunication between stakeholders can lead to unreliable test results and project delays. By implementing a robust data review process and maintaining clear communication channels, teams can quickly identify and address issues as they arise. - Ensure Equipment and Utilities are Readily Available
Delays in equipment availability or lack of necessary utilities can significantly impact the SAT schedule. Proper pre-test planning, including detailed checklists and coordination with vendors, can help mitigate these delays and maintain testing momentum.
Best Practices
- Use a formal change management process to approve any scope changes during the SAT.
- Regularly review data to ensure completeness and accuracy throughout the testing process.
- Document any changes to the SAT process and scope in a revision history, which should be maintained and referenced throughout the project.
- Include backup equipment and temporary solutions for critical tests if primary equipment is not available.
- Maintain clear roles and responsibilities and a centralised document repository to facilitate easy access to testing plans, results, and revisions.
These best practices are essential for maintaining the integrity and reliability of SATs. By focusing on clear communication, consistent documentation, and thorough preparation, teams can minimise the risk of common challenges like scope creep, incomplete data, and miscommunication. This proactive approach ultimately ensures that equipment is validated correctly and in line with regulatory standards, enabling smoother transitions from the factory floor to operation. For more detailed information on project management for equipment upgrades, read our guide.