Factory Acceptance Test (FAT) Checklist: Control Panel and DCS / PLC Template
A 24 point factory acceptance test checklist for control panels and PLC or DCS systems, with acceptance criteria for every item and an automatic pass and fail count.
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- How to Use sheet with steps
- Template sheet, blank and ready
- Example sheet, filled in
- 10 built in formulas
- A4 landscape print setup
- Works in Excel, Google Sheets and LibreOffice
Preview of the Filled Example
This is the Example sheet from the download, so you can see exactly how the completed factory acceptance test (fat) checklist: control panel and dcs / plc looks.
Test checklist
| No | Section | Check item | Acceptance criteria | Result | Remarks |
|---|---|---|---|---|---|
| 1 | Documentation | Approved drawings, I/O list and FAT procedure available | Latest revision on file | PASS | |
| 2 | Documentation | Bill of materials matches supplied hardware | Make, model and quantity match | PASS | |
| 3 | Visual | Panel dimensions, colour, IP rating and nameplates | As per approved GA drawing | PASS | |
| 4 | Visual | Wiring neat, ferruled, colour coded, segregated (IS / non IS, AC / DC) | No damage, loose strands or mix | PASS | |
| 5 | Visual | Earth bars (PE, IE / clean earth) and bonding | Separate bars, all doors bonded | PASS | |
| 6 | Power | Insulation resistance of incoming power circuits | ≥ 1 MΩ at 500 V DC | PASS | |
| 7 | Power | Power on; all supply voltages measured | Within ± 5 % of nominal | PASS | |
| 8 | Power | Redundant power supply changeover | No interruption to controllers | PASS | |
| 9 | Hardware | Controllers, I/O cards and network switches healthy | No diagnostic alarms | PASS | |
| 10 | I/O test | Analog inputs: 4, 12, 20 mA injected on every channel | Reading within ± 0.25 % of span | PASS | |
| 11 | I/O test | Analog outputs: 0, 50, 100 % from HMI measured | Within ± 0.25 % of span | PASS | |
| 12 | I/O test | Digital inputs: every channel toggled | Correct tag changes state on HMI | PASS |
… and 12 more rows in the download.
About the Factory Acceptance Test (FAT) Checklist: Control Panel and DCS / PLC
A factory acceptance test checks a control panel or automation system at the vendor's works before it is shipped. Faults found at FAT cost a fraction of what they cost on site. A structured checklist with acceptance criteria avoids arguments: both sides agree in advance what "working" means.
How to fill in this template
- Agree the FAT procedure and this checklist with the vendor before the test date. Add or remove rows to suit your system.
- Fill the project details and test each item in order, witnessed by the client.
- Select PASS, FAIL or NA for every row and write remarks for FAIL and NA items.
- Every FAIL becomes a punch item; retest and update the result once fixed.
- Sign the checklist when the FAT status shows PASS or the open items are agreed in the punch list.
What the formulas do
- Counts of PASS, FAIL, NA and untested rows.
- FAT status is FAIL if any row failed, CHECK while rows are untested, otherwise PASS.
Related tools
Frequently Asked Questions
What is the difference between FAT and SAT?
FAT is done at the vendor's factory before dispatch, usually with simulated field signals. SAT is done after installation at site with real field devices and utilities.
Who attends a FAT?
The vendor's test engineer and the client, often with a third party inspector for large projects.
Should every I/O channel be tested in FAT?
Yes, ideally 100 % of channels. Sampling saves time but faults on untested channels then appear during commissioning.
Learn more on the blog
Cold loop and hot loop testing procedures
A practical guide on instrumentationblog.in that explains the procedure behind this template and how engineers apply it on real plants.
Read Full Article