SAT (Site Acceptance Test): Safety and Efficiency

Site Acceptance Test (SAT) is a key stage in commissioning industrial systems and machinery. Carried out at the customer’s site, this process confirms that the equipment operates in line with previously defined specifications and is ready for use. The test is essential to verify that all components function correctly under real environmental conditions and in compliance with safety standards and regulations.

What is SAT?

Site Acceptance Test covers the final testing of machines or systems at the customer’s installation site. The purpose of SAT is to confirm that the equipment has been correctly installed, configured, and is ready for operation. Before on-site testing, a Factory Acceptance Test (FAT) is typically performed at the manufacturer’s facility to ensure the equipment meets the customer’s requirements.

Why is it important?

SAT allows the customer to verify that the equipment performs as required and is fully functional. This process is critical because it enables identification and correction of any issues before the system is released for use. As a result, costly and time-consuming repairs can be avoided later on.

Differences between SAT and FAT

The main difference between Site Acceptance Test (SAT) and Factory Acceptance Test (FAT) is where and when the tests are performed. FAT is carried out at the manufacturer’s facility before the equipment is delivered to the customer, while the test takes place at the installation site after the equipment has been delivered and installed.

Procedure

Planning

SAT planning includes preparing the test environment, defining test objectives, and selecting test methods. It is also essential to agree on acceptance criteria and prepare the documentation.

Preparation

Preparation includes installing and configuring the system or machine to be tested. Preliminary functional and performance tests should also be carried out.

Execution

SAT typically includes several tests, such as performance, functionality, operability, and safety tests. All results are documented and assessed for compliance with the requirements.

Documentation

SAT results are documented and evaluated to determine whether all requirements have been met. If issues are identified, corrective actions are taken and the test is repeated until compliance is achieved.

Acceptance

If the requirements are met, the system or machine is accepted by the customer. Otherwise, corrections are made and the test is performed again.

Benefits of performing SAT

• Quality verification: The test confirms that requirements and specifications are met.
• Early fault detection: SAT enables issues to be identified and corrected early, helping to avoid costly repairs.
• Customer satisfaction: The test increases customer satisfaction by ensuring the equipment meets their requirements.

Importance in industrial automation

SAT is an indispensable part of industrial automation because it confirms that all systems operate correctly under real operating conditions. These tests are particularly important for industrial robots and production lines, where even minor irregularities can lead to serious production issues.

Standards and regulations

SAT supports compliance with many standards and regulations, such as the Machinery Directive 2006/42/EC and the Machinery Regulation 2023/1230. As part of the testing, compliance with harmonised standards is also checked, as well as whether the manufacturer has carried out a risk assessment in accordance with EN ISO 12100:2012 (note: formally, the manufacturer does not have to present it, but is required to prepare it!). Another important element is verification of the CE marking, which confirms that the machinery complies with EU requirements.

Design office support and engineering outsourcing

Conducting SAT often requires cooperation with a design office that oversees the implementation. In some cases, engineering outsourcing is also necessary to ensure the right expertise is available to carry out comprehensive acceptance testing.

Site Acceptance Test (SAT) is a key stage in the commissioning of industrial machines and systems, ensuring that the equipment operates in line with the customer’s requirements under real operating conditions. With proper planning, preparation, execution, and documentation, the test helps identify and correct issues, thereby increasing customer satisfaction and the quality of the final product.

Additional SAT aspects in an industrial context

• Production process automation: SAT plays a crucial role in validating automated production lines and robotic workstations.
• CE certification of machinery: The test is the final stage of certification, where the completeness and compliance of all documentation and markings are verified.
• PLC programming and SCADA: SAT includes operator training on control systems and verification of safety functions.
• Machine safety and guarding: As part of the tests, the correct installation of machine guards is verified and interlocking systems are tested.
• Strength calculations (FEA): Technical documentation and checking the completeness of strength calculations are a key part of SAT.

Importance in the context of project management

SAT is one of the milestones in project management and often determines the acceptance of a production line or machine. Performing it correctly is critical to project success and achieving all assumed KPIs (key performance indicators). The test ensures that production lines and industrial robots meet all customer requirements and are ready for operation.

The role of SAT in certification and compliance processes

SAT is an important element of certification processes, such as machinery conformity assessment and verification of the EC Declaration of Conformity. As part of the tests, it is checked whether the machines have the required certificates and meet the requirements of the Machinery Directive 2006/42/EC and other regulations, such as the Low Voltage Directive or electromagnetic compatibility.

Importance in the context of safety and risk

As part of SAT, a workstation risk assessment related to the Work Equipment Directive is also carried out to ensure that all potential hazards have been properly managed. It is also verified that the machines have appropriate guards and service platforms providing safe access to all service areas​​.

The test also includes verification of compliance with ATEX requirements if the equipment is intended for use in explosive atmospheres. It is important that all components have the appropriate certificates and documentation confirming their safety​​.

The importance of SAT in the context of production optimization

SAT plays a key role in production process automation, enabling verification of system effectiveness and performance. As part of the tests, OEE (Overall Equipment Effectiveness) indicators are also checked, and SMED (Single-Minute Exchange of Dies) tests are carried out to optimize machine changeover time​​.

Importance in the context of design and technical documentation

Carrying out a SAT requires close cooperation with the design office, which oversees the implementation and verifies that all aspects of machine design have been properly delivered. Reviewing the technical documentation is a key part of the test, ensuring that all components meet the technical requirements​.

Support from an industrial automation integrator

SAT often requires the involvement of an industrial automation integrator, who is responsible for installing and configuring automation systems. As part of the test, training is also provided on operating SCADA and PLC systems, ensuring that the customer’s staff are fully prepared to manage the new systems​.

The importance of SAT in the context of compliance with standards and regulations

Conducting a SAT is critical for meeting the requirements of standards and regulations, such as the Low Voltage Directive and Electromagnetic Compatibility. As part of the test, it is verified that all components and systems comply with the relevant harmonised standards, which is necessary to obtain the CE marking​.

Site Acceptance Test is a key stage in the commissioning process for industrial machines and systems, ensuring that the equipment operates in line with the customer’s requirements under real operating conditions. With proper planning, preparation, execution, and documentation, the test helps identify and correct issues, thereby increasing customer satisfaction and the quality of the final product​​. Performing tests with due diligence and in accordance with guidelines is essential to ensure high quality and machine safety as well as system safety in an industrial environment.