The Crucial Role of FAT and Commissioning in Industrial UPS Systems for EPC Contractors

Lever Srl
2 days ago
3 min read

In mega-infrastructure projects, the Oil & Gas sector, and Power Generation plants, the reliability of critical power supply systems allows no room for compromise. For EPC Contractors, risk management and adherence to project timelines depend on choosing technology partners capable of ensuring excellence at every single stage.

Within this documentation and execution workflow, two milestones determine the success of supplying industrial UPS systems, inverters, and rectifiers: the FAT (Factory Acceptance Test) and on-site Commissioning.

As a leading international vendor, Lever Srl has structured its engineering and testing processes to eliminate integration risks and accelerate the Time-to-Market of major global plants.

1. FAT (Factory Acceptance Test): Validating Performance Before Shipping

The FAT is not a mere routine check, but the moment where theoretical engineering meets real-world performance. In Lever’s testing laboratories in Verona, every Heavy-Duty system undergoes rigorous testing in the presence of the EPC Contractor's inspectors and the final client (End User).

What does a Top Vendor-level FAT include?

Dynamic and Static Load Testing: Simulation of the harshest operating conditions at the destination site, including load transients and overloads.
Thermal Robustness Verification: Monitoring critical components under stress to ensure service continuity even in extreme temperature environments (desert climates or offshore installations).
Fault Simulation (Fault Injection): Real-time verification of protection systems and the redundant architecture of the UPS or rectifier, ensuring that power to the critical load is never interrupted.
Communication Systems Integration: Testing of interface protocols, eliminating software bottlenecks before arriving at the construction site.

The EPC Advantage: Identifying and resolving any non-conformity in the factory reduces site intervention costs by a factor of 1 to 10 and prevents penalties related to construction delays.

2. From Site to Start-up: The Value of Structured Commissioning

Once the FAT is passed, the equipment is shipped to the site. This marks the beginning of the Commissioning and Start-up phase, where the presence of field engineers makes the difference between a smooth start-up and an unexpected plant shutdown.

The commissioning of Lever systems follows standardized international protocols that remain flexible to specific project requirements:

SAT (Site Acceptance Test): Post-transport visual and mechanical inspection, insulation checks, and functional tests to demonstrate that the system maintains the exact performance verified during the FAT.
Energy Storage Systems Interface: Configuration and calibration of battery monitoring systems (featuring Lever’s proprietary technology), which are essential for maximizing battery lifespan and preventing thermal runaway.
Safe Energization: Coordination with site technicians for the initial power-up, ensuring the correct selectivity of upstream and downstream protections.

Why EPC Contractors Choose Lever as a Strategic Partner

Being a top vendor for EPC projects does not only mean manufacturing excellent hardware; it means understanding contract logic, managing complex documentation packages (quality control plans, ATEX certifications, standardized data exchanges), and providing rapid engineering responsiveness.

The Pillars of Lever’s Service for the EPC Market:

State-of-the-art Testing Laboratories: Flexible in-house facilities capable of hosting complex FAT sessions.
Tailor-Made Solutions: No two industrial plants are alike. We design customized UPS systems and rectifiers based on the proprietary technical specifications of the world's leading players in Energy and Oil & Gas.
Global Support Engineering: From drafting technical requirements during the Procurement phase to on-site after-sales assistance, our teams offer a single, highly competent point of contact.

Ensuring power continuity in mission-critical environments requires methodological rigor. Through meticulous FATs and flawless Commissioning procedures, Lever confirms its position as the ideal partner for EPC Contractors aiming to minimize operational risks and deliver successful projects on time and within budget.