What is the best way to commission integrated control systems?

First, you want to have a list of the controllers, and points that are to be commissioned. Have a spreadsheet of all the point names, what they are, i.e. digital or analogue, and what controller they are connected to. The spreadsheet should also break down location, and have additional notes for each column such as the date checked, a part for the engineer to confirm completion, plus a notes section. Ideally, you will already have created a copy of your software offsite, and can load that into your first controller. The aim is to check each point through the software, controller, to the sensor. This proves the panel wiring too.

Following the principles of IEC 62337, IEC 62381 and IEC 62382, a comprehensive commissioning plan is crucial for a successful integrated control system (ICS) project. This plan outlines the roadmap for verifying system functionality, safety, and performance. Below are Key Elements of the Commissioning Plan: - Scope and Objectives - Roles and Responsibilities - Schedule and Resources - Acceptance Criteria - Test Procedures - Safety Measures - Documentation and Reporting - Contingency Plans By collaboratively developing a comprehensive commissioning plan following these guidelines, all stakeholders can work towards a smooth and efficient commissioning process, ensuring a safe and functional ICS that meets the project's objectives.

During commissioning, systematic testing is vital to ensure the integrated control system functions as designed. Following the commissioning plan's procedures and criteria, tests are conducted at various levels: - Individual components (AI, AO, DI, DO) - HMI, Workstations - Controllers, I/O Cards - Power Supplies - Network Switches, Firewall, Communication - subsystems (third-party packages) - the entire system function test This verifies functionality, performance, and reliability under normal, abnormal, and even emergency scenarios. All tests are documented, with any deviations or issues reported and addressed before system handover.

There maybe some issues that are found during the testing phase of the software. This can be initially be an issue with the graphic, or a plant item not switching on in the given time frame for example. To start troubleshooting this always start with the basics, track the output point down, and it's controller, trace the software back from that point, you should build a good understanding of what is involved to switch this item on. For example, you could have certain criteria that are needed to switch the output on, is the plant in frost mode, is the fire alarm on, etc.. If the software is working as required a physical check of the hardware will be required. Test the inputs coming into the controller, check they are being read etc.

The DCS commissioning process utilizes a "punch list" to track and address identified issues. This list documents all non-conformances, errors, or malfunctions discovered during testing. Each item details the problem, its location, and its severity. The project team then works to resolve these issues, ensuring the DCS meets specifications. Once fixed, the punch list is updated with corrective actions taken and verification of successful resolution. This iterative process guarantees a fully functional and reliable DCS before handover.

With all stakeholders and parties present, so issues can be resolved in a timely manner without blaming or finger-pointing the party not present.

I believe the OEM should have much better internal quality standards which ensure that the system is built in a manner which identifies and corrects the inherent design flaws and obvious mistakes rather than waiting for the customer to point these out. Sometimes, it is very time consuming to correct major design problems in the system and may lead to delays in the project schedule and financial penalties for the supplier/vendor. The best way to avoid any non conformances is to have a well defined design criteria and well written philosophies and narratives. Also, if you strictly adhere to standards and specifications, you are most likely to breeze through the testing phase. Integration, both internal & external shall be prioritized.

Punch lists should not replace a test plan. If you take your line drawings and your functional specification, a test plan can be written showing where, how. what conditions to check circuits and you validate wiring, scaling, functionality, HMI code, PLC code alarms, all at once.

Essentially, for PCS tags, conduct individual loop checking, functional test like PID control, and other related matters such as color coding, alarm system, reset action, trends, etc. based on client's ICSS Functional Design Specs. While for SIS, the basis will be the Cause & Effect Matrix and other related matters defined in ICSS FDS. Any discrepancies from FDS will be included in the punch list that will be closed out later with complete documentation and if needed, repeat of commissioning procedures stated above.