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What are the best ways to test and commission a control system project?

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Testing and commissioning a control system project is a crucial step to ensure that the system meets the design specifications, performs reliably, and satisfies the customer requirements. However, testing and commissioning can also be challenging, time-consuming, and costly if not planned and executed properly. In this article, you will learn some of the best ways to test and commission a control system project, based on the industry standards and best practices.

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Zohaib Jahan

21k ? | DeltaV DCS Engineer | Commissioning | TüV SIS, PLC Programming, Automation | Empowering Industry Transformation…

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Keith Barker

CSA Chairperson

1 Define the scope and objectives

The first step to test and commission a control system project is to define the scope and objectives of the testing and commissioning activities. This includes identifying the system components, functions, interfaces, and performance criteria that need to be verified and validated. You should also define the roles and responsibilities of the testing and commissioning team, the acceptance criteria and procedures, the documentation and reporting requirements, and the schedule and budget constraints.

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Zohaib Jahan

21k ? | DeltaV DCS Engineer | Commissioning | TüV SIS, PLC Programming, Automation | Empowering Industry Transformation and Achieve Excellence
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Here are the steps for commissioning control systems: 1) Pre-FAT 2) FAT 3) SAT 4) iSAT 5) Performance and Handover Pre-FAT and FAT (starting point of testing and commissioning) is done at Control System Integrator / Contractor site, can be witnessed by Clients/End User but all of above steps should be defined and agreed among all stake holders in details including scope of work, objectives, procedures, Checklists (fail/pass criteria), reports, proper documentation and drawings.

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Keith Barker

CSA Chairperson
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Commissioning a control system actually starts at a project's design stage. When the list of plant and equipment to be controlled is known, check and make sure that all of those items can talk to the control software. Waiting until its all ordered, purchased and on its way to site is far too late. Having to make it work later always creates confusion, resentment and delay and costs a fortune.

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Nelson Paredes

Commissioning Manager at Stellar-Energy
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1. Add training manuals duly approved by consultants , requires an interpreter on non speaking english language participant, engineers and technicians/operator and equipment suppliers 2, submittal of O&M manuals duly approved by consultant and end-user engineers 3. Site commissioning documents should be approved by consultant 4. Insure all latest wiring diagrams, details of equipment suppliers are available on your submittals

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2 Prepare the test and commissioning plan

The next step is to create a detailed test and commissioning plan that outlines the testing and commissioning strategy, methodology, and tools. This plan should include a test and commissioning matrix, which maps the system requirements to the test cases and methods. Additionally, it should include a test and commissioning schedule that defines the sequence and duration of the testing and commissioning phases. Furthermore, it should feature a test and commissioning procedure that outlines the steps, instructions, and expected results for each test case. Moreover, it should have a test and commissioning checklist that summarizes the tasks, deliverables, and resources for each testing and commissioning phase. Lastly, the plan should include a test and commissioning report template that specifies the format, content, and frequency of the testing and commissioning reports.

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Zohaib Jahan

21k ? | DeltaV DCS Engineer | Commissioning | TüV SIS, PLC Programming, Automation | Empowering Industry Transformation and Achieve Excellence
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The execution plan is the most important part of commissioning after procedures. It should include; - Name and desgination of participants - Documentation and drawings - Certifications of equipment if any - Planned days/hours for each activity (Schedule) - Proper Tools List - Procedures including expected results - Conflict/modification form This plan should be approved by client/end users before starting commissioning of Control Systems.

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3 Execute the test and commissioning phases

The third step is to execute the test and commissioning phases according to the plan. This typically involves factory acceptance testing (FAT) at the manufacturer's site, site acceptance testing (SAT) at the installation site, functional testing (FT) at the operational site, and commissioning as the final phase. FAT verifies that system components are built and configured correctly, SAT ensures that components are integrated and interfaced correctly, FT confirms that the system functions as intended and meets performance criteria, and commissioning ensures that the system is ready for operation and handover to the customer.

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Zohaib Jahan

21k ? | DeltaV DCS Engineer | Commissioning | TüV SIS, PLC Programming, Automation | Empowering Industry Transformation and Achieve Excellence
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Here I would refer IEC 62337 standard that outlines a structured approach to testing and commissioning electrical, instrumentation, and control systems within the process industry. Following a well-defined plan, this phase verifies if the system meets the intended functionalities and performance criteria before handover to the client. Key Stages: 1) Factory Acceptance Testing (FAT) followed by Pre-FAT 3) Site Acceptance Testing (SAT) 4) Functional Testing (FT) 5) Commissioning 6) Performance Test and Handover

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4 Monitor and control the test and commissioning process

Monitoring and controlling the test and commissioning process is essential to ensure it is on track, on time, and on budget. This involves measuring and recording the results and comparing them to the acceptance criteria, as well as identifying and resolving any issues or defects that arise. Additionally, communicating and reporting the progress, status, and outcomes to stakeholders is important, as is managing any changes, risks, or contingencies that affect the test and commissioning plan.

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Zohaib Jahan

21k ? | DeltaV DCS Engineer | Commissioning | TüV SIS, PLC Programming, Automation | Empowering Industry Transformation and Achieve Excellence
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After system installation, performance testing verifies the control system meets its design goals. This involves simulating real-world scenarios or even on a running plant if permitted and measuring response times, accuracy, and stability. Once the system performs flawlessly, a handover meeting ensures all documentation, training materials, and operational procedures are transferred to the client. This signifies successful project completion and paves the way for smooth system operation.

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5 Review and document the test and commissioning outcomes

The fifth step is to review and document the test and commissioning outcomes to verify that the system meets the customer requirements and expectations. This includes conducting a final inspection and verification of the system, obtaining the customer's approval and sign-off for the system, preparing and submitting the test and commissioning report and other relevant documents, as well as providing the customer with the system manuals, training, and support. Each of these steps are essential in ensuring that the system meets customer requirements and expectations.

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Zohaib Jahan

21k ? | DeltaV DCS Engineer | Commissioning | TüV SIS, PLC Programming, Automation | Empowering Industry Transformation and Achieve Excellence
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After completing the test and commissioning phases, the outcomes are documented to ensure the system meets the client's requirements. This process involves several steps: - Final system inspection and verification - Customer sign-off - Preparation and submission of reports - As-built documentation and drawings - System manuals, training, and support By thoroughly documenting the test and commissioning process, all parties involved have a clear understanding of the system's performance and capabilities. This ensures a smooth handover to the client and sets the stage for successful system operation.

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6 Learn and improve from the test and commissioning experience

The sixth step is to learn and improve from the test and commissioning experience to enhance your skills and knowledge for future projects. This entails collecting and analyzing feedback and lessons learned from the test and commissioning team and the customer. Additionally, it involves identifying and implementing the best practices and improvement opportunities for the test and commissioning process, as well as updating and maintaining the plan, procedure, checklist, and report templates. Furthermore, it is important to share and disseminate the test and commissioning experience and insights with peers and colleagues.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are the best ways to test and commission a control system project?

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1 Define the scope and objectives

2 Prepare the test and commissioning plan

3 Execute the test and commissioning phases

4 Monitor and control the test and commissioning process

5 Review and document the test and commissioning outcomes

6 Learn and improve from the test and commissioning experience

7 Here’s what else to consider

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