How to Commission Distriubted Control System - comprehensive guide

DCS commissioning is a critical phase in the lifecycle of a process plant or facility. It ensures that the DCS system is set up correctly, functions as designed, and is ready for operation. The DCS manages and controls various equipment, processes, and systems in an industry.

You can follow the below mentioned steps for DCS commissioning. Remember that specific procedures may vary depending on the project.

DCS Commissioning Checklist:

1. Physical Checks: This step involves verifying the physical aspects of the DCS system, including cabinet and console furniture hardware, labeling, internal wiring, cable dressing, and main cable installation.
2. Pre-requisites: The article emphasizes that specific procedures should be followed depending on the project. There might be some pre-requisites that needs to be fulfilled before starting the commissioning process
3. Safety: Safety checks are crucial during commissioning. Ensure all safety procedures are followed to prevent any hazards.
4. Cabinet Alarm Check: Verify that the cabinet alarms are functioning correctly.
5. Redundancy Check: This step ensures that the redundant components of the DCS system are operational.
6. System Architecture Check: Verify that the system architecture matches the design specifications.
7. Time Synchronization Check: Ensure that all system clocks are synchronized.
8. Software License Check: Verify that the DCS software has the proper licenses installed.
9. Graphic Check: Verify that the DCS graphics are displaying correctly.
10. I/O Loop Check: This step involves checking the functionality of the DCS I/O loops, including continuity, MCBs/isolators, fuse rating, and nest loading.
11. Logic Check: Verify that the DCS logic is functioning as intended.
12. Trend & Control Group, Log Reports: Verify that the DCS is trending data correctly and generating logs as expected.
13. Controller Loading Check: Verify that the DCS controllers are loaded correctly.
14. Online/Offline Program Loading: Verify that the DCS program can be loaded online and offline.
15. Scan Time Check: Measure the DCS scan time to ensure it meets performance requirements.
16. Login Users and their access: Verify that login users have the appropriate access levels.
17. Communication with 3rd party systems: Verify that the DCS is communicating correctly with any third-party systems.
18. Modification: Implement any necessary modifications to the DCS system.
19. Spare Check: Verify that all spare parts are available and accounted for.
20. Miscellaneous Checks: Perform any other miscellaneous checks as required by the project specifications.
21. Punch list: Create a punch list to document any outstanding issues that need to be addressed.
22. Reports: Generate reports documenting the commissioning process and its findings.
23. Handover: Handover the DCS system to the operations team.

You can follow these international standards for Automation System Commissioning guidelines:

• IEC 62337: Commissioning of Electrical, Instrumentation and Control Systems
• IEC 62681: Procedures for Factory acceptance test (FAT), site acceptance test (SAT), and site integration test (SIT)
• IEC 62682: Electrical and Instrumentation Loop testing