The process of planning, documenting, scheduling, testing, adjusting, verifying, and training to provide a facility that operates as a fully functional system in accordance with the Owner's Project Requirements is known as commissioning. The Commissioning Process is intended to improve the quality of the delivered project by focusing the design and construction teams on the Owner's goals for a functional and energy efficient building. The earlier a Commissioning Provider is involved in the project process, the more likely the Commissioning Provider will be able to influence corrections without incurring additional costs later.
New Construction Commissioning
Pre-Design / Planning
Engineers test, validate, run, and then give over the system to the end user during the commissioning phase. To successfully hand over a system, it need good communication skills, technical know-how, an awareness of the site's conditions, process expertise, and customer tweaking. The purpose of the inquiry is not merely to hand over the product; rather, it helps the customer feel certain that the system is operating in accordance with their requirements and expectations. The PLC electrical panel is prepared for installation at the industrial site once it has been sent from the manufacturer's factory.The electrical panel at the real facility (site) is simply insufficient for the client to accept the equipment. For full approval, the machine's overall operation with actual process parameters will be taken into account.The equipment is tested for appropriate operation from top to bottom, not simply the electrical panel. The manufacturer's responsibility is to commission the client and deliver the product to them.
Essential principles and checklists that must be taken into account during commissioning at minimum.
- Assess that all of the remote IO devices are correctly installed in their assigned locations.
- Assess any missing device or instrument, or its incorrect positioning in the plant layout,
- Verify that all of the cables leading from a device to the panel are appropriately laid out.
- Megger test the motors, and make sure the electrical panel and instruments are earthed.
- Verify the wires' continuity. Make sure that there are no broken wires or other external damages to the electrical component, which is a crucial parameter.
- Utility accessibility should be carefully examined. It will not be able to run the system without essential utilities like power, steam, compressed air, etc.; therefore, it must be ensured that all of these are prepared and in place before starting a system.
- Assess that the electrical panel will receive the specified incoming voltage according to the system specifications.
- Check the voltage between the earth and the neutral must normally be less than 0.5 V. To ensure that there is no potential for noise in the system, this must be accomplished.
- Check the PLC to HMI, SCADA, or DCS communication cable layout and proper communication connections.
- Prepare all the paperwork needed to complete the commissioning procedures. It contains control loops, power and signal cables, electrical drawings, mechanical drawings, P&ID layout, BOM (Bill of Materials), and other papers pertinent to your system.
A test method has been established for each industrial automation system to step-by-step verify the system. Before starting the plant, make sure it is prepared because it addresses all of the conditions. The engineer will find it simple to operate the system as a result. Throughout the commissioning phase, your team should be regularly involving the client-side operators. When you start the system, your duty will be made easier by their availability and ongoing support. This is due to the fact that, once they are familiar with the system before it is put into operation, they will naturally adjust to the process when it is put into operation, which will lighten the workload.
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