Inst ToolsInst ToolsInst Tools
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Search
  • Books
  • Software
  • Projects
  • Process
  • Tools
  • Basics
  • Formula
  • Power Plant
  • Root Cause Analysis
  • Electrical Basics
  • Animation
  • Standards
  • 4-20 mA Course
  • Siemens PLC Course
Reading: Commissioning Checklists for Industrial Automation Systems
Share
Font ResizerAa
Inst ToolsInst Tools
Font ResizerAa
  • Courses
  • Design
  • PLC
  • Interview
  • Control System
Search
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Inst Tools > Blog > Control Systems > Commissioning Checklists for Industrial Automation Systems

Commissioning Checklists for Industrial Automation Systems

In this article, we will discuss basic general guidelines and commissioning checklists for industrial automation systems.

Last updated: January 24, 2023 11:46 am
Viral Nagda
Control Systems PLC Tutorials
No Comments
Share
6 Min Read
SHARE

In this post, we will see the checklist for commissioning an industrial automation system.

Contents
Industrial Automation SystemsCommissioning Checklists

Commissioning is the process performed by an engineer to test, validate, run and then hand over the system to the end customer. It is a tricky cycle and requires proper communication skills, technical skills, site condition understanding, process knowledge, and tuning with the customer to hand over a system.

The question is not just to hand over, but it builds up a trust with the customer that the system purchased is performing according to their specifications and fulfilling their demand.

Industrial Automation Systems

Once the PLC electrical panel has been dispatched from a manufacturer’s factory, it is then ready for installation at the industrial site.

Commissioning Checklist for Industrial Automation System

At the actual plant (site), the electrical panel is just not enough for the client to accept the machine. The overall working of the machine with actual process parameters will be considered for full acceptance.

The electrical panel is just a part of the system delivered; the whole machine is checked for proper performance. It is the job of the manufacturer to perform commissioning with the client and handover to them.

Commissioning Checklists

In this post, we will have a look at some of the basic general guidelines and checklists that must be considered for performing commissioning.

  • Make sure you have installed all the remote IO devices properly at their designated position. Because PLC is all about inputs and outputs, any missing device or instrument or its improper placement in the plant layout will disrupt the performance of the system.
  • Check whether all the cables are properly laid from a device to the panel.
  • Perform Megger test of the motors and verify the earthing of the instruments and electrical panel.
  • Checking the continuity of the wires is a must. The electrical part is a critical parameter and you need to ensure that there are no broken wires or any external damage to it.
  • The civil structure (GA drawing) of the components is an important criterion to check.
  • The fabrication and placement of each component must be checked properly so that it does not cause an accident.
  • Availability of utility is a very important parameter to check. Without important utilities like water, steam, air, etc. it will not be possible to run the system and so; it is to be ensured that all these are ready and in place to start a system.
  • Check the incoming voltage that will be given to the electrical panel.
  • Also, note that the voltage between earth to neutral must be typically less than 0.5 V. This must be achieved to eliminate any possibilities of noise in the system.
  • Check communication cable layout between PLC and HMI / SCADA / DCS.
  • Ready all the necessary documents that are required for performing the commissioning steps. It includes electrical drawings, mechanical drawings, P&ID layout, BOM (Bill of Materials), control loops, power and signal cables, and other documents related to your system.
  • Every industrial automation system has a test procedure developed to check the system stepwise. Make sure it is ready before starting the plant; as it covers all the conditions from start to end. This will make it easy for the engineer to run the system.
  • Your team is working all over the plant to start and hand over the system properly. They will be located at different sites and areas of the plant according to the work assigned to them. So, the best coordination will be required between all of them and this requires a good communication network of cell phones and radios with the best available network. Distortion in communication will hamper the process a lot.
  • Make sure to continuously involve the operators of the customer side with your team during the commissioning phase. Their availability and continuous support will make easy your task when you start the system. This is because, once they are familiar with the system before running, they will automatically adapt to the process when it is running and this will make your workload easier.
  • Ensure that you have informed your vendor about your commissioning activity pre-planned; and not on short notice. Every person is working and is not free every time to sit for you and receive your call instantly. So, vendor readiness is a must criterion; as it will help them prepare for support and availability with prior notice.

In this way, we saw some general checklist criteria and guidelines for performing commissioning for a PLC automation system.

If you liked this article, then please subscribe to our YouTube Channel for Electrical, Electronics, Instrumentation, PLC, and SCADA video tutorials.

You can also follow us on Facebook and Twitter to receive daily updates.

Read Next:

  • PLC Wiring Diagrams
  • Electrical Wiring Diagram
  • 4-20 mA Transmitter Wiring
  • Why 24 Volts DC Power Supply?
  • Interposing Relay Panel Wiring
Don't Miss Our Updates
Be the first to get exclusive content straight to your email.
We promise not to spam you. You can unsubscribe at any time.
Invalid email address
You've successfully subscribed !

Continue Reading

Configuration of Profibus Network in Siemens PLC
Function Blocks in PLC (FBs) – What You Need To Know?
PLC to PLC Communication using S7 Connection PUT & GET Instructions
Siemens S7 300 and STEP 7 PLC program using SIMATIC Software
How Process Control Loop Works
How to Do Loop Checks During Plant Pre-Commissioning
Share This Article
Facebook Whatsapp Whatsapp LinkedIn Copy Link
Share
Leave a Comment

Leave a Reply Cancel reply

Your email address will not be published. Required fields are marked *

Stay Connected

128.3kFollowersLike
69.1kFollowersFollow
210kSubscribersSubscribe
38kFollowersFollow

Categories

Explore More

Split Range Control Working Principle
Learn about PLC, DCS, RTU, SCADA, and PAC
Testing and Validation in PLC Development
Automation System for Hazardous Environments
Various Causes for PLC Going in Stop Mode
Troubleshooting PLC Permissive Inputs
DCS Alarm Summary Dashboard using Microsoft Power BI
Modbus Communication between Delta PLC with VFD

Keep Learning

Types of PLC

#14 PLC Best Practices – Restrict Third-party Data Interfaces

memory types in siemens plc

#13 PLC Best Practices – Disable Unused Communication Ports

3 to 8 Line Decoder Circuit Diagram

3 to 8 Line Decoder PLC Ladder Diagram

Preventive Maintenance of Variable Frequency Drive

Preventive Maintenance of Variable Frequency Drive (VFD)

scada hmi

Functions of SCADA

PLC Karnaugh maps

How to Simplify PLC Coding Using Karnaugh Maps?

SCADA

Top 100+ SCADA Questions

Interposing Relay Panel (IRP)

Interposing Relay Panel (IRP) – Wiring and Testing Requirements

Learn More

Control Valves Leak Tightness

Control Valves Leak Tightness Restoration Pose Difficulties

Instrument Percent of Span Error

Instrument Percent of Span Error

C-Bourdon Tube

C-Bourdon Tube Pressure Gauge Theory

Parts of Safety PLC

SIS Software Simulation – Safety Instrumented System

circuit breaker principle

What is a circuit breaker ?

Feedback Control Questions & Answers

Feedback Control Loop Questions & Answers

testing-thermocouples-and-rtds

Testing thermocouples and RTDs using Multi-function Calibrators

PLC Program with 2 Toggle Switches and 4 Motors

PLC Program with 2 Toggle Switches and 4 Motors

Menu

  • About
  • Privacy Policy
  • Copyright

Quick Links

  • Learn PLC
  • Helping Hand
  • Part Time Job

YouTube Subscribe

Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Welcome Back!

Sign in to your account

Username or Email Address
Password

Lost your password?