TEST AND COMMISSIONING FUNCTIONS :-

1. Pre-Commissioning Activities

  • Documentation Review: Verify design drawings and as-built documentation against project specifications and standards.

  • Equipment Installation Check: Confirm correct installation of cabling, control panels, I/O modules, and field instruments.

  • Electrical Verification: Perform continuity tests and insulation resistance measurements on all relevant circuits.

  • Software Preparation: Load and validate databases, configure controllers, and check initial parameters prior to energization.

2. System Testing

  • Subsystem Testing: Validate individual subsystems for functionality as per design requirements.

  • I/O Verification: Simulate and confirm all input/output signals including alarms, interlocks, and control commands.

  • Communication Test: Verify connectivity and data exchange between controllers, SCADA/HMI, and third-party systems.

  • Logic and Safety Validation: Test control logics, interlock functions, and emergency shutdown sequences as defined in the Functional Design Specification (FDS).

3. Site Acceptance Testing (SAT)

  • Field Validation: Conduct tests on site with client representatives under actual operating conditions.

  • Redundancy and Failover: Test server redundancy, controller redundancy, and network failover mechanisms.

  • Sequence and Alarm Management: Confirm operation of process sequences and alarm handling in compliance with specifications.

  • Equipment Run Tests: Execute initial operational tests of machinery and process equipment to verify readiness.

4. Commissioning and Handover

  • Documentation: Compile detailed Test Reports and Commissioning Reports for project records.

  • Training: Provide operational and maintenance training to client personnel.

  • Manuals: Deliver complete Operation and Maintenance (O&M) manuals.

  • Performance Testing: Conduct full-scale performance tests to verify system reliability and compliance with project requirements.

5. Deliverables and Outcomes

  • Fully tested and commissioned automation system ready for operational use.

  • Verified compliance with design, safety, and operational standards.

  • Complete technical documentation package including reports, manuals, and training records.

  • A maintainable and expandable system framework supporting long-term plant operations.

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