Terms

Pre-commissioning refers to the individual equipment trial/testing while there can be several pieces of equipment, each with different input-output/parameters and make ready for commercial production, and make a smooth starting of commercial production and reach the rated capacity.

Commissioning refers to an overall (combined or all the machine rather than just equipment) trial and then starting Production with raw materials input, and getting the end product.

Post-Commissioning means solving outstanding punch points (Punch list) after the plant has been handed over to the client.

De-commissioning: At the end of the life cycle of a plant, de-commissioning. De-commissioning means taking out of active use and dismantling an industrial plant.

Punch List: A punch list (also called a snag list, deficiency list, or punch out list), is “a document listing work that does not conform to contract specifications, usually attached to a certificate of substantial completion.” Put simply, it is a list of to-do’s that need to be completed before a project can be considered finished.

Dry Run: A dry run (or a bench test) is a testing process where the effects of a possible failure are intentionally mitigated. For example, an aerospace company may conduct a “dry run” test of a jet’s new pilot ejection seat while the jet is parked on the ground, rather than while it is in flight.

FAT: The factory acceptance test (FAT) refers to the functional test that is performed by the vendor upon completion of the manufacturing process to prove the equipment has the same specification and functionality indicated in the datasheet, specification and purchase order.

SAT: Site Acceptance Testing (SAT) provides an opportunity for final confirmation that the performance experienced during the Factory Acceptance Testing (FAT) is repeated after the systems are installed onsite, ensuring nothing has changed or was damaged during shipment and installation.

Prerequisite

Mechanical

The prerequisite for Electrical commissioning is checking the mechanical completion and checking the FAT or SAT of mechanical vendors. For example, the pump curve may be measured again on site to confirm that it still meets technical requirements

Grounding and Binding

Grounding and bonding checks before the power are applied integrity of the grounding system and bonding system needs to be verified. We want to check this before the first power is applied because if there are any issues during energization this is the 

the system that will direct hazardous energy to the ground and 

protect the equipment and protect any people that are working in the area

grounding and bonding checks are typically confirmed visually or can be measured with a multimeter measuring the resistance of bonds to ensure low impedance bonding to all metallic surfaces in place so following that the first power can be applied

Polarity

With power polarity checks we want to confirm that the cables are installed correctly so there is no cause damage to the equipment or cause any safety hazards

AC phase check

checks before three-phase systems are energized phase checks are completed to verify the installation of each electrical phase in the proper order if three-phase power is installed backwards called phase rotation the system may rotate in the wrong direction

Test Based on Documents

IO test sheet

sample:

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No.	Control Cabinet	Drawing No.	Rack ID	I/O Address	Description	TagID	PLC Map Address	Point to point	PLC	Processor Functionality
1	Main MCC	E201	-FL00A0	DI_00_0.00	Main Incomer C/B	TR_ACB_OK_I	DI_00[0].00	x	x	x
2	Main MCC	E202	-FL00A0	DI_00_0.01	MCC Internal Equipment & JB’s Feed	TR_INT_CBCL_I	DI_00[0].01	x	x	x
3	Main MCC		-FL00A0	DI_00_0.02			DI_00[0].02	–	–	–
4	Main MCC	E202	-FL00A0	DI_00_0.03	CC1 Feed Circuit Breaker Closed	TR_CC1_CBCL_I	DI_00[0].03	x	x	x
5	Main MCC	E205	-FL00A0	DI_00_0.04	CC2 Feed Circuit Breaker Closed	TR_CC2_CBCL_I	DI_00[0].04	x	x	x

Motor Test 

Sample:

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Drawing	Tag ID	Description	Power	Voltage	Current	Starter	MCCB	Trip	Earth Leakage	Contactor	Overload	Thermistor + PTC + W/H	Starter	Isolator/FCS	Dist. MCC	Cores/	Cable	Rotation Test	Continuity	Earth Test	Earth Leakage Breaker
Ref	MCC		[kW]	[V]	[A]	Type	(MERLIN GERIN)	(MERLIN GERIN)	(MERLIN GERIN)	(TELEMECANIQUE)	(TELEMECANIQUE)	(TELEMECANIQUE)	(ROCKWELL)		[m]	phase
E242	Q01	MCC Main Incomer C/B	672.08	400	1054.42	MCCB	NW1200SX	Micrologic 6							25	2	300 mm2 Circular TPS XLPE Single Core Cu	x	x	x	x
E243	Q02	CC1 Power Feed (3C + N)	16.08	400	25.26	MCCB	NS160SX	STR22SE	VIGI – MH 29211						273	1	70 mm2 Aluminuim XLPE 4 Core	x	x	x	x
E244		Earth Cable													100	1	120 mm2 Circular TPS XLPE Single Core Cu	–	x	x	N.A
E245	Q03	MCC Fishbone Feed	40	400	62.83	MCCB	NS100SX	TM63D	VIGI – MH 29211						26.3	1	16 mm2 Circular TPS PVC 4C+E Copper	x	x	x	x
E246	P111	Services 1 Ring Main	35	400	95.11	MCCB	NS100SX	MA100	VIGI – MH 29211			N/A		2P Isolator	56	1	185 mm2 PVC/PVC 4C + E Aluminuim	–	x	x	N.A
E247	P112	Services 1 Ring Main	35	400	95.11	MCCB	NS100SX	MA100	VIGI – MH 29211			N/A		2P Isolator	22	1	185 mm2 PVC/PVC 4C + E Aluminuim	–	x	x	–

Machine Sequence

Based on SFC sequential function chart, the PLC code must be the same as SFC documents. Note that SFC applies to the assembly line (Not the process control)

Loop Check

Loop checking is the process that confirms the components are wired correctly and also helps to ensure that the system is functioning as designed.

Hot and Cold Loop check

Cold loop checking is done without powering up, ie the wiring integrity is tested through loop resistance and continuity check. Whereas the hot loop checking is done by simulation of the automation controller (PLC, DCS) and the I/O.

During the Hot loop check all the calibration, HMI or SCADA visualization, Alarm checks will be checked too.

protection relay testing

protection relays are used within electrical systems to monitor voltage and current and provide rapid response to safe the system should there be any fault detected. 

The first thing that needs to be done is to verify that the correct settings have been applied to the relay 

Other important tests

There are more tests that need to be done but are not necessary by the Electrical Automation dept. Below are some of these tests:

Interlock checks- hypot stands or insulation test – battery discharge tests- Electrical building test (MEP)  

Classification

Classic classification has 3 types A-B-C. Type a deficiency would be anything that must be corrected immediately before proceeding any further with any commissioning steps. Type B deficiency is something that does need to be corrected before handover to the owner but doesn’t necessarily impact immediately the function or operation. Type c deficiency would be minor in nature that doesn’t need to be corrected now it could even be corrected after handing over to the owner.

Sample for Metering project

Installation and commissioning tests and checklist

The following commissioning tests need to be completed by the metering supplier or contractor to ensure the metering system is installed correctly:

1. Perform a visual inspection of the hardware, including the installed CTs and meter wiring.
2. Configure meter identifier and/or IP address.
3. Confirm voltage on correct sequence: V1-Red, V2-White, V3-Blue, VN-Black.
4. Confirm the CTs are of the correct ratio and polarity, and correctly located to record the required power flow:
   • Confirm the loads on any CTs are within the correct limits.
   • CT on correct phase: I1-Red, I2-White, I3-Blue.
   • CT on correct direction: arrow pointing to the load.
   • For split core CTs check for proper closing position.
5. Configure the CT settings in the meter and confirm they match the installed CTs.
6. Check the meter date and time settings.
7. Apply a known load to the circuit and record and confirm: phase voltages
   • phase currents
   • phase power factor
   • active, reactive, and apparent power.
   • For multi-phase installations, confirm the relationships between voltages and currents are correct and that phase rotation is standard at the meter terminals.
   • Verify the energy management and monitoring system is correctly reading energy usage data from the meter.
   • Re-seal any tamper-proof seals on energy billing meters post-commissioning.