Ever wonder how new systems spring to life without a hitch? It is all thanks to testing and commissioning. These two processes are like the dynamic duo of engineering, making sure everything works as it should.

So, what exactly are they?

Testing is all about checking individual parts or systems to see if they meet the required standards. It is like giving everything a thorough exam. This process helps identify defects or issues early on, saving a lot of time and money in the long run.

Commissioning, on the other hand, takes a broader view. It ensures that all systems work together like a well-oiled machine. Think of it as the final dress rehearsal before the big show. Commissioning verifies that the system operates as intended, meets performance requirements, and is safe to use.

Both are super important because they catch problems early, which saves time, money, and headaches down the road. They also ensure that systems are reliable, efficient, and safe to operate.

Testing: Giving Systems the Thumbs Up

The main goal of testing is simple: to verify that each part does what it is supposed to do. Depending on when and where they happen, tests are different types.

Two common types are:

Factory Acceptance Testing (FAT)

This happens at the manufacturer’s factory. It is a chance to spot any issues before the equipment even leaves the shop. FAT ensures that the equipment meets the specifications and works as expected in a controlled environment.

Site Acceptance Testing (SAT)

This happens on-site after installation. It confirms that everything was installed correctly and works in its new environment. SAT checks if the equipment integrates well with other systems and operates as intended in real-world conditions.

Testing Procedures

Testing usually involves following a detailed plan. Technicians perform specific checks and record the results. If something fails, it gets fixed and retested. This process ensures that all components meet the required standards and are ready for commissioning.

Fuji Electric Philippines offers a range of components that require careful testing, including:

Low Voltage Variable Speed Drives (LV VSD)

These control the speed of motors, so testing ensures accurate and reliable performance. Proper testing of LV VSDs helps in optimizing energy consumption and reducing wear on motors.

Medium Voltage Variable Speed Drives (MV VSD)

Similar to LV VSDs, but for higher power applications, rigorous testing is required for safety and efficiency. MV VSDs need thorough testing to handle high voltage levels without compromising performance.

Uninterruptible Power Supply (UPS)

UPS systems provide backup power, so testing their ability to switch seamlessly is crucial. This ensures that critical systems remain operational during power outages.

Transformers (Oil-immersed, Cast Resin)

These step up or step down voltage levels, which require tests to ensure proper insulation and load handling. Testing transformers helps prevent overheating and electrical failures.

Instrumentation

Accurate measurements are key; testing ensures sensors and transmitters provide reliable data. This is vital for monitoring and controlling processes effectively.

Safety During Testing

Safety is always a top priority. Technicians use safety gear and follow strict procedures to prevent accidents. This includes wearing protective equipment, ensuring proper grounding, and following lockout/tagout procedures.

Pro-Tip: Always use calibrated equipment. Accurate testing relies on accurate tools. Make sure your testing equipment is regularly calibrated to maintain its precision. This helps in getting reliable results and avoiding false positives or negatives.

Commissioning: Bringing It All Together

Commissioning makes sure all the systems work together like a symphony. It is more than just turning things on.

Purpose of Commissioning

Commissioning verifies that a system is designed, installed, tested, and ready to operate according to the owner’s requirements. This includes ensuring that the system meets performance standards, is safe for use, and can be maintained efficiently.

Commissioning Stages

Pre-Commissioning

This involves checking that everything is installed correctly and ready for testing. It includes verifying that all connections are secure, and all necessary documentation is available.

Start-up and Initial Operation

Powering up the system and making sure everything starts smoothly. This stage checks for any immediate issues and ensures the system can operate at a basic level.

Performance Testing

Running the system under different conditions to see if it meets the required performance levels. This includes testing under full load, partial load, and various environmental conditions.

Fuji Electric Products for Testing and Commissioning

Fuji Electric Philippines’ products often play a key role in larger systems, so their commissioning is essential:

Low Voltage Variable Speed Drives (LV VSD)

Ensuring they integrate seamlessly with motors and other equipment. Proper commissioning of LV VSDs helps optimize system performance and energy efficiency.

Medium Voltage Variable Speed Drives (MV VSD)

Coordinating their operation with the power grid and other high-voltage components. This ensures safe and efficient operation under high power conditions.

Uninterruptible Power Supply (UPS)

Verifying their ability to provide backup power to critical systems. Commissioning UPS systems ensures they can handle sudden power outages without disrupting operations.

Programmable Logic Controllers (PLC)

Testing their programming and integration with sensors and actuators ensures that the PLC can control the system as intended and respond to changes in real time.

Human Machine Interface (HMI)

Ensure the HMI provides a clear and intuitive interface for operators. Proper commissioning of HMIs helps reduce operator errors and improve system control.

Commissioning Team and Responsibilities

Commissioning usually involves a team of experts, including engineers, technicians, and the owner’s representatives. Each member has specific responsibilities to ensure a smooth process:

Engineers

They oversee the technical aspects, ensuring that systems meet design specifications.

Technicians

They perform the actual testing and commissioning tasks.

Owner’s Representatives

They ensure that the system meets the owner’s operational needs and requirements.

Testing and Commissioning Process: A Step-by-Step Guide

The process usually follows these steps:

Planning Phase

Define the scope, create a plan, and gather resources. This includes setting clear objectives, identifying necessary personnel, and scheduling tasks.

Execution Phase

Perform the tests and commissioning activities according to the plan. This involves conducting FAT and SAT, followed by pre-commissioning checks and performance testing.

Documentation and Reporting Phase

Record all the results and create reports. This documentation is crucial for future maintenance and troubleshooting.

Handover Phase

Turn the system over to the owner or operator, along with all the documentation. This ensures a smooth transition and provides necessary information for ongoing operation and maintenance.

Benefits of Effective Testing and Commissioning: Why It Matters

Sound testing and commissioning offer many benefits:

Improved System Reliability

Fewer surprises and breakdowns. Systems are more likely to operate consistently without unexpected failures.

Reduced Downtime

Problems get caught early, preventing major outages. This means less time spent on repairs and more time in operation.

Enhanced Safety

A safer working environment for everyone. Testing and commissioning reduce the risk of accidents by identifying and fixing potential hazards.

Optimal Performance

Systems run at their best. Proper testing and commissioning ensure that systems operate efficiently and effectively.

Extended Equipment Lifespan

Equipment lasts longer because it is properly maintained. Regular checks and early fixes prevent wear and tear.

Cost Savings

Reduced energy consumption and maintenance costs. Efficient systems consume less energy and require fewer repairs.

Peace of Mind

Knowing that your systems are running smoothly and safely. This reduces stress and allows for better planning and management.

Pro-Tip: Keep detailed records. Thorough documentation is your best friend. It helps with troubleshooting, maintenance, and future upgrades. Always ensure that all test results, commissioning reports, and maintenance records are well-organized and easily accessible.

Frequently Asked Questions

What comes first, testing or commissioning?

Testing generally happens before commissioning. Testing confirms each component meets the standards, while commissioning checks if all systems can work as intended. Think of testing as checking each piece of a puzzle, and commissioning as putting the whole puzzle together.

What is the purpose of commissioning?

The purpose of commissioning is to confirm that a system or building is designed, installed, tested, and ready to use based on the owner’s needs. It is about ensuring everything works together smoothly and safely.

Who is responsible for commissioning?

The person in charge of commissioning can change depending on the project, but it often means a team with the owner, engineers, contractors, and a special commissioning person. Each member plays a crucial role in ensuring the process goes smoothly.

What is a commissioning checklist?

A commissioning checklist is a complete list of tasks and checks during the process to confirm that all systems and parts work correctly. It helps ensure nothing gets missed and that everything is thoroughly tested.

What is the process of commissioning?

The process usually involves planning, pre-checks, testing, recording information, and training staff to use the system. It is a step-by-step approach to ensuring the system is fully operational and meets all requirements.

Conclusion

Testing and commissioning are essential for ensuring any system’s smooth and reliable operation. By following best practices and paying attention to detail, you can reap the many benefits of these processes. Always remember that thorough testing and commissioning contribute to a safer, more efficient, and more reliable operation. Whether dealing with complex industrial systems or simple installations, these processes are key to success.

About Fuji Electric Sales Philippines, Inc.

Bringing innovative energy solutions to the Philippines, Fuji Electric Sales Philippines, Inc. represents Fuji Electric Co., Ltd. from Japan. The company handles product sales, promotion, and support to help industries and electrical infrastructure develop.

Modernize your automation systems with testing and commissioning. Fuji Electric is here to help!

Rickson Manalo

Assistant Sales Manager

0917-115 6102