Commissioning
Structured Commissioning for Reliable Industrial Automation
Installing new automation equipment is only part of delivering a successful control system. Before machinery or processes enter normal production, the complete system needs to be tested under real operating conditions to confirm that electrical equipment, PLC software, instrumentation, communications and operator interfaces work together correctly.
Industrial automation commissioning provides the structured transition between installation and operational use.
Stratos provides commissioning services for new automation systems, control panel installations, PLC upgrades, machinery modifications and wider control system projects. Our engineers verify the complete automation environment, identify issues before handover and help ensure the system is ready for reliable production.
What Is Industrial Automation Commissioning?
Industrial automation commissioning is the process of inspecting, testing and validating an installed control system before it enters normal operation.
Commissioning may cover:
Industrial control panels.
PLC hardware and software.
Remote I/O.
Sensors and instrumentation.
Variable Speed Drives.
Motors and actuators.
Industrial networks.
HMIs.
SCADA systems.
Safety interfaces.
Process sequences.
The objective is to verify that the installed system operates according to the agreed design and functional requirements.
Pre-Commissioning Checks
Before equipment is operated, preliminary checks help identify installation or configuration issues that could affect later testing.
Pre-commissioning activities may include:
Visual inspections.
Control panel checks.
Power supply verification.
Cable and termination checks.
PLC hardware inspection.
Network configuration.
Instrument verification.
Drive configuration.
Software version checks.
Documentation review.
Identifying problems at this stage can prevent unnecessary delays once functional commissioning begins.
Control Panel Commissioning
PLC commissioning verifies that the controller communicates correctly with the equipment installed in the field.
Testing may include:
Digital inputs.
Digital outputs.
Analogue inputs.
Analogue outputs.
Remote I/O.
Network devices.
Equipment status.
Interlocks.
PLC communications.
Fault conditions.
Each signal should correspond correctly with the physical equipment and the PLC program before automatic sequences are fully tested.
Instrumentation and Field Device Commissioning
Automation depends on accurate information from sensors and instrumentation.
Field commissioning may verify equipment such as:
Temperature sensors.
Pressure transmitters.
Flow instruments.
Level measurement.
Position sensors.
Encoders.
Proximity sensors.
Control valves.
Actuators.
Other process instrumentation.
Signals are checked against the PLC and operator interface to confirm that process information is being measured and displayed correctly.
Drive, Motor and Equipment Commissioning
Variable Speed Drives, motors and other controlled equipment need to respond correctly to commands from the automation system.
Commissioning may include:
Drive parameter verification.
Motor direction.
Speed references.
Start and stop commands.
Equipment feedback.
Fault signals.
Operating limits.
Local and automatic modes.
PLC communications.
Testing individual equipment before complete sequences are run helps isolate problems and reduces the complexity of final system commissioning.
HMI and SCADA Commissioning
Operators rely on HMI and SCADA systems to understand and interact with the process.
Commissioning therefore verifies that the information presented on screen accurately represents the equipment in the field.
Testing may include:
Equipment status.
Operator commands.
Setpoints.
Process values.
Alarm conditions.
Screen navigation.
Trends.
User permissions.
PLC communications.
Historical information.
This helps ensure operators receive accurate information before the system enters production.
Functional and Sequence Testing
Once individual devices have been commissioned, the complete automation sequence can be tested.
Functional testing may include:
Automatic sequences.
Manual operation.
Start-up sequences.
Shutdown sequences.
Equipment interlocks.
Process control.
Fault handling.
Recovery after faults.
Operating modes.
Production scenarios.
Testing should include both expected operation and appropriate abnormal conditions to confirm the system responds correctly when problems occur.
FAT, SAT and Commissioning
Factory Acceptance Testing, Site Acceptance Testing and commissioning are related stages, but they perform different functions.
Factory Acceptance Testing (FAT) verifies the system before delivery or installation where appropriate.
Site Acceptance Testing (SAT) confirms that the installed system meets agreed requirements at the customer's facility.
Commissioning involves bringing the equipment into operational use and verifying its behaviour under actual site conditions.
Using a structured approach across these stages can identify problems earlier and provide a clearer route from engineering through to production handover.
Commissioning Documentation and Handover
Commissioning should leave the customer with an automation system that can be understood and maintained after the project team leaves site.
Project handover may include:
Updated PLC software.
HMI or SCADA applications.
Software backups.
Drive parameters.
Commissioning records.
Test results.
Electrical drawings.
I/O documentation.
Equipment settings.
Outstanding actions.
Where project changes have been made during commissioning, documentation should be updated to reflect the final installed system.
Post-Commissioning Support and Maintenance
Automation requirements do not end when commissioning is complete.
Initial production may identify opportunities for optimisation, while ongoing support can help maintain the reliability of the system throughout its operational life.
Post-commissioning support may include:
PLC adjustments.
Process optimisation.
Alarm improvements.
HMI changes.
Backup management.
Documentation updates.
Control system health checks.
Obsolescence monitoring.
Planned maintenance.
Where ongoing support is required, maintenance and service contracts can provide a structured approach to reviewing the automation system after handover and supporting it as production requirements develop.
Why Choose Stratos for Industrial Automation Commissioning?
Commissioning requires an understanding of how every part of the automation system interacts.
A problem identified at the PLC may originate from field wiring, instrumentation, a drive, network communication or equipment within the control panel. Looking at individual technologies in isolation can make these problems more difficult to diagnose.
Stratos combines control panel engineering, PLC programming, SCADA and HMI development, industrial communications and automation fault finding to commission the complete control environment.
From initial checks through to functional testing and final handover, our engineers focus on ensuring the installed system works reliably in the environment where it actually needs to perform.
Commission Your Automation System with Confidence
Successful commissioning connects engineering design with reliable production. Stratos commissions industrial control panels, PLCs, instrumentation, drives, HMI and SCADA systems as a complete automation environment, helping identify problems before final handover and ensuring the system is ready for operational use.
Speak to our engineers about commissioning a new automation system, control system upgrade or industrial machinery project.
Frequently Asked Questions
What is industrial automation commissioning?
Industrial automation commissioning is the structured testing and validation of control panels, PLCs, instrumentation, drives, HMI, SCADA and associated equipment before an automation system enters normal production.
What is the difference between PLC commissioning and automation commissioning?
PLC commissioning focuses specifically on the controller, software, I/O and connected devices. Industrial automation commissioning has a broader scope and considers how the complete control system operates together.
What is the difference between FAT, SAT and commissioning?
FAT generally verifies equipment before site installation, SAT validates the installed system against agreed requirements at site, while commissioning brings the system into operational use and verifies its performance under real operating conditions.
Can Stratos commission control panels and PLC software together?
Yes. Stratos provides control panel and automation engineering capabilities, allowing the electrical panel, PLC software, connected equipment and operator systems to be considered together during commissioning.
Do you provide support after commissioning?
Yes. Post-commissioning support can include optimisation, software changes, backup management, system health checks and planned maintenance. Maintenance and service contracts can also provide structured ongoing automation support.