INSTALLATION

&
COMMISSIONING
Krishnend .s

COMMISSIONING has the function to move

the installation into a function-enabled
operation mode.
Set up , installation, programming errors
are thus corrected.
During commissioning, errors leads to error
functions

OPERATIONS WHILE COMMISSIONING

VISUAL INSPECTION
TEST THE ELECTRICAL INSTALLATION
MECHANICAL & ELECTRICAL CALIBRATION
TESTING & ADJUSTMENTS
TESTING & LOADING
FUNCTION TEST OF THE INSTALLATION
COMMISSIONING & COMPLETION

VISUAL INSPECTION
Each commissioning starts with visual inspection
Completeness with the help of a part list
Correct arrangement & damage
Operational safety: during commissioning utmost care &
precaution must be taken to ensure that damages to the
plant and injuries to the people are avoided.

TESTING THE ELECTRICAL SAFETY

Before the installation is supplied with electrical power, it
must be ensured that there are no electrical hazards.
The testing of electrical safety is the therefore the first
commissioning procedure after the visual inspection.

CALIBRATION
Pneumatic & Hydraulic actuators must be aligned
mechanically before the commissioning.
The sensors are adjusted for commissioning of the individual
subsystem. Thus for this, the installation must be supplied
with power.

TESTING & ADJUSTMENTS

The operating pressure of pneumatic and hydraulic
installations must be tested and adjusted.
Subsequently the outward and inward speeds of working
parts eg: of hydraulic cylinders are adjusted.
The control program created and tested by the programmer
is transferred to the system.

FUNCTIONAL TEST OF THE INSTALLATION

It must be ensured that all actuators are arranged in their
initial position, before the overall function of the installation
can be tested.
The first run should be performed in the single step mode
and should be controlled, a final test is performed in
automatic mode.

DOCUMENTATION
All important test results are documented in writing to be
able to prove the safety and faultless function of the
installation.
Check lists simulates the test run and serve as
documentation of the results.

ENGIN
E

ELECTRICAL SUBSYSTEM

ELECTRICAL
POWER

HYRAULIC
POWER
UNIT

GENERATION OF
COMPRESSED AIR
ENGINE

ASSEMBLY
SECTION

PRESSURE
REGULATION

400V /
230V AC
SPEED
CONTROLLER

CONVEYOR
BELT
MAGNETIC
STOPPER
CONVEYOR
ENGINE

All electrical components in the electrical installation are

centralized to an electrical subsystem.
Electrical subsystem is tested for electrical safety of
equipment of electrical machine & ordinance on industrial
safety and health.
Visual inspection
Verification against technical documentation
Insulation
Voltage test
Function test

Function test:
Example..on the engine of hydraulics power unit is tested,
checked. If the engine works and the direction of rotation
is correct. The engine of the installation to generate
pressure is tested for its function & the pressure regulator
is adjusted to the required value.
The electrical installations are tested using special measuring
devices by persons who can assess the dangers of
electrical power due to their training, experience, standard
knowledge onlythey are

ELECTRICIANS

PNEUMATIC INSTALLATION
GENERATION OF
COMPRESSED AIR
COMPESSOR

Pneumatic control

Actuators
-cylinder
-suction

ENGINE
PRESSURE
REGULATOR

Regulator control

The commissioning starts with visual inspection of pneumatic

subsystems.
The pneumatic lines are checked for correct installation &
proper connection, it is especially taken into consideration
that the lines for movable installation parts may not clamp.

The lubricator must be filled with the correct oil in the right
amount for oiled compressed air.
The amount of oil that must be supplied to the air is set as
per manufacturers instructions
(approximately 1 to 2 drops of oil per m3 air)

Procedure recommended:

Actuators & regulator control elements (direction valves)

are reset to default on the pressure free installations.
All flow control valves are off to keep the piston speeds low
during first mode.
The pressure is increased slowly on the pressure regulator
till it reaches operating pressure.
During the movement of actuators, sensors can be checked
for end positions & calibrate if required.

Finally, all actuators and valves must be reset to default.

The complete control run as per function plan or the
displacement step diagram is tested first during
commissioning of the control.

Operational safety:
There is no individual in the range of
motion of then actuators.

ELECTRO MAGNETIC COMPATIBILITY

The use of electrical power is always linked to the conversion
into other energy forms.
Eg: radiation (light), mechanical(engine)
Thus electromagnetic fields do not necessarily remain same
with in the electric field...but can also spread beyond.
Fields that spread can influence the function of other
equipments.

Frequency convertor generate high electrical disturbance

signals on the engine supply line.
This may disturb other electrical equipment or lead to error
function

Suggested solutions.

Shields
Filters
Groundings
Keeping distance(coupling path)

Electromagnetic

fields can generate

electric tension, this may leads to
unforeseen disturbances & break down

HYDRAULIC INSTALLATION

HYDRAULIC
VALVES
ENGINE

HYDRAULIC
POWER UNIT
HYDRAULIC
CYLINDERS

Similar to all subsystems, installation starts with visual

inspection.
Hydraulic pipes
Proper connections
Max. storage, period of life for hoses
No twisting & bending
Max. operating pressure
Before tank is filled with oil, it can be cleaned to completely
remove impurities due to manufacturing, transporting,
storage or installation.
Filters & suction hoses should be clean
The manufacture stipulates a hydraulic oil to be used.

Leakages
Bubbles
Noise
Oil level
Temperature of pumps
Pressure relief valve is set at low pressure
Now it is shifted from idle to pressure mode and for this
pressure is slowly increased.

This must be controlled by operation the valve manually.

After installation is completed, the movement speeds and

operating pressures are set using flow beans and pressure
relief valves.

ELECTRICAL CONTROL
CONTROL UNIT

SIGNALS
CONTROL
-INPUTS
-OUTPUTS

POWER SUPPLY

The electrical control consist of SPS(symbolic programming

system),control unit.
o
o
o
o
o
o
o
o

Electrical power supply to SPS is checked

While switching ON it should be in STOP mode
The SPS program is tested in a simulation mode before the
commissioning
Transfer the program to virtual SPS and monitor
Errors detected and are removed
Thus installation damages are removed
After successful testing, control program is transferred to
the SPS
Test results are recorded in the test certificate

OVERALL FUNCTION
After starting up the different subsystem the total installation
is put into operation.
SETUP MODE
All different actuators can be controlled individually
The respective actuator can be chosen by the selector switch
and actuation can be controlled directly
Safety interlocking mechanism will not work. for this reason
only qualified person is allowed to work in this mode.

SINGLE STEP MODE

Installation will be operated step by step by pressing the
start key for each next step.
The following operational sequence can be verified in this
mode.

AUTOMATIC MODE
Pressing start, installation will automatically run through its
sequence of process

While putting the installation into operation all

relevant events are noted and commented in a check
list.

TEST CERTIFICATE

The test certificate is produced based on the completed

checklists.
A general machine description
A general layout drawing of machine & illustration of
functionality
A list of applied standards
Technical test results
Operating manual

Thank you.