Linkedin Facebook Instagram

News

News, Cutting-Edge Technologies, and Sustainable Solutions.

Advanced Technology. Simple Solutions.

The strength of the Thompson work culture is its people. We provide an empowering environment built on trust, loyalty and family values.

Categories

Join our Newsletter

No Spam. Just emails related to our industries.

Five Automation Issues We Commonly Encounter During Commissioning

One of the biggest misconceptions in industrial automation is that startup begins when the PLC program is downloaded. In reality, startup is where all of the design decisions, installation work, documentation, and configuration settings come together for the first time.

"Over the years, we've learned that successful startups are won or lost in the details. The issues that create the biggest delays are rarely complex problems. They're usually small configuration, installation, or documentation gaps that surface when the system is expected to perform."

– Dustin Wenger, Sr. Manager - Automation
Dustin Wenger

Common Startup Issues That Can Delay Commissioning

When startup day arrives, every minute counts. These are five of the most common automation issues that can derail commissioning and what can be done to prevent them.

IMG_0840
IMG_0867
IMG_5360
IMG_6131

1. Instrument Scaling and Configuration Errors

A critical step before startup is ensuring that every instrument is properly configured and scaled for the process it is monitoring. Just as important, those settings must be clearly communicated to the programming team.

We’ve seen situations where a transmitter was configured correctly in the field, but the PLC was programmed using different engineering units or scaling values. The result is unnecessary troubleshooting during startup when operators and technicians are trying to determine whether the issue is in the instrument, wiring, or control system.

Taking the time to verify configuration settings and document them early can significantly reduce startup headaches and allow the commissioning team to trust the data being received from the field.

2. Network and Communications Issues

A network design can look perfect on paper until devices are connected and expected to communicate in the field.

One of the best ways to reduce startup risk is to bench test network equipment before installation whenever possible. This helps identify addressing conflicts and device compatibility issues before valuable commissioning time is spent troubleshooting on site.

Accurate and up to date network documentation is equally important. Field technicians need to know how devices are intended to communicate, what IP addresses are assigned, and how equipment should be configured. Clear documentation helps everyone stay aligned and prevents unnecessary confusion during installation and startup.

3. VFD Setup

Variable Frequency Drives (VFD) come in many different brands and models, but they all require the same basic information:

  • Motor nameplate data.
  • What tells the drive to run?
  • What tells the drive how fast to run?
  • How should the drive respond when stopping or faulting?

Small parameter differences can lead to significant startup delays. A drive may run but not respond to speed references, start commands, or operate as intended during an emergency.

Creating a standard VFD parameter template for your organization can greatly improve consistency and reduce commissioning time. Standardization helps ensure drives are configured the same way from project to project and allows technicians to troubleshoot more effectively when issues arise.

4. Field Device Installation Problems

Improperly installed field devices can quickly create project delays, especially when specialized equipment or long lead time components are involved.

In many cases, the issue isn’t the device itself. Instead, it may be an incorrect process connection, device voltage, available space, or installation considerations like environment. These problems often aren’t discovered until equipment arrives on site and crews begin installation.

Clear communication is essential. Instrument specifications, drawings, and installation requirements should be shared with everyone involved, including contractors, installers, piping crews, and project managers. The more visibility the team has before installation begins, the less likely rework or replacement components will be required.

5. Documentation and Drawing Discrepancies

In today’s digital environment, access to project documentation has never been easier. However, having access to drawings is only valuable if those drawings accurately reflect what was installed.

During commissioning, field changes are common. Devices are relocated, wiring is adjusted, and equipment is modified to address real world conditions. If these changes are not captured, the customer is left with documentation that no longer matches their system.

Keeping drawings up to date throughout the project benefits everyone involved and is now easier than ever using iPads to digitally markup and share. It reduces future troubleshooting time and provides the customer with an accurate representation of their facility for years to come.

"Successful commissioning doesn't come down to a single event or milestone. It's the result of dozens of details being planned, verified, and documented before startup ever begins. When those pieces come together, startups are smoother, troubleshooting is reduced, and the facility reaches production faster."

– Blair Harp, Vice President of Building Systems
Blair Harp

How TSG Reduces Commissioning Risk

At TSG, we’ve found that investing time in these areas early often results in smoother startups and more reliable systems long after the project is complete. To help maintain consistency across projects, our team utilizes device checkout tools that guide technicians through installation verification, configuration settings, functional testing, and commissioning activities based on the specific device type being installed.

Beyond ensuring equipment is configured correctly, these tools provide a way to document completed work, capture field feedback, and identify punch list items before they become startup delays. The result is a more organized commissioning process and better visibility into the status of each device as a project moves toward startup.

While no project is completely free of challenges, a structured commissioning process combined with thorough documentation can dramatically reduce risk and help customers achieve a more successful startup.