On-Site Commissioning, FAT & SAT Services
Zero-defect plant integration. Expert Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), point-to-point I/O loop checkout, and 24/7 start-up engineering.
FAT Protocol & I/O Checkout Pipeline
Rigorous pre-shipment simulation and on-site validation methodology engineered to guarantee flawless automation deployment.
FAT_SIMULATION_SUMMARY:
- Control_Panel: Jfata_Main_PLC_Rack_01 (Siemens S7-1500)
- Simulated_Inputs: 128 Digital / 32 Analog channels tested via simulator box
- Logic_Interlocks: Emergency stop chain, guard locking, and sequence checks verified
- FAT_Status: APPROVED (Zero critical discrepancies logged)
Controlled workshop testing simulating all physical inputs and outputs to validate control logic prior to machine dispatch.
Commissioning Specializations
Professional automation testing, FAT/SAT protocols, and field engineering services engineered for seamless plant integration.
Rigorous Pre-Shipment Factory Acceptance Testing (FAT)
Executing thorough simulation testing on control panels, PLCs, safety relays, and HMI screens inside our facility using I/O simulation rigs prior to equipment dispatch to guarantee zero hardware or software defects on-site.
On-Site Site Acceptance Testing (SAT) & System Integration
Executing complete mechanical alignment, field wiring checkout, bus topology verification, and sequence-of-operation validation on the customer's factory floor under real production operating conditions.
Point-to-Point I/O Checkout & Analog Loop Calibration
Validating every digital sensor state, 4-20mA analog loop, pneumatic directional valve, thermocouple feedback, and VFD drive handshake to ensure complete electrical and physical signaling integrity.
24/7 Production Start-Up Support & Technical Training
Providing dedicated on-site engineering coverage during initial production ramp-up—performing real-time PID loop tuning, resolving line bottlenecks, and conducting structured training for plant operators and technicians.
Commissioning Engineering Parameters
| Testing Parameter | Engineering Scope & Deliverables | Governing Standard |
|---|---|---|
| Commissioning & Testing Frameworks | IEC 61131-3, ISA-88 / ISA-95 commissioning standards, GAMP 5 software validation guidelines | IEC / ISA International Standard |
| Signal Simulation & Diagnostic Hardware | Calibrated 4-20mA loop calibrators, Fluke True-RMS multimeters, oscilloscopes, fieldbus bus-analyzers | NIST Traceable Calibration |
| Quality Control & Handover Documentation | Signed FAT/SAT protocols, formal punch-list registers, red-lined & finalized as-built CAD electrical schematics | ISO 9001 Quality Management |
| Loop & Transducer Verification | Signal injection (0-10V, 4-20mA), RTD/TC thermal simulation, encoder quadrature pulse tracking | ISA Recommended Practice |
| Safety Interlock & E-Stop Validation | Dual-channel cross-circuit fault injection, light curtain response verification, safety contactor feedback audits | ISO 13849-1 Validation Specs |
4-Step Commissioning & Testing Workflow
Pre-Commissioning Audit & Plan Review
Auditing CAD schematics, PLC code backups, instrument datasheets, field cabling schedules, and custom FAT/SAT test procedure matrices.
Factory Acceptance Test (FAT) Execution
Performing simulated I/O fault injection, interlock testing, HMI state verification, and client sign-off prior to crating and logistics.
Field Installation, Loop Checkout & SAT
Supervising field wiring terminations, conducting point-to-point I/O cold checks, powering up sub-systems, and executing live production SAT trials.
Punch-List Clearing, Training & Handover
Clearing outstanding site punch-list items, delivering updated as-built documentation, training operations personnel, and securing final sign-off.
Commissioning & FAT FAQs
What is the key functional difference between FAT (Factory Acceptance Testing) and SAT (Site Acceptance Testing)?
FAT is conducted inside our assembly facility prior to shipment, utilizing software simulation tools and test rigs to verify control logic, safety circuits, panel wiring, and HMI navigation. SAT is executed directly on your factory floor after final positioning and electrical hookup, validating that the integrated equipment operates reliably under real raw material feeds, utility loads, and plant environmental conditions.
How do your engineers manage and clear punch-list items discovered during on-site commissioning?
Every discrepancy, hardware modification, or software logic refinement identified during on-site testing is logged into a structured punch-list tracker. Critical path items affecting safety or production are resolved immediately on-site, red-line drawing updates are marked directly on schematics, and PLC code is updated before securing formal engineering sign-off.
What specific safety checks are performed during functional safety commissioning?
We perform rigorous functional validation of all Safety-Related Control Systems (SRCS) according to ISO 13849-2. This includes testing dual-channel emergency stop loops, verifying optical light curtain response and reset logic, auditing safety gate guard-locking interlocks, and forcing cross-circuit fault conditions to confirm that safety PLCs and force-guided contactors drop into a safe state unconditionally.
Do you provide post-commissioning operator training and site handover documentation?
Yes. Our commissioning process concludes with hands-on technical training for machine operators, maintenance staff, and plant engineers. We supply a full handover package containing signed FAT/SAT protocol logs, fully red-lined and updated as-built CAD electrical schematics, PLC/HMI source code backups, parameter lists, and operational troubleshooting guides.
Let's execute your next industrial milestone.
From initial engineering architecture blueprints to final field commissioning, JFATA Engineering maps directly to your complex automation requirements. Select a specialized service track below to initiate formal project consultation with our engineering team.