Many people have asked me about the commissioning service. There is curiosity to know if the promised benefits are really fulfilled and if the investment is justified. Faced with this reality, I confess to feeling happy, because we have been able to detect the problem and create a possible solution.
By Germán Alexis Cortés H.*
When end users or the electronic networks guild (security, communications, audio/video, monitoring, control and integration) are interested in knowing how to achieve efficiency in their processes, it is because they know that they have shortcomings, but that we want to correct them and then the first step is already taken in the right direction.
When to start the commissioning service?
Preferably from the moment of the conceptualization of the project. It's like the voice of conscience next to the project owner. However, I recognize that you do not always have that opportunity. So my suggestion is to hire him at the same time that conscience allows. Even at the final stage of the project (in fact, there is a service called end-commissioning).
What is really the scope?
In this case the scope may vary, depending on the phase where the commissioning service is started. However, although the scope may be different, the objective is the same: To achieve excellence in the quality of the networks and electronic systems installed.
Design
1. The ideal is to start from the moment of the conceptualization of the project, that is, even before starting the design. Then accompaniment and supervision is made to the stages of conceptual, basic and detailed design. Following Project Management methodology and allowing there to be a logical and documented process that includes the requirements of the end user (OPR) and the bases of the design (BOD).
When there is commissioning in the design, you really have several points of view that make the design more complete and efficient, but above all integrated to the other specialties (electrical, mechanical, hydraulic, electronic, structural, architectural, bioclimatic, urban, among many others).
2. The presence of commissioning in the design stage, takes into account the total cost of operation (TCO) of the system, estimating operating expenses (OpEx) and capital expenditures (CapEx); with the aim of making a good cash flow that guarantees the continuity of the installation process and the continuity of the operation once installed.
3. It is the job of the commissioning service to determine the true feasibility of the process. That is, determine if the associated costs (TCO) and other implications are feasible within the project and if not, make adjustments to the design (phases) and plan over time to achieve the final objective and the benefits for the end user.
4. During the generation phase of Tender Specifications (RFP) based on the design criteria, the commissioning service can together with the designer, make the support before the possible proponents in a market of suppliers already studied and analyzed... in this case, an adequate commissioning service follows documented and transparent processes for the objective selection (statistics, real measurements, weightings, comments and suggestions) of the proposals at a technical, legal, financial and economic level.
This manages to make an efficient and intelligent purchase, without the fear of vices of corruption and subjective favoritism... In many cases, a good commissioner manages to make an excellent negotiation with the integrators, since they do not concentrate on traditional commercial positions, but the true interests of the parties are discovered.
5. The collaboration of an authority for the commissioning of the networks, makes the contracting processes and start of work, are planned and situations are not left to chance. The contracted supplier must then understand that there is not only an owner to answer to, or an auditor to deliver, but there is a group of professionals who know in detail about their subject and who must do the contracted work in the most efficient way possible, without deception, without hidden costs, complying with the rules and improving the processes. The advance planning of all activities and compliance with the scope, time, cost and quality agreed are "the north", which guides the presence of the commissioning professional.
Construction
6. During the phase of installation of infrastructure (spaces, ductwork and wiring), the tasks of supervision on site are done, but, being strict in the issues generated by the current regulations, especially ISO / IEC and national standards. The detailed inspection and detailed monitoring of the cable routes through ducts and necessary spaces thinking about maintenance and updating tasks; they are vitally important.
7. At the end of the cabling phases, the first comprehensive continuity and certification tests of data networks begin. Verifying markings, signage, passage boxes, wiring arrangement, minimum distances, electrical safety, among many aspects of passive elements of analog or digital communications.
8. During the assembly phase of equipment and configuration... improvements are achieved by requiring internal bench tests (pre-assembly) and accuracy in the assembly and connectorization of elements. Here the coordination with other specialties is supported by defining the crossing points and the borders of zero meters between one system and another.
9. At the end of the assembly, energization, connectorization and basic configuration phase, the most wasteful phase of the commissioning of electronic equipment really begins, where we are 100% involved with the supplier and integrator to properly adjust the parameters of each system, in each case. Always thinking about the Integration of the systems and making the best use of the capabilities of the equipment, according to the needs of the end user.
10. The commissioning service ensures that the supplier makes diagrams of processes, operation and operation of each system working autonomously and operating in an integrated manner. It is in this phase, when it fails most frequently and where it is invaluable the presence of someone who not only demands it, but who guides on how to do it well done, because suppliers are not used to doing things with methodology and analysis.
11. This implies that the phase of refinement of the system, of the special parameters, the graphical interface and the complete integration is supervised and guided by the commissioning team, in conjunction with the supplier that performs the installation.
12. The final phase of commissioning and consists of receiving the installed systems in a physical and functional way. At the level of physical inventory, it is based on documentation (plans, tables, tables) that must, in an orderly manner, include all the installed elements, agreeing with the scope of the contract. Here the exercise is summarized with a general picture with greater or lesser amounts of elements.
Operation
13. At the operational level, it is based on documentation consisting of an immense checklist and results of test protocols for each subsystem, including all the elements supplied and installed, in 4 scenarios (normal, alarm, emergency and failure), both operating at an autonomous level and integrated with the rest of the systems (of the same contractor or others).
14. The tests must be verified in different places: a. each device, b. in the interconnection rooms and / or where there are controllers or intermediate active equipment and c. in the equipment that performs the centralization of information at the hardware and software level, almost always in the main control room.
15. Commissioning generates extensive and detailed test protocols. Together with the integrator, it carries out the necessary activities to place the system at its peak of performance and test for sure the benefits of the installed equipment, foreseeing the different scenarios and possibilities that may happen in each case.
16. Many of these tests are not satisfactorily passed by the integrator, therefore the commissioning authority supports, recommends improvements and adjustments so that the tests can be passed. In such a way that in many cases the "fine tuning" of all systems are tasks suggested by the commissioner.
17. At the end of the tests and satisfactorily pass all the protocols mentioned, a record is signed where it is guaranteed that the system is correctly installed and working properly. Attaching all the documentation that supports the satisfactory physical and functional cadastre.
Documentation
18. The next step of the commissioning service is to receive the documentation from the integrator who supplied and installed the equipment. Ensuring that the plans and diagrams of interconnection "as builded", are adjusted to reality and that all manuals, licenses and other elements are complete.
19. A key part is to ensure that the operation of integrated equipment and networks will be continuous. Commissioning supervises and evaluates the training that is done to operators, supervisors and administrators of the systems, making sure that the transfer of knowledge is really adequate.
20. The commissioning service is completed by ensuring the details of the maintenance contract and service levels for the technical support of the equipment, guaranteeing that the operation of the same is assured.
Excellence in quality
When a system has been commissioned and has passed all the necessary tests, it is calibrated to avoid as much as possible the failures in the expected operation. Therefore it becomes a quality process, so that current electronic systems are a true efficient management tool.
Time of a Commissioning service
It usually takes the same time as the project, however in the end-commissioning phase, specifically during extensive testing and fine tuning, an additional one or two can be taken depending on the number of devices to be tested and the complexity of the adjustments required.
Estimated cost of the service
The normal value of the service depends on the number of subsystems in the project, their complexity, the number of professionals who must be involved and especially the time required to be present on the site. Normally a team of 3 to 5 different professionals, highly trained, can be enough for medium projects. In this case, the estimation rate is close to 5% of the total value of the electronic project.
Work team
The work team for commissioning is interdisciplinary, that is, it is not a single engineer pending all aspects, but a group of engineers from various specialties who at the right time attend meetings with contractors to guide them in the process, the continuous improvement plan of the project, professional tests and detailed adjustments to achieve the benefits proposed. Having measurement, verification and registration equipment means that the tests are objectively supported.
A project manager, ideal in methodologies that involve technology and who technically knows the systems, becomes the axis of communication and efficiency of the process, reducing risks, improving quality and protecting the investment made.
* Germán Alexis Cortés H. is a Colombian Electronic Engineer, with a postgraduate degree in Engineering Management Systems. Consultant of the National Institute of Standards and Technology – NIST, in Electronic Security and Building Automation. CCP of ASIS, and CISSP of ISC2. He has over 20 years of experience in the electronic security industry. Renowned lecturer and university professor on high-tech issues at the Latino level. He has been a director of several companies in the sector and is currently a partner and directs Insetrón Ltda, an engineering and technical consulting company in electronic network projects for security, communications and automation. He has successfully participated in more than 150 projects at the Latino level. Contact him in the email [email protected]
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