Services

Control-system testing, FAT, SAT and commissioning

TBC plans and executes control-system testing against agreed functional requirements, operating sequences and failure scenarios, then closes defects and changes into the final controlled handover.

Factory testing

What the testing actually proves

A controls FAT should demonstrate how the system behaves through agreed operating and failure scenarios, not finish once every I/O point has changed state once.

I/O, communications and third-party interfaces against the current design
Sequences, permissives, interlocks and operator commands
Alarms, trips, equipment failures and communications-loss responses
Acceptance criteria, defect recording, correction and targeted retesting

I/O & interfacesSignals, scaling, communications and equipment states checked against the approved information.

OperationModes, sequences and transitions tested from realistic starting conditions.

Failure responseTrips, unavailable equipment, lost communications and abnormal states introduced safely where practical.

EvidenceResults, defects, changes and retests recorded against the relevant software and drawing revision.

Site acceptance

Installed system proved in context

SAT and commissioning confirm that the installed wiring, devices, networks and equipment behave with the software and operating philosophy as intended.

I/O and point-to-point testing
SAT and sequence proving
Generator and power-management testing
Integrated systems testing (IST) where required

I/OInputs, outputs, scaling, polarity and device states checked against drawings.

SequencesOperating transitions and control authority verified with installed equipment.

Failure modesTrips, unavailable equipment, lost communications and abnormal states tested safely.

CoordinationClient, contractor and vendor interfaces managed around an agreed test plan.

Recovery & closeout

Fault finding followed through to controlled handover

Where a project is already live or stalled, TBC can structure the investigation, identify the fault or interface issue, implement agreed changes and update the affected drawings, software and records for final handover.

Structured fault finding and diagnostic review
Site software or drawing modifications
Defect lists, retesting and acceptance closeout
As-built software, drawings and test records

InvestigationLogs, I/O, communications and sequences reviewed against intended operation.

ModificationChanges controlled rather than applied as undocumented site fixes.

RetestAffected functions re-proved after correction.

HandoverFinal software and drawings reflect the accepted installed condition.

Related engineering

Testing is where the separate engineering disciplines have to work as one system.

FAT and SAT expose gaps between the functional requirement, drawings, PLC logic, operator interface and third-party equipment. TBC uses the agreed design baseline to prove those interfaces and control the changes that follow.

Functional designAcceptance criteria and failure scenarios defined before the test procedure is written.

PLC engineeringSoftware simulation, sequence proving and controlled modification during closeout.

Electrical & control designI/O, schematics and field interfaces checked against the installed system.

Control systems integrationInterfaces between PLC, SCADA, electrical controls and third-party equipment proved through coordinated operating and failure scenarios.

Need a control system properly tested before or during site delivery?

Share the current FDS, drawings, software status and programme and TBC can build the test plan around the functions and interfaces that actually need proving.

Discuss a project