Test & Commissioning

Pre-site, on-site, and integrated. Designed test plans, witness reports, calibrated instruments.

The factory acceptance test (FAT), site acceptance test (SAT) and integrated system test (IST) together form the only objective verification that the system performs as designed. We engineer those tests as carefully as we engineer the system itself — because a flawed test plan can pass a flawed installation.

ES4PS test and commissioning work uses calibrated, certified instruments (current revision certificates), follows ISO 8528-5 and NFPA 110 procedures, and produces reports that survive future audits.

What we do

Pre-site (Factory Acceptance Test — FAT)

• Test-plan development before manufacturing starts (so the design is testable)
• Witness testing at the manufacturer (we attend on the customer’s behalf)
• Block-load step testing (ISO 8528-5 G-class verification)
• Performance verification against rated specifications
• Documentation: photographic record + measured value vs spec

On-site (Site Acceptance Test — SAT)

• Pre-energisation checklist (cable terminations, earthing, instrumentation, safety lockouts)
• Insulation resistance + dielectric withstand testing
• Function testing of controls (start sequence, transfer, sync, shutdown)
• Load testing — resistive load bank to rated capacity
• Site noise survey vs design prediction

Integrated System Test (IST)

• Full system test against the documented commissioning plan
• ATS transfer (open / closed / soft) per topology
• Multi-unit synchronisation + load sharing
• Black-start sequence (utility loss → genset start → load pickup)
• Fault-injection testing (where customer permits) — protection coordination verification

Independent third-party witness

We are often engaged not to commission a system we designed, but to witness a third party’s commissioning on behalf of the customer:

• Independent verification that the OE / EPC’s commissioning plan is sufficient
• Witness-style observation with our own checklist
• Independent commissioning report
• Punch-list with traceable severity grading

This is one of our most-requested services in MENA — customers want a second pair of expert eyes on an OE / EPC commissioning where the commercial pressure to “pass” is strong.

Calibrated instruments — non-negotiable

Every test we do uses calibrated, certified instruments. Calibration certificates are within current revision. Instrument list is in the FAT / SAT report. This is fundamental for any test to be defensible at a later audit.

• Power-quality analyser (Class A per IEC 61000-4-30)
• Sound-level meter (Class 1 per IEC 61672)
• Vibration meter (per ISO 10816)
• Temperature & humidity loggers
• Resistive + reactive load banks (with calibration cert)

Standards we apply

• ISO 8528-5 — transient (block-load) performance class G1 / G2 / G3 / G4
• ISO 8528-6 — performance test methods
• NFPA 110 Chapter 8 — periodic test + maintenance methods (US emergency power)
• NETA ATS — Acceptance Testing Specifications (US electrical)
• IEEE 1547 — interconnection testing (where applicable)
• ASHRAE Guideline 0 — commissioning process
• ASHRAE Guideline 1.1 — HVAC&R technical requirements
• Uptime Institute Tier Standard — Tier I-IV commissioning levels
• IEC 60068 — environmental testing methods

Typical engagements

• FAT supervision at manufacturer — 1–3 days on-site at the factory
• SAT execution — 3–7 days on customer site
• IST + commissioning — 1–3 weeks (depending on system complexity)
• Independent witness — variable, per the OE / EPC’s plan
• Commissioning audit — review of existing third-party commissioning records (1–2 weeks)

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