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Loop Checks, Calibration, Commissioning and FAT/SAT–Backed by ISA-105 Standards
Reliability and performance in the process industries depend on how well your automation systems are tested, calibrated and commissioned. ISA-105 provides the framework to do just that by offering comprehensive guidance through the standards and recommended practices developed for factory acceptance esting (FAT), site acceptance testing (SAT), site integration testing (SIT), loop checks and calibration programs.
ANSI/ISA-62381-2011 (IEC 62381 Modified), Automation Systems in the Process Industry - Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT)
This standard provides a structured methodology for conducting FAT, SAT and SIT in the process industries. It supports comprehensive testing of automation systems, starting with validation at the vendor’s site and continuing through full integration on location, before startup.
Highlights include:
Pre-test planning, execution procedures and readiness checks
Punch list tracking and defined completion criteria
Detailed checklists covering documentation, hardware, software, operator interfaces and communication paths
Clear roles and collaboration between owners, vendors and contractors to promote consistency and accountability
This standard helps streamline testing practices to reduce risk and support successful system deployment.
Note: FAT/SAT does not cover loop checks, commissioning or manufacturing execution system (MES) testing.
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ANSI/ISA-62382-2012 (IEC 62382 Modified), Automation Systems in the Process Industry – Electrical and Instrumentation Loop Check
This standard provides guidance for verifying the integrity of electrical and instrumentation loops after installation and before cold commissioning. It applies to both new plant construction and revamp projects, maintaining proper signal flow and loop functionality across:
Field devices and control panels
PLC, DCS, BAS and other control systems
Related infrastructure connecting the field to the automation system
It helps verify that each control loop is wired and functioning correctly, an essential step before system startup.
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ISA-RP105.00.01-2017, Management of a Calibration Program for Industrial Automation and Control Systems
This recommended practice provides a structured approach to developing and maintaining effective calibration programs for industrial automation and control systems (IACS). It offers practical guidance to help organizations maintain accuracy, reliability and compliance across their instrumentation.
Key areas covered include:
Building a quality-driven calibration framework
Calibrating control loops based on required process accuracy
Supporting safety instrumented systems with proper documentation and adjustment procedures
A well-managed calibration program is essential for maintaining system integrity and operational consistency over time.
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Why the ISA-105 Standards and Recommended Practices Matter
The ISA-105 standards and recommended practices provide tools and methodologies to help organizations optimize their automation systems’ performance, mitigate risks, comply with regulations and ultimately achieve smoother operations and better results.
Risk Reduction: By following these standards and recommended practices, companies can identify and address potential issues early in the testing and commissioning phases, minimizing the risk of system failures during operation. This helps avoid costly repairs, production delays and safety incidents.
System Integrity and Performance: The standards guide organizations in thoroughly validating automation systems to make sure they function as intended, meeting performance and operational goals. Proper loop checks, calibration and testing are essential to confirm that each part of the system works correctly.
Compliance: Adhering to recognized standards helps maintain compliance with industry regulations and safety requirements. This is important for avoiding penalties and maintaining a good reputation within the industry.
Consistency and Accountability: These standards create clear roles and procedures for all stakeholders (owners, vendors, contractors), promoting consistent practices across projects. This helps everyone involved to be accountable for their part in the testing and commissioning process.
Operational Efficiency: The structured approach to FAT, SAT and calibration programs streamlines the commissioning process, saving time and resources. Effective testing and calibration programs also contribute to smoother system startups and operational continuity.
Long-Term Reliability: A well-executed calibration and testing program supports the long-term reliability of automation systems. Regular calibration helps instruments and controls maintain their accuracy over time, which is crucial for sustaining operational consistency and efficiency.
Meet the Experts Behind the Standards: ISA105 Committee
The ISA105 committee develops and coordinates standards and recommended practices that support the commissioning and verification of industrial automation systems. This includes guidance on commissioning - instrumentation, control and electrical systems to confirm they function as intended from installation through startup. The committee also focuses on procedures for instrumentation and electrical loop checks, helping to validate system integrity and performance. In addition, ISA105 provides best practices and standardized approaches for conducting FAT, SAT and SIT, which are essential steps in verifying that systems meet design specifications and are ready for operational deployment. View current ISA105 committee members.
Ready to Make an Impact? Join a global network of industry professionals driving innovation and best practices in control valve systems. Apply Now to Join the ISA105 Committee!
For additional information, please get in touch with the ISA standards team!
*Does not apply to ISA standards that are identical IEC adoptions
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