In mining, utilities, and heavy industrial environments, the final stages of a project are often the most critical.

After months, or even years, of design, procurement, and construction, there is strong pressure to bring systems online and begin operations.

Automation systems are typically among the last components to be commissioned. PLC and HMI systems must integrate with installed equipment, interface with existing infrastructure, and support safe and reliable operation from day one. At this stage, delays or unexpected issues can directly impact startup schedules and production targets.

Unplanned downtime in industrial operations can cost thousands to hundreds of thousands of dollars per hour, depending on the facility (Deloitte). This places significant pressure on commissioning to deliver a reliable startup from day one.

Effective commissioning is not achieved through speed alone. It requires planning, coordination, and a structured approach that begins well before arriving on site.

Why Commissioning Matters

Commissioning connects construction to operation. Timelines are tight, expectations are high, and any delays can directly affect production.
PLC and HMI systems sit at the center of this transition, bringing together equipment, control logic, and operator interaction. In practice, a significant portion of system issues are often first identified during commissioning, when systems are tested under real operating conditions rather than in isolation.

Late-stage integration and commissioning are widely recognized as common sources of project delays, particularly when system readiness has not been fully validated in advance (PMI).

A common challenge is accelerating commissioning to meet schedule demands. While the intent is to move quickly, insufficient preparation often leads to extended troubleshooting, rework, and unplanned downtime.

Building a Structured Approach to Commissioning

The difference between a smooth startup and a delayed one is rarely system complexity. It is preparation.

PLC logic, HMI interfaces, and system interactions can be developed and tested in simulation prior to site work. This allows interlocks, sequences, alarms, and operator workflows to be validated early, reducing the amount of troubleshooting required during commissioning.

Digital simulation and validation approaches have been shown to reduce commissioning time and improve startup performance by identifying issues before deployment (McKinsey & Company). Industry studies have consistently shown that issues identified later in the project lifecycle require significantly more effort to resolve than those addressed during design or pre-commissioning (NIST).

Pre-commissioning and simulation can significantly reduce on-site troubleshooting and shorten commissioning timelines by validating system behavior before arriving on site.

This approach was applied at the Rainy River Mine, where a fresh air fan system supporting underground development was fully validated in advance using simulation that replicated both normal and abnormal operating conditions. Interlocks, alarms, and automatic sequences were confirmed prior to site work, allowing commissioning to focus on verification rather than full system debugging.

When systems arrive in a known state, commissioning shifts from reactive debugging to structured validation.

Managing Complexity in Brownfield Environments

In brownfield environments, new systems must often be integrated alongside live processes. This adds complexity and limits available downtime.

Running new systems in parallel with existing infrastructure allows operators to become familiar with updated controls while maintaining production. Testing can be staged, and cutovers executed in a controlled manner, reducing operational risk.

Successful commissioning in these environments depends on control, coordination, and a clear understanding of both legacy and new systems.

Integration and Operator Readiness

Successful commissioning goes beyond proving that a system functions. It includes validating communication between systems, confirming alarm and control functionality, and ensuring that operator interfaces are clear and usable.

Operator readiness is equally important. Training, documentation, and commissioning reports support the transition to independent operation. When operators are confident in the system, the handover is smoother and post-startup support is reduced.

At Rainy River, this extended beyond commissioning into operator readiness. Training materials, alarm response guidance, and operating procedures were developed alongside system delivery, supporting a more confident transition into operation and long-term use of the system.

Where Commissioning Challenges Arise

Automation commissioning is often treated as the final step in a long project. By this stage, installation is complete, schedules are compressed, and expectations are high.

As a result, commissioning inherits project constraints. Limited time, shifting priorities, and incomplete information can lead to issues being discovered during startup rather than earlier, when they are easier to resolve.

Commissioning also depends on alignment across automation, electrical, mechanical, and operations teams. Without this coordination, delays can occur due to equipment readiness, access limitations, or differing expectations.

What Changes When Commissioning Is Done Effectively

With proper preparation, commissioning becomes structured rather than reactive. Systems are tested in sequence, issues are addressed efficiently, and startup becomes more predictable.

Validating logic and interfaces ahead of time allows projects to move more directly into stable operation rather than extended troubleshooting.

A structured approach also improves alignment across teams. Clear plans define when systems will be tested, what is required, and how issues will be addressed.

Operators are introduced to systems in a controlled way, supported by training and documentation. This builds confidence earlier and reduces reliance on commissioning teams after startup.

Applying This Approach in Practice

This same approach is being applied at the Island Gold Mine, where a water handling facility control system is currently in development.

The system integrates multiple vendor packages into a unified PLC and HMI platform, with a strong focus on standardization, interlocks, and long-term maintainability. A key objective has been to validate system functionality in advance through pre-commissioning, allowing control logic, safety interlocks, and system behaviour to be confirmed before arriving on site.

The system has already been tested through simulation and has successfully passed factory acceptance testing, reducing uncertainty ahead of site commissioning and supporting a more efficient transition into operation.

While commissioning is still ongoing, this reflects a consistent focus on preparation, validation, and reducing field risk.

From Startup to Stable Operations

In industrial projects, the final push to startup carries significant pressure. Commissioning can either introduce delays or enable a controlled transition into operation.

Successful commissioning is built on preparation. When PLC and HMI systems are developed and tested before site arrival, on-site work becomes more focused, predictable, and aligned with operational needs.

A structured approach does more than support startup. It improves handover quality, builds operator confidence, and creates a stronger foundation for long-term performance.

For mining and industrial operations, effective commissioning is what turns startup pressure into seamless operation.

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Prepared in collaboration with Adam Farrow