When construction ends and commissioning begins, the workforce balance changes sharply. Mechanical and civil crews leave, and much of the remaining work falls on electrical and instrumentation specialists: energizing switchgear, testing protection relays, checking thousands of loops, proving interlocks and supporting control system integration. If the E&I commissioning workforce is short or underqualified, systems queue for testing while the rest of the team waits. Planning the electrical and instrumentation workforce for commissioning is the subject below, for commissioning managers, E&I leads and workforce planners.
How the overall commissioning team is sized and timed is covered in how to build a commissioning workforce plan, and sourcing commissioning specialists in technical staffing for commissioning and startup teams. Here the focus is the E&I side.
What E&I roles does commissioning need?
| Role | Main responsibility |
|---|---|
| E&I commissioning engineers | Plan and lead electrical and instrumentation commissioning by system |
| Electrical commissioning technicians | Energization, switchgear testing, motor solo runs |
| Protection relay testers | Secondary injection testing and relay setting verification |
| Instrument commissioning technicians | Calibration checks, loop checks, valve stroking |
| Control system specialists | DCS and PLC integration, interlock and sequence testing |
| Safety system specialists | Testing safety instrumented functions and fire and gas systems |
| Vendor representatives | Package controls, switchgear and analyzer commissioning |
Sizing loop check teams
Loop checks are usually the largest E&I commissioning workload. The team size depends on:
- Loop count per system and the turnover sequence
- Loop complexity, since a simple transmitter loop takes far less time than a control valve or interlock loop
- Team structure, commonly two people per loop team, one in the field and one at the console
- Shift pattern, since round-the-clock loop checking halves the calendar time but doubles supervision needs
- Defect rate, because faults found during loop checks slow progress
Planning by system, starting with utilities, keeps loop teams working on systems that commissioning needs first. The checks themselves are described in pre-commissioning checks for E&I systems.
Electrical commissioning specifics
Electrical commissioning includes energizing substations and switchgear, verifying protection settings, solo-running motors and testing UPS and emergency power. Each energization is a controlled event under an approved switching program and electrical permit system, so electrical commissioning teams need authorized persons with the right competence.
Common E and I commissioning bottlenecks
- Too few loop check teams for the turnover rate
- Protection relay testers available only on certain days
- Control system specialists tied up with configuration changes
- Vendor representatives booked for dates the systems cannot meet
- Faults from construction found late, slowing every loop
Test equipment matters too
Commissioning teams need calibrated loop calibrators, multifunction testers, relay test sets and radios for every team. A shortage of test equipment can idle a qualified team as surely as a shortage of people, so plan equipment numbers alongside headcount.
Shift coverage and continuity
Commissioning often moves to round-the-clock work as startup approaches. Plan E&I coverage on every shift, with clear handovers of loop status, open faults and permits. Losing continuity between shifts is a common source of repeated work. A shared loop status board, updated at the end of every shift, keeps day and night teams working from the same picture.
Verifying competency
Commissioning E&I roles demand proven experience as well as trade certificates. Verify:
- Systems and equipment the candidate has commissioned
- Hands-on experience with the control system used on the project
- Protection relay testing experience and test equipment familiarity
- Safety system testing under bypass and authorization procedures
- References from commissioning managers
Transferring construction technicians
Construction E&I technicians who installed the systems can move into commissioning roles and bring useful knowledge, provided their competence matches the commissioning role. Plan these transfers before construction demobilization, as discussed in the overall instrument technician role.
E&I commissioning workforce from Apex Core Engineering
Apex Core Engineering supplies E&I commissioning engineers, technicians and loop check teams through its skilled manpower supply service and supports commissioning through its project support services, with candidates assessed against the systems and roles required.
Frequently asked questions
Why is E&I so central to commissioning?
Because commissioning energizes systems and proves controls, alarms and trips, which are electrical and instrumentation activities.
How many people are in a loop check team?
Commonly two, one at the field device and one at the control system console, communicating by radio.
Who can energize equipment during commissioning?
Only authorized persons working under the project’s electrical safety rules and an approved switching program.
Can construction technicians join the commissioning team?
Yes, if they meet the competency requirements, and their system knowledge is valuable.
Staff your E and I commissioning team with Apex Core Engineering.