COMMISSIONING & STARTUP SERVICES
Professional Commissioning untuk Ensure Safe & Reliable Startup
Systematic commissioning service dari pre-commissioning checks hingga performance verification. Ensure equipment & system ready untuk operation dengan proper testing, calibration, dan operator training.
Commissioning Services Scope
Witanabe provide comprehensive commissioning services untuk mechanical, electrical, instrumentation, dan control system
Mechanical Commissioning
Pump, compressor, agitator, conveyor – alignment check, lubrication, rotation check, vibration baseline
Electrical Commissioning
Panel testing, motor meg test, cable continuity, grounding verification, protection relay setting
I&C Commissioning
Instrument calibration, loop check, control logic testing, interlock verification, SCADA integration
Commissioning Phases & Activities
Commissioning dilakukan secara systematic dengan clear milestone untuk ensure quality & safety di setiap tahap
Pre-Commissioning Phase
- Document review: P&ID, loop diagrams, SLD, O&M manual, test procedure
- Physical inspection: Equipment installation, piping installation, electrical termination
- Mechanical checks: Alignment, lubrication, coupling gap, rotation direction
- Electrical checks: Meg test, continuity test, grounding, phase rotation
- Instrument checks: Calibration certificates, loop continuity, valve stroking
- Cleaning & flushing: Piping cleaning, chemical cleaning (if needed), filter installation
- Leak testing: Hydro test, pneumatic test sesuai P&ID requirement
Commissioning & Startup
- Control system check: PLC logic verification, HMI functional test, alarm check
- Interlock testing: Safety interlock, sequence logic, emergency shutdown test
- Individual equipment test: No-load test, bump test, initial startup
- System startup: Sequential startup, process parameter monitoring, adjustment
- Performance testing: Flow, pressure, temperature, vibration measurement vs design
- Load test: Full load operation, efficiency verification, stability test
- Operator training: Normal operation, startup/shutdown procedure, troubleshooting
Testing & Performance Verification
Functional Tests
- Pump performance: Flow, head, power vs pump curve verification
- Vibration test: Baseline vibration measurement, acceptance criteria per ISO 20816
- Heat exchanger: Heat duty, LMTD, approach temperature, pressure drop
- Control valve: Stroking test, control response, fail-safe position verification
- Safety devices: PSV set pressure, rupture disc, flame arrestor, fire detection
Performance Acceptance Criteria
- Mechanical: ≥95% design capacity, vibration within ISO limit, temperature normal
- Process: Product quality spec met, yield per design, stable operation 24+ hours
- Efficiency: Energy consumption vs design, utility usage verification
- Instrumentation: Accuracy ±1% span, control stability, alarm function
- Safety: All interlocks functional, emergency procedure tested, no safety deviation
Commissioning Deliverables & Documentation
Test Reports
Hydro test, meg test, alignment, vibration, performance test – dengan actual vs design comparison
Checklists
Pre-commissioning checklist, commissioning checklist, punch list dengan completion status
System Data
Instrument calibration data, control loop tuning parameters, setpoint configuration
Handover Certificate
System handover certificate, acceptance protocol, warranty activation, training record
Mengapa Professional Commissioning Penting?
Safety Assurance
Verify semua safety device & interlock functional sebelum production start – prevent accident & injury
Performance Guarantee
Ensure equipment meet design specification & performance guarantee – avoid rework & claim dispute
Avoid Costly Downtime
Detect & fix issue during commissioning phase – prevent production loss & unplanned shutdown
Butuh Commissioning Support?
Diskusikan commissioning requirement Anda dengan tim kami. Kami provide systematic commissioning service dengan experienced engineer & technician.
Phone: +62 857-8096-1572 | Email: commissioning@witanabe.com