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Commissioning services

Rambutan Automation coordinates activities with the owner, engineering, procurement and construction to organize the activity sequencing for a quick start-up.

 

Projects which are well engineered, constructed, and thoroughly pre-operationally tested, are quickly commissioned on load and begin production and ramp-up to design throughput in the shortest possible time.

a multi-tier approach

 

Each project has a detailed planning which includes scoping of systems, developing test plans, and providing an integrated commissioning schedule that drives construction completion and provides our clients a rapid ramp up.

 

Our internal quality software system handle all project phases, keeping under control all documentation, management, organization, scheduling, tracking, reports on testing as well as QA/QC.

Tier 1
zero energy condition testing, examining the equipment while in a non-energized state

 

this includes all electrical, instrumentation and communication parts:

 

  • point-to-point, continuity testing and fiber termination testing

  • IR (Megger) testing

  • static motor rotation testing

 

Rambutan Automation is able to complete these deliverables safely and track live progress, ensure safe testing of equipment, develop a detailed test matrix during the planning phase.

 

Using our library of standard check sheets compiled from project experience we ensure the delivery of highest quality product and make sure that equipment/systems are ready for pre-operational testing.

 

We track live progress, produce handover packages and punch lists inclusive of causes, categories, priorities, discipline, date of completion and so on.

 

Once inspection and testing of each piece of equipment is completed for a scoped system and approved by the commissioning manager, the equipment and associated documentation can be transferred to the next phase, where tier 2 takes part.

 

Tier 2
energized equipment, pre-operational static tests 

 

Rambutan Automation commissioning teams inspect each piece of equipment to make sure it is safely energized and tested in accordance with the approved test matrix.

 

Tier 2 tests performed by Rambutan Automation include:

 

  • motor bump and rotation tests including extended uncoupled motor runs as well as setup and/or VFDs tests.

  • testing of digital and analog inputs/outputs from field and electrical rooms to the control room

  • communication test among control rooms, field communication panels, remote I/O, PLCs & relays and telemetry systems/devices.

  • configuration and calibration of instrumentation

 

Rambutan Automation will develop a tried and proven execution plan tailored to the client’s specific project needs: the use of our library of test sheets, inspection sheets and safety & test procedures enable thorough and complete testing of equipment by our experienced team of test engineers.

 

All these test well documented are part of the QA/QC book released to the customer at the end of the commissioning.

 

Tier 3
energized systems, dynamic and functional equipment tests with inert material

 

this tier level is focused on testing of the control logic features and a complete test of the system with water or inert material in order to reach steady-state operation.

 

This phase validate the system functional description (testing of start/stop sequences, manual operations, semi-automatic  sequencies and automatic sequencies), interlocks. 

 

Morover a tuning of control loop as well as an eventual signal filtering take part in this phase, bringing plant to steady-state operation.

 

During this commissioning phase, various equipment such as conveyor, pumps, walking beam, etc... etc... run unloaded or however tested with intert material or water.

 

This phase will test also all safety functional specification and logic. In fact safety areas of the plant are now functional.

 

Vendors on site are continually managed to support the commissioning of specialty equipment and facilitate warranty sign-off.

 

Operators and maintenance personnel embedded in the pre-operational testing team take an increased responsibility in the testing program to prepare for a smooth handover.

 

A successiful completion of this tier ensures that the plant will be able to safely handle process material: systems are handed over to the operations team who will first introduce process material during the next tier level.

 

Tier 4
systems load tested with process material and gradually ramped-up to nameplate capacity

 

in this tier level the plant is charged using the first fill material and processes begin to be tested under loaded conditions in order to identify and resolve potential equipment or design weaknesses. Final adjustments and corrections are made before the ramp-up phase begins.

 

In collaboration with the operational services personnel, Rambutan Automation deals with process upsets, plant bottlenecks, and other complications that can arise when introducing process material for the first time.

 

In this tier level take place an additional  to the previous tier level, here take place an additional tuning of control loops with load, tweaking the control logic (alarms, signal filtering, delays, trips, etc...) as well as protection equipments (i.e. remote smart soft starter, motor relays, etc...).

 

This phase will run the entire facility under load bringing it to a steady state condition.

 

All devices and plant specific procedure, check sheets and test manual are followed; equipment and process are put under stress in order to highlight any weakness or need to re-tune parameters which are effectively, in this phase, strictly monitored by Rambutan Automation personnel.

 

Training of operators continues until they are able to take full control of the plant. Once both plant and operator personnel is able to function with material and the plant begins producing, the plant is rumped-up to namplate capacity.

 

 

 

Rambutan Automation services portfolio
 

  • training personnel

  • management of (pre)commissioning program

  • develop a prioritized commissioning schedule tied to the construction schedule

  • manage progress tracking documentation and issue weekly reports

  • pre-commissioning, and operational services audits to identify gaps and provide realistic estimates of commissioning completion for planning purposes

  • scope P&IDs, single line schematics, and control system drawings to identify commissionable systems

  • plan and manage lock-out /tag-out

  • develop organizational charts and define roles and responsibilities specific to the project

  • provide expert resources to manage and participate in project handover (instrumentation, control logic, electrical, etc...)

  • define and develop procedures for construction, pre-commissioning and commissioning tests

  • define plant performance tests (commissioning assistance to operations)

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