COMMIS S I ON IN G

POWER PLANT
COMMISSIONING ITU APA SIH ?
COMMISSIONING ITU ADALAH SUATU AKTIFITAS PENGUJIAN DAN TEST
KEHANDALAN SUATU SYSTEM PADA SUATU PLANT YANG SUDAH SELESAI PROSES
KONSTRUKSINYA. HAL INI DILAKUKAN SEBELUM PLANT TERSEBUT DI OPERASIKAN
KAN ATAU DISERAH TERIMAKAN KE OWNER SEBAGAI PEMILIK PLANT.
SYSTEM DI POWER PLANT YANG WAJIB DIKETAHUI ADALAH :

• BALANCE OF PLANT (BOP) SYSTEM

• BOILER SYSTEM
• TURBINE AND GENERATOR SYSTEM
• COAL HANDLING SYSTEM
• ASH HANDLING SYSTEM
• FLU GAS SYSTEM
ADA SIKLUS APA SAJA SIH YG ADA DI POWER PLANT

• WATER SYSTEM
• FUEL OIL SYSTEM
• STEAM SYSTEM
• FLUE GAS SYSTEM
• AIR SYSTEM
• LUBE OIL SYSTEM
• ASH HANDLING SYSTEM
• COAL HANDLING SYSTEM
• COMPRESSION AIR SYSTEM
• FIRE PROTECTION SYSTEM
TAHAPAN POKOK KONSTRUKSI

• ENGINEERING : DESIGN DRAWING, PROPOSE, REVIEW, FOR CONSTRUCTION

• PROCUREMENT : PURCHASE ALL MATERIAL & EQUIPMENT AS PER DESIGN DRAWING & BQ
• CONSTRUCTION : INSTALLATION, INSPECTION & TEST
• COMMISSIONING : INDIVIDUAL TEST, PRECOMMISSIONING & COMMISSIONING
TAHAPAN TAHAPAN PENTING DALAM KONSTRUKSI PEMBANGKIT
(MILESTONE AT POWER PLANT)

•KICK OF MEETING •LOAD REJECTION

•FIRST COLUMN •STEAM BLOWING
•LIFTING OF STEAM DRUM •SYNCHRONE
•BOILER HYDROSTATIC TEST •LOAD TEST
•BOILER CHEMICAL CLEANING •RELIABILITY RUN TEST
•FIRST FIRING •PERFORMANCE TEST
•COD
TAHAPAN COMMISSIONING
• TOP (TURN OF PACKAGE) FINISH
• ERECTION COMPLETION CERTIFICATE (ECC) WITH ECC WALKDOWN
• MECHANICAL COMPLETION CERTIFICATE (MCC) WITH MCC WALKDOWN
• SAFETY REGULATION COMPLETION CERTIFICATE (SRCC) WITH SRCC WALKDOWN
• INDIVIDUAL TEST : SOLORUNS TEST, HYDROTEST PIPE, WATER FILLING TANK, END CLOSURE PRESSURE
VESSEL

• PRE COMMISSIONING : TEST AS PER SUB SYSTEM

• COMMISSIONING : TEST PER SYSTEM
DOKUMEN APA SAJA YG HARUS DISIAPKAN SEBELUM COMMISSIONING :
• ORGANIZATION CHART DAN GARIS KOMANDO YG JELAS BESERTA JOB DESCRIPTIONYA
• TURN OF PACKAGE (TOP) : DRAWING, INSPECTION REPORT, TEST REPORT, NDE REPORT, CALIBRATION REPORT, ETC
• DRAWING : ARRANGEMENT DRAWING, ISOMETRIC DRAWING, P&ID, FLOW DIAGRAM PROCESS, SINGLE LINE DIAGRAM.
• FAT (FACTORY ACCEPTANCE TEST)
• SCHEDULE FOR COMMISSIONING
• MDR (MANUFACTURING DATA REPORT) / MANUAL BOOK
• SPECIFICATION & LINE DESIGNATION LIST
• COMMISSIONING PROCEDURE
• DOCUMENT CONTRACT
• SAFETY REGULATION : JSA, PERMIT, SRCC, ETC.
• FORMS / REPORT TEST (DILAMPIRAN)
ALAT UKUR DAN ALAT KERJA

• TACHO METER
• GUN THEMPERATURE
• NOISE LEVEL
• VIBRO METER
• FILLER GOUGE
• MEASUREMENT TAPE
• MIRROR
• DIAL INDICATOR
• WELDING MACHINE
• GRINDING MACHINE
• CHAIN BLOCK, LEVER BLOCK
• HAND TOOLS
ALAT UKUR UNTUK ELECTRICAL

• VOLTAGE TESTER
• AMPERE METER
• FREKUENSI METER
• OHM METER
• HV TEST HIPOT
• INSULATION TESTING
• CT RASIO
• ETC.
SATUAN UKURAN

• VIBRASI = VIBRATION METER = SATUANNYA CPS (CYCLES PER

SECOND) ATAU HERTZ MAX 7 HERTZ

•  THEMPERATURE = GUN THEMPERATURE = SATUANYA DERAJAT

CELCIUS 75 DERAJAT CELCIUS

• NOISE = NOISE LEVEL = NOISE LEVEL METER = SATUANNYA DBA

(DESIBEL EKUIVALEN)  KEP- 51/MEN/1999, TENTANG
NILAI AMBANG BATAS (NAB) KEBISINGAN DI TEMPAT KERJA,
DITETAPKAN SEBESAR 85 DBA.

• RPM = TACHOMETER = SATUANYA RPM (ROTASION PER MINUTE)

SIAPA SAJA YG TERLIBAT DALAM PROSES
COMMISSIONING

•PROJECT MANAGER
•COMMISSIONING MANAGER
•COMMISSIONING ENGINEER
•COMMISSIONING SUPERVISOR
•SKILL TECHNICIAN
•DOCUMENT CONTROL
STANDARD & CODE
STANDARD
& CODE
JOB DESCRIPTION COMMISSIONING ENGINEER
• TO INSPECT AND VERIFY BOTH MECHANICAL AND ELECTRICAL INSTALLATION DONE BY CONTRACTOR AT SITE.
• RESPONSIBLE FOR ENSURING THAT ALL MECHANICAL AND ROTATING EQUIPMENT PACKAGES ARE DESIGNED, PROCURED,
CONSTRUCTED, TESTED, INSTALLED, AND COMMISSIONED IN ACCORDANCE WITH COMPANY TECHNICAL REQUIREMENTS AND
SPECIFICATIONS

• REVIEW DESIGN, REQUISITIONS , SPECIFICATIONS, BID LISTS, VENDOR QUOTATIONS/BIDS (ENSURE THAT ALL EQUIPMENT ARE IN
ACCORDANCE WITH THE INSTALLATION DOCUMENT ABOVE) BE COMMISSIONING.

• ENSURE THE INSTALLATION IS INSTALLED CORRECTLY TO COMPLY WITH THE COMMISSION ABILITY
• PREPARE ERECTION CLEARANCE CECRTIFICATE AS PER CLIENT BOUNDARY PACKAGE
• COORDINATE WITH TEAM THAT THE SYSTEM CAN BE COMMISSIONING
• ENSURING THE SAFE TESTING AND COMMISSIONING OF COMPLETED INSTALLATIONS TO ACHIEVE THE NECESSARY PLANT
PERFORMANCE IN ACCORDANCE WITH PROJECT REQUIREMENTS

• MANAGES THE PLANNING AND EXECUTION COMMISSIONING

• LEAD THE SITE COMMISSIONING ACTIVITIES FOR ROTATING EQUIPMENT.
JOB DESCRIPTION COMMISSIONING ENGINEER

• LEAD COMMISSIONING TEAM IN TIMELY REVIEWING COMMISSIONING PROCEDURES.

• MANAGE AND COORDINATE THE TRAINING PROGRAMS FOR COMMISSIONING ACTIVITIES.
• MANAGE, CREATE AND MAINTAIN RAPPORT WITH PERSONNEL (OPERATIONS, PMT, ETC) AND OTHER STAKEHOLDERS.
• MANAGE THE SAFETY PROGRAM DURING COMMISSIONING & START UP PHASE AND INVOLVE IN COMMISSIONING
SAFETY DOCUMENT DEVELOPMENT E.G. JOB SAFETY ANALYSIS (JSA).

• SUPERVISE AND MENTOR THE COMMISSIONING

• ASSIST DURING SITE INSPECTION BY GOVERNMENT BODIES, PLANT OWNERS AND CONTRACTORS.
• RESPONSIBLE TO ENSURE ORGANIZATION SAFETY, HEALTH & ENVIRONMENT REQUIREMENTS ARE BEEN ADHERED
AT SITE.

• REPORTING TO COMMISSIONING MANAGER AND ASSIST DEPARTMENT TO DELIVER PRE-COMMISSIONING AND

COMMISSIONING START UP ACTIVITIES FOR THE PROJECT.
INDIVIDUAL TEST INI ADALAH HAL YG PERTAMA KALI DI KERJAKAN DI SITE :

SETELAH DI CHECK DAN DIRASA SEMUA DOCUMENT SUDAH LENGKAP, KITA AKAN MULAI PELAKSANAAN
COMMISSIONING DARI INDIVIDUAL TEST , CONTOH NYA :
SOLORUN TEST MOTOR OLEH ELECTRICAL TEAM
LEAK TEST , FLUSHING AND BLOWING AT PIPING
WATER FILLING STORAGE TANK
END CLOSURE PRESSURE VESSEL
DUCTING LEAK TEST
ETC.

INI MASIH SCOPE PEKERJAAN COSNTRUCTION

PELAKSANAAN PRECOMMISSIONING PADA POMPA

SETELAH POMPA MELALUI PROSES FINAL ALIGNMENT COUPLING SETELAH SOLO RUNS TEST, POMPA AKAN DI
COUPLE COPLINGNYA DAN DI LAKUKAN LOAD RUN TEST YAITU DIOPERASIKAN DI BERI BEBAN ALIRAN AIR
ATAU MINYAK PADA JALUR PIPA.
HTTPS://YOUTU.BE/VOZSIQYX2EE
• LOAD RUN TEST PUMP ADALAH SUATU KEGIATAN UNTUK MENGUJI KEHANDALAN DAN KEKUATAN POMPA DENGAN MEMBERI BEBAN PADA POMPA DENGAN CARA DI
OPERASIKAN DALAM JANGKA WAKTU TERTENTU DAN DI CHECK VIBRASI, THEMPERATUR, NOISE DAN RPM NYA.

• VIBRASI = VIBRATION METER = SATUANNYA CPS (CYCLES PER SECOND) ATAU HERTZ

• THEMPERATURE = GUN THEMPERATURE = SATUANYA DERAJAT CELCIUS

• NOISE = NOISE LEVEL = NOISE LEVEL METER = SATUANNYA DBA (DESIBEL EKUVALEN)  KEP- 51/MEN/1999, TENTANG NILAI AMBANG BATAS (NAB) KEBISINGAN DI
TEMPAT KERJA, DITETAPKAN SEBESAR 85 DBA.

• RPM = TACHOMETER = SATUANYA RPM (ROTASI PER MINUTE

PENGUKURAN VIBRASI PADA POMPA
POMPA CENTRIFUGAL
 VIBRO METER

LOAD RUN TEST PUMP

GUN THEMPERATURE

NOISE LEVEL

TACHO METER
NAH… MARI KITA MENCOBA SIMULASI UNTUK COMMISSIONING WATER
TREATMENT PLANT UNTUK MEMBUAT DEMINERALIZED WATER
YANG HARUS KITA SIAPKAN ADALAH :
JSA & WORK PERMIT
FLOW DIAGRAM PROCESS & ARRANGEMENT DRAWING
PIPING & INSTRUMEN DIAGRAM
SPECIFICATION
PIPE DESIGNATION LINE
SPECIFICATION OF EQUIPMENT ; KITA CARI BQ NYA DAN MDR NYA
SIAPKAN MANPOWER, TOOLS, MEASUREMENT TOOLS, FORM ATAU ISIAN UNTUK MERECORD HASIL TEST
FLOW DIAGRAM PROCESS

DEMINERALIZATION PLANT SYSTEM

• ADALAH SEBUAH PROSES

PENGHILANGAN KADAR GARAM
DAN MINERAL DALAM AIR MELALUI
PROSES PERTUKARAN ION ( ION
EXCHANGE PROCESS ) DENGAN
MENGGUNAKAN MEDIA
RESIN/SOFTENER ANION DAN
KATIONSUATU SYST
DEMINERALIZED WATER
• PURPOSE IS TO PRODUCE DEMINERALIZED WATER FOR PROCESS WATER
USE

• MAKE UP WATER TO BOILERS, HEATERS, ETC.

Treated Water Quality
DEMINERALIZATION MAIN COMPONENTS 1 :
• BWRO CARTRIDGE FILTER (2 X 100%)
• BWRO HP FEED PUMP (2 X 100%)
• BRWO MODULES (2 X 100%)
• BWRO PERMEATE TANK (1 X 100%)
• CATION EXCHANGER (2 X 100%)
• ANION EXCHANGER (2 X 100%)
• MIXED BED EXCHANGER (2 X 100%)
• DEMINERALIZED STORAGE TANK (2 X 100%)
• DEMINERALIZED START-UP PUMP, LOW (1 X 100%)
• DEMINERALIZED START-UP PUMP, HIGH (1 X 100%)
• DEMINERALIZED MAKE-UP PUMP (2 X 100%)
Demineralization main components 2 :

• 2 X 100% BWRO SUPPLY PUMPS

• CARTRIDGE FILTER RATED AT 5 MICRON PRECEDES BWRO MODULES
• BWRO HP PUMP PRESSURIZES WATER FOR BWRO MODULES
• BWRO VESSELS ARE 8-IN DIAMETER, EACH CONTAINING 7 SPIRAL-WOUND POLYAMIDE
MEMBRANES
PIPING & INSTRUMENT DIAGRAM (P&ID)
PROCESS FLOW DIAGRAM

• ATTACHED OTHER FILE

PRODUCTIVITY DEMIN WATER

•2 X 100% MIXED BED EXCHANGERS

•DESIGNED FOR 30 DAY SERVICE CYCLE
•NET PRODUCTION PER CYCLE OF 49,320 M3 (70
M3/HR X 720 HOURS)
• REGENERATION PROCESS FOR ANION/CATION EXCHANGER:
A. COMPACTION: LIFTS BED
B. CHEMICAL INJECTION: 31% HCL DILUTED TO 4% FOR ANION EXCHANGER, 30% NAOH
DILUTED TO 4% FOR CATION EXCHANGER
C. SLOW RINSE: DEMIN WATER FLOWS IN SAME DIRECTION AS CHEMICAL DILUTION
D. SETTLING: FINES SETTLE TO TOP AS RESIN BED FALLS
E. FAST RINSE: SERVICE FLOW RATE RINSE TO REMOVE TRACES OF CHEMICALS
• MIXED BED REGENERATION PROCESS:
A. BACKWASH: SEPARATES CATION AND ANION RESINS
B. SETTLE: RESINS SETTLE AND SEPARATE
C. CHEMICAL INJECTION: DILUTE HCL INJECTED FROM BOTTOM OF
EXCHANGER, DILUTE NAOH FROM TOP
D. SLOW RINSE: DILUTION WATER PASSED THROUGH EXCHANGER IN
SAME DIRECTION AS REGENERANTS
E. DRAIN DOWN: WATER DRAINED TO 2-4 INCHES ABOVE RESIN LEVEL
F. AIR MIX 1 AND 2: RESINS MIXED USING BLOWER AIR
G. REFILL: EXCHANGER FILLED WITH WATER USING CAUSTIC DILUTION
LINE
H. FINAL RINSE: RINSE TO REQUIRED WATER QUALITY
MEMULAI COMMISSIONING
• JANGAN LUPA BACA PROCEDURENYA DULU SEBELUM COMMISSIONING
• TOOLS BOX MEETING
• PASTIKAN WORK PERMIT SUDAH ADA
• PASTIKAN JSA NYA SUDAH ADA
• PASTIKAN INTERLOCK, PROTEKSI DAN PEKERJAAN ELECTRICAL SUDAH OK
• LINE CHECK UNTUK MEMASTIKAN SYSTEM BERJALAN DENGAN BAIK
• SIAPKAN FORM UNTUK MERECORD HASIL COMMISSIONING
• CHECK LIST NYA DISIAPKAN MINTA SAYA COMMISSIONING ENGINEER
• KOORDINASI ANTAR LINI MECHANICAL & ELECTRICAL
• KOORDINASI ANTAR ENGINEER, DCS OPERATOR, TEKNISI DAN SUPERVISOR
• MULAI DI LAKUKAN TEST
MENCATAT HASIL

• PADA POMPA CHECK VIBRASI, THEMPERATURE, NOISE DAN RPM NYA SESUAI FORM DAN CHECK LIST YG
SDH DIBERIKAN ENGINEER COMMISSIONING PER PERIODE YG SDH ADA DI FORM

• PASTIKAN LINE PIPINGNYA TIDAK ADA KEBOCORAN

• PASTIKAN VALVE NYA TIDAK RUSAK ATAU TIDAK RETAK
• CHECK LOAD FLOW ALIRAN FLUIDA DIDALAMNYA SESUAIKAN DENGAN SPECIFIKASI YG ADA DI P&ID
• CHECK SPECIFIKASI KADAR AIR SESUAI SPECIFIKASI
• BUAT LAPORAN AKHIR HASIL UJI UNTUK DI SIGN OLEH OWNER / MAINCON