Commissioning a treatment plant is a critical process that ensures every component—from individual instruments to entire systems—is functioning as intended before the plant goes live. It involves a series of engineering techniques and procedures that span from construction and assembly to final handover to a qualified operations team.
Done properly, commissioning lays the foundation for long-term success. It ensures your plant operates safely, meets environmental compliance, and delivers consistent performance from day one.
1. Commissioning:
- This is the process of bringing a newly built plant into working order.
- It involves design, delivery, construction, assembly, testing, start-up, operator training, and proof of performance testing.
- The entire process can take 5–6 months or longer, and the full project from design to commissioning may take 18–24 months.
2. Importance of Doing It Right:
- A well-commissioned plant can last 25+ years.
- Poor commissioning can halve the plant’s lifespan, making it a costly mistake.
- Since even small plants cost millions, protecting the investment is critical.
3. Commissioning Team:
- The project team usually involved in commissioning of a plant includes construction firms, process design engineers, water/wastewater specialists, and equipment suppliers.
4. Key Testing Phases:
- Factory Acceptance Testing (FAT): Ensures equipment shipped from the factory is working as expected and that all equipment together is a working system.
- Site Acceptance Testing (SAT): Involves wet testing (pipes, pressure, electrical systems, etc.) once equipment is installed.
5. Start-Up:
- The plant is turned on.
- Settings must be optimized to support biomass/sludge growth.
- If near another town, sludge can be “seeded” from an existing plant. Otherwise, biomass must be grown from scratch, which takes weeks and careful monitoring.
6. Proof of Performance Testing (PoPT):
- Confirms the plant meets its operational targets.
- Typically lasts 2–4 weeks, but can be longer.
- Also includes training local operators to ensure long-term success.
Commissioning in practice
Whether you’re working with a water or sewage treatment plant, commissioning isn’t one-size-fits-all. Each plant type—and its operational history—requires a tailored approach.
Read up on the commissioning journey of a new sewage treatment plant in a remote tropical community:
What does it take to get a sewage or water treatment plant running?
Need help commissioning your plant? Partner with us for expert commissioning support.
