Commissioning & Startup Services
Bringing industrial process equipment online reliably — from first I/O checkout through functional testing, loop tuning, and operator sign-off. Deep expertise in combustion systems, thermal processing, and environmental equipment.
What We Do
Commissioning is where engineering meets reality. We systematically verify every signal, every interlock, and every sequence before handing over to your operations team. If you're preparing for startup, our guides on TO vs. RTO selection and destruction efficiency provide useful background on system choice and performance targets:
I/O Checkout & Verification
Point-by-point verification of every digital and analog I/O channel against wiring drawings and instrument lists.
Loop Testing & PID Tuning
End-to-end loop verification from sensor to controller to final element, with PID tuning for stable process control.
Point-to-Point Testing
Verify signal paths from field devices through junction boxes, marshaling cabinets, and into the control system.
Sequence Verification
Step-by-step validation of automated sequences, interlocks, and safety shutdowns under controlled conditions.
Factory Acceptance Testing (FAT)
Pre-shipment testing at the panel shop to validate hardware, wiring, and software before installation on-site.
Site Acceptance Testing (SAT)
On-site functional testing after installation to confirm the integrated system meets specification requirements.
Deliverables
You don't just get a running system — you get the documentation and training your team needs to own it. Many startups follow our PLC programming work — particularly for thermal oxidizer and RTO systems — and connect to compliance data systems for long-term reporting:
As-Built Documentation
Updated drawings, I/O lists, and program backups reflecting the actual installed system
Test Reports
Comprehensive I/O checkout sheets, loop test records, and sequence verification logs
Operator Training
Hands-on training for your operations and maintenance teams on the new system
Punch List Resolution
Systematic tracking and closeout of all outstanding items before final handover
Ongoing Remote Support
Post-startup remote assistance for troubleshooting, optimizations, and program changes
Our Process
A structured commissioning methodology ensures nothing gets missed and your startup stays on schedule:
Pre-Commissioning Planning
Review drawings, I/O lists, and specifications. Develop test procedures and schedules before arriving on-site.
I/O Verification
Systematic checkout of every input and output — digital, analog, and network-connected devices.
Loop Tuning
Calibrate transmitters, tune PID loops, and verify control valve response for stable process performance.
Sequence Testing
Run every automated sequence under controlled conditions. Verify interlocks, safety shutdowns, and alarm responses.
Acceptance Sign-Off
Formal FAT/SAT testing with your team. Document results, resolve punch list items, and obtain sign-off.
Handover & Training
Deliver as-built documentation, train operators and maintenance staff, and establish remote support access.