2023Finished
Balongan EWTP controls & instrumentation
Panels, PLC, HMI/SCADA, instrumentation and testing
- Year
- 2023
- Location
- Jawa Barat
- Status
- Finished
- Citia's role
- Control and instrumentation work within a project package
- Work types
- Panel, PLC
- Updated
The EWTP work package includes control panels, field devices, PLC and visualization integration, with wiring, loop checks, functional testing and commissioning. Configuration records, test results and field coordination connect engineering work to system operating readiness.
Overview
The Balongan EWTP (Effluent Water Treatment Plant) project improves the reliability and efficiency of the wastewater treatment system by modernizing the instrumentation, electrical, and automation systems. It covers installation, integration, and testing of the control system, so that wastewater treatment runs optimally and meets operational requirements and environmental quality standards.
The scope covers control panel installation, installation and configuration of field instruments, integration of PLC, HMI, and SCADA, cabling, loop checking, I/O testing, functional testing, Site Acceptance Test (SAT), and commissioning, until the system is ready for reliable operation.
Challenges
The work was done in a facility that stayed in operation, so close coordination was needed to avoid process disturbance.
Integrating new instruments and control systems with the existing system required verifying device and communication compatibility.
Commissioning time was limited to the shutdown or maintenance window schedule.
Instrument reading accuracy and control system reliability had to be assured before handover.
All work had to meet HSSE requirements and work permits in the refinery operating area.
Solutions
Preparing a structured implementation and commissioning plan together with the operations team, the maintenance team, and the contractors.
Carrying out installation inspection, instrument calibration, loop checks, I/O tests, and communication verification before the system was energized.
Running functional tests in stages to confirm that all interlocks, alarms, and control logic work as designed.
Troubleshooting and adjusting system parameters based on the field test results.
Applying HSSE procedures consistently through Permit to Work (PTW), Job Safety Analysis (JSA), toolbox meetings, use of PPE, and supervision during the work.
Lessons learned
Planning and coordination across disciplines from the start helped reduce delays and rework.
Verifying wiring, PLC/SCADA configuration, and instrument calibration before commissioning speeds up system startup.
Test results, final configuration, and as-built drawings must be updated regularly to support operation and maintenance.
Thorough testing of every instrument, alarm, and interlock improves system reliability and reduces the chance of operating faults.
A consistent HSSE culture was the main factor in finishing the project safely, with good quality, and on schedule.
A similar need?
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Name the equipment you run and what has to change. We reply with the questions we would ask on site.