Banjarbakula

Overview

The IPA II Banjarbakula project is part of the development of the Banjarbakula Regional Drinking Water Supply System (SPAM). Its aim is to increase the capacity and reliability of clean water supply for the Banjarbakula area, South Kalimantan. The project covers construction and integration of the mechanical, electrical, instrumentation and automation systems that support a safe, efficient and sustainable water treatment process.

The scope of work includes installation of control panels, power distribution, field instrumentation, PLC, SCADA, communication networks, cabling and device configuration. It also includes loop checking, functional testing, Site Acceptance Test (SAT), commissioning, and verification of system performance before handover to the user. All work followed the technical specifications, quality standards and Health, Safety, Security, and Environment (HSSE) requirements.

Challenges

• Work had to be coordinated across several disciplines (civil, mechanical, electrical and instrumentation), so schedules needed close synchronisation.

• Communication had to be integrated between PLC, SCADA and instrumentation devices from different vendors.

• Instrument parameters had to be adjusted so that the data was accurate and stable.

• Testing had to follow the operational schedule, which limited the time available for commissioning.

• All installations had to meet quality, work safety and technical requirements before the system went into operation.

Solutions

• The team held regular coordination with all parties to align work schedules and resolve problems in the field.

• A full installation check (pre-commissioning) was done before system testing started.

• Loop checks, I/O tests and functional tests were done in stages to confirm that all signals, interlocks, alarms and system communication work correctly.

• Instruments were reconfigured, calibrated and tuned based on the field test results.

• HSSE procedures were applied consistently through toolbox meetings, Permit to Work (PTW), Job Safety Analysis (JSA), use of personal protective equipment (PPE), and supervision of work during commissioning.

Lessons learned

• Cross-discipline coordination from the planning stage keeps the project running smoothly and reduces rework.

• Verifying the design, wiring and device configuration before energizing reduces troubleshooting time during commissioning.

• Test results, configuration changes and as-built drawings must be updated regularly so that future maintenance is easier.

• Systematic FAT, SAT and commissioning make the system more reliable and speed up project handover.

• A consistent HSSE culture keeps personnel safe, protects company assets, and lets the project finish without significant incidents.