Phase 4: Project Execution & Handover
Step 12: Commissioning & Performance Trials
Executing water trials, wet commissioning, and final performance guarantee sign-offs.
1. Pre-Commissioning & Water Trials
Before introducing any biological feedstock or chemicals, the plant must undergo rigorous mechanical and electrical checks:
- Hydrotesting: Pressure testing of all piping networks, distillation columns, and pressure vessels.
- Electrical & Instrumentation (E&I) Checks: Loop checking, calibration of control valves, sensors, and safety interlocks.
- Water Runs: Flushing lines and testing pumps, cooling towers, and the water treatment plant using raw/treated water to verify flow rates and leak-tightness.
2. Wet Commissioning & Performance Guarantee Tests
Once pre-commissioning clearance is signed off by the PMC and Lender's Independent Engineer (LIE), wet commissioning begins:
| Test Phase | Objective & Verification Standard |
|---|---|
| Milling & Liquefaction | Test maize milling and slurry preparation with enzyme addition and gelatinization. |
| Fermentation Trial | Yeast propagation and batch fermentation tracking conversion efficiency and cycle times. |
| Distillation & Dehydration | Production of rectified spirit and anhydrous ethanol via molecular sieve unit (99.9% purity). |
| Continuous Guarantee Run | 72-hour continuous operation test measuring actual yield (litres/MT grain) and utility consumption (steam/power per litre) against vendor guarantees. |
3. Critical Financial Link & Payment Hold Directive
Vendor Payment Hold Directive
Do not release final vendor payments until these guarantees are formally verified on-site. Strict adherence to this milestone protects capital efficiency and ensures all output, yield, and utility specifications are fully satisfied before account closure and commercial handover.