Phase 3: From Factory Floor to First Product
Delivery • On-Site Setup • Commissioning
Phase 3 is where every drawing, weld, and line of code meets reality. It takes the pilot or demonstration plant built in earlier phases and turns it into a live, productive unit on your site—safely, smoothly, and on schedule.
1. Logistics & Delivery — Getting It There Safely
OSVARD applies a “no-surprises” approach to shipping. Skids and vessels are designed to fit standard trucks or containers so most modules travel intact; special-permit routes are secured in advance for any oversized loads. Instruments ride under waterproof covers with shock mounts, and climate-controlled crates protect analyzers that dislike humidity. Our team handles customs, insurance, and real-time tracking—whether the plant is crossing Thailand or an ocean. The result is straightforward: equipment arrives on time, undamaged, and ready for immediate re-assembly.
2. On-Site Setup — “Plug-and-Play” Made Real
Before the first crane lift, an OSVARD supervisor walks the site to confirm foundations are cured, utilities are live, and every permit is signed off. Only then does rigging begin. Skids are lowered into place with millimetre accuracy, flanges are bolted, cable trays connected, and control fibres landed in the DCS cabinet exactly as mapped in the installation plan.
With everything bolted up, the team moves straight into pre-commissioning checks:
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Piping integrity — hydrostatic tests to verify zero leaks.
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Electrical readiness — continuity and insulation tests on every circuit.
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I/O verification — each sensor tag appears in the control system and every valve strokes on command.
Operators shadow these activities, turning routine checks into hands-on training sessions.
3. Commissioning & Startup — Making It Breathe
Commissioning unfolds in four deliberate stages:
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Dry Runs
Motors, pumps, and heaters cycle without process fluids while alarms and interlocks are stress-tested. Safety trips must work before anything hazardous flows. -
Cold Circulation
The plant fills with inert flush liquid. Pumps run at low speed to chase out air pockets, spot vibration issues, and let seals bed in. -
Hot Introduction
Feedstock is admitted at gentle rates, then ramped toward design conditions. Operators fine-tune controller set-points and identify any hidden bottlenecks. -
Performance Trial
A continuous 24-to-72-hour run at nameplate capacity proves the plant hits its quality, yield, and energy targets. Data from this trial becomes the new baseline for future optimisation.
Typical hiccups—an oscillating flow loop, a dribbling valve gland—are fixed on the spot. OSVARD stays until the whole unit runs steady, safe, and within spec.
4. Handover & Training — Ownership with Confidence
Training blends classroom sessions with field walk-downs. Operators rehearse start-up, shutdown, and upset recovery while maintenance staff learn lubrication points, calibration routines, and spare-parts strategy. As-built drawings, control logic, calibration certificates, and SOPs arrive in both print and digital formats.
Finally, OSVARD stages a soft handover: our engineers remain on call—or on site—through the first production campaigns, stepping back only when your crew is comfortable flying solo.
Key Gains for the Client
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Zero-surprise startup thanks to rigorous checks and real-time fixes.
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Faster time to data—rapid commissioning means you begin your R&D trials or early product shipments days, not months, after delivery.
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Team empowerment—operators learn by doing, not merely reading manuals, leaving them confident to tackle future scale-up challenges.
“Build it right, ship it safe, start it smart—then hand the keys to a team that knows the ropes.”
Phase 3 turns a finished plant into a living asset that delivers product—and knowledge—on day one. When you’re ready to launch, OSVARD is ready to lead the way.
