Commissioning Manager

Job responsibilities:

• Commissioning Planning & Execution: Develop commissioning strategy, system-wise plans, procedures, checklists, schedules and protocols, coordinate with Civil, Mechanical, Electrical and Instrumentation work Completion, Pre-Commissioning, Commissioning, Start-up, Trial Run, Performance Testing and Handover, Preparing and Closer of punch point lists, risks and daily progress. Coordination with Vendors Bioprocess Team and other stakeholders Familiar with line sizing calculations, Heat Exchanger sizing Line, Pressure Drop Calculation
• Paddy / Biomass Feed System: Commission and verify alignment, lubrication, guards, rotation, interlocks, emergency stops, levels and material flow.
• Mixing, Agitation System and Transfer / Recirculation Pumps: Commission mixing tanks and agitators, pumps, suction/discharge readiness, priming, rotation, flow, pressure, motor load, vibration and cavitation/leakage issues. check alignment, shaft, gearbox, coupling, lubrication, mechanical seal, rotation, vibration, temperature, motor current and operating interlocks.
• Digesters & Biogas Balloon: Verify digester readiness, internals, agitators, slurry/gas piping, pressure/vacuum protection. supervise gas balloon installation, anchoring, connections, integrity/leak checks and initial filling/start-up and interlocks.
• SLS Screw Press & Decanter: Commission pretreatment, filtration, cooling, moisture/H2S removal, compression and membrane skid, verify valves, instruments, analyzers, control logic, gas quality, methane recovery and CO2 removal.
• High-Pressure Compressor CBG Filling/Dispensing: Commission CBG compressors and verify alignment, lubrication, cooling, instrumentation, trips, alarms and permissive and interlocks commission high-pressure cascade storage and interfaces. High-pressure piping, valves, hoses, pressure controls, filling sequence, ESD/interlocks and leak testing; support safe CBG filling trials and Gas Detection system and testing.
• Fire Hydrant / Fire Protection: Commission firewater tank, hydrant network, electric/diesel/jockey pumps and associated systems, verify auto/manual operation, pressure, flow, alarms and emergency interfaces and complet fore water network and Loop checking of FDA (Fire detection alarm) system.
• Electrical, Instrumentation & Control Commissioning: Review SLDs, load schedules and cable schedules, HT/LT system, transformers, MCC/PCC, motors, VFDs, DG, UPS, earthing and lightning protection, verify IR, phase sequence, rotation, protection and interlock. P&IDs, instrument index, I/O list, control philosophy, cause & effect and loop diagrams, instrument calibration, loop checks, PLC/SCADA logic, alarms, trips, permissive, ESD and communications.
• PFD / P&ID / Drawings: Interpret PFD, P&ID, equipment layouts, piping GAs/isometrics, utility diagrams, loop diagrams, cause & effect, control narratives and vendor drawings and equipment SOP, Manuels.
• Civil Interface: Basic understanding of foundations, RCC structures, equipment levels, anchor bolts, pipe racks/supports, drainage, trenches, platforms and civil readiness constraints.
• Piping & Mechanical Readiness: Review piping isometrics, verify supports, valves, strainers, drains, vents, expansion joints and equipment connection, hydro/pneumatic testing, flushing, air blowing, cleaning and leak testing.
• Pre-Commissioning: Manage mechanical completion checks, lubrication, alignment, electrical tests, calibration, loop checking, flushing, pressure testing, valve functional checks, energization, PLC/SCADA readiness and dry/no-load trials.
• Documentation: Prepare/review commissioning procedures, checklists, punch point lists, inspection/test reports, calibration certificates, loop checks, motor/equipment trial reports, interlock tests, performance reports and handover.
• Safety & Statutory Compliance: Ensure PTW, LOTO, gas safety, electrical safety, confined-space and HSE requirements, verify methane/H2S controls, gas detection, ESD and applicable statutory inspections before high-pressure gas operation.
• Vendor & Contractor Management: Coordinate OEM/vendor engineers, commissioning procedures, technical issues, contractors, spares, special tools, consumables, manuals, performance testing and vendor recommendations.
• Performance Testing & Stabilization: Lead plant start-up and stabilization, monitor biogas production, methane purity/recovery, CO2/H2S, CBG pressure, compressor performance, energy/feedstock consumption and digestate separation, troubleshoot bottlenecks.
• Team Management: Lead multidisciplinary Mechanical, Electrical, Instrumentation, Piping, Process, Civil and Operations, allocate work, conduct toolbox talks/meetings and coordinate Project, Construction, QA/QC, HSE and O&M teams.

Technical Skills:

• Hands-on commissioning, PFD/P&ID mechanical equipment, electrical systems and motor commissioning, instrumentation, PLC/SCADA, interlock, piping isometrics, basic civil drawings, pressure testing, flushing, leak testing, troubleshooting, commissioning protocols, HSE/PTW.

• Paddy/biomass feed systems, anaerobic digesters, agitators, slurry pumps, SLS screw press, decanters, biogas balloons/gas holders, flaring unit, desulfurization, membrane upgrading, HP CBG compressors, cascade storage, CBG filling, firewater systems, PLC/SCADA, gas analyzers.

• Leadership, multidisciplinary coordination, hands-on troubleshooting, analytical/problem solving, drawing interpretation, communication; schedule/deadline management, safety mindset, vendor/contractor management, site independence, reporting/documentation.

Minimum Qualification & Experience:

• B.E./B.Tech/Diploma in Mechanical, Electrical, Instrumentation, Chemical or related engineering discipline.

• Preferably 10 years in commissioning, start-up or project execution of process plants, CBG, waste-to-energy, anaerobic digestion, gas processing or similar experience preferred.

Key Performance Indicators (KPIs)

• Commissioning completed within approved project schedule.

• Safe commissioning with zero major safety incidents.

• Timely closure of commissioning punch points.

• Achievement of plant capacity and performance parameters with required CBG quality/specification.

• Equipment reliability during trial operation.

• Successful performance guarantee testing.

• Effective vendor and contractor coordination.

• Complete and accurate commissioning documentation.