Installation & Commissioning
From the truck to first production cycle — site installation, hot-oil flushing to defined ISO 4406 targets, pressure and leak testing, controls validation, and signed handover with full documentation.
Most HPU Failures Trace to Commissioning
A correctly designed and manufactured HPU still fails early if the site piping is dirty, the fluid is not flushed to spec, or the controls are not properly validated under load. Commissioning is not a checklist exercise — it is the difference between a system that runs for ten years and one that needs intervention in the first six months.
Our commissioning engineers carry calibrated instruments, ISO-certified cleanliness reference samples, and pressure test pumps. Every commissioning closes with a fluid sample analysed to ISO 4406 in our Cuttack laboratory and a certificate stating the actual cleanliness achieved before the system is released to production.
Commissioning Scope
- Mechanical installation supervision
- Pipe-work flushing to ISO 4406 Class 17/15/12
- Initial fluid fill and de-aeration
- Hydrostatic and pneumatic pressure tests
- Pump rotation, prime, and pressure setting
- Valve setting (relief, sequence, reducing, proportional)
- Cylinder stroke and cushion adjustment
- Controls and interlock validation
- Functional testing under no-load and load conditions
- Final fluid sample and cleanliness certificate
- Signed handover document and as-built drawings
Commissioning Sequence
Pre-Installation Survey
Verify site readiness — power, water, drains, foundation, ambient conditions, lifting equipment access.
Mechanical Installation
HPU placement, alignment, pipe and hose connection, cylinder mounting, electrical termination.
Hot-Oil Flushing
Loop flushing with high-velocity heated fluid through 3-micron offline filtration until ISO 4406 cleanliness target is met.
Pressure & Leak Test
System pressure-tested to 1.5x working pressure, held for documented duration, all joints inspected.
Functional Testing
Sequential operation of all valves, cylinders, and accumulators verified against the control narrative.
SAT & Handover
Site Acceptance Test executed jointly with customer. Handover dossier issued, training delivered if scoped.
Handover Documentation
Test Records
Pressure test certificate, flushing log with cleanliness measurements, valve setting record, pump performance curve.
As-Built Drawings
Marked-up schematic and P&ID reflecting any field changes. Final electrical and control drawings.
O&M Manual
Component data sheets, service intervals, recommended spares list, troubleshooting guide, and emergency contact register.