Introduction

Start-up and commissioning are among the most critical phases in the lifecycle of a process plant. They ensure that systems are installed correctly, operate as intended, and meet performance, safety, and regulatory requirements before full production begins. Poorly executed commissioning can lead to delays, safety incidents, and costly rework.

This program, designed by Global Horizon Training Center, equips participants with structured methodologies, practical tools, and best practices to plan, execute, and manage start-up and commissioning activities safely and efficiently.

Course Objectives

By the end of this program, participants will be able to:

• Understand the phases of commissioning and start-up
• Develop commissioning plans and procedures
• Execute pre-commissioning and commissioning activities
• Coordinate multidisciplinary teams during start-up
• Verify system readiness and performance
• Identify and resolve start-up issues
• Ensure compliance with safety and operational standards
• Achieve smooth transition to normal operations

Target Audience

This program is designed for:

• Process and Chemical Engineers
• Commissioning and Start-up Engineers
• Project and Construction Engineers
• Operations and Maintenance Personnel
• HSE and Quality Professionals
• Oil & Gas and Industrial Project Teams

Outline

Day 1: Fundamentals of Commissioning and Start-up

• Overview of commissioning phases (pre-commissioning, commissioning, start-up)
• Roles and responsibilities
• Project handover and readiness
• Commissioning documentation
• Safety fundamentals

Day 2: Pre-Commissioning Activities

• Mechanical completion and system handover
• Cleaning, flushing, and drying
• Leak testing and pressure testing
• Instrument calibration and loop checking
• Verification of installation

Day 3: Commissioning of Systems and Equipment

• Static and dynamic commissioning
• Equipment testing (pumps, compressors, valves)
• Control systems and instrumentation commissioning
• Utilities and support systems
• Troubleshooting during commissioning

Day 4: Plant Start-up and Operational Readiness

• Start-up procedures and sequencing
• Initial operation and stabilization
• Monitoring process parameters
• Managing deviations and risks
• Safety and emergency response

Day 5: Performance Testing and Handover

• Performance testing and acceptance criteria
• Optimization during start-up
• Documentation and reporting
• Lessons learned and best practices
• Final handover to operations