Training Course: Process Plant Start-up and Commissioning

Introduction

Start-up and commissioning are among the most critical phases in any process plant project, marking the transition from construction to full operational performance. Proper execution ensures systems function as designed, meet performance targets, and operate safely and efficiently.

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

Course Objectives

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

• Understand the full commissioning and start-up lifecycle
• Plan and organize commissioning activities effectively
• Execute pre-commissioning and commissioning procedures
• Verify system readiness and performance
• Apply safe start-up practices and sequencing
• Coordinate multidisciplinary teams
• Identify and resolve commissioning issues
• Ensure smooth handover to 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
• Control and Instrumentation Engineers
• HSE and Quality Professionals

Outline

Day 1: Fundamentals of Start-up and Commissioning

• Overview of commissioning phases
• Roles and responsibilities
• Systemization and turnover concepts
• Mechanical Completion (MC) and Ready for Commissioning (RFC)
• Safety considerations

Day 2: Pre-Commissioning Activities

• Cleaning, flushing, and blowing
• Pressure testing (hydrostatic and pneumatic)
• Instrument calibration and loop checking
• Electrical checks and energization
• System verification

Day 3: Commissioning of Equipment and Systems

• Static and dynamic commissioning
• Rotating equipment (pumps, compressors)
• Utilities and support systems
• Control systems and automation
• Functional testing

Day 4: Start-up Execution and Monitoring

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

Day 5: Performance Testing and Handover

• Performance testing and acceptance criteria
• System optimization
• Documentation and reporting
• Handover to operations
• Lessons learned and best practices