Introduction

Process plant start-up and commissioning are critical phases in the lifecycle of industrial facilities, ensuring that systems are installed correctly, operate safely, and meet design performance requirements. Proper planning and execution of commissioning activities minimize risks, reduce delays, and ensure a smooth transition from construction to full operation.

This program, designed by Global Horizon Training Center, equips participants with the knowledge and practical skills required to plan, execute, and manage start-up and commissioning activities effectively in process plants.

Course Objectives

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

• Understand the phases of plant commissioning and start-up
• Develop commissioning plans and procedures
• Perform pre-commissioning and commissioning activities
• Ensure system readiness and performance validation
• Manage safety and risk during start-up operations
• Coordinate multidisciplinary teams and stakeholders
• Troubleshoot operational issues during start-up
• Ensure compliance with design and regulatory requirements

Target Audience

This program is designed for:

• Process and Chemical Engineers
• Commissioning and Start-up Engineers
• Project and Operations Engineers
• Maintenance and Reliability Engineers
• HSE and Safety Professionals
• Technical personnel involved in plant operations

Outline

Day 1: Fundamentals of Commissioning and Start-up

• Overview of commissioning phases (pre-commissioning, commissioning, start-up)
• Roles and responsibilities of commissioning teams
• Project handover from construction to operations
• Documentation and checklists
• Safety considerations and planning

Day 2: Pre-Commissioning Activities

• Mechanical completion and system verification
• Cleaning, flushing, and drying systems
• Equipment inspection and testing
• Instrumentation and control system checks
• Preparing for commissioning

Day 3: Commissioning Procedures and Execution

• Functional testing of systems and equipment
• Energization and system integration
• Calibration and control system tuning
• Performance testing and validation
• Troubleshooting during commissioning

Day 4: Plant Start-up and Operational Readiness

• Start-up planning and sequencing
• Operating procedures and control strategies
• Managing risks during start-up
• Process stabilization and optimization
• Handover to operations

Day 5: Performance Optimization and Case Studies

• Monitoring plant performance
• Identifying and resolving operational issues
• Continuous improvement strategies
• Lessons learned and best practices
• Case studies and real-world applications