Introduction

Start-up and commissioning are high-risk, high-impact phases in the lifecycle of any process plant. They require rigorous planning, precise execution, and rapid troubleshooting to ensure safe operation, achieve design performance, and transition smoothly to steady-state production.

This advanced 10-day program, designed by Global Horizon Training Center, equips participants with structured methodologies, detailed procedures, and real-world techniques to manage commissioning, execute start-up, and troubleshoot complex process and equipment issues effectively.

Course Objectives

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

• Plan and manage commissioning and start-up activities end-to-end
• Execute pre-commissioning tasks and verify system readiness
• Commission equipment, utilities, and control systems
• Apply safe and efficient start-up procedures
• Diagnose and troubleshoot process, mechanical, and control issues
• Perform root cause analysis (RCA) and implement corrective actions
• Optimize plant performance during early operation
• Ensure compliance with safety, quality, and operational standards

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: Commissioning Fundamentals and Project Integration

• Commissioning lifecycle and phases
• Roles, responsibilities, and interfaces
• Systemization and turnover philosophy
• Mechanical Completion (MC), Ready for Commissioning (RFC)
• Documentation and planning

Day 2: Commissioning Planning and Documentation

• Commissioning strategies and execution plans
• Checklists, procedures, and punch lists
• Commissioning schedules and resource planning
• Risk assessment and safety planning
• Quality assurance and compliance

Day 3: Pre-Commissioning Activities – Mechanical Systems

• Cleaning, flushing, and blowing
• Drying and preservation
• Hydrostatic and pneumatic testing
• Leak detection and rectification
• Reinstatement procedures

Day 4: Pre-Commissioning Activities – Electrical & Instrumentation

• Electrical testing and energization
• Cable testing and insulation checks
• Instrument calibration and loop checking
• Control system verification (I/O checks)
• Safety system testing

Day 5: Commissioning of Equipment and Utilities

• Static and dynamic commissioning
• Pumps, compressors, and rotating equipment
• Boilers, heat exchangers, and process units
• Utilities (steam, water, air, power)
• Functional testing

Day 6: Control Systems and Automation

• DCS/PLC commissioning
• Control loops and tuning basics
• Interlocks and safety systems (ESD, SIS)
• Cause & effect verification
• Troubleshooting control issues

Day 7: Start-up Planning and Execution

• Start-up philosophy and sequencing
• System line-up and readiness checks
• Initial operation procedures
• Monitoring key process parameters
• Managing deviations and risks

Day 8: Advanced Troubleshooting Techniques

• Identifying process deviations
• Equipment troubleshooting (pumps, compressors, valves)
• Heat transfer and flow issues
• Instrumentation and control problems
• Data-driven diagnostics

Day 9: Root Cause Analysis and Optimization

• RCA methodologies (5 Whys, Fishbone, FMEA)
• Failure analysis and reporting
• Corrective and preventive actions
• Performance optimization strategies
• Early operation improvements

Day 10: Performance Testing, Handover, and Best Practices

• Performance testing and acceptance criteria
• System optimization and stabilization
• Documentation and handover to operations
• Lessons learned and best practices
• Case studies and final assessment