Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Operations Engineers
• Commissioning Engineers
• Plant Supervisors
• Maintenance Engineers
• Process Engineers
• Technical Personnel involved in start-up activities

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand commissioning and start-up processes
• Verify plant and system readiness
• Apply safe start-up procedures
• Troubleshoot process and equipment issues
• Validate control and safety systems
• Optimize plant performance and reliability

DAY 1

Process Plant Start-Up and Commissioning Fundamentals

• Process Plant Start-Up Overview
• Plant Systems and Process Readiness
• Pre-Commissioning Activities
• Commissioning Procedures and Practices
• Start-up planning, execution strategy, and risk management
• Mechanical completion, system turnover, and plant readiness verification
• Utility, equipment, instrumentation, and control system readiness
• Cleaning, testing, calibration, loop checking, and equipment verification
• Safe and systematic transition from pre-commissioning to commissioning
   

DAY 2

Plant Start-Up Execution and Operational Readiness 

• Start-Up Preparation
• Utility and Auxiliary Systems Start-Up
• Process Equipment Start-Up
• Control and Safety System Validation
• Start-up sequence development and operational readiness reviews
• Permit-to-work, isolation/LOTO, emergency preparedness, and environmental requirements
• Electrical, steam, compressed air, cooling water, fuel gas, and inert gas start-up
• Pumps, compressors, turbines, heat exchangers, boilers, and fired heater start-up
• DCS, PLC, ESD, SIS, alarms, interlocks, and cause-and-effect validation

DAY 3

Plant Troubleshooting, Optimization, and Performance Verification

• Troubleshooting, Optimization, and Performance Verification
• Troubleshooting Methodology
• Process Troubleshooting
• Equipment and System Troubleshooting
• Plant Performance Optimization and Handover
• Root cause analysis, data collection, process deviation identification, and corrective actions
• Troubleshooting flow, pressure, temperature, level, instrumentation, utilities, and process instability
• Troubleshooting pumps, compressors, heat exchangers, valves, actuators, electrical, and mechanical systems
• Performance testing, capacity, efficiency, energy optimization, reliability, and availability
• Final acceptance, documentation closeout, operational handover, lessons learned, and continuous improvement