Bringing Plants to Life: Process Plant Commissioning and Start-Up Training Course

Introduction

The transition from a constructed process plant to a fully operational facility is a critical and complex phase known as commissioning and start-up (CSU). This period is fraught with potential risks, as equipment is tested, systems are integrated, and processes are brought online for the first time with hazardous materials. A meticulously planned and flawlessly executed CSU phase is paramount for ensuring the plant's safety, reliability, and efficient performance, directly impacting project timelines, budgets, and long-term operational success.

This intensive training course is meticulously designed to equip participants with a comprehensive and practical understanding of process plant commissioning and start-up. From exploring the fundamental principles of pre-commissioning and system testing to mastering various start-up methodologies, performance verification, and troubleshooting techniques, you will gain the expertise to manage this critical project phase effectively. This empowers you to mitigate risks, optimize start-up schedules, ensure operational readiness, and strategically contribute to the safe, efficient, and successful handover of new or upgraded process facilities.

Target Audience

  • Commissioning and Start-Up Engineers.
  • Process Engineers and Chemical Engineers.
  • Operations Managers and Supervisors.
  • Project Engineers and Project Managers.
  • Mechanical, Electrical, and Instrumentation Engineers.
  • HSE (Health, Safety, and Environment) Professionals.
  • Technical Staff and Operators involved in New Plant Operations.
  • Quality Assurance and Control Personnel.

Duration: 10 days

Course Objectives

Upon completion of this training course, participants will be able to:

  • Understand the overall process and phases of commissioning and start-up (CSU).
  • Grasp the importance of meticulous planning and preparation for CSU.
  • Analyze various pre-commissioning activities and their objectives.
  • Comprehend different start-up methodologies for process units.
  • Evaluate performance testing and verification procedures.
  • Develop practical skills in troubleshooting common CSU problems.
  • Navigate safety and environmental considerations during CSU.
  • Formulate robust strategies for managing CSU projects effectively and ensuring operational readiness.

Course Content

  1. Introduction to Commissioning and Start-Up (CSU)
  • Definition of commissioning, start-up, and handover.
  • Importance of CSU in the project lifecycle.
  • Key objectives of CSU: safety, reliability, performance, schedule, budget.
  • Roles and responsibilities of the CSU team.
  • Overview of the CSU workflow and interfaces with construction and operations.
  1. CSU Planning and Organization
  • Developing the CSU philosophy and strategy.
  • Master CSU schedule and detailed activity planning.
  • Resource planning: personnel, equipment, spare parts, consumables.
  • Development of CSU procedures and checklists.
  • Risk assessment and contingency planning for CSU.
  1. Pre-Commissioning Activities
  • Mechanical completion verification and punch listing.
  • Leak testing (hydrotesting, pneumatic testing) of piping and equipment.
  • Flushing and cleaning of systems (water flushing, chemical cleaning, air blowing).
  • Drying and inerting of systems (air drying, nitrogen purging).
  • Instrument calibration and loop checking.
  1. System Turnover and Ready for Commissioning (RFC)
  • Definition of System Turnover Packages (STP).
  • Mechanical Completion (MC) and Ready For Commissioning (RFC) milestones.
  • Documentation requirements for turnover.
  • Walkdowns and punch list management.
  • Ensuring systems are ready for introduction of utilities and feed.
  1. Commissioning of Utilities and Sub-Systems
  • Commissioning of electrical systems: power distribution, motor control centers.
  • Commissioning of instrumentation and control systems (DCS, ESD, F&G).
  • Commissioning of utility systems: steam, cooling water, instrument air, nitrogen.
  • Commissioning of safety systems: emergency shutdown (ESD), fire & gas (F&G).
  • Ensuring all non-process systems are fully functional.
  1. Initial Start-Up Procedures
  • Developing detailed start-up procedures for individual units and the entire plant.
  • Introduction of inert gas (nitrogen purging).
  • Introduction of feed and gradual increase in flow and temperature.
  • Line-up verification and valve positioning.
  • Managing start-up transients and upsets.
  1. Performance Testing and Optimization
  • Performance testing protocols: guaranteed performance tests.
  • Material and energy balance verification.
  • Product quality testing and specification compliance.
  • Troubleshooting during performance testing.
  • Optimization of operating parameters to achieve design capacity and efficiency.
  1. Troubleshooting During CSU
  • Common problems encountered during commissioning and start-up (e.g., equipment malfunction, control issues, leaks).
  • Systematic troubleshooting methodology: data collection, analysis, hypothesis, testing, resolution.
  • Root cause analysis (RCA) for CSU incidents.
  • Communication and coordination during troubleshooting.
  • Learning from CSU challenges.
  1. Safety, Health, and Environmental (HSE) Management in CSU
  • Specific HSE risks during CSU: fire, explosion, toxic release, confined space, lockout/tagout.
  • Pre-Startup Safety Reviews (PSSR).
  • Emergency preparedness and response planning for CSU.
  • Permit-to-work system implementation.
  • Environmental monitoring during CSU.
  1. Handover to Operations and Post-Start-Up Activities
  • Definition of Handover and Provisional Acceptance.
  • Documentation handover: operating manuals, maintenance procedures, as-builts.
  • Operator training and competency assessment.
  • Post-start-up performance monitoring and debottlenecking.
  • Continuous improvement and lessons learned from CSU.

CERTIFICATION

  • Upon successful completion of this training, participants will be issued with Macskills Training and Development Institute Certificate

TRAINING VENUE

  • Training will be held at Macskills Training Centre. We also tailor make the training upon request at different locations across the world.

AIRPORT PICK UP AND ACCOMMODATION

  • Airport pick up and accommodation is arranged upon request

TERMS OF PAYMENT

Payment should be made to Macskills Development Institute bank account before the start of the training and receipts sent to info@macskillsdevelopment.com

For More Details call: +254-114-087-180

 

 

 

 bringing Plants To Life: Process Plant Commissioning And Start-up Training Course in Nepal
Dates Fees Location Action