Process Plant Start-up and Commissioning

Overview

The start-up and commissioning of a new process plant or a major modification is one of the most demanding phases in the life of a facility. Mechanical completion, pre-commissioning, commissioning and initial start-up must be carefully planned and executed to bring equipment safely into service and reach stable production quickly. Many serious incidents happen during start-up, and poor preparation leads to delays, damaged equipment, extended flaring and costly rework. A structured approach, clear responsibilities and well-trained teams are essential to achieve a safe, efficient and timely handover from construction to operations.

This course provides a practical understanding of how to plan and carry out the start-up and commissioning of process plants in oil, gas, refining and petrochemical industries. Participants learn the commissioning sequence from mechanical completion through pre-commissioning, commissioning and performance testing, and the use of systems and subsystems to manage the work. The course covers flushing, cleaning, pressure testing, drying, inerting and leak testing, the commissioning of utilities, rotating equipment, instruments and control systems, and the introduction of hydrocarbons. It also explains start-up procedures, pre-start-up safety reviews, risk management, documentation, punch lists and the handover to operations.

Objectives

• Explain the phases from mechanical completion to performance testing
• Plan commissioning using systems, subsystems and clear responsibilities
• Apply flushing, cleaning, pressure testing, drying and inerting methods
• Commission utilities, rotating equipment, instruments and control systems
• Prepare and execute safe start-up procedures and hydrocarbon introduction
• Conduct pre-start-up safety reviews and manage start-up risks
• Manage documentation, punch lists and the handover to operations

Who should attend

Training methodology

The course follows the commissioning sequence step by step, combining explanation with real commissioning plans, procedures, checklists and system boundary drawings. Participants divide a plant into systems, prepare commissioning sequences, review flushing and pressure test plans and draft a start-up procedure for a process unit. Pre-start-up safety review checklists and punch list examples are used in practical exercises. Case studies of start-up incidents and delayed projects are analysed in groups to identify lessons. Each day ends with a short quiz and discussion of commissioning experience from participants' own projects.

Programme outline

Dates and fees

Certificate

Frequently asked questions