Process Plant Start-up, Commissioning & Troubleshooting

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Venue Starting Date Duration Fees Join Now
Kuala Lumpur - Malaysia , 20240701 01 - Jul - 2024 5 - Day $5,950 Register
Online - Virtual , 20241001 01 - Oct - 2024 2 Hrs X 8 Sessions $2,100 Register
Dubai - UAE , 20241209 09 - Dec - 2024 5 - Day $4,950 Register


Process plant commissioning and start-up refers to both new facilities and restarting an existing plant after major modifications. Commissioning and start-up of new plant and equipment presents both a major technical and management challenge. The initial start-up of any plant, irrespective of size, type, or industry, is a unique occurrence. Therefore, the start-up phase poses some special problems. Lack of experience in dealing with these problems has frequently resulted in prolonged and costly start-ups.

An organization’s personnel must familiarize themselves with the new equipment, processes and technologies, and develop the relevant operating and safety procedures.

Successful commissioning of new facilities involves all the activities of preparation and planning; mechanical completion and integrity checking; P&ID checking and verification; pre-commissioning and operational testing; commissioning; start-up; initial operation; performance testing and acceptance and post-commissioning. It is also imperative that close relations be maintained amongst all parties involved in the project in order to ensure successful.


Upon the successful completion of this seminar, participants will have a good knowledge of:

  • The various activities/steps (check lists) of the pre-commissioning and commissioning of a process
  • How to develop an overall commissioning strategy and plant start-up management
  • How to deal with machinery and equipment specific commissioning issues
  • How to manage issues dealing with the commissioning of Electrical, Instrumentation and Utilities Systems
  • How to develop an overall commissioning management plan, resource planning and commissioning budget?
  • Typical process plant Start up and Commissioning procedures
  • Performance Test, Troubleshooting and Problem Solving Strategies


This training seminar is suitable for a wide range of professionals but will greatly benefit:

  • Technical personnel involved in supporting Plant Commissioning and Start-up activities;
  • Supervisors and Engineers, both operations and maintenance who are involved or likely to be involved in Plant Commissioning and Start-up activities;
  • Team Leaders, Project Managers, Refinery Managers, Plant Managers, Section Heads, Plant Supervisors, Process Engineers, technicians, technical staff and contractor personnel involved in project execution and plant Commissioning and Start-up in the Oil and Gas Process industry;
  • Managers and specialists who lead or facilitate in the designing, selecting, specifying, operating, installing, repairing and trouble-shooting of oil and gas processing facilities;
  • Mechanical, Electrical, Instrumentation and Control Engineers who are involved in Pre-commissioning, start-up and trouble shooting


This highly practical and results-oriented program is based on adult learning concept. The facilitator will give plenty of input and then help participants to make sense of the themes through discussion and practice. It incorporates short inspiring demonstrations, role play and much practice to enhance learning. Delegates will be encouraged to introduce problems of their own for discussion and analysis. There will be ample time for Q&A, discussions with ‘return to work’ action planning. The course will reinforce key concepts within an inspiring and engaging learning environment.

Pre & Post course assessments will be used to measure the effectiveness of this training.


Module 1 - Introduction, Scope & General Requirement

  • KeyTopics:

    • Introduction
    • Scope
    • General Requirements
    • What is commissioning? Why?
    • What is Process Engineering?
    • Different processes in oil and gas
    • What are the stages of a project?
    • When does Commissioning start?
    • What are deliverables?
    • Commissioning management

Module 2 - Preparation Prior to Start-up

  • KeyTopics:

    • Preparation Prior to Start-up
    • Mechanical completion certificates
    • Dry-out and boil-out.
    • Catalyst loading.
    • Tightness test.
    • Leak tests
    • Cleaning and flushing
    • Machinery testing
    • Pre-commissioning procedures (General)

Module 3 - Pre-Commissioning Procedures for Different Disciplines

  • KeyTopics:

    • Process equipment pre-commissioning (Air coolers, heaters, exchanger, columns, …etc.)
    • Piping pre-commissioning (piping system, supports, drainage, …etc.)
    • Mechanical equipment pre-commissioning (Pumps, compressors, generators, blowers, …etc.)
    • Instrument equipment pre-commissioning (Switches, ESD signals, DCS, BDVs, …etc.)
    • Electric equipment pre-commissioning (LVSW, HVSG, MCC, UPS, VFD, Motors, …etc.)
    • Loss Prevention pre-commissioning (F&G detectors, FF systems, …etc.)
    • HVAC pre-commissioning (Air, Ducts, AC, …etc.)
    • FAT, SAT

Module 4 - Commissioning and Startup

  • KeyTopics:

    • Requirements to start commissioning.
    • Commissioning activities and check lists
    • HSE precautions
    • Equipment drying and purging.
    • Rotating equipment commissioning
    • Heaters commissioning
    • Utility commissioning
    • PSSR
    • Startup the processing equipment

Module 5 - Performance test, Troubleshooting and Problem Solving

  • KeyTopics:

    • Performance test of the proceeding equipment
    • Troubleshooting the problem of the startup.
    • Acceptance criteria

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