:: DEFINE | Management Consultancy & Training Provider In UAE, Abu Dhabi,Dubai,Saudi Arabia ::

DEVELOPING EFFECTIVE COMMISSIONING AND STARTUP PLANS (CSU)

Location

Dubai, UAE

Date

From Date: 06-Oct-2025
To Date: 10-Oct-2025

Duration

5 days

Language

ENGLISH

Discipline

MANAGEMENT & LEADERSHIP

Introduction

Start Up and Shutdown of process plants present both a major technical and management challenge. This course explains and illustrates all the necessary steps that are needed to plan and manage start-ups and shutdowns in a process plant environment, which is increasingly becoming a complex and demanding task. Moreover, Improper planning, managing and controlling of plant start-ups and shutdowns will lead to unpredictable risks and costly delays. Therefore, this course is designed to provide the participants with the most recent techniques of planning, management and controlling of the process plants startups, shutdowns and maintenance operations. In addition to scientific procedures and contents of this program, many of real life case studies and implementations are planned to be presented in an open discussion forum with the participants. The course will also cover the troubleshooting of the start-up process. Upon the successful completion of this course, participant will gain enough skills to anticipate and avoid problems associated with such start-up processes related to petrochemical plant start-up and commissioning.

Objective

At the end of the training, the participants will be able to:

Recognize the six key stages of the commissioning process
Develop and overall commissioning and plant start-up strategy
Deal with machinery and equipment specific commissioning issues
Manage issues dealing with the commissioning of Electrical, Instrumentation and Utilities Systems
Develop an overall commissioning management plan, resource plan and budget
Apply troubleshooting and problem-solving strategies to address issues commonly arising during start up and commissioning
Manage risks associated with commissioning

Audience

This course is ideal for:

Team Leaders
Project Managers
Refinery Managers
Refinery operations personnel
Refinery process engineers.
Refinery maintenance supervisors
Maintenance Planners
Plant Mangers
Section Heads
Technical Staff
Mechanical, Electrical and Instrumentation Engineers who are involved in Process Plant Start up and Commissioning will benefit from this course.

Content

Introduction and Preparation

Course Introduction & Pre-assessment

Refinery Overview
Crude Oil classification and Properties
Products From Crude Oil Refining
Refinery Configuration
Commissioning Activities Overview
Start-up and Shutdown Rules of Thumb
Planning Methods for Start-Up
Preparation for a Successful Start-up or Shutdown
Startup Safety Review (Case Study)
Preparation for Initial Start-Up
Organization and Roles
Cost Estimation
Spare Parts Planning

Hydrostatic Pressure Testing
Plant Inspection
Commissioning of Utilities
Final Inspection of Vessels
Acid Cleaning
Flushing of lines and Equipment
Inspection and Running of Pumps
Break-In Gas Compressor
Service and Calibrate Instruments
Dry Out Fired Heaters
Leak Testing
Purging and Gas Blanketing.

Start-up Material Issues and Control

Process Unit Start-Up Procedure
First-time Start-Up: General Precautions for first-time Start-up
Problems associated with first-time Start-up
Process flow description
Start-up procedure
Process flow Description
Start-up Procedure
Reasons of problems associated with first-time start-up and
How to avoid them & troubleshooting first-time start-up
Start-up instrumentation issues and control

Commissioning Strategy

Commissioning Strategy
Mechanical Completion & Integrity Checking
Pre-commissioning and Operational Testing
Start-up/Initial Operation, Testing and Acceptance

Process Plant and Machinery Commissioning
Instrumentation and Control Systems
Preparing and Isolating Process Plant

Managing Risks during Commissioning

Trouble Shooting and Problem Solving
Risk Management
Managing Safety and Quality
How to Anticipate and Avoid Problems and Consequences During Commissioning and Start-Up.
Process Failure: Loss of feed, Furnace tube rupture, Loss of makeup gas, Loss of wash water, Loss of recycle gas compressor, Loss of column top reflux, Loss of column pump around.
Utilities Failure: Electrical power failure, Steam failure, Instrument air failure, Cooling water failure, Fuel gas failure, Explosion, fire, line rupture, or serious leak.
Importance of Check Lists.
Start-up Equipment Issues and Control.
Refinery Equipment Start-Up Troubleshooting
Fired Heaters, Heat Exchangers, Water Coolers, Pumps, Compressors
Case Study: Operational Troubleshooting (Root Cause Analysis).
Video Demo (pre-commissioning, commissioning, startup, post commissioning).

Safe Handling of Equipment
Shutdown and Decommissioning
Normal Shutdown
Decommissioning and demolition
Unplanned Shutdown
Planning Methods for Shutdown
Troubleshooting Case Studies
Crude Distillation operation & troubleshooting
Shutdown Environmental and Safety Issues and Control
Final Assessment and Course Closing
Conclusion

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences. Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

30% Lectures
30% Workshops and work presentation
20% Group Work& Practical Exercises
20% Videos& General Discussions

Course Details