COMMISSIONING – START-UP – SHUTDOWN
“Mastering the Critical Phases of Plant Lifecycle to Ensure Safe and Efficient Operations”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 16 – 20 Feb 2025 | Manama, Bahrain | USD 3495 per delegate |
Course Introduction
Commissioning, start-up, and shutdown are the most critical phases in a facility’s lifecycle—where planning, coordination, and precision have a direct impact on safety, cost, and long-term operational reliability. Missteps during these stages can result in significant delays, equipment damage, and safety incidents.
This intensive five-day course equips plant and project professionals with the methodologies, tools, and best practices needed to successfully plan and execute commissioning, start-up, and shutdown procedures. Participants will gain hands-on strategies to mitigate risks, ensure readiness, and manage multidisciplinary teams during transitional phases of plant operations.
Course Objectives
By the end of this course, participants will be able to:
• Plan and execute pre-commissioning, commissioning, start-up, and shutdown activities
• Coordinate cross-functional tasks and documentation across stakeholders
• Implement safety, inspection, and functional test protocols
• Manage punch lists, handover, and performance testing
• Mitigate operational and environmental risks during critical transitions
Key Benefits of Attending
• Learn proven frameworks to reduce commissioning time and cost overruns
• Ensure smooth transition from construction to operational phase
• Improve safety and environmental compliance during system transitions
• Avoid common failures through structured planning and team coordination
• Enhance communication between engineering, operations, and project management
Intended Audience
This program is designed for:
• Project engineers, construction and commissioning managers
• Operations, process, and mechanical engineers
• Maintenance and reliability professionals
• Safety, QA/QC, and instrumentation personnel
• EPC contractors and client representatives involved in handover and start-up phases
Individual Benefits
Key competencies that will be developed include:
• End-to-end commissioning and start-up planning
• Functional testing and validation skills
• Documentation control and handover procedures
• Risk identification and contingency planning
• Interdisciplinary coordination and leadership
Organization Benefits
Upon completing the training course, participants will demonstrate:
• More efficient, timely, and safe project start-ups and shutdowns
• Reduced risk of system failures post-handover
• Stronger integration between construction, commissioning, and operations teams
• Improved documentation, compliance, and system integrity
• Better lifecycle asset performance from day one of operation
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – Detailed instruction on commissioning workflow and system readiness
• Case Studies – Real-world examples of commissioning successes and shutdown failures
• Workshops – Team exercises in punch list management, functional testing, and risk analysis
• Peer Exchange – Industry experience sharing on commissioning and handover scenarios
• Tools – Templates for pre-commissioning checklists, start-up plans, and shutdown logs
Course Outline
Detailed 5-Day Course Outline
Training Hours: 07:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Introduction and Pre-Commissioning Planning
- Module 1: Lifecycle Overview – From Construction to Operation (07:30 – 09:30)
• Definitions: pre-commissioning, commissioning, start-up, shutdown
• Interfaces between EPC, vendors, operations, and QA/QC
• Phase gates and handover milestones - Module 2: Pre-Commissioning Scope and Preparation (09:45 – 11:15)
• Utility availability, system cleaning, and loop checks
• Pre-commissioning checklist and equipment readiness
• Vendor support and documentation control - Module 3: Safety and Risk Management Planning (11:30 – 01:00)
• Hazard identification and control measures
• Permit to work (PTW), LOTO, and confined space protocols
• Emergency response planning - Module 4: Workshop – Pre-Commissioning Readiness Review (02:00 – 03:30)
• Group exercise using a sample P&ID and checklist
• Cross-discipline input validation
Day 2: Commissioning Execution and System Testing
- Module 1: Commissioning Philosophy and Workflows (07:30 – 09:30)
• Mechanical completion and subsystem definition
• Systems approach and functional testing levels
• Interdisciplinary communication and punch list management - Module 2: Instrumentation and Control System Checks (09:45 – 11:15)
• Loop verification, alarm testing, and calibration
• Commissioning DCS/PLC integration
• Instrument datasheet cross-checks - Module 3: Electrical and Mechanical Commissioning (11:30 – 01:00)
• Energization procedures and load testing
• Motor rotation checks and lubrication systems
• Static and dynamic equipment test procedures - Module 4: Workshop – Developing a Commissioning Plan (02:00 – 03:30)
• Sample project breakdown and activity sequencing
• Building work packs and responsibility matrices
Day 3: Start-Up Planning and Initial Operation
- Module 1: Start-Up Readiness and Go/No-Go Decisions (07:30 – 09:30)
• System walk-downs and readiness inspections
• Checklists for go-live approval
• Stakeholder sign-offs and communication - Module 2: First-Time Start-Up Procedures (09:45 – 11:15)
• Initial energization and controlled process loading
• Start-up sequencing and ramp-up management
• Monitoring performance parameters - Module 3: Emergency Start-Up Scenarios (11:30 – 01:00)
• Start-up under abnormal or time-constrained conditions
• Safety systems and trip logic validation
• Documentation and learning capture - Module 4: Workshop – Start-Up Simulation (02:00 – 03:30)
• Simulated start-up of a simple process
• Identifying weak points and adjusting the plan
Day 4: Shutdown, Decommissioning, and Turnarounds
- Module 1: Planned and Emergency Shutdown Strategies (07:30 – 09:30)
• Shutdown sequencing and load shedding
• Equipment isolation and depressurization
• Shutdown risk scenarios and fail-safe procedures - Module 2: Decommissioning and Preservation (09:45 – 11:15)
• Draining, flushing, and inerting systems
• Asset preservation and lay-up best practices
• Environmental and disposal considerations - Module 3: Turnaround Planning and Lessons Learned (11:30 – 01:00)
• Shutdown window planning and critical path items
• Resource and contractor coordination
• Post-shutdown review documentation - Module 4: Workshop – Shutdown Safety Drill Planning (02:00 – 03:30)
• Emergency shutdown checklist development
• Roles, responsibilities, and communication lines
Day 5: Integration, Handover, and Certification
- Module 1: Handover to Operations and Documentation (07:30 – 09:30)
• Punch list closure, redlining, and as-built drawings
• O&M manual submission and asset registers
• Handover protocols and team briefings - Module 2: Performance Testing and Optimization (09:45 – 11:15)
• Testing against design and contractual specs
• Performance verification and guarantee testing
• Reliability-centered commissioning metrics - Module 3: Final Q&A and Action Planning (11:30 – 01:00)
• Review of course concepts and tools
• Participant action plan for their upcoming project phases - Module 4: Certification and Closing Session (02:00 – 03:30)
• Final knowledge check or team presentation
• Distribution of certificates
• Wrap-up and feedback session
Certification
Participants will receive a Certificate of Completion in Commissioning – Start-Up – Shutdown, validating their expertise in planning and executing critical transitional phases in plant operations, with a strong focus on safety, system integrity, and cross-functional coordination.