Process Plant Commissioning and Start-up: Mechanical Completion, PSSR and Handover – Dubai, 8–12 Mar 2027

Programme overview

Introduction:

Process plant commissioning is where a finished construction site becomes a producing unit, and where schedule slippage, damaged equipment and unsafe first starts most often originate. Late systemisation, incomplete pre-commissioning, open punch items and unclear owner and contractor roles push risk into the start-up window. This Core Concept course equips commissioning and operations leads to plan and execute commissioning and start-up of oil, gas and petrochemical units system by system, from mechanical completion through first fill and performance testing. Participants produce a Commissioning Execution and Start-up Readiness Plan for a real or planned unit.

Course Objectives:

• Build a commissioning philosophy, organisation and systemisation that drive construction completion and turnover sequence
• Control mechanical completion, pre-commissioning activities and punch list closure through a completions management database
• Prepare commissioning procedures, check sheets and handover dossiers that operations will accept
• Lead a pre-start-up safety review and confirm ready-for-start-up status before hydrocarbons are introduced
• Execute start-up sequences, inerting, first fill and performance testing while managing commissioning risks and contractor interfaces
• Produce a Commissioning Execution and Start-up Readiness Plan for a real or planned process unit

Target Audience:

• Managers responsible for planning and leading commissioning and start-up of new or revamped process units
• Operations and production leads who accept systems from construction and run the first start
• Process and technology engineers responsible for start-up procedures, catalysts and performance tests
• Completions and turnover leads who manage systemisation, check sheets, punch lists and certificates
• Owner's project and interface leads coordinating EPC contractor, vendor and licensor activities
• Maintenance, instrumentation and electrical leads responsible for pre-commissioning and equipment run-in

Course Outline:

Day 1: Commissioning Foundations and Readiness Baseline

• Construction Completion, Pre-Commissioning, Commissioning and Start-up Phase Definitions
• Commissioning Philosophy Document and Execution Strategy
• Commissioning Organisation Chart and Owner, Contractor and Vendor Roles
• CII Implementation Resource 312-2 Commissioning Best Practices
• Commissioning Readiness Self-Assessment for a Current Project

Day 2: Systemisation, Completions Management and Mechanical Completion

• Systemisation Guidelines: System and Subsystem Boundary Marking on P&IDs
• Completions Management Database: Tag Registers and Check Sheet Libraries
• Mechanical Completion Certificate and Ready-for-Commissioning Criteria
• Punch List Categories A, B and C and Clearance Rules
• Construction-to-Commissioning Turnover Package Content

Day 3: Pre-Commissioning Activities and Commissioning Procedures

• Line Flushing, Air Blowing and Steam Blowing Procedures
• Hydrotest Reinstatement, Leak Testing and Tightness Testing Plans
• Drying, Chemical Cleaning and Equipment Preservation Removal
• Instrument Loop Checks, Function Tests and Cause-and-Effect Verification
• Rotating Equipment Solo Run and Mechanical Run-In Check Sheets

Day 4: PSSR, Start-up Sequence and Commissioning Risk

• Pre-Start-up Safety Review Team, Checklist and Ready-for-Start-up Sign-Off
• Nitrogen Inerting, Oxygen Freeing and Leak-Before-Introduction Checks
• First Fill of Feedstock, Utilities, Chemicals and Catalyst Loading
• Start-up Sequence Logic and Simultaneous Operations Controls
• Commissioning Risk Register and EPC Contractor-Owner Interface Matrix

Day 5: Case Work and the Commissioning Execution and Start-up Readiness Plan

• Gas Processing Case Study: Delayed Systemisation and Turnover Backlog
• Petrochemical Unit Case Study: Failed Performance and Reliability Test Run
• Handover Dossier and Care, Custody and Control Transfer Review
• Commissioning Execution and Start-up Readiness Plan Drafting
• Lessons Learned Register and Peer Review Panel

Skills You Will Gain:

• Commissioning Planning
• Systemisation
• Completions Management
• Pre-Commissioning Supervision
• Punch List Control
• Pre-Start-up Safety Review
• Start-up Sequencing
• Performance Test Management

Why Attend This Course:

• Take back a Commissioning Execution and Start-up Readiness Plan tested against peer review
• Recognise the completion gaps and open punch items that delay first start before they reach the critical path
• Run a pre-start-up safety review that operations and contractors both trust
• Compare commissioning practice with owner and contractor teams from gas processing, refining, petrochemicals and utilities

Conclusion:

Plants that start safely and on time are commissioned by systems, with clear completion criteria, disciplined pre-commissioning and a verified readiness review before hydrocarbons are introduced. This course moves from commissioning philosophy and organisation, through systemisation, completions management and mechanical completion, to pre-commissioning, procedures, PSSR, first fill and performance testing. The final day applies that material to case units and produces a Commissioning Execution and Start-up Readiness Plan that participants can use on their next project or turnaround.