COURSE OVERVIEW:

The transition of high-value rotating equipment from the construction phase to active operation is a critical period that determines the long-term reliability of the asset. This course provides a rigorous framework for the commissioning of pumps and compressors, ensuring that all mechanical, electrical, and control systems are verified before full-scale production begins. Participants will explore the systematic approach required to move from mechanical completion through pre-commissioning and into final performance testing.

The scope of this training encompasses the technical validation of auxiliary systems, including lubrication, cooling, and seal support units. We will examine the essential protocols for flushing, blowing, and chemical cleaning of piping to prevent debris from damaging internal components during the initial startup. The course also addresses the critical "first run" procedures, focusing on monitoring thermal stability, vibration signatures, and hydraulic performance to ensure the machine operates within its design envelope.

Coverage includes the development of comprehensive commissioning checklists and the integration of safety management systems during the startup phase. Attendees will learn how to coordinate between different engineering disciplines and vendors to ensure a seamless handover to the operations team. By mastering these procedures, participants will be equipped to mitigate the risks of infant mortality in machinery and establish a baseline for future condition monitoring and maintenance activities.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the distinct stages of the commissioning lifecycle for rotating equipment.
• Execute pre-operational checks for lubrication and cooling auxiliary systems.
• Validate the integrity of emergency shutdown and control logic loops.
• Supervise the cleaning and flushing of suction and discharge piping.
• Perform mechanical seal, atmospheric, and pressure tests before startup.
• Conduct initial uncoupled runs for drivers to verify rotation and vibration.
• Manage the gradual loading of compressors to avoid surge conditions.
• Monitor pump performance curves during the initial commissioning run.
• Evaluate the effectiveness of foundation grouting and piping supports.
• Coordinate vendor support and documentation during the handover process.
• Implement safety protocols for handling high-pressure fluids during startup.
• Analyze initial vibration and temperature data as a baseline for reliability.
• Troubleshooting control valve and instrumentation malfunctions during commissioning.
• Prepare professional commissioning reports and final acceptance certificates.

TARGET AUDIENCE:

Commissioning Engineers, Plant Operators, Maintenance Managers, Mechanical Engineers, and Project Engineers involved in the installation and startup of new or overhauled industrial machinery.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.