This program addresses in an integrated manner the key activities involved in the safe, effective and timely commissioning and start-up of a new plant or facility. Start Up and Commissioning of new plant and equipment presents both a major technical and management challenge. An organisation’s personnel must familiarise themselves with new equipment, processes and technologies, develop the relevant operating and safety procedures. At the same time there is the requirement to execute an exceptionally large scope of work – much of it complex when compared to routine operations - over a short period of time, with equipment and plant which is as yet unproven and that may pose significant risks to personnel, environment and profitability. This 5 day training course addresses the technical issues of commissioning and starting up various equipment and asset types commonly found in processing plant environments, the development of specific commissioning procedures, process and facility wide commissioning strategies. The course will also address the broader managerial issues of commissioning and start up planning, resourcing, budgeting and cost control, risk management – safety, environmental, financial and operational, problem solving and trouble shooting.

1. PROCESS PLANT START UP &
COMMISSIONING
Your Expert Course Director:
MAX ZORNADA B.E. (MECH), HONS. M.B.A.
Max was a Commissioning Engineer on the largest onshore petrochemical project, which included
commissioning of Power House, Crude Stabilisation Plant, Gas Sweetening, NGL and LNG plan. He has
also had experience in construction and commissioning of plant in the Fertiliser and Cement Industries.
He has been running his “flagship” program on Process Plant Start-Up and Commissioning in the
Middle East for some 15 years both as a public program and on an in-house basis.
www.petroEDGEasia.net

2. PROCESS PLANT START UP AND COMMISSIONING
Conduct this training course in-house for more effective savings!
Call us at +65 6579 1293 or email to yong@asiaedge.net. For more information, visit us at
www.petroedgeasia.net
Course Objectives
This program addresses in an integrated manner the key activities involved in the safe, effective and timely
commissioning and start-up of a new plant or facility. Start Up and Commissioning of new plant and equipment
presents both a major technical and management challenge. An organisation’s personnel must familiarise
themselves with new equipment, processes and technologies, develop the relevant operating and safety
procedures.
At the same time there is the requirement to execute an exceptionally large scope of work – much of it complex
when compared to routine operations - over a short period of time, with equipment and plant which is as yet
unproven and that may pose significant risks to personnel, environment and profitability.
This 5 day training course addresses the technical issues of commissioning and starting up various equipment
and asset types commonly found in processing plant environments, the development of specific commissioning
procedures, process and facility wide commissioning strategies. The course will also address the broader
managerial issues of commissioning and start up planning, resourcing, budgeting and cost control, risk
management – safety, environmental, financial and operational, problem solving and trouble shooting.
Learning Objectives
The objectives of this program are to provide participants with an awareness of the unique challenges
associated with plant start-up and commissioning situations.
 Gain an understanding of the key concepts, tools and techniques that can be used to facilitate the effective
planning, execution, control and management of these situations, including performance testing and
acceptance into operation.
 Contribute confidently to the planning and execution of effective strategies for plant commissioning and
start-up in their own specific work and process plant situations.
Who Should Attend?
This program addresses the needs of a diverse audience with an interest in Plant Start-up and Commission,
including:
 General Managers who have oversight responsibility for Plant Start-up and Commissioning;
 Operations and Maintenance Managers with direct line responsibility as well as staff support responsibility
for delivering on effective Plant Start-up and Commissioning;
 Plant Start-up and Commissioning Managers and Engineers;
 Technical personnel involved in supporting Plant Start-up and Commissioning activities;
 Supervisors and Engineers, both operations and maintenance who are involved or likely to be involved in
Plant Start-up and Commissioning situations.
Training Methodology
Process Plant Start-up and Commissioning is a hands-on, stimulating learning experience. The program will be
highly interactive, with opportunities to advance your opinions and ideas. Participation is encouraged in a
supportive environment. To ensure the concepts introduced during the program are understood, they will be
reinforced through a mix of learning methods, including lecture style presentation, open discussion, case
studies, simulations and group work.

3. PROCESS PLANT START UP AND COMMISSIONING
Conduct this training course in-house for more effective savings!
Call us at +65 6579 1293 or email to yong@asiaedge.net. For more information, visit us at
www.petroedgeasia.net
Organisational Impact
The need for Plant Start Up and Commissioning is ongoing in any business that is growing, as new plant is added
to expand capacity and to replace obsolete technology.
This program aims to develop employees through exposure to the training and development experience
provided by this program, to build a “cadre” of knowledgeable and skilled staff who will be able to add value
through their contributions to any situations involving plant start-up and commissioning.
They will be able to contribute in leadership or operational roles, both with knowledge and skills to ensure such
projects are effectively and efficiently managed in a manner consistent with recognised best practices. A spin
off benefit will be their ability to coach and impart learning to their peers and subordinates to the mutual
benefit of individuals and organisation.
About your Expert Trainer: Max Zornada B.E. (Mech), Hons. M.B.A.
Max spent several years with the London based international management and technology
consultancy PA Consulting Group, after holding various managerial and professional engineering
positions in the chemicals processing and petrochemicals industry with Adelaide and Wallaroo
Fertilisers, ICI and Santos.
During his time working in the Petrochemical Industry, Max developed specific expertise in
Operational Excellence, Maintenance Management, Shutdown and Turnaround Management,
Process Plant Start-up and Commissioning through hands-on involvement in commissioning of new plant, as a
Shutdown/Turnaround Manager and implementing computerised maintenance management systems.
Max was a Commissioning Engineer on the largest onshore petrochemical project, which included commissioning of
Power House, Crude Stabilisation Plant, Gas Sweetening, NGL and LNG plan. He has also had experience in
construction and commissioning of plant in the Fertiliser and Cement Industries.
He has been running his “flagship” program on Process Plant Start-Up and Commissioning in the Middle East for some
15 years both as a public program and on an inhouse basis.
Max maintains an active international consulting and education practice, with a focus on the management of capital
intensive (petrochemical, energy and chemicals) businesses in the Middle East, Europe and Asia. Max Zornada is also
an Adjunct Lecturer at the University of Adelaide Business School where he currently teaches the Operations
Management and Business Improvement in the MBA Program. He delivers various Executive Education Programs
including Yellow Belt, Green Belt and Black Belt level Lean Six Sigma programs. He has presented programs for the
University of New South Wales, Southern Cross and was a Visiting Professor at the Consorzio MIP at the Politecnico di
Milano.

4. PROCESS PLANT START UP AND COMMISSIONING
Conduct this training course in-house for more effective savings!
Call us at +65 6579 1293 or email to yong@asiaedge.net. For more information, visit us at
www.petroedgeasia.net
5-DAY COURSE AGENDA
DAY ONE
INTRODUCTION AND PREPARATION
 Introduction to Process Plant Start Up and Commissioning
o The Commissioning Process
o The Operating Instruction Manual
o The Role of Simulators
 Commissioning Team Organisation and Roles
o Commissioning Team Structure
o Roles and Responsibilities
 Support Function
o Maintenance Department Involvement
o Documentation and Information Management
o Laboratory Involvement
 Cost Estimation and Budgeting
 Commissioning and Start Up Logistics Issues
o Determining Spare Parts and Consumables
Requirements for Commissioning
o Determining Spare Parts Stocks Requirements for
ongoing support
DAY TWO
COMMISSIONING STRATEGY
 Overall Commissioning Strategy Development
 The Six Key Stages of Process Plant Start Up and
Commissioning
 Preparation, Planning and Commissioning strategy
Mechanical completion, integrity checking, P&ID checking
and verification
o Piping and Spring Supports
o Pressure Testing
o Cleaning and Flushing
 Pre-commissioning and operational testing
o Commissioning Utilities
o Electrical Sytems
o Operational Testing
o Dynamic Testing
 Start-up and Initial operation;
o Start-Up and Initial Operation
o Troubleshooting
 Performance testing and acceptance;
 Post-commissioning
DAY THREE
PROCESS PLANT AND MACHINERY SPECIFIC ISSUES
 Process Plant and Machinery Commissioning
o General Machinery Commissioning Principles
o Pumps
o Compressors
o Turbines
o Distillation Columns
 Instrumentation and Control Systems
o Distributed Control System Commissioning
o Field Instrumentation Commissioning
 Preparing and Isolating Process Plant
o Preparation and Isolation of Plant
o Electrical Isolation
o Removal of Hazardous Substances
o Testing and Access
DAY FOUR
MANAGEMENT, PLANNING AND CONTROL
 The Start Up and Commissioning Planning and Control
 Developing Commissioning Scope of Work
 The Critical Path Method of Planning and Control
 A Short-cut Approaches to Planning
 Progress Monitoring and Control
o Budget Development and Cost Control
o Earned Value Analysis
o Earned Hours Analysis
DAY FIVE
MANAGING RISKS DURING COMMISSIONING
 OH&S and Risk Management
o Safety Management
o Safety Audits and Inspections
o Permit to work system
o Formal Safety Analysis Techniques
- Take 5 Analysis
- Job Safety Analysis
- Qualitative Risk Assessment
o Accident Prevention and Investigation
 Trouble shooting and problem solving
o Trouble shooting and problem solving
o Trouble shooting instrumentation systems
 Trouble Shooting and Problem Solving
 Managing Quality
 Conclusion

5. PROCESS PLANT START UP AND COMMISSIONING
Conduct this training course in-house for more effective savings!
Call us at +65 6579 1293 or email to yong@asiaedge.net. For more information, visit us at
www.petroedgeasia.net
DELEGATE DETAILS
Delegate 1 Please note
- Indicate if you have already registered by Phone +Fax +Email +Web
- If you have not received an acknowledgement before the training
course, please call us to confirm your booking.
- Photocopy this form to register multiple delegates.
PAYMENT METHODS
By Cheque/ Bank Draft
Make Payable to Asia Edge Pte. Ltd.
By Direct Transfer
Please quote your invoice number with the remittance advise
Account Name: Asia Edge Pte. Ltd.
Bank Number: 508 Account Number: 762903-001
Swift Code: OCBCSGSG
All bank charges to be borne by payer. Please ensure that Asia Edge
Pte Ltd receives the full invoiced amount.
PAYMENT POLICY
Payment is due in full at the time of registration. Full payment is
mandatory for event attendance. By submitting this registration form,
you have agreed to Asia Edge Pte Ltd’s payment terms
CANCELLATIONS & SUBSTITUTIONS
You may substitute delegates at any time. ASIA EDGE PTE LTD does not
provide refunds for cancellations. For cancellations received in writing
more than seven (7) days prior to the training course you will receive a
100% credit to be used at another ASIA EDGE PTE LTD training course
for up to one year from the date of issuance. For cancellations
received seven (7) days or less prior to an event (including day 7), no
credits will be issued. In the event that ASIA EDGE PTE LTD cancels an
event, delegate payments at the date of cancellation will be credited
to a future ASIA EDGE PTE LTD event. This credit will be available for
up to one year from the date of issuance. In the event that ASIA EDGE
PTE LTD postpones an event, delegate payments at the postponement
date will be credited towards the rescheduled date. If the delegate is
unable to attend the rescheduled event, the delegate will receive a
100% credit representing payments made towards a future ASIA EDGE
PTE LTD event. This credit will be available for up to one year from the
date of issuance. No refunds will be available for cancellations or
postponements.
ASIA EDGE PTE LTD is not responsible for any loss or damage as a
result of a substitution, alteration or cancellation/postponement of an
event. ASIA EDGE PTE LTD shall assume no liability whatsoever in the
event this training course is cancelled, rescheduled or postponed due
to a fortuitous event, Act of God, unforeseen occurrence or any other
event that renders performance of this training course impracticable
or impossible. For purposes of this clause, a fortuitous event shall
include, but not be limited to: war, fire, labor strike, extreme weather
or other emergency.
PROGRAM CHANGE POLICY
Please note that speakers and topics were confirmed at the time of
publishing; however, circumstances beyond the control of the
organizers may necessitate substitutions, alterations or cancellations
of the speakers and/or topics. As such, ASIA EDGE PTE LTD reserves
the right to alter or modify the advertised speakers and/or topics if
necessary. Any substitutions or alterations will be updated on our web
page as soon as possible.
ASIA EDGE PTE. LTD.
Company Registration No: No. 200710561C
Copyright@ 2005 ASIA EDGE PTE LTD. All rights reserved.
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Delegate 2
 Mr  Ms  Mrs  Dr  Others:
Name :
Job Title :
Department :
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Company :
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Attention
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4 EASY WAYS TO REGISTER
 Online: www.petroedgeasia.net
 Email: yong@asiaedge.net
 Phone: +65 579 1293
 Fax: +65 6747 8737
This brochure may not be copied, photocopied, reproduced, translated, or converted to any electronic or machine-readable form in whole or in part
without prior written approval of ASIA EDGE PTE LTD
PROCESS PLANT START UP AND COMMISSIONING
R E G I S T R A T I O N F O R M