Commissioning Training - Thomas Stuenkel

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Commissioning Video Training Course – “The 9 Key Elements of Successful Plant Commissioning” – Part 1 of 10

Free Online Commissioning Video Training

Commissioning Video Training Course in 10 Parts

I am happy to publish the first video of my 10 parts commissioning video training course. In this video I will give you an overview about “The 9 Key Elements of Successful Plant Commissioning”.

Please write a comment and let me know what you like on that video and what I should improve for the next lessons.

You can watch the same video on YouTube as well.

Click here to watch the next video “COMMISSIONING PLANNING” (part 02 of 10).

And here is an overview about ALL commissioning training videos.

Download the mind map “The 9 Key Elements of Successful Plant Commissioning” in PDF format for FREE now

"The 9 Key Elements of Successful Plant Commissioning" - Free Online Commissioning Video Training

“The 9 Key Elements of Successful Plant Commissioning”
Click the mind map above to download your free PDF now!

Commissioning Video Training – Video Transcript

Hello Everybody,

Here’s Thomas Stuenkel, founder of; a commissioning manager and a commissioning engineer. Welcome to part one of my ten parts commissioning video mini-training course for commissioning newbies. In this course I want to give you an overview about the nine key elements for successful plant commissioning. It doesn’t matter if you want to commission a petrochemical plant, a refinery, a power station or water treatment plant, the nine key elements are the same everywhere.

In this first lesson you will learn to name the nine key elements and you will learn the right order of the nine key elements. I choose the mind map format for my presentation, because it’s easier to remember and of course you can download these mind map in HD quality from my download section on

So let’s start with key element number one. You guess, yes, the first key element is planning; without proper planning you will not be able to commission a plant safely and in time. Second key element is MC or Mechanical Completion, this is a time when the commissioning team takes over the systems from the construction team.

The third key element is at the same time the first big task in the field for the commissioning team. It’s the P&ID check; the commissioning engineer will verify that everything in the field is built according to the specifications.

Pre-Commissioning is the fourth key element; it includes cleaning of pipes by blowing and flushing, mechanical cleaning of vessels and tanks, no load test runs of motors and much, much more.

The fifth key element is Commissioning; this step includes for example introduction of utilities, dry running trials, hot running trials, safe fluid dynamic testing, solvent dynamic testing and process fluid tests. Now we will face a lot of problems to be solved before key element number six, Start-Up.  This means the entire plant will be taken slowly to full operation.

And now we are coming to the Initial Operation; this phase is necessary to prepare the performance test. During the initial operation the entire plant will be optimized.

Key element number eight, the Performance Test is a big moment for the whole commissioning team, now we have to prove that the plant meets all specifications under normal operating conditions.

During the Post Commissioning phase a reduced commissioning staff will take care and solve open punch points; don’t underestimate the time necessary for post commissioning activities.

I want to remind you that you can download these mind map in HD quality from my download section on

I summarize the first lesson, we learnt to name the nine key elements of successful plant commissioning and we learnt the right order of it. In lesson number two I will speak about the first key element, Planning, in more detail.

So please sign up for my newsletter and I will keep you up to date about new training lessons. Thank you for watching and see you soon.

Thomas Stuenkel

Leave a Comment

  • Terry March 18, 2011, 11:37 pm

    This is well laid out!! Well done!!!

  • Raja Kumar. M. March 19, 2011, 9:25 am

    Dear Thomas Stunkel,
    Nice to see/hear you on this occasion.
    Very good approach to educate commissioning team all over the world.
    Thank you very much to share your knowledge and experience.
    I hope that this is a great presentation.
    All the best for your video training course.
    Best regards,

  • Thomas Stuenkel March 19, 2011, 11:27 am

    Hello Terry,

    Thank you for your kind words!

    Best regards,


  • Thomas Stuenkel March 19, 2011, 11:29 am

    Hello Raja,

    Yanbu, Saudi Arabia It’s a long time ago … Nice to read your comment!



  • Rick Rhead March 19, 2011, 7:26 pm

    Very well done–short and too the point. Look forward to the next video.

    Rick Rhead

  • Thomas Stuenkel March 19, 2011, 10:44 pm

    Hello Rick,

    I am happy to hear from you – and I am happy to hear such nice words. 🙂

    Video No. 2 will be finished and published within the next week.

    Best regards,


  • ghias mian March 20, 2011, 5:15 am

    Dear Thomas,
    Realy I was looking such informations and to day I got it, Dear I have no words to say . I am thankful to you you help me in any way. If you have any more pls send me. Yours
    Ghais Mian.

  • ghias mian March 20, 2011, 5:27 am

    Mr Thomas, Thanks you remember me and send me all document for commissioning and commissioning and start up. I am proud to say you are having through knowledge and it will help to all people.Regards. ghias mian

  • Medi March 20, 2011, 3:08 pm

    Thank you Thomas for your commissioning training video.
    It’s great, perfect & professional !!!?
    I liked it, because it organised my mind about what I’ve done in different commissioning stages of several projects.


  • Thomas Stuenkel March 20, 2011, 3:54 pm

    Hello Medi,

    Thank you very much for your comment!

    Are there any other topics you want to be covered by a training video?



  • Thomas Stuenkel March 20, 2011, 3:55 pm

    Hello Mian,

    Thank you very much for your kind word! This makes me feel good. 🙂

    I will publish more videos during the next weeks.



  • Grman Miroslav March 21, 2011, 9:00 am

    Hello Thomas ! 🙂
    This is Miroslav, we have worked togeather in Slovakia – Malzenice, this video is soo cool !
    It was a good experience for me

  • Tibor March 21, 2011, 10:14 am

    What can I say? I am looking forward to next videos.

  • Thomas Stuenkel March 21, 2011, 8:05 pm

    Hi Miro,

    Thank you! Yes, it was a pleasure to work with you in Malzenice!

    See you,


  • Thomas Stuenkel March 21, 2011, 8:06 pm

    Hello Tibor,

    Nice to read your comment here!

    Video No. 2 will be produced this week. 🙂



  • Marleen Vermeersch( EngiPro ) March 21, 2011, 8:21 pm

    Hello Thomas,
    Very nice initiative .
    Looking forward for the next sessions
    ir Marleen Vermeersch, EngiPro

  • Daolv69 March 22, 2011, 6:26 am

    Thanks Thomas a lot. The 1st lesson attracted me very much. It helps me to overview all what we will do in near future. Appreciate if you post remaining parts of this video.

    Best regards
    Dao LV

  • Khaled Rasheed March 22, 2011, 7:36 am

    I need to see all related videos

  • Thomas Stuenkel March 22, 2011, 7:44 am

    Hello Khaled,

    As I told in this first video I will produce and publish videos No. 2 till 10 over the next time.

    Video No. 2 will be published within this week.



  • Thomas Stuenkel March 22, 2011, 7:44 am

    Hi Dao,

    Thank you for watching & commenting!



  • Thomas Stuenkel March 22, 2011, 7:45 am

    Hello Marleen,

    Thank you for watching & commenting!



  • Pete March 23, 2011, 3:23 am

    Thomas: Great work! I am very excited about your series and our next 5 day session together which as I discussed with you today via e-mail. Very nice words from our friend M.R. Bashiri.

    As we told all attendees from our past TrueWorkShop sessions, we need to remember that we promised to send everyone any updates to our past session attendees. This is an excellent resource for our goal of continuous support to these attendees.

    And we told all of them that we strive to enhance every session for future presentations of our public or inhouse event. Your completed work will be an exceptional addition very soon with our next 5 day session!

    Best Regards,
    Ralph W. “Pete” Peters
    The Maintenance Excellence Institute

  • Aminian8 March 26, 2011, 7:04 am

    Dear Tomas,
    our new year begins so i was in vacation! sorry because of my speak nery fluently on your trainning video.

    thank you very much

  • Peter lane March 27, 2011, 3:36 pm

    I assume by PID checking you mean walking the lines and checking the plant, but for pre commissioning a main and very important factor is checking cables, not only that they are installed correctly but also that they go to where they are supposed to go and only there, and there are no shorts or grounding issues.

    The worst screw ups I have seen is where this stage has been neglected and people just start powering up the plant and find motor A is wired up as motor B, which can be just a little bit on the dangerous side.

    I look forward to the rest of the series, hopefully we will get the next steps soon.

  • Thomas Stuenkel March 28, 2011, 3:56 pm

    Hi Peter,

    Yes, PID checking means walking the lines and checking the plant.

    You are absolutely right: checking of electrical and instrumentation items is very important.

    I just published video training lesson No. 2 – Planning. I hope you will enjoy it too. 🙂

    Best regards,


  • Thomas Stuenkel March 28, 2011, 4:00 pm

    Dear Aminian,

    Happy New Year to you and your family!



  • Thomas Stuenkel March 28, 2011, 4:03 pm

    Dear Pete,

    Thank you very much!

    Yes, will be developed to THE support ressource for our training attendees.

    I am looking forward to our next session!



  • Houari March 28, 2011, 5:57 pm

    in commissioning we use mark ups , following system subsystem breakdown
    different than as builts
    punch is at all stages
    each stap is defined in completion PC , C , Start up , ready for operation , ready for hand over …

    good for beginners , but commissioning manager cannot come from course but from field

  • Thomas Stuenkel March 28, 2011, 6:09 pm

    Hello Houari,

    > good for beginners , but commissioning manager
    > cannot come from course but from field

    I agree absolutey! Good commissioning engineers & commissioning managers have gained their knowledge from years of working and experience.

    This mini course is designed to give newbies as well other related disciplines an overview about “What is commissioning?”



  • Peki Hariyanto April 7, 2011, 5:46 am

    Thank you very much, I’m very appreciated.

    Peki – Batam

  • Roni Sartika April 7, 2011, 8:49 am

    Hello Thomas

    thanks for your generosity to share your knowledge/skill/competencies about commissioning.


  • Jkallolangi April 19, 2011, 4:15 am

    Dear Thomas Stuenkel,

    Thank for your Video , very helpful , could you please send me the document all stage that you explain in your Video. PRE-COMMISSIONING, COMMISSIONING, START-UP.


    Joni Kallolangi
    Instrumentation Commissioning Oil and Gas EPC.

  • samith May 16, 2011, 12:48 am

    Hi Thomas,
    As Rani commenting here, I would say same thing, thank you very much sharing your knowledge with the world.
    i am processing engineering graduate student, and currently involving some commissioning project during my internship program. first and second video gave me valuable insight about commissioning and I am looking forward rest of lessons as well.

    Thank you very much.


  • Matthew Edogun May 22, 2011, 1:38 pm

    The part 1 vedeo is very clear. 
    There is no doubt about your experience and capability.
    The presentation is logical and self explanatory.

    Matthew Edogun  

  • Vmp_2002 June 5, 2011, 6:46 pm

    Excellent In formation for basics fundamental for commissioning the plant. It is very helpful for commissioning the any plant. 
    Thanks Thomas.
    Vishnu Patel

  • Javier Colina November 12, 2011, 11:23 pm

    Excelt for our training in Utilities Project in Venezuela.
    J. Colina
    Chemical Eng – Commisioning and Start Up Manager

  • Thomas Stuenkel November 13, 2011, 7:05 am

    Dear Javier,

    What do you mean with “excelt”?

    Best regards,


  • Romycaban June 15, 2012, 5:18 am

    This is so good Sir.Thanks Very much PID check involved all mostly We find after contruction Wrong Wire yes but Wrong connection of Orifice and Flow Intrumentation and Other that’s Why We called Pre Commissioning.DAnke Schon..Sir Thomas.

  • Jose January 30, 2013, 2:07 am

    Hello Thomas:
    Thanks for sharing this info; i just started learning about commissioning (mining plants) and your information sure is handy. Its seems the commissioning department scope is big.

  • Thomas Stuenkel February 23, 2013, 12:29 am

    Hello Jose,

    Thank you for your great picture!

    Where is this plant located?

    Talk soon,


  • Jose February 23, 2013, 4:50 pm

    The plant is called “Peñasquito” in the state of Zacatecas, Mexico. The owner is the Canadian company, Goldcorp.


  • José Uzziel Arteaga Gandarilla April 2, 2014, 8:55 pm

    Hello Thomas,
    Greetings from South America.
    Thanks for the useful information.
    Would you mind explaining what the difference is between pre-commissioning and commissioning? If you could focus your answer on instrumentation and control systems, it would be great.
    Thanks in advanced for your reply.
    Best regards,