Fluidised Bed Roaster Commissioning Procedures Training

Learning Outcomes

• Apply pre-commissioning inspection and safety checklists to fluidised bed roaster systems.
• Demonstrate correct start-up and shutdown sequences for fluidised bed roasters.
• Analyze roaster performance data to verify commissioning criteria are met.
• Implement corrective actions for common commissioning faults and deviations.
• Evaluate system integrity and safety interlocks during commissioning trials.
• Document commissioning results and handover procedures according to site protocols.

Target Audience

This training is designed for process engineers, plant operators, and maintenance technicians involved in the commissioning or operation of fluidised bed roasters in mining, metallurgical, or industrial processing environments.

Prerequisites

None — open enrollment

Course Outline

Practicals

Overview

Hands-on practicals are essential for learners to apply commissioning procedures on a real or simulated fluidised bed roaster. Learners will perform mechanical inspections, instrument calibration, cold and hot commissioning tests, and troubleshooting under supervision.

Practical Activities

• Practical 1: Pre-Commissioning Inspection and Checklist — Learners perform visual and mechanical inspections of the roaster, complete the pre-commissioning checklist, and identify any deficiencies. (6h)
• Practical 2: Instrument Calibration and Loop Check — Learners calibrate temperature and pressure transmitters, perform loop checks, and verify interlocks using a simulator or actual controller. (6h)
• Practical 3: Cold Commissioning – Air Flow and Pressure Tests — Learners measure air flow distribution, pressure drop across the bed, and adjust dampers to achieve uniform fluidisation. (6h)
• Practical 4: Hot Commissioning – Burner Light-off and Tuning — Learners execute burner light-off procedure, ramp temperature, and tune PID controllers for stable bed temperature. (8h)
• Practical 5: Troubleshooting Simulation — Learners diagnose and resolve common commissioning faults using a simulator or actual plant, such as uneven fluidisation or temperature excursions. (6h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total

Component	Out of	Weight
Practical Assignments (rubric-scored)	100%	30%
Daily Average (multiple choice)	100%	20%
Final Test (multi-answer multiple choice)	100%	50%
Final Total	—	100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

How it works

• Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
• Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
• You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
• If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.

Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates	Discount
5	3% off
10	6% off
15	9% off
20	12% off
25	15% off
30	18% off
50	30% off
75	35% off
100	40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.