Pilot Plants: Principles of Design, Operation and Maintenance

Online /
Apr 25 - 27, 2023 /
Course Code: 13-0112-ONL23

The confirmation of this course depends on early registration; Register early to avoid the postponement or cancellation of a course.
  • Overview
  • Syllabus
  • Instructor


Please note, This instructor-led course has specific dates and times:
This course is held online over 3 days on the following schedule (All times in Eastern Time Zone):

9:30 am to 5:30 pm Eastern

After participating in this course, you will be able to:

  • Improve your knowledge of common types of pilot plants in various branches of industry
  • Familiarize yourself with the main design principles of pilot plants, their construction and efficient operation
  • Apply updated information on how to follow the start-up procedures and data acquisition
  • Recognize the need for analysis of capital and operation costs of operation in batch or continuous operation mode
  • Acquire an awareness of safety associated with the operation of pilot plants and the protection of personnel and the environment
  • Make your company products more profitable by increasing the reliability of design procedures and data validation


The design of a commercial plant can be risky and very expensive if the available experience is not sufficient enough to scale up the information from bench-scale laboratory tests. Unless one has extensive experience with similar materials and products, it is a very wise approach to verify the laboratory results in a pilot plant.

An old saying: "Make your mistakes on a small scale and make your profit on a large scale", can be applied to pilot plants which represent the intermediate stage between the laboratory simulation tests and the future industrial plant. In these cases, the decision to proceed with the full-scale plant project will be based on a proven process, and on a more reliable economic estimate.

This course will cover all aspects of the consideration of pilot plants, including design, construction, and operation. It will explain the main design principles of pilot plants, the selection of appropriate materials for fabrication and the selection and installation of the vital components of equipment. Discussed will be the elements of financial aspects of pilot plants: systematic analysis of capital and operation costs of pilot plants will be provided. Attention in the course will also be devoted to instrumentation and control systems as well as to aspects of the safety of personnel and environmental protection.

All course materials will be provided.

Course Outline

  • Pilot Plant Selection and Sizing
  • Location and Organization
  • Prototypes and Scale-Up
  • Stationary and Rotating Equipment
  • Utility Connections
  • Budget Control and Cost Optimization
  • Instrumentation and Control Systems
  • Safety and Alarm Systems
  • Inspection
  • Wastes and Environmental Protection

Who Should Attend

Engineers and Technicians • Operators of Pilot Plants • Maintenance Technical Personnel • 

Supervisors and Plant Managers • Consultants and Contractors • Inspectors and Technical personnel

More Information

Time: 9:30 AM - 5:30 PM Eastern Time

Please note: You can check other time zones here.


Day 1

Pilot Plant Design Concepts and Objectives

  • Pilot Plants Feasibility & Product Development
  • Prerequisites & Size Selection
  • Laboratory & Prototype Investigations: Method of Scaling up
  • Technical Characteristics of Equipment: Material Selection
  • Optimization of Costs of Construction & Operation
  • Budget Constraints & Economic Considerations
  • Project Administration: Management & Planning
  • Workshop: Case Studies & Problem Solutions

Day 2

Design Methodology & Plant Site Management

  • Design of Pilot Plants & Capacity Calculation
  • Site Location & Equipment & Piping Layouts
  • Equipment Installation, Commissioning & Start-Up
  • Selection of Instrumentation & Control System
  • Measurement and Monitoring of Pressure, Temperature & Flow Rate
  • Connection to Utilities: Electricity, Water, Steam, Compressed Air
  • Disposal of Waste & Environmental Considerations
  • Workshop: Case Studies & Problem Solutions

Day 3

Operation & Control Systems

  • Pilot Plant Start-Up Procedure
  • Operation of Pilot Plants: Batch or Continuous
  • Computer Control Systems & Performance Monitoring
  • Operating Data Acquisition and Recording
  • Safety Problems in Operation, Inspection & Hazard Estimate
  • Maintenance Management & Planning
  • Guidelines to Reduce Downtime & Costs
  • Summary & Conclusions


Mike Ivanovic, Ph.D.

Dr. Mike Ivanovic is President of UBAMIP Consulting, and also former Adjunct Associate Professor with over 30 years of experience in the field of thermal engineering. After working in the consulting group of ANSYS Canada Ltd., he now runs the private consulting company UBAMIP Consulting, dealing with analysis and problem solving in operation of vital stationary and rotating equipment in the process and petrochemical industry. Mike has also been active in providing training technical courses of various levels of complexity for professionals in industry in Canada, USA and overseas.

His area of expertize among others, includes design, operation and maintenance of various types of storage tanks, pressure vessels, piping systems, including pumps and compressors. The focus in the consulting projects has been on the risk assessment during operation and maintenance activities, as well as equipment failure analysis and accident prevention technologies based on the results of inspection and fitness for service studies.

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Fee & Credits

$1995 + taxes

  • 2.1 Continuing Education Units (CEUs)
  • 21 Professional Development Hours (PDHs)
  • ECAA Annual Professional Development Points

Group Training
This course can be customized and delivered to your group of staff at your facility, saving time and money.
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Canada Job Grant
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