Process Plant Start-up, Commissioning, and Troubleshooting

About the Course

Process Plant Commissioning and Start-up refer to new facilities and restarting an existing plant after significant modifications. Commissioning and start-up new plant and equipment presents a significant technical and management challenge. The initial start-up of any plant, irrespective of size, type, or industry, is a unique occurrence. Therefore, the start-up phase poses some particular problems. Lack of experience in dealing with these problems has frequently resulted in prolonged and costly start-ups.

This 5-day interactive Process Plant Start-up, Commissioning, and Troubleshooting training course will assist all organisations' personnel familiarise themselves with the new equipment, processes, and technologies and develop the relevant operating and safety procedures. Successful commissioning of new facilities involves all the activities of preparation and planning, mechanical completion and integrity checking, P&ID checking and verification, pre-commissioning and operational testing, commissioning, start-up, initial operation, performance testing and acceptance, and post-commissioning. It is also imperative that close relations be maintained amongst all parties involved in the project to ensure successful commissioning. Ultimately, any delay in commissioning for whatever reason, whether due to insufficient preparations, incidents or mishaps, results in the owner's revenue loss.

Core Objectives

The delegates will achieve the following objectives:

• The key activities/steps of the commissioning process
• Develop an overall commissioning and plant start-up strategy
• Understand how to deal with machinery and equipment-specific commissioning issues
• Know how to manage issues dealing with the commissioning of Electrical, Instrumentation, and Utilities Systems
• Develop an overall commissioning management plan, resource planning and commissioning
• Acquire troubleshooting and problem-solving strategies which can be applied during commissioning

Training Approach

This training course employs a blended learning approach, combining interactive classroom sessions. Real-life case studies and practical exercises will reinforce theoretical concepts, offering delegates a hands-on experience. The training materials cater to diverse learning styles, fostering engagement and knowledge retention.

The Attendees

This training course provides a complete and up-to-date overview of the process plant start-up and commissioning for those involved in the start-up operations of a process plant.

Likewise, it will be valuable to the professionals but not limited to the following:

• Team Leaders
• Project Managers
• Refinery Managers
• Plant Managers and Supervisors
• Process Engineers, Technical Staff and Contractor Personnel
• Technical personnel involved in supporting Plant Commissioning and Start-up activities
• Supervisors and Engineers, both operations and maintenance, who are involved or likely to be involved in Plant Commissioning and Start-up activities
• Managers and Specialists who lead or facilitate in the designing, selecting, specifying, operating, installing, repairing and troubleshooting of oil & gas processing facilities

Daily Discussion

DAY ONE: INTRODUCTION TO PROCESS PLANT COMMISSIONING AND START-UP

• Overview and Definitions
• Terminology
• Project Requirements and Details
• Contracting Strategies
• Organisational Structure & Responsibilities
• Success Measures and Problem Avoidance
• Project Planning
• Cost Estimation
• Critical Path (CPM/PERT)
• Gantt Chart
• Logic Diagrams

DAY TWO: COMMISSIONING ACTIVITIES

• Planning Methods
• Preparation of Checklists and Spare Parts Planning
• Spare Parts Planning
• Commissioning Strategy
• Mechanical Completion and Integrity Checking
• P&ID Checking and Verification
• Pre-commissioning and Operational Testing
• Commissioning

DAY THREE: MACHINERY COMMISSIONING AND SPECIFIC ISSUES

• Start-up
• Initial Operation
• Performance Testing and Acceptance
• Post-commissioning
• Process Plant and Machinery Commissioning
• Types of Process Equipment Plant Machinery

DAY FOUR: START-UP PROGRESS MONITORING AND CONTROL

• Preparation of Machines and Equipment
• Instrumentation and Control Systems
• Preparing and Isolating Process Plant
• The Start Up and Commissioning Planning and Control: Planning for Success
• Start-up Sequence by Units
• Progress Monitoring and Control
• Recovery from False Start-ups

DAY FIVE: MANAGING RISKS DURING COMMISSIONING

• Trouble Shooting and Problem Solving
• Risk Management
• Managing Safety and Quality
• Change Management and Implementation of Change
• Success Measures
• Operational Techniques
• Key Concepts and Practical Applications