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Process Plant Start-up and Commissioning



There is an alarming trend in the industry to discount the potential contribution of the Technical/Operations function to productivity improvement, product quality, and gains in market share. Principles taught in this training session will help you to understand the true nature and different techniques of problem-solving and problem prevention in the operational/process environment.

Excellent Troubleshooting skills are considered a core competency for 'Best-in-Class' industrial companies. If your company’s goals include minimizing downtime then this workshop is a must because it delivers rapid, safe Troubleshooting.

Course Objectives:

At the end of this course the participants will be able to:

  • Become a 'Top Gun' Troubleshooter by acquiring new skills
  • Develop a structured approach to Troubleshooting and Problem Solving which uses common terminology and shared understanding
  • Point the way to Continuous Improvement in the way they run their processes and make incremental efficiency gains
  • Understand the difference between having techniques manual on the bookshelf - and making it work
  • Identify the "motivated" people who should be the champions of Troubleshooting and Problem Solving - and who should just follow
  • Understand work practices which "allow" success in Troubleshooting and Problem Solving through reducing the variability of your process

Targeted Audience:

  • 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
  • Production, Maintenance Engineering, and Process Engineering personnel

Course Outlines:

Unit 1: Introduction and Preparation:

  • Introduction to Process Plant Start-Up and Commissioning
  • Organization and Roles
  • Supplementary Topics
  • Cost Estimation
  • Spare Parts Planning

Unit 2: Commissioning Strategy:

  • Commissioning Strategy
  • Mechanical Completion & Integrity Checking
  • Pre-commissioning and Operational Testing
  • Start-up/Initial Operation
  • Testing and Acceptance

Unit 3: Process Plant and Machinery Specific Issues:

  • Process Plant and Machinery Commissioning
  • Instrumentation and Control Systems
  • Preparing and Isolating Process Plant

Unit 4: Management, Planning, and Control:

  • The Start-Up and Commissioning Planning and Control
  • A Short-cut Approaches to Planning
  • Progress Monitoring and Control
  • Earned Value Analysis

Unit 5: Managing Risks during Commissioning:

  • Trouble Shooting and Problem Solving
  • Risk Management
  • Managing Safety and Quality

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