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Process Plant Start-Up, Commissioning and Troubleshooting

Introduction

Process Plant Start-Up, Commissioning and Troubleshooting

Course Objectives

At the end of this process plant startup, commissioning, and troubleshooting course, the participants will be able to:

• Acquire advanced troubleshooting skills to become a top gun troubleshooter.
• Learn a structured approach to troubleshooting and problem-solving with a common terminology and shared understanding.
• Discover the pathway to continuous improvement in operational processes for incremental efficiency gains.
• Discern the difference between merely possessing a techniques manual and actively implementing it.
• Identify key personnel who should champion troubleshooting and problem-solving and those who should follow suit.
• Comprehend work practices that encourage success in troubleshooting and problem-solving by minimizing process variability.

Targeted

• General Managers have oversight responsibilities for plant startup and commissioning.
• Operations and Maintenance Managers have direct responsibility or staff support roles in plant startup and commissioning.
• Commissioning Managers, Engineers, and Technical Personnel are seeking support for plant startup and commissioning initiatives.
• Supervisors and Engineers from both Operations and Maintenance engaged or potential participants in Plant Startup and Commissioning.
• Production, Maintenance Engineering, and Process Engineering Staff.

Course Content

Unit 1: Introduction and Preparation

• Overview of process plant startup and commissioning.
• Organizational roles and responsibilities.
• Additional subjects.
• Techniques for cost estimation.
• Plan for spare parts.

Unit 2: Commissioning Strategy

• Develop a commissioning strategy.
• Learn about mechanical completion and integrity checks.
• Understand pre-commissioning tasks and operational testing methodologies.
• Learn about the initial phase of startup/initial operation.
• What are detailed testing and acceptance criteria?

Unit 3: Process Plant and Machinery-Specific Issues

• Specialize in commissioning for process plants and machinery.
• Commission of instrumentation and control systems.
• Learn about procedures for preparing and isolating process plants.

Unit 4: Management, Planning, and Control

• Learn about strategic planning and control for startup and commissioning.
• Accelerate planning techniques.
• Understand effective monitoring and control of progress.
• Overview introduction to earned value analysis.

Unit 5: Managing Risks during Commissioning

• Adopt best practices for troubleshooting and problem-solving.
• Stringent risk management.
• Uphold safety and quality during the commissioning process.

Unit 6: Concepts

• Explore the nature of process issues that affect performance.
• Define performance through generic variables speed, quality, and cost.
• Contextualizing effort inputs.
• Differentiate between asset-based and business process-based methods.
• Structured approaches to challenges.
• Clarify the operations process.
• Overview of configuration, operation, and optimization.
• Learn about maturity indexing in terms of planning, control, congruence, and empowerment.
• Understand the 6 significant losses and the 7 wastes concepts.

Unit 7: Tools and Techniques

• Understand the analysis of interactive and dynamic variable relationships.
• Understand the introduction to various techniques and tools.
• In-depth problem analysis.
• Learn about the practical application of tools and techniques.
• Choose the appropriate Tools and techniques methods.

Unit 8: People Issues

• Discuss the impact of working practices on empowerment.
• Learn about group dynamics and their relevance to commissioning.
• Identify individual motivators.
• Develop troubleshooting and problem-solving expertise.
• Manage change within the organization.

Unit 9: Operator, Maintainer, Designer Interface

• Foster cross-functional and teamwork skills.
• Understand the introduction to the theory of inventive problem-solving (TRIZ).
• Auditing processes against dynamic standards.
• Analyze the effects of maintenance/operations strategies.
• Develop standards and critical performance indicators.
• Emphasize life cycle costing, design for operation, and design for maintenance.
• Review of concepts, tools, and techniques.