PROGRAM DETAILS

Introduction

Process plant commissioning and start-up refer to both new facilities and restarting an existing plant after major modifications. Commissioning and start-up of new plant and equipment presents both a major 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 special problems. Lack of experience in dealing with these problems has frequently resulted in prolonged and costly start-ups. An organization’s personnel must familiarize 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 in order to ensure successful commissioning. Ultimately, any delay in commissioning for whatever reason, whether due to insufficient preparations, incidents or mishaps, results in a loss of revenue.

This seminar is intended to provide participants with a complete and up-to-date overview of the start-up and commissioning of Process Plants. The seminar will also cover the troubleshooting of the start-up process. Upon the successful completion of this seminar, participant will have gained enough skills to anticipate and avoid problems associated with such start-up processes. Further, this seminar will provide participants with a satisfactory understanding of the commissioning strategy, organizational issues, estimation of required resources, planning, mechanical integrity, troubleshooting, start-up operations, technical inspection, instrumentation/control systems, HSE and much other necessary knowledge associated with the petrochemical plant start-up and commissioning.

Learning Objectives

 Upon completion of this seminar, participants will have a good knowledge of:

• The key activities of the commissioning process
• How to develop and overall commissioning and plant start-up strategy
• How to deal with machinery and equipment specific commissioning issues
• How to manage issues dealing with the commissioning of Electrical, Instrumentation and Utilities Systems
• How to develop an overall commissioning management plan, resource planning and commissioning budget
• Troubleshooting and Problem Solving strategies which can be applied during commissioning
• How to manage risks associated with Commissioning and Start-up of new facilities

Target Audience

This seminar addresses the needs of a diverse audience with an interest in Plant Commissioning and Start-up, including:

• Senior Personnel who have oversight responsibility for Plant Commissioning and Start-up
• Operations and Maintenance Professionals with direct line responsibility as well as staff support responsibility for delivering on effective Plant Commissioning and Start-up
• Plant Commissioning and Start-up Officers and Engineers
• Supervisors and Engineers, both operations and maintenance, who are involved or likely to be involved in Plant Commissioning and Start-up activities
• Team Leaders, Project Professionals, Refinery Personnel, Plant Engineers, Section Heads, Plant Supervisors, Process Engineers, technical staff and contractor personnel involved in project execution and plant Commissioning and Start-up in the Oil and Gas Process industry
• Mechanical, Electrical, Instrumentation and Control Engineers who are involved in Process Plant Start-up and Commissioning.

Training Methodology

This highly interactive seminar is based on adult learning concept. It incorporates inspiring lectures with structured lessons from the learning manual; PowerPoint slides and videos to enhance learning; ongoing discussions with action planning as well as ample time for Q & A.

Program Content

Day 1

Introduction

• Overview and Definitions
• Introduction to Process Plant Commissioning and Start-up
• Terminology
• Project Requirements and Details
• Contracting Strategies
• Organizational Structure & Responsibilities
• Success Measures and Problem Avoidance
•  

Preparation and Planning

• Project Planning
• Cost Estimation
• Critical Path (CPM/PERT)
• Gantt Chart
• Logic Diagrams
• Planning Methods
• Preparation of Checklists and Spare Parts Planning
• Spare Parts Planning

Day 2

 Commissioning Activities

• Commissioning strategy
• Mechanical completion and integrity checking
• P&ID checking and verification
• Pre-commissioning and operational testing
• Commissioning
• Start-up
• Initial operation
• Performance testing and acceptance
• Post-commissioning

 Day 3

 Machinery Commissioning and Specific Issues

• Process Plant and Machinery Commissioning
• Types of Process Equipment Plant Machinery
• Preparation of Machines and Equipment
• Instrumentation and Control Systems
• Preparing and Isolating Process Plant

 Day 4

 Start-Up Progress Monitoring and Control

• 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 5

 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