Process Plant Start-Up, Commissioning, and Troubleshooting Strategies

Introduction:

In today’s world, there is a growing tendency to underestimate the significant potential of the Technical/Operations function in driving productivity improvements, enhancing product quality, and increasing market share. This session is designed to improve understanding of the approaches used to solve operational/process-related problems and implement measures to prevent their recurrence.

This Process Plant Start-Up, Commissioning, and Troubleshooting Strategies workshop is vital as it aligns with the goals of companies striving to be Best-in-Class, especially if your corporation aims to reduce downtime.

Attendees of this seminar come from diverse industries such as chemical engineering, mechanical engineering, and process engineering. It is valuable for engineers interested in plant start-up, commissioning, and troubleshooting, providing both seasoned professionals and fresh graduates with the opportunity to improve or build a solid foundation of knowledge and skills.

The Process Plant Start-Up, Commissioning, and Troubleshooting Strategies course brings together professionals from oil and gas, petrochemicals, pharmaceuticals, and power industries, all eager to learn about the efficient operation of process plants, which rely heavily on operational excellence.

Objectives:

By the conclusion of the Process Plant Start-Up, Commissioning, and Troubleshooting Strategies seminar, participants will:

• Master advanced troubleshooting techniques to excel in plant start-up and commissioning procedures.
• Recognize the need for a shared problem-solving language to address issues systematically.
• Implement operational improvements that lead to incremental efficiency gains.
• Differentiate between having a techniques manual and effectively applying it in practice.
• Identify motivated individuals and empower them to lead troubleshooting and problem-solving initiatives.
• Develop work habits that contribute to successful troubleshooting by reducing process variability.

Training Methodology:

• Interactive expert-led lectures
• Case studies and real-world examples
• Group discussions
• Simulation exercises
• Problem-solving workshops
• Troubleshooting case studies
• Process optimization demonstrations
• Continuous improvement exercises
• Experience sharing and best practices

Course Outline:

Unit 1: Introduction to Plant Start-Up and Commissioning Process:

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

Unit 2: Commissioning Strategy:

• Outlining the Initial Commissioning Strategy
• Completion and Integrity Checking Mechanisms
• Pre-Commissioning and Operational Testing Activities
• Preliminary Operation During Start-Up Phase
• Testing, Completion, and Acceptance

Unit 3: Process Plant and Machinery-Specific Issues:

• Commissioning Peculiarities in Process Plants and Machinery
• Instrumentation and Control Systems in Commissioning
• Process Plant Isolation and Procedures

Unit 4: Management, Planning, and Control:

• Planning and Control Strategies for Start-Up and Commissioning
• Short-Cut Planning Methods
• Progress Assessment and Control
• Measuring Start-Up and Commissioning Progress Using Earned Value Analysis

Unit 5: Managing Risks during Commissioning:

• Efficient Plant Start-Up Procedures and Troubleshooting Concepts
• Risk Management Principles
• Ensuring Safety and Quality in Plant Start-Up and Commissioning

Unit 6: Commissioning Concepts:

• Process Problems Affecting Performance
• Key Performance Metrics: Speed, Quality, and Cost
• Asset-Based or Business Process-Oriented Approaches
• Systematic Operations Review and Redefinition
• Maturity Assessment in Planning, Control, and Empowerment
• Big Six Losses and Seven Waste

Unit 7: Tools and Techniques:

• Analyzing Relationships Between Interactive and Dynamic Variables
• Drawing Techniques and Tools
• Understanding and Addressing Problems
• Applying Tools and Techniques Effectively

Unit 8: People Issues in Plant Commissioning:

• Practices that Enhance or Hinder Work Practices
• Team Dynamics and Motivation
• Developing Troubleshooting and Problem-Solving Capabilities
• Managing Changes During Plant Commissioning

Unit 9: Interaction of the Operator, Maintainer, and Designer:

• Cross-Discipline and Team Cooperation
• Problem-Solving Strategies and Technologies
• Comparing Processes Against Static Models
• Impact of Maintenance/Operations Strategies
• Standardization and KPI Development
• Operation and Maintenance Concepts, Affordable Zero-Day Design, and Life Cycle Activity
• Introduction to Key Concepts, Tools, and Techniques