Process Plant Startup, Commissioning, and Troubleshooting Techniques

Introduction:

In today’s volatile and competitive environment, the strategic role of technical and operational techniques in process plant operations is often underappreciated. However, these techniques are crucial for enhancing productivity, improving product quality, and gaining market share. Mastery of troubleshooting and problem-solving is essential for maintaining operational efficiency and minimizing downtime.

This Process Plant Startup, Commissioning, and Troubleshooting Training Course is designed to impart foundational principles of problem-solving and preventive strategies within operational and process environments. It aims to equip participants with advanced troubleshooting skills and effective methodologies for minimizing system downtimes.

Objectives:

By the end of this course, participants will:

• Develop advanced troubleshooting skills to excel in challenging situations.
• Follow a structured approach to problem analysis and resolution using common terminology.
• Implement systems for continuous improvement to enhance operational efficiency.
• Distinguish between having a techniques manual and actively applying its methods.
• Identify key personnel responsible for leading and supporting troubleshooting activities.
• Minimize process variability to promote effective troubleshooting practices.

Training Methodology:

• Case Studies
• Games
• Practice and Application
• Class Discussions
• Role Exercises
• Lectures
• Interactive Sessions

Course Outline:

Unit 1: Introduction and Preparation

• What is plant start-up and commissioning?
• Organizational roles and responsibilities
• Ancillary techniques
• Methods for cost calculation
• Spare parts planning

Unit 2: Commissioning Strategy

• Developing a commissioning strategy
• Checking mechanical completion and integrity
• Pre-commissioning tasks and methodologies
• Initial operation steps
• Detailed testing and acceptance criteria

Unit 3: Process Plant and Machinery-Specific Issues

• Instrumentation and C&I systems commissioning
• Preparation and clearing procedures for process plants

Unit 4: Management, Planning, and Control

• Strategic planning and control for start-up and commissioning
• Fast-tracked planning techniques
• Progress assessment and control
• Overview of Earned Value Analysis

Unit 5: Managing Risks during Commissioning

• Applying systems engineering practices
• Effective risk management
• Adhering to safety and quality assurance standards

Unit 6: Ideas

• Process issues impacting performance
• Performance variables: speed, quality, cost
• Asset-based vs. business process-based approaches
• Stepwise problem-solving
• Introduction to configuration, operation, optimization
• Maturity indexing: planning & control, congruence & empowerment
• Understanding the 6 big losses and 7 wastes

Unit 7: Tools and Techniques

• Analyzing interactive and dynamic variables
• Introduction to various techniques and tools
• Detailed understanding of problems
• Practical aspects of tools and techniques
• Selecting appropriate methods

Unit 8: People Issues

• Impact of working practices on individuals
• Insights into group dynamics during commissioning
• Identifying intrinsic and extrinsic motivators
• Managing sponsor complaints
• Conducting organizational change management

Unit 9: Operator, Maintainer, Designer Interface

• Enhancing cross-functional collaboration and teamwork
• Basics of inventive problem-solving (TRIZ)
• Auditing processes with changing standards
• Evaluating maintenance/operations strategies
• Establishing benchmarks and minimum standards
• Life cycle cost management and proactive design
• Review of concepts, tools, and techniques