Process Plant Startup and Commissioning: Best Practices and Strategies

Introduction:

The construction of new plants and installation of new equipment presents significant technical and management challenges. Given the substantial investment involved, it is crucial for organizational personnel to become familiar with the new equipment, processes, and technologies. Additionally, developing effective operational and safety procedures is essential.

This Process Plant Commissioning and Startup course outlines the critical steps necessary for the safe, efficient, and timely initiation of new plants or facilities.

Objectives:

At the end of this Process Plant Commissioning and Startup Training Course, participants will be able to:

• Simplify the six key stages of the commissioning cycle.
• Formulate a detailed commissioning and plant startup plan.
• Manage the commissioning aspects of machinery and equipment, targeting specific issues.
• Coordinate the commissioning of electrical, instrumentation, and utility systems.
• Develop and manage procurement plans, resource plans, and budgets for commissioning.
• Apply troubleshooting and repair techniques for startup and commissioning issues.
• Assess and control risks associated with the commissioning phase.

Training Methodology:

• Management Games
• Business Organization Simulations
• Interpersonal Communication Exercises
• Lead-to-Follow Methods
• Hands-on Engagement and Exercises

Course Outline:

Unit 1: Introduction and Preparation

• Basic understanding of process plant operations
• Organizational structure and roles
• Budgeting and costing
• Acquisition of spare parts

Unit 2: Commissioning Strategy

• Establishing a commissioning plan
• Mechanical completion and integrity checking: visual inspections and operational tests
• Pre-commissioning and operational tests
• Startup and initial operation strategies
• Performance tests and acceptance facilitation

Unit 3: Process Plant and Machines-Specific Matters

• Detailed commissioning processes for plants and machines
• Business case development for plant security systems and access security barriers
• Preparation and setup of process plants for commissioning

Unit 4: Management, Planning, and Control

• Preparation and direction of plant and equipment installation and operation procedures
• Scheduling and planning of commissioning stages
• Identifying and addressing issues for efficiency
• Using performance metrics for trend analysis

Unit 5: Managing Risks During Commissioning

• Methods and procedures for troubleshooting and solving recurring problems
• Risk management principles and critical risks associated with commissioning
• Safety and quality control during the commissioning process
• Evaluating commissioning outcomes and effectiveness