Process Plant Start-up Commissioning & Troubleshooting
The aim of this course is to provide participants with a complete and up-to-date over view of the pre-commissioning, commissioning and start up activities of process plants. The course will also cover the preparation and closing out of plant punch list and the troubleshooting of the start-up process.
Upon successful completion of this course participants will gain enough skills anticipate and avoid problems associated with such start- up processes.
Further this course will provide participants with a satisfactory understanding of the commissioning strategy, organizational issues, estimation of required resources CPM planning, mechanical integrity, troubleshooting, start- up operations, technical inspections, instrumentations / control system, HSE and much other necessary knowledge associated with the oil and gas plant start-up and commissioning.
Actual case study from around the world will be demonstrated to highlight the course topics discussed.
Upon completion of this course the participants will be able to:-
- Have a good understanding of process plant pre-commissioning and commissioning including their terminology, requirements, organizational structures & responsibility.
- Have a good understanding of process plant punch list category, preparation and closed out.
- Recognize health, safety and environment principles as applied in process plant commissioning, start-up & troubleshooting.
- Review process plant start-up management including the responsibility, authorities, organizational structure, and manpower & staffing.
- Design an effective process plant commissioning strategy and become familiar with mechanical integrity testing & pre-commissioning.
- Understanding & carry out technical inspection and dynamic hydraulic testing and become familiar with the procedure on structure completion.
- Know the concept of machinery commissioning including the types of process equipment plant machinery, preparation of machines and compressors commissioning.
- Review and employ troubleshooting and problems solved procedures.
•GeneralManagers
• Operations andMaintenanceManagers
• Plant Start-up and Commissioning Managers and Engineers
• Technical personnel supporting Plant Start-up and commissioning activities
• Supervisors and Engineers, both operations andmaintenance
This interactive training course includes the following training methodologies as a percentage of the total tuition hours:-
- 30% Lectures, Concepts, Role Play
- 30% Workshops & Work Presentations, Techniques
- 20% Based on Case Studies & Practical Exercises
- 20% Videos, Software & General Discussions
- Pre and Post Test
Course Outline
PRE -TEST
- Introduction to process plant commissioning Terminology, Requirement, Project details, Contacting strategy, Organizational structure & Responsibility, Success measures and problems avoidance.
- Planning and preparation.
- Project Planning, Critical Path, Gantt chart, Logic Diagrams, Planning methods.
- Preparation of Checklists & Spare parts Planning.
- Health, safety and environment.
- Hazard and Operability Analysis (HAZOP), Hazard Analysis (HAZAN), Process Safety Management (PSM), Root Cause Analysis and why trees.
- Risk assessment, Hazard identification, Safety training, HSE problems and contingency plans; safety procedures and implementation.
- Process plant operation management.
- Responsibility and Authorities; Organizational structure; Manpower staffing, Coordination Procedures, Leadership.
- Process plant commissioning strategy.
- The commissioning team, training, commissioning strategy, Startup procedures & logic.
- Mechanical integrity testing and pre-commissioning.
- Hydraulic test, Flushing, Breaking-in pumps, Drying heaters.
- Technical inspection and dynamic hydraulic testing.
- Vessel and columns internals, Dynamic loop testing, Tightness testing.
- Construction completion (beginning of startup).
- Construction schedules vs. start-up needs; start –up by systems; systems definitions;Punch listing; Hand over.
- Punch list preparation.
- Machinery commissioning.
- Types of process equipment plant machinery, Preparation of machines, compressors commissioning and compressor surge.
- Start-up operations.
- Isolation of vessels and pips, types of isolations, Initial startup activities,
- Steaming, Fuel gas or nitrogen purge, feed-in.
- Start-up progress monitoring and control.
- Planning for success, sequence by Units, Sequence by systems, recovery from false start.
- Instrumentation and control systems.
- Instrument commissioning, Startup problems & causes.
- Performance trails.
- Performance and Acceptance testing, preliminary tests, performance test runs.
- Troubleshooting and problems solving.
- Identification of problems & properties; Allocation & teamwork; Data collection & solution Selection, Troubleshooting techniques; RCFA & RCM.
- Change management.
- Implementations of change; Success measures; Operational techniques, Post commissioning Audit, Closed –out Certificates.
- Case studies.
- Post test