Process Plant Start up Commissioning and Troubleshooting

Description:

The initial start-up of any plant, irrespective of size, type, or industry, is a unique occurrence. Therefore, start-up poses some special problems. Lack of experience in dealing with these problems has frequently resulted in prolonged and costly startups. This 10-day course will provide guidelines for all those involved in the execution of a project on how to achieve a successful plant start-up. The requirements for start-up oriented thinking at all stages of the project, from engineering to commissioning, will be demonstrated.

The course covers estimating of start-up costs, personnel requirements, and resources. It defines the vital role of project management and plant personnel in the preparation and planning for successful start-up of any process plant. Emphasis is on effective planning and use of available resources, both material and manpower.

Troubleshooting performed during the actual start-up can be very expensive and must be done as effectively as possible. This course demonstrate how effective troubleshooting can minimize the time and cost of going from the initial start-up to full production. The last day will provide a review of techniques and discussion of numerous examples to develop skills in troubleshooting.

Goal:

To enhance participants' knowledge, skills, and abilities necessary to anticipate and avoid financial, technical, operational, and organizational problems associated with start-up

Objectives:

By the end of this course, participants will be able to:

  • Understand start-up terminology

  • Understand how to evaluate a project

  • Determine requirement for start-up success

  • Understand plant personnel involvement

  • Be familiar with problem sources from project inception to completion

  • Understand how to minimize problems and consequences during commissioning and start-up

  • Plan for starting-up

  • Predict start-up cost

  • Minimize equipment problems

  • Understand start-up safety and environmental issues

  • Understand contractor / owner / engineering / operations involvement & responsibilities

  • Be familiar with types of project and start-up organizations

  • Be familiar with lines of responsibility/levels of supervision

  • Be familiar with decision making process

  • Be familiar with meeting coordination

  • Manage start-up manpower

  • Work as a start-up leadership

  • Understand why construction inspection, who perform construction inspection and how to perform construction inspection

  • Understand construction completion as the beginning of start-up

  • Understand commissioning as the heart of start-up

  • Perform the initial start-up activities

  • Understand the start- up troubleshooting techniques

  • Implement changes

  • Plan for shutdown and decommissioning

Outlines:

  • Terms and Tools
  • Introduction
  • Start-Up Problems
  • Discussion: Potential Problems Associated with the Project and Its Start-Up
  • Start-Up Planning
  • Start-Up Cost Prediction
  • Minimizing Equipment Problems
  • Management
  • Start-Up Safety and Environmental Issues
  • Start-Up Management
  • Start-Up Manpower
  • Start-Up Leadership
  • Discussion
  • In The Field
  • Construction Inspection
  • Construction Completion—the Beginning of Start-Up
  • Commissioning—The Heart of Start-Up
  • Start-Up Operations: Performing the Initial Start-Up Activities
  • Discussion: Troubleshooting or Commissioning, Example Situation.
  • Start- Up Troubleshooting
  • Technical Issues
  • Solutions:
  • Implementing Changes
  • Start- Up and Process Simulation (Hands-On Demonstration)
  • Shutdown and Decommissioning
  • Normal Shutdown
  • Decommissioning and Demolition