Plant Startup and Commissioning

Course details

Outcomes: At the end of the Training delegates will be able:

• Plan and prepare for plant start-up after shutdown.
• Prepare and isolate a process Plant.
• Manage Plant start up after shut down.
• Identify and control health and safety hazards in start up.
• Contribute effectively to planning and execution of Commissioning
• Troubleshoot start-up problems.
• Develop relevant operating and safety Procedures.
• Address Technical Issues of Commissioning and starting up various equipment (Pumps, Compressors, Heat exchanger etc.)

Who should attend:

This program addresses the needs of a diverse audience with an interest in Plant Start-Up and Commission, including: Operators and Maintenance Tech. with direct line responsibility as well as staff support responsibility for delivering on effective Plant Start-Up and Commissioning activities; Supervisors and Engineers, both operations and Maintenance who are involved or likely to be involved in Plant Start-up and Commissioning situations.

Course Outline:

Introduction and Preparation

• Introduction to Process Plant Start Up and Commissioning including discussion on importance of correct procedures
• Organization and Roles
• Supplementary Topics
• Cost Estimation including practical exercises in assessing cost
• Spare Parts Planning, including practical exercises in planning and managing a schedule for ordering spare parts

Commissioning Strategy

• Commissioning Strategy including a practical exercise based on designing a commissioning strategy for a machine
• Mechanical Completion & Integrity Checking by simulation
• Pre-Commissioning and Operational Testing by simulation
• Start-Up/Initial Operation, Testing and Acceptance by simulation

Process Plant and Machinery Specific Issues

• Process Plant and Machinery Commissioning
• Instrumentation and Control Systems
• Preparing and Isolating Process Plant.
• All above include practical exercises and simulations to aid understanding, group discussions, and question and answer sessions to clarify students knowledge

Management, Planning and Control

• The Start-Up and Commissioning Planning and Control - students will be asked to design and plan the start up and commissioning [process for one piece of machinery
• A Short-cut Approaches to Planning - Group Activity and brainstorming on how to carry out more efficient commissioning
• Progress Monitoring and Control - Students will be given examples of simulated machinery reports and will be asked to report to the group what has happened to the machinery
• Group discussion on Earned Value Analysis

Managing Risks during Commissioning

• Trouble Shooting and Problem Solving including practical scenarios and simulations for students to work through
• Risk Management including practical examples in risk assessment and risk management
• Managing Safety and Quality including group discussion on the importance of managing safety and quality
• Conclusion