Process Plant Start-up and Commissioning

Introduction:

Start-Up and Commissioning of new plant and equipment presents both a major technical and management challenge. An organization’s personnel must familiarise themselves with new equipment, processes, and technologies, develop the relevant operating and safety procedures.

This program addresses in an integrated manner the key activities involved in the safe, effective, and timely commissioning and start-up of a new plant or facility

Targeted Groups:

• General Managers who have oversight responsibility for Plant Start-up and Commissioning
• Operations and Maintenance Managers with direct line responsibility as well as staff support responsibility for delivering on effective Plant Start-up and Commissioning
• Plant Start-up and Commissioning Managers and Engineers
• Technical personnel involved in supporting 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 Objectives:

At the end of this course the participants will be able to:

• Understand the six key stages of the commissioning process
• Develop an overall commissioning and plant start-up strategy
• Deal with machinery and equipment specific commissioning issues
• Manage issues dealing with the commissioning of Electrical, Instrumentation and Utilities Systems
• Develop an overall commissioning management plan, resource plan and budget
• Apply troubleshooting and problem-solving strategies to address issues commonly arising during start-up and commissioning
• Manage risks associated with commissioning

Targeted Competencies:

• The key stages of the commissioning process
• Balancing the technical and management challenges of commissioning
• Dealing with machinery and equipment specific commissioning issues
• Managing risks and solving the types of problems likely to occur during commissioning

Course Content:

Unit 1: Introduction and Preparation:

• Introduction to Process Plant Start-Up and Commissioning
• Organization and Roles
• Supplementary Topics
• Cost Estimation
• Spare Parts Planning

Unit 2: Commissioning Strategy:

• Commissioning Strategy
• Mechanical Completion & Integrity Checking
• Pre-commissioning and Operational Testing
• Start-up/Initial Operation
• Testing and Acceptance

Unit 3: Process Plant and Machinery Specific Issues:

• Process Plant and Machinery Commissioning
• Instrumentation and Control Systems
• Preparing and Isolating Process Plant

Unit 4: Management, Planning, and Control:

• The Start-Up and Commissioning Planning and Control
• A Short-cut Approaches to Planning
• Progress Monitoring and Control
• Earned Value Analysis

Unit 5: Managing Risks During Commissioning:

• Trouble Shooting and Problem Solving
• Risk Management
• Managing Safety and Quality
• Conclusion