Process Plant Start-up, Commissioning & Troubleshooting

DAY 1:

Introduction and Preparation

• Introduction to Process Plant Start-Up and Commissioning

• Organization and Roles

• Supplementary Topics

• Cost Estimation

• Spare Parts Planning

DAY 2:

Commissioning Strategy

• Commissioning Strategy

• Mechanical Completion & Integrity Checking

• Pre-commissioning and Operational Testing

• Start-up/Initial Operation, Testing, and Acceptance

DAY 3

Process Plant and Machinery Specific Issues

• Process Plant and Machinery Commissioning

• Instrumentation and Control Systems

• Preparing and Isolating Process Plant

DAY 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

DAY 5:

Managing Risks during Commissioning

• Trouble Shooting and Problem Solving

• Risk Management

• Managing Safety and Quality

• Conclusion

DAY 6:

Concepts

• The nature of process problems affecting performance

• Performance defined in terms of generic variables: Speed, Quality and Cost

• Effort inputs in context - Asset-based or Business Process-based

• Structured approach - The Operations Process redefined

• Configuration; Operation; and Optimization

• Maturity Indexing: Planning, Control, Congruence, Empowerment

• 6 Big Losses, 7 Wastes

DAY 7:

Tools and Techniques - Practical Experience

• Interactive and Dynamic variable relationships analysis

• Techniques introduction

• Tools introduction

• Problem Analysis

• Practical Use of Tools and Techniques

• Case Studies

• Tools & Techniques - selecting the right one

DAY 8:

People Issues

• Working practices - empowerment or impairment?

• Group dynamics

• Individual motivators

• Developing Troubleshooting and Problem-Solving skills

• Managing change

DAY 9:

Operator, Maintainer, Designer Interface

• Cross-functional and Teamworking

• Introduction to the Theory of Inventive Problem Solving

• Auditing your process to a dynamic standard

• Effect of Maintenance/Operations strategy

• Development of Standards and Key Performance Indicators

• Life Cycle Costing, Design for Operation, Design for Maintenance

DAY 10:

Open Forum

• Revisit Concepts, Tools and Techniques

• Your Problems - Case Studies

• Your Action Plan

• Wrap up