Process Plant Start-up with Commissioning and Troubleshooting

Overview:

Introduction:

This conference is designed to equip participants with comprehensive knowledge and skills essential for process plant start-up, commissioning, and troubleshooting. Through it, participants will learn effective strategies and methodologies to ensure efficient and safe operations in various industrial settings.

Conference Objectives:

At the end of this conference, participants will be able to: 

• Become a 'Top Gun' Troubleshooter by acquiring new skills.

• Develop a structured approach to Troubleshooting and Problem Solving which uses a common terminology and shared understanding.

• Point the way to Continuous Improvement in the way they run their processes and make incremental efficiency gains.

• Understand the difference between having a techniques manual on the bookshelf - and making it work.

• Identify the "motivated" people who should be the champions of Troubleshooting and Problem Solving - and who should just follow.

• Understand work practices which "allow" success in Troubleshooting and Problem Solving through reducing the variability of your process.

Targeted Audience:

• 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.

• Production, Maintenance Engineering, and Process Engineering personnel.

Conference Outlines:

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.

• Approaches for 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.

Unit 6:

Concepts:

• The nature of process problems affecting performance.

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

• Effort inputs in the 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.

Unit 7:

Tools and Techniques:

• Interactive and Dynamic variable relationships analysis.

• Techniques introduction.

• Tools introduction.

• Problem Analysis.

• Practical Use of Tools and Techniques.

• Tools & Techniques - selecting the right one.

Unit 8:

People Issues:

• Working practices - empowerment or impairment?

• Group dynamics.

• Individual motivators.

• Developing Troubleshooting and Problem-Solving skills.

• Managing change.

Unit 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.

• Revisit Concepts, Tools, and Techniques.

Unit 10:

Case Studies and Real-World Applications:

• Real-World Case Studies: Review of successful process plant start-up and commissioning projects.

• Lessons Learned: Analysis of challenges faced and solutions implemented in various projects.

• Industry Best Practices: Discussion on industry best practices and their application in real scenarios.

• Project Simulations: Simulated scenarios to apply knowledge gained and test problem-solving skills.

• Continuous Improvement: Strategies for continuous improvement and optimization post-commissioning.