Course Overview

Process plant commissioning and start-up refer to both new facilities and restarting an existing plant after major modifications. Commissioning and start-up of new plant and equipment presents both a major technical and management challenge. The initial start-up of any plant, irrespective of size, type, or industry, is a unique occurrence. Therefore, the start-up phase poses some special problems. Lack of experience in dealing with these problems has frequently resulted in prolonged and costly start-ups.An organization’s personnel must familiarize themselves with the new equipment, processes and technologies, and develop the relevant operating and safety procedures.Successful commissioning of new facilities involves all the activities of: preparation and planning; mechanical completion and integrity checking; P&ID checking and verification; pre-commissioning and operational testing; commissioning; start-up; initial operation; performance testing and acceptance and post-commissioning. It is also imperative that close relations be maintained amongst all parties involved in the project in order to ensure successful commissioning. Ultimately, any delay in commissioning for whatever reason, whether due to insufficient preparations, incidents or mishaps, results in a loss of revenue for the owner.

Course Objectives

Upon completion of this course, the trainees will be aware and understanding of the following:

• The nine key activities/steps of the commissioning process
• How to develop and overall commissioning and plant start-up strategy
• How to deal with machinery and equipment specific commissioning issues
• How to manage issues dealing with the commissioning of Electrical, Instrumentation and Utilities Systems
• How to develop an overall commissioning management plan, resource planning and commissioning
• Troubleshooting and Problem Solving strategies which can be applied during commissioning

Who Should Attend?

• Technical personnel involved in supporting Plant Commissioning and Start-up activities;
• Supervisors and Engineers, both operations and maintenance who are involved or likely to be involved in Plant Commissioning and Start-up activities;
• Team Leaders, Project Managers, Refinery Managers, Plant Managers, Section Heads, Plant Supervisors, Process Engineers, technical staff and contractor personnel involved in project execution and plant Commissioning and Start-up in the Oil and Gas Process industry;
• Managers and specialists who lead or facilitate in the designing, selecting, specifying, operating, installing, repairing and trouble-shooting of oil and gas processing facilities;

Course Contents

Module (01) Introduction

• Overview and Definitions
• Introduction to Process Plant Commissioning and Start-up
• Terminology
• Project Requirements and Details
• Contracting Strategies
• Organizational Structure & Responsibilities
• Success Measures and Problem Avoidance

Module (02) Preparation and Planning

• Project Planning
• Cost Estimation
• Critical Path (CPM/PERT)
• Gantt Chart
• Logic Diagrams
• Planning Methods
• Preparation of Checklists and Spare Parts Planning
• Spare Parts Planning

Module (03) Commissioning Activities

• Commissioning strategy
• Mechanical completion and integrity checking
• P&ID checking and verification
• Pre-commissioning and operational testing
• Commissioning
• Start-up
• Initial operation
• Performance testing and acceptance
• Post-commissioning

Module (04) Machinery Commissioning and Specific Issues

• Process Plant and Machinery Commissioning
• Types of Process Equipment Plant Machinery
• Preparation of Machines and Equipment
• Instrumentation and Control Systems
• Preparing and Isolating Process Plant

Module (05) Start-Up Progress Monitoring and Control

• The Start Up and Commissioning Planning and Control, Planning for Success
• Start-up sequence by Units
• Progress Monitoring and Control
• Recovery from False Start-ups

Module (06) Managing Risks during Commissioning

• Trouble Shooting and Problem Solving
• Risk Management
• Managing Safety and Quality
• Change Management and Implementation of Change
• Success Measures
• Operational Techniques