Process Plant Start Up Commissioning & Troubleshooting

Process Plant Start Up Commissioning & Troubleshooting

OBJECTIVES

• How to become a Top Gun Troubleshooter by acquiring new skills
• To develop a structured approach to Troubleshooting and Problem Solving this uses a common terminology and shared understanding
• To point the way to Continuous Improvement in the way you run your processes and make incremental efficiency gains
• To understand the difference between having a techniques manual on the bookshelf and actually making it work
• To identify the motivated people who should be the champions of Troubleshooting and Problem Solving and who should just follow
• To understand work practices which allow success in Troubleshooting and Problem Solving through reducing the variability of your process?

WHO SHOULD ATTEND?

• This course is directed at those Supervisors who are involved in the operations function and who are responsible for leading and directing people to achieve and improve productivity levels
• Those faced with the challenge of actually using the various techniques of Troubleshooting and Problem Solving to reduce downtime and waste and improve run efficiencies will benefit
• The course elements are of equal importance to Production, Maintenance Engineering and Process Engineering personnel

COURSE OUTLINE

Introduction and Preparation

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

Commissioning Strategy

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

Process Plant and Machinery Specific Issues

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

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

Managing Risks during Commissioning

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

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

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 and Techniques – selecting the right one

People Issues

• Working practices – empowerment or impairment?
• Group dynamics
• Individual motivators
• Developing Troubleshooting and Problem Solving skills
• Managing change

Operator, Maintainer, Designer Interface

• Cross functional and Team working
• 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

Open Forum

• Revisit Concepts, Tools and Techniques
• Action Plan