Planned Shutdown, Critical Activities, Isolation, Start-up & Commissioning

What are the Goals?

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. This training course will support to create awareness of planning methods and an integrated organizational approach in the execution of successful turnarounds

By the end of this training course, participants will be able to:

• Do a successful commissioning & start Up Operations
• Learn the technical strategy for bringing the plant from being a construction site to an operating plant
• Manage the shutdown, outage & turnaround for the plant facilities
• Develop a good plan for any critical isolation activities

Who is this Training Course for?

This training course addresses the needs of a diverse audience with an interest in Commission, Plant Start-up and Shut down, including:

• Operation Engineers who have oversight responsibility for Plant Commissioning, Start-up and shut down
• Maintenance Engineers with direct line responsibility as well as staff support responsibility for delivering on effective Plant Start-up & shutdown
• Plant Start-up and Commissioning Managers and Engineers
• Technical personnel & supervisors involved in supporting Plant Start-up & shutdown

Daily Agenda

Day One: Introduction to Start Up & Shutdown Operation and Methodology

• The startup Universal Process definition
• Terminology & Definitions
• Project life cycle
• Contracting Strategy
• Why to Effectively Manage Start-Up
• Avoiding start up delays & problems
• Start Up key dates
• Commissioning & start up flow process
• What Makes Commissioning and Plant Startup Difficult

Day Two: Pre-commissioning & Mechanical Completion

• Organization & Roles
• Commissioning & Start up team organization & structure
• Startup task force responsibilities
• Commissioning & start up manger role
• Project planning & work breakdown structure
• The critical path method CPM
• Spare parts management process
• What is startup check list? & how to prepare a check list? Punch list preparation & filtering
• Inspecting pipe lines & plant facilities
• Commissioning tests & recommended practices

Day Three: Shutdown / Turnaround Operations

• Introduction to Shut down and Turnaround Management
• The Shutdown Management Process
• Organization and Roles
• Plant Shutdown and Preparation for Maintenance
• Scope of Work Development and Work Breakdown Structures
• Preparation and Execution Issues
• Logistics, infrastructure and materials management
• Developing Shutdown and Turnaround Plans
• The Critical Path Planning Method
• Developing the overall Shutdown Plan
• Shut down Progress Monitoring and Control

Day Four: Isolation & Critical Activities

• Types of Isolation
• Mechanical & Electrical isolation
• Isolation standards & techniques
• Documents necessary prior starting the plant isolation
• Confined space Entry requirements
• Pigging & smart pigging prior plant start up

Day Five: Start-up & Initial Operation

• Utilities start up
• Process units start up
• Sources of problems during the startup operations
• Hazards associated with the startup operation
• Risks or Startup Faults
• Performance & acceptance testing
• Closed-Out Certificates
• Lining up the Plant facilities
• Coordination and Supervision during Start-up