The Principles and Techniques of Process Operation, Start Up, Shutdown and Troubleshooting

Objectives

• The 9 key Elements of Successful Plant Commissioning.
• Startup Sequence and General Commissioning Procedures
• How to Operate the major plant equipment’s efficiently and Shutdown safely.
• How to Do Troubleshooting for the major plant equipment’s.
• How to manage risks, health, safety and environment issues in Plant Operation and Shutdown environment.
• Recognize the Human Factors affecting the Operation, Start-up and Shutdown of the process plant.
• Familiar with the Troubleshooting Techniques for the Process Plant Equipment’s 

Outline

The 9 key Elements of Successful Plant Commissioning;

• Planning.
• Mechanical Completion.
• P&ID Checking
• Pre-Commissioning
• Commissioning
• Start-up
• Initial Operation
• Performance Testing
• Post-Commissioning

Startup Sequence and General Commissioning Procedures

• Operational checkout list.                  
• Hydrostatic testing.
• Final inspection of vessels.
• Flushing of lines.
• Instruments.   
• Acid cleaning of compressor lines.
• Breaking in pumps.                
• Breaking in compressors.
• Dry-out and boil-out.             
• Catalyst loading.
• Tightness test Work
• Plant units commissioning

Pumps;

• Operations.
• Start-up and Shutdown.
• Troubleshooting.
• Case Studies
• Cooling Water.
• Fire Water.
• Boiler feed water.
• Waste water; API units.

Compressors;

• Operations.
• Start-up and Shutdown.
• Troubleshooting.
• Case Studies;
• Instrument air compressors.
• Gas compressors.

Steam Boilers;

• ASME Guidelines for Water Quality and ABMA for Steam Purity
• Operations.
• Start-up and Shutdown.
• Troubleshooting.
• Case Studies;
• BFW – Problems and Solutions Cooling Water.
• Steam systems; Snuffing Steam.

Fractionation and distillation;

• Operations.
• Start-up and Shutdown.
• Troubleshooting.
• Case Studies;
• De-ethanizer.

Heat Exchangers;

• Operations.
• Start-up and Shutdown.
• Troubleshooting.
• Case Studies;
• The factors affecting the design of Heat Exchangers.

Fired Equipment’s – Furnace / Heaters;

• Operations.
• Start-up and Shutdown.
• Troubleshooting
• Case Studies
• Drying out importance.

Reactors

• Operations.
• Start-up and Shutdown.
• Troubleshooting.
• Case Studies
• Catalyst loading / unloading.
• Catalysts Deactivation

Separators;

• Operations.
• Start-up and Shutdown.
• Troubleshooting.
• Case Studies;
• Horizontal / Vertical Types.

Relief Systems;

• Operations.
• Start-up and Shutdown.  
• Troubleshooting.
• Case Studies; High Flare Tips change out.

Human Factors;

• The Human Factors Analysis and Classification System (HFACS)
• The HFACS taxonomy (Four Level)
• HFACS Level 1: Unsafe Acts

  • HFACS Level 2: Preconditions for Unsafe Acts
  • HFACS Level 3: Unsafe Supervision
  • HFACS Level 4: Organizational Influences

• Training and Performance
• Incident Investigation
• Audits and Corrective Action

Who Should Attend ?

Operations, maintenance staff, peoples who are working with the day to day plant activities.