Pre-Commissioning, Commissioning & Start-Up

Pre-Commissioning, Commissioning & Start-Up

Date/Time: Date(s) - 15/08/2022 - 19/08/2022( 8:00 am - 5:00 pm )
Location: Malaysia, Kuala Lumpur


Course Objectives

  • Improve work efficiency and effectively by understanding the 9 key elements of successful plant commissioning so that you can be done your work without any incident, on time, and on budget.
  • Enhance safety aspect knowledge to minimize the incident happen by learning the risk analysis and safety procedures available in the industry.
  • Prevent incidents occur by learning the past case histories and planning solutions so that the operation will be done well and without incident happening.

Who should Attend?

  • The course is designed for, but not limited to key personnel who are responsible for commissioning, start-up, acceptance and operation of new processing facilities or revamping projects such as Managing Directors, Vice Presidents, COOs, Heads, GMs, Senior
  • Managers, Section Leaders, Team Leaders, engineers and Superintendents from several departments: Plant, Commissioning, Plant Start-Up, Plant Engineers, Operations, Equipment Specialist, Construction Department, Contractors, Asset Integrity, Facilities Management, Safety, Factory

Outlines

  • Elements of Successful Plant Commissioning
  • 9 Key Elements of Successful Plant Commissioning
    A step by step guide
    • Planning
    • Mechanical completion
    • P&ID checking
    • Pre-Commissioning
    • Commissioning
    • Start-up
    • Initial operation
    • Performance testing
    • Post commissioning
  • Strategic Planning and Management—Commissioning
  • Phases PART 1
    • Prepare to Plan
    • Tactical Planning – Manage the Commissioning Project to Deliver Producing units.
    • Oversee Shutdown – Purging, Clean Up, Zero Energy, Isolating, Vessel Entry
    • Oversee Preventive Maintenance, Inspections, Tests, Repair, Overhaul, Rebuild, Replacement
    • Overwatch Turn-Around and New Construction by System, by Equipment, By Vessel.
    • Overwatch Mechanical and Systems Completion (may include hundreds of vessels and systems)
    • Overwatch Equipment Verification and Design Compliance.
    • Plan and Supervise Systems Validation
    • Plan Continuing Production Operations
    • Plan and Supervise Start-Up and Initiating Production

     

  • Elements of Successful Plant Commissioning
  • Strategic Planning and Management—Commissioning
  • Phases PART 2
    • Strategic Planning
    • Purpose – To re-life Unit and its Equipment
    • Mission
    • Values and Beliefs that Drive Performance
    • Goals – Organization, Project, Team, Personal
    • Measures of Success
  • Values
    • Communicate means pushing information to the lowest level of people.
    • Communicate means working at a level of detail where the lowest-level people are making the commitments and monitoring those commitments by reporting, tracking and measuring response
  • Leadership
    • Project engineering leads equipment acceptance supported by process engineering, operations, maintenance and assisted by contractors, vendors.
    • Process engineering leads system validation supported by operations, maintenance assisted by vendors, contractors, and project engineering.
    • Production start up is lead by operations and maintenance supported by process engineering and assisted by vendors, contractors, project engineering.
  • Planning Issues
    • Review Schedules, Protocols, Simulations, Document Control, Documents, Start- up Flow Sheets over and over. Establish a Review Process for all elements of preparation and planning.
    • Document control is crucial and must have a process flow chart with each document defined. Documents must be tracked, quality of information verified, and completeness verified.
    • Establish equipment verification protocols and systems validation protocols early and allow comment and criticism before issuing the protocols.
    • Control systems are vital to systems validation. Review control system acceptance protocols and standards with care to ensure all understand the expectation.
    • Protocols address what is verified (mission), by what means (how), according to what standard (measure), by a team of what people (who), according to what schedule) when), and who signs as completed (authority)
  • Strategic Risk
    • Failure to Complete
    • Failure to Complete on Time
    • Low Throughput – Capacity
    • Inconsistent Product Quality
    • Causes
  • Risk Response
    • Unknowns
    • Knowns
  • Operation Planning and Phase Management
    • Plan and Schedule Mechanical and Systems Completion ( may include hundreds of vessels and systems).
    • Plan Equipment Verification/Acceptance
    • Plan Systems Validation/Acceptance
    • Plan Production Operations
    • Plan Start-Up and Initiating
    • Plan Continuing Production
    • Execute
  • Schedule Mechanical and Systems Completion
    • Leadership
    • Priority of Start-Up
    • Project Engineering
    • Result
    • Scope
    • Performance
    • Resources
  • Risk and Safety Management
    • Mechanical and Systems Completion
    • Equipment Verification
    • Production System Validation
    • Continuing Production
  • Plant Start-Up, Re-Energizing, Initiating
    • Start Up Imperative
    • Leadership Start Up
    • Result Start Up
    • Scope Start Up
    • Performance Start Up
    • Resources Start Up
    • Risk Start Up
      • Explosion
      • Accident
      • Product Contamination
      • Spills
      • Production Systems Failure
      • Control Systems malfunction
      • Control Systems are not stable
      • Faulty Procedures
      • Faulty Sequence
      • Construction is late completing
      • Construction Quality is Inadequate
      • NDT results lost or misplaced
      • Changed Conditions
      • Constructive Changes
      • Contractor Failures
      • Inspection Variation
  • Review—Practice makes Perfect
  • Motivation and Leadership
    • Commissioning, leadership & motivation for on time start up
    • The surprising truth about what motivates us
    • Autonomy, mastery & purpose
    • Leadership definitions
    • Leadership framework
    • Four factors of leadership
    • Leadership – The commissioning manager
  • The 21 Irrefutable Laws of Leadership
    • The Law of the Lid
    • The Law of Influence
    • The Law of Process
    • The Law of Navigation
    • The Law of Addition
    • The Law of Solid Ground
    • The Law of Intuition
    • The Law of Respect
    • The Law of Magnetism
    • The Law of Connection
    • The Law of the Inner Circle
    • The Law of Empowerment
    • The Law of the Picture
    • The Law of Buy-In
    • The Law of Victory
    • The Law of the Big Mo
    • The Law of Priorities
    • The Law of Sacrifice
    • The Law of Timing
    • The Law of Explosive Growth
    • The Law of Legacy

Training Methodology

  • Case Studies.
  • Individual and group discussions and exercises.
  • Intensive training by using templates, diagrams, and charts.
  • Planning activities and presentations.
  • Self-assessments.
  • Action plan.

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