By the end of this programme, participants will be able to:
- Understand the steps and checklists for pre-commissioning and commissioning a process plant.
- Develop an overall commissioning strategy and manage plant startup effectively.
- Address machinery and equipment-specific commissioning issues.
- Manage commissioning of electrical, instrumentation, and utilities systems.
- Create a comprehensive commissioning management plan, including resource planning and budgeting.
- Apply typical process plant startup and commissioning procedures.
- Utilize troubleshooting and problem-solving strategies for oil and gas processes, including gas and liquid separation, natural gas dehydration, and amine treatment.
DAY 1
Introduction and Pre-Commissioning Preparation
Introduction to Plant Startup and Commissioning
- Understanding the scope and importance of process plant startup and commissioning
- Exploring the role of the technical/operations function in productivity and quality
- Reviewing general requirements for pre-commissioning activities
Initial Preparation Activities
- Conducting operational check-outs and final inspections of vessels
- Performing hydrostatic testing and line flushing (steam, process, and utility piping)
- Checking and calibrating instruments
- Practical Exercise: Developing a pre-commissioning checklist for a sample process plant, focusing on vessel inspections and flushing procedures
DAY 2
Equipment-Specific Pre-Commissioning
Equipment Preparation
- Breaking in pumps and compressors
- Conducting dry-out and boil-out procedures
- Managing catalyst loading and tightness tests
Electrical and Instrumentation Systems
- Addressing commissioning issues for electrical and instrumentation systems
- Ensuring proper setup and testing of control systems
- Practical Exercise: Simulating the setup and testing of a pump or compressor, including troubleshooting common pre-commissioning issues
DAY 3
Commissioning Strategy and Startup Procedures
Developing a Commissioning Strategy
- Creating an overall commissioning management plan
- Resource planning and budgeting for commissioning activities
Normal Plant Startup Procedures
- Reviewing pre-startup checklists and ensuring area safety
- Commissioning utilities and conducting air purging/gas blanketing for non-catalytic and catalytic sections
- Activating heat exchangers and performing vacuum tests
- Practical Exercise: Drafting a commissioning plan for a sample plant, including a pre-startup checklist and utility commissioning steps
DAY 4
Advanced Commissioning and Process Optimization
Completing Startup Procedures
- Establishing flow in the unit and managing inhibitor/chemical injections
- Adjusting operations to meet product quality specifications
Acid Cleaning and Heater Dry-Out
- Executing acid cleaning procedures for compressor lines
- Implementing chemical boil-out sequences
- Performing heater dry-out for gas- and oil-fired heaters, including burner management
- Practical Exercise: Simulating a startup procedure for a process unit, focusing on flow establishment and chemical injections, followed by peer review
DAY 5
Performance Guarantees and Troubleshooting
Performance Guarantees
- Evaluating plant capacity, yield, and product specifications
- Assessing catalyst performance, chemical consumption, and utility consumption
- Reviewing environmental guarantees (effluent wastewater, solid waste, gaseous waste)
- Executing and completing performance guarantee tests
Troubleshooting and Problem Solving
- Applying troubleshooting strategies for oil and gas separation processes
- Addressing issues in natural gas dehydration and amine treatment through case studies
- Developing problem-solving techniques to minimize downtime and ensure safety
