PROCESS PLANT START UP, COMMISSIONING and TROUBLESHOOTING

INTRODUCTION:

There is an alarming trend in industry to discount the potential contribution of the Technical Operations function to productivity improvement, product quality and gains in market share. Principles taught in this training session will help you to understand the true nature and different techniques of problem solving and problem prevention in the operational process environment.

Both modules are delivered by leading experts who provide innovative and interesting training sessions. Participants will have access to the latest research in Maintenance Management which forms the basis of the course.

Excellent Troubleshooting skills are considered a core competency for Best-in-Class industrial companies. If your company’s goals include minimizing downtime then this workshop is a must because it delivers rapid, safe Troubleshooting.

OBJECTIVES:

By the end of this course participants will learn

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