Oil and Gas Field Start-Up and Troubleshooting

Introduction

There is an alarming trend in the 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 Process Plant Start-up, Commissioning and Troubleshooting training course will help you to understand the true nature and different techniques of problem-solving and problem prevention in the operational / process environment.

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

Objectives

Upon the successful completion of the course, participants will be able to:- 

• How to become a ‘Top Gun’ Troubleshooter by acquiring new skills
• To develop a structured approach to Troubleshooting and Problem Solving which uses 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 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 thought to reduce the variability of your process

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

Who Should Attend?

This training 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 Oil & Gas Plant Start-up, Commissioning and Troubleshooting training course elements are of equal importance to Production, Maintenance Engineering, and Process Engineering personnel.

Course Outline

Day 1: Introduction and Preparation for Start-Up and Commissioning

• Introduction to Process Plant Start-Up and Commissioning
• The organization, Roles and Leadership
• Support Functions
• Cost Estimation
• Spare Parts Planning

Commissioning Strategy and Process

• Commissioning Strategy
• Commissioning Strategy Case Study
• Mechanical Completion and Integrity Checking
• Pre-commissioning and Operational Testing
• Start-up / Initial Operation, Testing, and Acceptance

Day 2: Process Plant and Machinery Specific Issues

• Process Plant and Machinery Commissioning
• Instrumentation and Control Systems
• Preparing and Isolating Process Plant

Project Managing Start-Up / Commissioning Projects

• Work Breakdown Structures
• The Critical Path Method of Planning and Control
• Short-Cut Planning Methods
• Budgeting, Progress and Cost Control
• Earned Value Analysis

Day 3: Problem Solving, Risk and Safety Management

• Introduction to Problem Solving and Troubleshooting
• Troubleshooting in Commissioning and Start-Up Situations
• Safety and Environment Management
• Managing Risk

Post Commissioning Activities

• Asset Classes
• Pro-Active vs. Reactive Problem Solving
• Modeling of the Operational Process to simplify operations
• Single Task Performance measurement defined in terms of generic variables: Speed; Quality; and Cost
• Complexity and Complex Systems Performance measurement
• Pyramid of Excellence - The Operations Process redefined
• Configuration, Operation, and Optimization
• Maturity Indexing: Planning; Control, Congruence, Empowerment
• A World-Class Operations Case Study

Day 4: Tools and Techniques – Practical Experience

• Interactive and Dynamic Variable Relationships Analysis
• Techniques Introduction
• Tools Introduction
• Problem Analysis
• Practical Use of Tools and Techniques
• Tools & Techniques - selecting the right one

Day 5: People Issues – The Glue that holds everything together

• Risk Management
• Group Dynamics
• Individual Motivators
• Developing Troubleshooting and Problem-Solving skills
• Managing Change – Transition Matrix
• Leadership Attributes

Operator, Maintainer, Designer Interface

• Cross-Functional and Teamworking
• 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