Akademie

Co ur se De scr iption
The initial start-up of any plant, irrespective of size, type,
or industry, is a unique occurrence. Therefore, start-up
poses some special problems. Lack of experience in
dealing with these problems has frequently resulted in
prolonged and costly startups. This course will provide
guidelines for all those involved in the execution of a
project on how to achieve a successful plant start-up. C ourse Objectives
The requirements for start-up oriented thinking at all
stages of the project, from engineering to commission- Upon completion of this course, you will gain
ing, will be demonstrated. knowledge of the problems and their sourc-
The course material covers estimating of start-up costs, es, associated with first-time start-ups. You
personnel requirements, and resources. It defines the vi-
tal role of project management and plant personnel in will have the necessary skills for anticipating
the preparation and planning for successful start-up of and avoiding financial, technical, operational,
OE247

any process plant. Emphasis is on effective planning and and organizational problems associated with
use of available resources, both material and manpower. start-up.
Troubleshooting performed during the actual start-up
can be very expensive and must be done as effectively
as possible. Effective troubleshooting can minimize the
time and cost of going from the initial start-up to full pro-
duction. The last day will provide a review of techniques
and discussion of numerous examples to develop skills in
troubleshooting.
Participant interaction is welcome, to take full advantage
of the range of viewpoints and experience and to exam-
ine typical startup problems, both technical and man-
power related, and their solutions. The faculty has ex-
tensive start-up experience in a wide range of processing
Process Plant Start-up, Commissioning and

units including material handling, mineral processes, and

chemical, petrochemical, and refining operations, and
will be available to discuss individual start-up problems.

W ho sho uld attend?

This course is designed for project managers, plant managers, plant supervisors, technical staff, and contractor person-
nel involved in project execution and plant start-up in any process industry. The greatest benefit arises from the applica-
tion of these start-up oriented ideas throughout a project, beginning at the conceptual phase. The practical techniques
and examples provide useful insights that are valuable at any stage of project execution and preparation for start-up.

In s t r ucto r P r o f ile
Dr. Musa Abdalla, University of Jordan
Dr. Musa Abdalla is a Mechatronics Engineering Professor with a background
in Mechanical (BS, MS), Electrical (MS) and control Engineering (PhD). Dr.
Abdalla has hands-on experience in designing and controlling Mechatronics
systems. In today’s complex industrial systems, a diversity of background
11th - 15th April 2010 - Doha

is needed to shed more light onto their design and integration.

Troubleshooting

Dr. Abdalla has been working in the educational field for over sixteen years and with
the industry at least five years. During this time frame he has managed, designed, and
implemented many electro-mechanical engineering projects, such as: Interface with
Medical Machines, Continuous Filling Machine for dry food, Solar Powered Car, Diversity
of Robotic Projects, PID controllers, CNC Router, and Simple Automated System with
Industrial Communication Protocols (Pneumatic), etc.

C ontact :
Ms. Annie
Tel : +971 2 4478500
Email: anniec@tuv-nord.com
C o u rse O ut l i ne C ontact Information

TERMS AND TOOLS Main Office

Introduction: Start-Up Terminology; Project Evolution; Requirement for
Start-Up Success; Plant Personnel Involvement.
Start-Up Problems: History of Start-Up Problems and Causes of Out- TUV Akademie Middle East
ages; Problem Sources from Project Inception to Completion; How P O Box 46030
to Minimize Problems and Consequences During Commissioning and Abu Dhabi
Start-Up.
Discussion: Potential Problems Associated with Your Project and Its United Arab Emirates
Start-Up Tel : +971 2 4478500
Start-Up Planning: When to Start; Commissioning and Start-Up Sched- Fax : +971 2 4478558
ules; Planning Tools, Controls and Checklists; Reaction Plans, Proce-
dures and Other Necessary Planning.
Email : me-akademie@tuv-nord.com
Start-Up Cost Prediction: Historical Examples; Start-Up Cost Estima-
tion Factors; Detailed Start-Up Budget Considerations; Forgotten Start- For any information or registration for the course, you
Up Costs; Minimizing Start-Up Costs. can contact the Course Co-ordinator at the contact de-
Minimizing Equipment Problems: Review of Equipment Problem Sourc-
es; Determining Critical Equipment; Understanding Equipment Failure; tails mentioned overleaf.
Precautions to Minimize Equipment Failures; Equipment Reliability Data
and Sources.

MANAGEMENT C ourse Fee

Start-Up Safety and Environmental Issues: Recognizing Unique Safety
and Environmental Problems Before, During, and After Start-Up; Emer-
gencies; Safety Preparation, Training, Audits, HAZOPs and Other Meth- Fee : US$ 3,690 per delegate
ods to Minimize Risk, Environmental Issues Discussion.
Start-Up Management: Contractor/Owner/Engineering/ Operations
Involvement and Responsibilities; Types of Project and Start-Up Or- Duration of course : 5 days
ganizations; The Start-Up Manager and the Start-Up Team; Lines of
Responsibility/Levels of Supervision; Decision Making, Meeting Coordi-
nation, Fine Tuning of Organizational Responses and Delegation. Date :11th - 15th April 2010
Start-Up Manpower: Estimating Plant Staffing for Start-Up; Defining
Experience Levels; Effect of Inexperience on Start-Up; Compensating
for Inexperience; Training; Hidden Manpower Shortages; Manpower Location : Doha
Build-Up.
Start-Up Leadership: Key Positions; Balanced Leadership; Morale and
Team Spirit Technology: New Technology and How to Recognize It;
Plant Computers During Start-Up; Laboratory Preparation; Specialist Other Information
Services; Process Engineering Services During Start-Up.
Discussion: Selected Topics Associated with Your Project and Its Start-
Up; Start-Up Planning Exercise.
TUV Akademie Certificate will be issued to all attend-
ees.
IN THE FIELD

Construction Inspection: Why, Who, How; Establishing Quality Stan- Course Fee mentioned is per delegate.
dards; Inspection Manpower and Training; Field Inspection Techniques;
Inspection Authority and Communications.
Construction Completion—the Beginning of Start-Up: Construction
Avail an attractive 5% discount on course fee if you
Schedules vs. Start-Up Needs; Construction Completion by Test Sys- register 30 days before course start date.
tems; Start-Up by Systems; Systems Definition; Punch Listing; Han-
dover—the Interface between Construction and Operations. Courses will be conducted during the designated dates
Commissioning—The Heart of Start-Up: Developing the Commission-
ing Sequence, Resource Needs and Procedures; Commissioning and at a 4 star or 5 star hotel in the designated city.
Mock Operations Techniques; Instrument Preparation, Loop Checking
and Troubleshooting. Payments to be made in advance. Exact venue of the
Start-Up Operations: Performing the Initial Start-Up Activities; Main-
taining Forward Momentum; What to Expect Until Plant Acceptance;
training will be notified two weeks prior to course start
Test Run Preparation and Performance. date.
Discussion: Troubleshooting or Commissioning, Example Situation.
This rate includes course notes, buffet lunch, coffee/tea
START- UP TROUBLESHOOTING on arrival, morning and afternoon of each day.
Technical Issues: Instrumentation and measuring devices; All Other
Causes; Root-Cause Analysis; Data Reconciliation; History vs. Hyste- Accomodation is not included in course fees. However,
ria; FACTS; Assessing Likelihood; Testing of Hypothesis.
Solutions: Avoiding Expensive “Fixes;” Avoiding Ineffective “Fixes;”
any accomodation required can be arranged by TUV
SAFETY Issues; Engineering Requirements and Standards in the Field. Akademie at time of booking.
Implementing Changes: Operational Measures; Co-Operation; Plan
Trails, Quality Blames vs. Success.

START- UP and PROCESS SIMULATION (HANDS-ON DEMONSTRATION)

SHUTDOWN and DECOMMISSIONING

Normal Shutdown; Pre-shutdown Planning; Shutdown Sequence Steps;
Sudden or Emergency Shutdown.
Decommissioning and demolition; Decommissioning/Demolition Plan;
Operation and Maintenance Roles; Decommissioning Procedures; Main- Partners
tenance of Decommissioned Status; Demolition Concerns.