COURSE OVERVIEW:

The core meaning of this course is the technical and operational mastery of complex process plant outages and the advanced troubleshooting skills required during the critical startup phase. In a process environment—such as oil and gas, chemicals, or power—shutdowns are non-linear events where mechanical maintenance, process chemistry, and control logic must be perfectly synchronized. This course focuses on the "Systems Thinking" required to take a plant offline and bring it back online safely and efficiently.

The scope of this training involves the technical "Decontamination and Isolation" of process units, the management of specialized "Internal Inspections" (Vessels, Reactors, Columns), and the systematic "Troubleshooting" of process upsets. Participants will examine the "Critical Path" of a process shutdown, which is often dictated by cooling rates and catalyst handling rather than just mechanical labor. The curriculum emphasizes the identification of "Hidden Defects" that only become apparent when the process is in a non-steady state.

Coverage includes the development of "Detailed Isolation Plans" (P and ID based), the management of "Inert Entry" into vessels, and the use of "Advanced Troubleshooting" methodologies like Kepner-Tregoe for rapid problem-solving. Attendees will explore the specific "Commissioning and Startup" risks, where thermal expansion, pressure surges, and control loop tuning are critical. By the end of this course, participants will be able to manage the high-risk "Process-to-Maintenance" interface and lead a technical team through the most challenging phases of a plant's operational life.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the integrated "Process and Mechanical" stages of a plant shutdown.
• Develop "Detailed Isolation and Blinding" plans based on P and IDs.
• Manage "Decontamination, Purging, and Steaming" of process equipment.
• Conduct "Internal Inspections" of reactors, towers, and heat exchangers.
• Utilize "Advanced Troubleshooting" techniques for process upsets.
• Identify "Root Causes" of failures during the shutdown discovery phase.
• Manage "Inert Entry" and "Confined Space" risks in process vessels.
• Design a "Systematic Startup" sequence to prevent thermal shock.
• Troubleshoot "Control Loop" and "Instrumentation" issues during commissioning.
• Conduct "PSSR" (Pre-Startup Safety Review) for all process modifications.
• Manage "Catalyst and Internal Packing" replacement procedures.
• Coordinate the "Process-to-Maintenance" handover for zero-incident execution.

TARGET AUDIENCE:

This course is essential for Process Engineers, Plant Managers, Maintenance Supervisors, Operations Leads, and Turnaround Coordinators.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.