COURSE OVERVIEW:

The startup and shutdown phases of process plants are the most high-risk periods of industrial operation, characterized by transient states where equipment is subjected to rapidly changing temperatures, pressures, and flow rates. Statistics show that the majority of significant process safety incidents occur during these non-routine activities. This course is designed to equip operators and engineers with the technical expertise and cognitive skills required to manage these critical transitions safely, with a specific focus on identifying and mitigating abnormal conditions before they escalate into emergencies.

The scope of this course covers the systematic preparation for startup, including line blowing, vessel charging, and the synchronization of complex rotating machinery. Participants will explore the logic of "Standard Operating Procedures" (SOPs) and why they must be followed meticulously to prevent thermal shock, water hammer, or surge. The Coverage includes the dynamics of "Abnormal Situation Management" (ASM), teaching attendees how to interpret ambiguous sensor data and maintain situational awareness when process parameters begin to drift outside of safe operating envelopes.

Furthermore, the training addresses the shutdown process, whether planned for maintenance or executed as an emergency trip. Participants will learn the importance of controlled cooling and depressurization to protect the mechanical integrity of assets. The course emphasizes human factors, communication protocols, and the use of checklists to prevent errors during high-stress scenarios. By the end of this program, attendees will be prepared to lead their teams through plant transitions with a "safety-first" mindset, ensuring that abnormal conditions are handled with precision and calm.

COURSE OBJECTIVES:

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

1. Explain the risks associated with transient states in process plants.
2. Develop and audit effective Startup and Shutdown Procedures (SOPs).
3. Execute pre-startup safety reviews (PSSR) and system lineups.
4. Manage thermal expansion and pressure ramping to protect equipment.
5. Identify early warning signs of abnormal conditions during transitions.
6. Apply "Situational Awareness" techniques to prevent "Tunnel Vision" in crises.
7. Manage the startup of large rotating equipment drivers and compressors.
8. Distinguish between "Normal Deviations" and "Safety Critical Alarms."
9. Implement controlled shutdown sequences for plant stabilization.
10. Handle emergency shutdowns (ESD) and subsequent stabilization tasks.
11. Communicate effectively between the control room and field personnel.
12. Analyze past incidents to learn from startup and shutdown failures.
13. Utilize decision-making frameworks for "Go / No-Go" startup criteria.
14. Ensure environmental compliance during flaring and venting activities.

TARGET AUDIENCE:

This course is intended for Shift Supervisors, Panel Operators, Process Engineers, Production Managers, and Safety Specialists involved in plant operations.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.