COURSE OVERVIEW:

Statistics show that the majority of process safety incidents occur during non-steady-state operations, specifically during plant start-up and shutdown. This course focuses on the technical and management skills required to navigate these high-risk phases safely. Participants will learn how to design and follow rigorous procedures that account for thermal stresses, pressure surges, and changing fluid compositions.

The curriculum covers the step-by-step logic of bringing a plant from a cold-idle state to full production, and vice versa. Attendees will explore "Abnormal Operations," learning how to recognize early warning signs of system instability and how to intervene before an upset escalates into a trip or an accident. The course emphasizes the importance of human factors, communication, and procedural adherence.

By the end of the program, operations engineers, shift supervisors, and lead operators will be able to manage plant transitions with high precision, ensuring that equipment is protected, emissions are minimized, and personnel safety is maintained throughout the most volatile periods of the plant’s operation.

COURSE OBJECTIVES:

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

• Identify the risks associated with non-steady-state plant operations.
• Develop comprehensive, step-by-step Start-up and Shutdown procedures.
• Manage "Cold," "Warm," and "Hot" start-up scenarios.
• Understand the mechanics of thermal expansion and pressure transients.
• Execute safe purging and inerting of vessels and pipelines.
• Identify and respond to early signs of abnormal operation (Instability).
• Manage Alarm Flooding and prioritize operator response during upsets.
• Utilize Checklists and "Read-Do" protocols effectively.
• Perform safe Emergency Shutdowns (ESD) and Black-start procedures.
• Manage the transition between manual and automated control modes.
• Conduct effective handovers and briefings during critical phases.
• Analyze "Near-Misses" during plant transitions to improve procedures.
• Lead the "Pre-Startup Safety Review" (PSSR) process.

TARGET AUDIENCE:

Plant Operators, Shift Supervisors, Operations Engineers, and Commissioning Specialists.

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.