PETROSYNC’S EPC SERIES

PRE-COMMISSIONING,
COMMISSIONING & START-UP
Deliver Excellence in Every Commissioning Phase
14 March 2016 — 17 March 2016
Kuala Lumpur, Malaysia

Supported By
EPC | PRE-COMMISSIONING, COMMISSIONING & START UP

Course Overview
Successful commissioning new or starting-up revised equipment
and systems requires meticulous planning, organizing and
controlling. Careful methodical, detailed planning – early – is the
key to the success of any commissioning.
This training program, Pre-Commissioning, Commissioning and Start Up, is developed for the
commissioning team people learn the thought, the logic and approach that leads to the plan
in order to increase the work speed and quality of work.
Customized Course Content
The course material relates specifically to the 9 key elements of successful plant
commissioning in the comprehensive sequences from strategies, tactics, task tools,
checklists, guidelines for specific equipment, procedures, manuals etc. in order to maximize
your learning benefits.

Includes Specific Case History and Practical Workshop

Past case history will be given during the exercise session, it will helps you to understand in-
depth about the commissioning process requirements and the safety concern. There is a
Leadership Style Self-Assessment Workshop toward the end of the course for you to improve

You will also benefit from successful portrayed and will learn from the failures presented too
so that success rate is maximized and failure is minimized.

How Does This Course Benefits You?

Improve Work Efficiency
Improve work efficiency and effectively by understanding the 9 key elements of successful
plant commissioning so that you can done your work without any incident, on time and on
budget.

Enhance Safety Aspect Knowledge

Enhance safety aspect knowledge to minimize the incident happen by learning the risk
analysis and safety procedures available in the industry.

Prevent Incident Occur

Prevent incident occur by learning the past case histories and planning solutions so that the
operation will be done well and without incident happen.

The implementation of commissioning is the most

critical part !
Do you know the consequences without proper
commissioning plan? Effective Motivation and Leadership Skills should be
learned by a commissioning team lead or manager.
Do you know that commissioning team should include
experts with different background? What is the best way to
communicate with each others?

general@petrosync.com | +65 6451 4500 | www.petrosync.com

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EPC | PRE-COMMISSIONING, COMMISSIONING & START UP

PetroSync Distinguished Instructor

Practical & Consulting

 Over 20 years of experience in commissioning of water
treatment plants, petrochemical plants, chemical plants and
solar silicon plants.
 He has specialized in plant pre-commissioning,
commissioning and start-up philosophy, troubleshooting,
strategy and management; equipment and machinery
commissioning; commissioning paperwork, progress
monitoring, safety and commissioning, motivation and
Thomas Stunkel leadership.
Independent Training
 Thomas is one of the speaker for Plant Commissioning and
Commissioning
Start-Up Conference since 2011, his speech about
Consultant
commissioning, leadership and motivation. Besides, he run
mini workshop during the conferences is about “Leadership
Style Assessment”. He run several commissioning
conferences in various county such as Dubai, Qaatar,
Malaysia, Panama, Germany, Switzerland, Iran etc .

Who Needs This Program

 The course is designed for, but not limited to key personnel who responsible for
commissioning, start-up, acceptance and operation of new processing facilities or
revamping projects such as Managing Directors, Vice Presidents, COOs, Heads, GMs, Senior
Managers, Section Leaders, Team Leaders, engineers and Superintendents from several
departments :
 Plant  Operations  Asset Integrity

 Commissioning  Equipment Specialist  Facilities Management

 Plant Start Up  Construction Depart-  Safety

 Plant Engineers
ment
 Factory
 Contractors

Course Schedule

08:00—09:00 Registration (Day 1) 13:00—14:00 Lunch

09:00—11:00 Session I 14:00—15:30 Session III
11:00—11.15 Refreshment Session I 15:30—15:45 Refreshment Session II
11:15—13:00 Session II 15:45—17:00 Session Iv (Last Session)

PetroSync Quality Assurance

All PetroSync courses are developed with top quality to
address all your training needs and purposes. Our courses
are vetted strictly to ensure that we always deliver the best
courses with the best industry expert.
PetroSync Inhouse Solutions
PetroSync can tailor our courses to meet your specific
needs at your preferred location and schedule. Contact us
for more information at +65 6415 4500 or email to
general @petrosync.com

general@petrosync.com | +65 6451 4500 | www.petrosync.com

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EPC | PRE-COMMISSIONING, COMMISSIONING & START UP

Course Agenda — 4 Days

DAY 1
Elements of Successful Plant Commissioning Strategic Planning and Management—Commissioning
9 Key Elements of Successful Plant Commissioning Phases PART 1
A step by step guide  Prepare to Plan
 Planning  Tactical Planning – Manage the Commissioning Project to
 Mechanical completion Deliver Producing units.
 P&ID checking  Oversee Shutdown – Purging, Clean Up, Zero Energy,
 Pre-Commissioning Isolating, Vessel Entry
 Commissioning  Oversee Preventive Maintenance, Inspections, Tests,
 Start-up Repair, Overhaul, Rebuild, Replacement
 Initial operation  Overwatch Turn-Around and New Construction by System,
 Performance testing by Equipment, By Vessel.
 Post commissioning  Overwatch Mechanical and Systems Completion (may
include hundreds of vessels and systems).
 Overwatch Equipment Verification and Design Compliance.
 Plan and Supervise Systems Validation
 Plan Continuing Production Operations
 Plan and Supervise Start-Up and Initiating Production

DAY 2
Elements of Successful Plant Commissioning
Strategic Planning and Management—Commissioning Planning Issues
Phases PART 2  Review Schedules, Protocols, Simulations, Document

Strategic Planning
 Purpose – To re-life Unit and its Equipment
 Mission
 Values and Beliefs that Drive Performance
 Goals – Organization, Project, Team, Personal
 Measures of Success
Values
 Communicate means pushing information to the lowest
level of people.
 Communicate means working at a level of detail where
the lowest-level people are making the commitments and
monitoring those commitments by reporting, tracking and
measuring response.
Leadership
 Project engineering leads equipment acceptance
supported by process engineering, operations,
maintenance and assisted by contractors, vendors.
 Process engineering leads system validation supported by
operations, maintenance assisted by vendors,
contractors, and project engineering.
 Production start up is lead by operations and maintenance
supported by process engineering and assisted by
vendors, contractors, project engineering.
Control, Documents, Start-up Flow Sheets over and over.
Establish a Review Process for all elements of preparation
and planning.
 Document control is crucial and must have a process flow
chart with each document defined. Documents must be
tracked, quality of information verified, and completeness
verified.
 Establish equipment verification protocols and systems
validation protocols early and allow comment and
criticism before issuing the protocols.
 Control systems are vital to systems validation. Review
control system acceptance protocols and standards with
care to ensure all understand the expectation.
 Protocols address what is verified (mission), by what
means (how), according to what standard (measure), by a
team of what people (who), according to what schedule
(when), and who signs as completed (authority).
Strategic Risk
 Failure to Complete
 Failure to Complete on Time
 Low Throughput - Capacity
 Inconsistent Product Quality
 Causes
Risk Response
 Unknowns
 Knowns

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EPC | PRE-COMMISSIONING, COMMISSIONING & START UP

DAY 3
Operation Planning and Phase Management Plant Start-Up, Re-Energizing, Initiating
 Plan and Schedule Mechanical and Systems Completion  Start Up Imperative

(may include hundreds of vessels and systems).  Leadership Start Up

 Plan Equipment Verification/Acceptance  Result Start Up

 Plan Systems Validation/Acceptance  Scope Start Up

 Plan Production Operations  Performance Start Up

 Plan Start-Up and Initiating  Resources Start Up

 Plan Continuing Production  Risk Start Up

 Execute  Explosion
 Accident
Schedule Mechanical and Systems Completion  Product Contamination
 Leadership  Spills
 Priority of Start-Up  Production Systems Failure
 Project Engineering  Control Systems malfunction
 Result  Control Systems are not stable
 Scope  Faulty Procedures
 Performance  Faulty Sequence
 Resources  Construction is late completing
 Construction Quality is Inadequate
Risk and Safety Management  NDT results lost or misplaced
 Mechanical and Systems Completion  Changed Conditions
 Equipment Verification  Constructive Changes
 Production System Validation  Contractor Failures
 Continuing Production  Inspection Variation
 Review—Practice makes Perfect

DAY 4
Motivation and Leadership
 Commissioning, leadership & motivation for on time start The 21 Irrefutable Laws of Leadership (Continues)
-up  The Law of the Inner Circle
 The surprising truth about what motivates us  The Law of Empowerment
 Autonomy, mastery & purpose  The Law of the Picture
 Leadership definitions  The Law of Buy-In
 Leadership framework  The Law of Victory
 Four factors of leadership  The Law of the Big Mo
 Leadership – The commissioning manager  The Law of Priorities
 The Law of Sacrifice
 The Law of Timing
 The Law of Explosive Growth
Mini Workshop: “Leadership style assessment”  The Law of Legacy

The 21 Irrefutable Laws of Leadership

 The Law of the Lid Mini Workshop: “21 Laws Leadership Evaluation”
 The Law of Influence
 The Law of Process
 The Law of Navigation
 The Law of Addition
 The Law of Solid Ground
 The Law of Intuition
 The Law of Respect
 The Law of Magnetism
 The Law of Connection
Register For This Course Now!

Kindly fill up your particulars in the

registration form placed at the end of this
brochure, and send it to us or email to
registration@petrosync.com

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COURSE DETAILS COURSE CONSULTANT
Title : Pre-Commissioning, Commissioning & Start Up Name : Cay Aagen
Date : 14—17 March 2016 Email : registration@petrosync.com
Location : Kuala Lumpur, Malaysia Phone : +65 6415 4500
Fax : +65 6415 4322
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Enjoy 10% discount for substitutions or alterations will be updated on our web
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