Course Overview

The success of every company depends of each employee’s understanding of the key business components. Employee training and development will unlock the companies’ profitability and reliability. When people, processes and technology work together as a team developing practical solutions, companies can maximize profitability and assets in a sustainable manner. Training and development is an investment in future success— give yourself and your employees the keys to success.

It is strategically important that your operations team understands the fundamentals of process unit operations concepts. This is the different between being in the best quartile of operational ability and being in the last quartile . There is vast different in the operational ability of operating companies and most benchmarking studies have confirmed this gap in operational abilities.

Whether you have a team of new or seasoned employees, an introduction or review of these concepts is very beneficial in closing the gap if you are not in the best quartile, or maintaining a leadership position. Most studies show that a continuous reinforcement of best practise in operation principles is the most effective way to obtain the desired results.


Course Objectives

This course will guide the participants to develop key concepts and techniques to preÌ¢‰âÂåcommission, commission, operate and troubleshoot key fundamental unit operation systems. These key concepts can be utilized to make operating decisions that can improve your unit’s performance.

Many aspects of operations can be improved including, product recoveries, purities and energy utilization, and safety. This cannot be achieved without first an understating of basic fundamental principles of design and operation. These principles need to be understood in advance of operating and troubleshooting a process unit operation for the operator or problem solving to be effective.

This course focuses on the core building blocks of the process unit equipment. This program will emphasize process unit equipment fundamentals, safe utilization of these fundamentals by operations and maintenance personnel, equipment troubleshooting techniques. This course is focused for Engineers, Supervisors and Plant Operators in Plant Process.

Who Should Attend

This course is designed for who are making day to day decisions regarding, commissioning, start up and normal operations of Isolation Processing plants such as Operations Supervisors, Engineers , Plants Operators and Process Support Engineers.

Course Content

Module (01) Introduction of Safe Isolation

1.1 Principles of Safe Isolation

1.2 Basic Isolation Procedures

1.3 Work Injuries

1.4 Identifying Energy & Hazards Sources

1.5 Identify all Isolation Points

1.6 Locking out, Tagging and Guarding

1.7 Personal Danger Tags

1.8 Shutting Down of Equipments

1.9 Responsibility of Operation

1.10 Responsibility of Maintenance

Module (02) Preparation for Safe Isolation

2.1 CoÌ¢‰âÂåordination

2.2 Planning (Plan to work)

2.3 Hazard Assessment

2.4 Types / Categories of Work

2.5 Cross Reference

2.6 Life / Validity of Permits

2.7 Isolation Process

2.8 Precautions

2.9 Signatures (issue , release & approve)

Module (03) Process of Isolation

3.1 Display of Permits

3.2 Revalidation

3.3 Suspension

3.4 Shift Hand—Over

3.5 Action in an Emergency

3.6 Monitoring

3.7 Case Study on Isolation Systems

3.8 Case Study on Isolation Equipment

Module (04) Safe Isolation Practices & Tips

4.1 Safe Work Instructions (SWI)

4.2 Requirements for Isolation of Machinery

4.3 Information Suppliers, Designers, Manufactures

and Importers of Machinery/Equipments

4.4 SWI for Isolation of Machinery / Equipment

4.5 Case Study

Module (05) Isolation of Machinery / Equipment

5.1 Using the Hierarchy of Control

5.2 Identification and Isolation of Energy Sources

5.3 Portable Machinery / Equipments

5.4 Multiple Parties working on Machinery/ Equipment

5.5 Procedures for Isolation of Machinery/ Equipment

5.6 Flow Chart for Isolation of Machinery/Equipment

Module (06) Completion of Work

6.1 Rerun of Permit

6.2 Site Inspection

6.3 Removal of Isolation Tags or Devices

6.3 Cancellation of Overrides

6.4 Return to Service

6.5 Logs / Records

6.6 Important Isolation Tips

Module (07) Application of Safe Isolation

7.1 Boiler and it’s Auxiliaries System

7.2 Steam System

7.3 Turbine & it’s Accessories

7.4 Tanks / Vessels

7.5 Piping (Pressure, Flow and Temperature Limits)

7.6 Heat Exchangers

7.7 Electrical Systems (Switchgears / MCC )

7.8 Relief Valves and Flare Systems

7.9 Drains, Vents and Blow down

7.10 Black out Restoration of the Plant Systems

Module (08) How to Prevent and Minimize Accidents

8.1 Keeping Safety Costs Down

8.2 Selling Safety

8.3 Effective Meeting Techniques

8.4 How to Prevent Accidents

8.5 Unsafe Conditions Ì¢‰âÂå Mechanical /Electrical Failures

8.6 Your Role in Job Safety

8.7 Be a Fire Fighter

8.8 Human Errors during Isolation

8.9 Improving / Enhancement your Isolation Skill

8.10 Controlling / Managing Human Errors