7th Annual

Plant Commissioning and Start-Up

Strategising Commissioning Techniques, Conducting Detailed Testing and Critical Issues Management to
Achieve Flawless Start-Up

Kuala Lumpur, Malaysia

If you fail to plan, you are
25th – 27th August 2014 planning to fail!
Benjamin Franklin

Incorporating effective planning and implementation throughout

the commissioning phases to achieve operational smooth start-up.

Featuring Post Conference Interactive Course: Featuring Our Esteemed Panel of Speakers:
Achieving Flawless Start-Up and Solidifying Martin Killcross
Commissioning Scopes Commissioning Manager, US Mega Projects
Martin Killcross Sasol, USA
Commissioning Manager, US Mega Projects Michael Bausch
Sasol, USA Commissioning and Start up Manager
Author of Chemical and Process Plant Commissioning Handbook Dow Chemical Company, Saudi Arabia
Martin Killcross has over 33 years of diverse experience in the Anthony Warner
industrial chemical, petrochemical, polymers, silicates, fertilizer Project Completions Lead
and nuclear business sectors for commissioning, decontamination, QatarGas, Qatar
decommissioning, process plant start up and unit operations.
Martin has also recently been awarded “Brennan Medal” by the Leong Sik Foo
IChemE for the best IChemE publication of 2012 Senior Drives and Condition Monitoring Engineer
BlueScope Steel, Australia
Mohd Faizal Ghazali
Attend this Premier Conference and Gain Insight Into: Commissioning Manager
• Minimising the risk of delays through a streamlined process Petronas, Malaysia
• Achieving smooth start-up while staying within budget
Gavin McLeod
and schedule
Senior Staff Operations Specialist and Technical Service Manager
• Preventing machine and equipment failure
Chevron, Singapore
• Optimising process safety throughout the commissioning phases
• Strengthening the leadership, manpower skills and Murali Venkataraman
resource capabilities Global Process Manager
• Ensuring effective planning and smooth handover Shell, India
Karl Cleary
Sodium Bicarbonate Operations Manager
Testimonials from Similar Past Events: Tata Chemicals, UK

Well done with topics relevant to my area of assignment. Mark Gerkema

PETRONAS Carigali Technology and Engineering Manager
PURAC, Thailand
Good experience sharing from various industry.
Conoco Phillips Indonesia Madhu Pattan
Operations Manager
Good sharing experience with very knowledgeable speakers on a very VTTI Fujairah, UAE
important topic that can be put into good practice.
UMW Industrial Power Mohd Nasir Man
Principal Engineer
Organisation and most speakers are experienced and relevant with Petronas, Malaysia
interesting subjects. Online documentation is good.
Shell Malaysia Derry Dasuki
Facility General Manager
Cabot Corporation, Indonesia and Malaysia
Wahyu Muliana
Facilities Manager
Star Energy, Indonesia
Muddassar Rathore
General Manager Operations
Engro, Pakistan

conferences
Day One

Monday 25th August 2014

0830 Registration and Coffee PRE-COMMISSIONING, COMMISSIONING TECHNIQUES AND SAFETY

0900 Opening Remarks from the Chairperson 1400 Case Study:

Equipment and Pipe Cleaning: Formulating Effective, Reliable
STRATEGIC PLANT COMMISSIONING CONSIDERATIONS and Safe Pre-Commissioning Procedures
• Exploring enhanced and innovative methods to cleaning process
0915 Expert Insight: equipment and pipelines
Overcoming Manpower Shortages and Structuring the Ideal • Preventing damages to your equipments and pipelines caused by
Commissioning Team unwanted construction particles
• Collaborating with vendors and contractors: Manpower resource • Ensuring “zero” unwanted particles within your pipelines
preparation throughout various parties • Taking steps to rectify issues and minimise schedule delays when
• Team selection and recruitment: A leverage for quality commissioning damage occurs from unwanted particles
• Retaining skilled workforce for optimal commissioning and start-up • Considering potential safety issues and incorporating reliable safety
capability for current and future projects measure into the cleaning process
• Building a high quality team through innovative commissioning Muddassar Rathore
training and development initiatives General Manager Operations
• Sustaining the right management and technical know-how for Engro, Pakistan
future projects
Karl Cleary 1445 Case Study:
Sodium Bicarbonate Operations Manager Aiming for a Leak Free Start-Up and Avoiding the High Cost
Tata Chemicals, UK of Leakages
• Testing pipe integrity and conducting reliable inspection
1000 Case Study: • Analysing and eliminating the root causes of leakages throughout
Creating Guidelines to Overcome Lack of Communication and the process
Assessing the Risk Implications of Non-Compliance • Conducting pressure testing: Steps to ensure safe and reliable leak tests
• Knowing how reliable and clear communication minimises delays, • Examining joints and flange management procedures - getting them
costs and project risks right to minimise leakage
• Getting communication right between vendors, contractors and Wahyu Muliana
owner teams Facilities Manager
• Adopting communication approaches that foster process safety Star Energy, Indonesia
throughout the plant commissioning phases
• Exploring key communication channels and tools to effectively get the 1530 Coffee and Networking Break
right message across
Gavin McLeod 1600 Case Study:
Senior Staff Operations Specialist and Technical Service Manager Conducting Inspection on Equipment and Instrumentation:
Chevron, Singapore Ensuring Optimised Quality and Functionality
• Gathering appropriate inputs from design and project execution for
1045 Coffee and Networking Break optimal equipment and instrumentation quality and functionality
• Ensuring involvement of the right and experienced commissioning
1115 Keynote Presentation: personnel in the early conceptual engineering phase of a project to
Achieving Flawless Start-Up: Cost, Budget and Scheduling minimise upcoming adverse equipment and instrumentation issues
Considerations When Constructing Detailed • Reviewing impacts of construction and engineering quality on
Commissioning Strategies equipments and instrumentation
• What makes the commissioning process ahead of schedule and • Heightening inspection techniques to minimise the risk of equipment
cost effective? and instrumentation failure
• Resource optimisation: Minimising costs and staying within budget • Inspecting the functionality of rotating and static equipments -
• Being innovative in the establishment and integrating construction strengthening your equipment quality control
and commissioning activities Derry Dasuki
• Determining the optimal duration for each project phase for successful Facility General Manager
and timely completion Cabot Corporation, Indonesia and Malaysia
• Examining the process and determining cost saving opportunities
without compromising quality
• Identifying and removing the root cause of cost escalation and delays:
1645 Case Study:
Operational Implementation of Commissioning Risk
What are the key obstacles to well coordinated functions and activities?
Management and HAZOP Techniques
Martin Killcross • Keeping risks at bay through systematic implementation of
Commissioning Manager, US Mega Projects commissioning risk policies
Sasol, USA • Knowing the threats: Profiling your risks to ensure readiness
• Developing efficient counter measures to tackle adverse
1200 Case Study: commissioning risks
Studying Construction Design and Process Specifications Prior • Conducting an operational review: Possible scenarios, their impact and
to Initiating Commissioning Workflow actions to consider
• Calculating the deviation from design specifications and its • Planning for contingencies to ensure smooth operational continuity
implications on cost and testing work Madhu Pattan
• Assessing construction and the quality of structures before the Operations Manager
commissioning process VTTI Fujairah, UAE
• Analysing the design specifications and process plan to determine
necessary modifications to optimise commissioning and start-up capability 1730 Closing Remarks from the Chairperson and End of Day One
• Establishing a reliable procedure: A roadmap for quality commissioning
and start-up process
Anthony Warner
Project Completions Lead marcus evans would like to thank everyone who has helped with the
QatarGas, Qatar research and organisation of this event, particularly the speakers and
their staff for their support and commitment.
1245 Networking Luncheon
Day Two

Tuesday 26th August 2014

0830 Registration and Coffee 1400 Case Study:

Evaluating Modular Construction and the Cost and Value
0900 Opening Remarks from the Chairperson Implications to your Commissioning Process
• Minimising the risk of schedule delays through modular construction
0915 Case Study: • Walking through the current innovations modular construction procedures
Enhancing Commissioning Safety through Reliable Safety and • Optimising quality control in modular construction
Incident Management Initiatives • Achieving high performance construction through streamlined design
• Reviewing your safety and incident management plans and and construction procedures
procedures: Improvement areas for maximum commissioning safety • Getting the most value out of the modular construction at minimum cost
• Utilising current, past and related incidents to your advantage in Murali Venkataraman
strengthening your safety and incident management procedures Global Process Manager
• Minimising risk of incidents related to instrumentation, machines Shell, India
and equipments
• When incidents occur: What does it take to minimise adverse
operational impact?
1445 Case Study:
Allocating Resources, Spares and Materials Management
Mohd Nasir Man throughout the Commissioning Phase
Principal Engineer • Optimising your resources and materials planning to minimise cost and
Petronas, Malaysia risk of shortages
• Maximising spares and material availability to ensure readiness when
START-UP, TESTING AND CRITICAL ISSUES MANAGEMENT material and equipment issues arise in the commissioning process
• Enhancing your troubleshooting capability when shortage occurs
1000 Keynote Presentation: Mohd Faizal Ghazali
Conducting Reliable Acceptance and Performance Testing for Commissioning Manager
Smooth Start-Up Petronas, Malaysia
• Walking through trouble-shooting procedure, possible issues and
corrective actions 1530 Coffee and Networking Break
• Testing the equipments and instrumentation; and handling
equipment failure R BRAINSTORMING AND ROUNDTABLE DISCUSSION
• Conducting inspection and testing to the equipments and plant
operations to ensure optimal reliability and integrity 1600 This session allows the audience to interact and to obtain immediate
Michael Bausch feedback from their direct peers on different key concerns in a roundtable
Commissioning and Start up Manager setting. With a facilitator for each table, participants are encouraged
Dow Chemical Company, Saudi Arabia to voice their opinions, exchange ideas and appraise the good, the bad
and the ugly. It is essential that all are prepared to participate in order to
1045 Coffee and Networking Break ensure discussion flowing and a fruitful session

1115 Case Study: Roundtable One

Analysing Potential Critical Issues and Walking Through the Following Through with Operations Post Start-Up: Identifying
Procedure for Reliable Start-Up Issues that Occur After the Handover
• Detecting potential “red flags” prior to live operation Roundtable Two
• Highlighting areas to consider for final tests and inspection for smooth Addressing the Issue of Commissioning Manpower and
start-up and operation Resource Limitation within Asia Pacific
• Introducing feed-stocks while optimising process safety
• Ensuring that the emergency shutdown systems are properly in place Roundtable Three
• Walking through the contingencies and the handling of emergency Troubleshooting, Potential Problems and Causes of Outages
shutdown to ensure effective recovery during the Start-Up Phase
• Handover to operations: Steps to take and issues to consider
Leong Sik Foo At the end of the discussion the roundtable host will summarise the
Senior Drives and Condition Monitoring Engineer feedback to the rest of the group
BlueScope Steel, Australia
1730 Closing Remarks from the Chairperson and End of Conference
1200 Case Study:
Ensuring Reliable Punch Listing, Handover Readiness and
Who Should Attend:
Effectiveness from Planning to Start-Up
• Covering all the bases in your commissioning process through efficient Directors, Vice Presidents, General Managers, Heads of
punch listing for handover readiness Departments, Senior Managers, Managers, Supervisors,
• Streamlining your handover procedure: A walk through criteria and Engineers from the following job areas:
process from construction to commission to operation • Commissioning • Engineering
• Analysing problems and issues during handover and steps to take to • Start-Up • Production Engineering
minimise them • Operations • Technical Services
• Process Engineering • Process
Mark Gerkema
• Projects • Facilities Management
Technology and Engineering Manager
• Expansion • Contractors
PURAC, Thailand
• Revamp • Equipment Specialist

• Plant • Construction
1245 Networking Luncheon
• Factory • Maintenance Planner
• Maintenance • Manufacturing
From:
• Oil and Gas
• Petrochemicals and Chemicals
• Power and Energy
• Heavy Industries
• Manufacturing Industry: Chemicals and Hazardous Goods /
Hazardous Operational Processes / Heavy Manufacturing
W Post Conference Interactive Course
Wednesday 27th August 2014

ACHIEVING FLAWLESS START-UP AND SOLIDIFYING COMMISSIONING SCOPES

About your Course Facilitator:
Session One Martin Killcross
Refresher of a Methodical Commissioning Process and Its Phases Commissioning Manager, US Mega Projects
• A review on general commissioning methodology Sasol, USA
• Appraisal of key steps from the three phases
• Answer what is commissioning Martin’s experience includes primary and key roles in pre-commissioning,
• Address why we need to organise commissioning commissioning, start-up and operations management as well as providing
consultancy for training and development of best practices for engineering and
Session Two production staff. In September of 2011, Martin Killcross published the Chemical
Prioritised Systemisation of The Process and Process Plant. Commissioning Handbook (Elsevier), a very practical guide to the
• Systemisation of the process and why? methodology and application required in the effective and efficient commissioning
• Ordering of systems by priority order and why? of all types of plant. He has also recently been awarded the “Brennan Medal” given
• Negative implications to none prioritisation by the IChemE for the best IChemE publication of 2012.
• Review of systematic approach He has been accountable for projects ranging from $1MM to $700MM for safe and
on schedule start up of chemical process plants and capital projects, during design,
Group Exercise: construction through beneficial production and final handover to the project
Appraisal of a typical project, systemising and ordering by priority operations team.
Session Three Martin’s commissioning experience spans a huge variety of diverse chemical, oil
Defining Commissioning Scope and Contracts and gas, utility and nuclear processes including Chlorine and its derivatives, Fluorine
• What to consider including in a contract based processes, Refrigerents, LNG, Solvents, Polymers, Fertilizers, Sulphuric Acid,
• Defining and documenting the commissioning teams scope Silicas and Thermal Oxidation. Operational sectors commissioned and operated are
• Key questions to ask when drafting commissioning contracts numerous and include reaction, thermal oxidization, extrusion, distillation, packing
• The client’s commissioning view plants, storage and feed systems, refrigeration and compression, vaporization,
• The contracting commissioning view cooling water circuits and utility systems, Distributed Control Systems (DCS),
• Contract development evaporators, drying and scrubbing systems, kilns, mills and turbines.
His book covers all aspects of the commissioning field and is as useful
Session Four
to experienced commissioning engineers as well as those entering the
Resource Planning and Management: Ensuring Flawless Start-Up
discipline for the first time!
within Budget
• Analysing the commissioning and start-up cost estimation factors and looking at
detailed budget considerations for the project
• Understanding the pre-production cost definition and identifying the cost involved
• Studying the impact of cost and scheduling on the project handover and how it
Why you Cannot Miss this Event:
affects your overall commissioning budget We have seen technological advancement and innovations happening all around
• Ensuring project completion within schedule and budget by optimising available us throughout these years. The right combination of these with new approach,
resource and overcoming lack of resource strategies and application to the commissioning process has led to gradual
• Streamlining your commissioning activities and resource management continuous improvement throughout these years. Process plants have been
• Analysing costs and devising process and resource management plans that successfully built and commissioned and have reaped great benefit from the
minimise cost while optimising quality advancement. Yet the question of achieving flawless start-up still remains.
With tremendous advancement and innovations taking place also comes new
Session Five
challenges which require continuous improvement. The issues and challenges, from
Factory Acceptance Testing (FAT) and Modular Construction
resource and manpower management and commissioning delays to achieving
• Why attend FAT
flawless start-up within budget ahead of time, still persist. New ways of thinking
• FAT protocol and pre-work
with forward-looking insights and approaches that can be incorporated and
• Analysing what can go wrong at FAT
applied into the commissioning process are very much needed especially in today’s
• Activities at the Module Shop
environment to stay ahead of the curve.
• What can be conducted at FAT
• Implication to change identification marcus evans 7th Annual Plant Commissioning and Start-Up will address
• Writing FAT reports the current issues from planning and pre-commissioning to the start-up phase. It
• Legacy implication of module shop work will also provide insights and food for thought in the application of commissioning
approaches in minimising delays and what it takes to optimise your chances
Session Six of achieving smooth and flawless start-up on schedule and within budget. Do
Troubleshooting and Achieving Safe and Incident Free Process from not miss this opportunity to take the advantage of exploring the current
Commissioning to Start-Up activities, insights and trends within the plant commissioning arena for your
• Equipment failure and safety implications commissioning success!
• Streamlining your trouble-shooting process and corrective actions to overcome
commissioning and start-up issues
• Ensuring the safety of your equipments as well as your commissioning team
• Mitigating adverse commissioning risks and achieving favourable outcome Business Development Opportunities:
• Pre Start-Up Safety Review (PSSR) execution and its benefit Does your company have services, solutions or technologies that the conference
delegates would benefit from knowing about?
Session Seven
Commissioning Paperwork: The System File If so, you can find out more about the exhibiting, networking and branding
• Review of commissioning documents opportunities available by contacting:
• Develop commissioning document requirements for the system Peter Morgan on +61 2 9238 7200 or email PeterM@marcusevansau.com
• Organisation of paperwork
• Definition of roles and responsibilities for documentation preparation

Group Exercise:
Introduction to a commissioning “system”

Course Facilitator:
Martin Killcross
Commissioning Manager, US Mega Projects
Sasol, USA