Cómo Realizar el Arranque de una Planta de Procesos - SIMPSA

Cómo Realizar el Arranque de una Planta de
Procesos
Aspectos referentes a Seguridad, Impacto Ambiental y Reducción de
Problemas relacionados con los Equipos. Detección Efectiva de Fallas,
Secuencia de “Commissioning”. Incluyendo Detección de fallas en el Arranque
y Ejemplos con Casos Reales.
Curso Intensivo de Cuatro días
Quienes pueden asistir:
Este curso ha sido diseñado y esta dirigido al personal técnico de niveles medio y
alto involucrado en la ejecución de Proyectos y la preparación del Arranque de
cualquier tipo de Planta de la industria de Procesos. Aunque en la actualidad, el
Arranque de Plantas es diferente según el tipo de industria, los aspectos comunes
incluidos en su preparación, suministrarán lecciones valiosas que serán de utilidad
para:
• Gerentes de Proyecto
• Gerentes de Planta
• Gerentes de Arranque, Gerentes de “Commissioning”
• Expertos en Proceso y Especialistas en Equipos
• Gerentes de Construcción/Capataces
• Contratistas
• Supervisores de Planta
• Gerentes de Mantenimiento
Se ha demostrado que los mayores beneficios, provienen de la aplicación durante
todo el desarrollo del Proyecto, de ideas orientadas al Arranque - comenzando
desde la Fase Conceptual. Durante el desarrollo de este curso se expondrán
técnicas prácticas, ilustradas con discusiones y ejemplos, las cuales proveerán al
participante del útil discernimiento, que le será de gran valor en cualquiera de las
etapas de la ejecución de un Proyecto y sobre todo en la preparación para el
Arranque.
Objetivos del Adiestramiento:
Luego de la culminación satisfactoria del curso, el participante será capaz de:
• Entender las fuentes y los tipos de problemas asociados con el primer
arranque de nuevas instalaciones o de aquellas que se han re-potenciado.
•
Anticipar y evitar impactos financieros, técnicos, operacionales y
organizacionales en los arranques iniciales.
Descripción del Curso:
El Arranque inicial de una Planta, sin importar su tamaño, tipo, tecnología o industria,
es una experiencia única que presenta ciertos problemas especiales. La falta de
experiencia en el manejo de estos problemas, en la mayoría de los casos, ocasiona
Arranques costosos y con retardo. Este curso proveerá al participante de los
lineamientos que le permitirán realizar la preparación requerida para el logro de un
Arranque de Planta exitoso. Y el primer paso hacia una apropiada preparación es el
mantener durante todas las etapas del Proyecto un pensamiento orientado al
Arranque - desde la Ingeniería hasta el “Commissioning”.
Dentro del curso se incluirán los estimados de costos del Arranque, requerimientos
de personal y los distintos recursos necesarios. Se definirá y se ilustrará el papel
vital que juegan tanto el Gerente de Proyectos como el Personal de Planta. También
se considerarán los eventos que no se habían previsto durante el Arranque, los
cuales agregan condiciones peligrosas que requerirán de la preparación de un
esfuerzo adicional para evitar incidentes de Seguridad.
La detección de fallas realizada durante el Arranque, puede ser muy costosa y debe
ser realizada de la forma más efectiva posible. La meta de la Detección de Fallas es
la de minimizar el tiempo y el costo de ir desde el Arranque Inicial hasta Producción
Total. Por ello durante los cuatro días de desarrollo del curso, se efectuará una
revisión de las técnicas y se hará una discusión de numerosos ejemplos que le
permitirán desarrollar destrezas en la Detección de Fallas.
Para un mayor aprovechamiento, se agradecerá la interacción entre los participantes,
ya que será la forma más significativa de aprovechar todo el rango de puntos de
vistas y las experiencias acumuladas en sus respectivas carreras profesionales.
Igualmente el planteamiento de preguntas a los Instructores, ya que ellos poseen
dilatada experiencia en un amplio rango de unidades de proceso, dentro de las
cuales podemos mencionar: las químicas, petroquímicas, las de operaciones de
refinación, de manejo de materiales, procesamiento de minerales y de producción
catalítica. Siempre y cuando exista el tiempo disponible, se discutirán los casos
particulares que traigan los participantes.
Contenido del Curso:
Nota importante....
Todo el material del curso y las presentaciones que realizará el Instructor, serán en
idioma ingles, sin embargo, las presentaciones previstas para Venezuela, contarán
con personal y equipos de traducción simultánea.
Primer día
TERMINOS Y HERRAMIENTAS
Introducción:
• Objetivos
• Arranque
• Terminología
• Evolución del Proyecto
• Requerimientos
para
un
Arranque exitoso
• Cómo esta involucrado el
personal de Planta.
Problemas en el Arranque:
• Problemas históricos y causas
de las interrupciones
• Fuente de los problemas:
desde la iniciación hasta la
culminación del Proyecto
• Cómo minimizar los problemas
y las consecuencias.
Discusión:
• Problemas
potenciales
relacionados con tu Proyecto y
su Arranque.
Planificación del Arranque:
•
•
Cuando iniciarla
Cronogramas
para
el
“Commissioning” y el Arranque
• Herramientas de Planificación,
Control y Listas de Verificación
• Planes de Respuesta
• Procedimientos
y
otros
preparativos.
Predicción de los Costos de Arranque:
• Definición de los Costos de
Arranque
• Ejemplos históricos
• Factores para la estimación de
los costos de Arranque
• Consideraciones
para
el
presupuesto de Arranque
• Costos del Arranque que son
olvidados
• Minimizando lo costos de
Arranque
Minimizando problemas con los
Equipos:
•
•
•
•
Revisión de las fuentes de
problemas en Equipos
Determinación de los Equipos
críticos
Entendiendo las fallas de los
Equipos
Precauciones que minimizan el
impacto de las fallas de los
Equipos.
Segundo día
GERENCIA
Seguridad en el Arranque y aspectos
Ambientales:
• Reconociendo
problemas
únicos de Seguridad y de
Ambiente, antes, durante y
después del Arranque
• Emergencias
• Preparativos de Seguridad,
Adiestramiento,
Auditorias,
HAZOP y otros métodos para
minimizar riesgos
• Discusión
de
aspectos
Ambientales.
Gerencia del Arranque:
• Gerencia
de
los
requerimientos
correspondientes a cada uno
de los eventos
• Contratistas/Propietarios/Ingen
ieros/Personal de Operaciones
involucrados
y
sus
responsabilidades
• Tipos de organizaciones: para
Proyectos y para su Arranque
• El Gerente de Arranque y el
Equipo de Arranque
• Líneas de Responsabilidad /
Niveles de Supervisión
• Toma de decisiones
• Coordinación
de
las
Reuniones
• Ajustes de las respuestas y de
la delegación
Equipo de Arranque:
• Personal de Planta para el
Arranque
• Experiencia requerida
• Ejemplo de conformación de
un Equipo de Arranque
• Efectos de la inexperiencia
durante el Arranque
• Compensando la inexperiencia
• Programas de Adiestramiento.
Liderazgo durante el Arranque:
• Posiciones clave
• Liderazgo balanceado
• Moral y Espíritu de Equipo.
Tecnología:
• Fuentes de nueva tecnología y
su impacto en el Arranque
• Computadoras de Planta y la
infraestructura de Información
• Preparación del Laboratorio
• Servicios Especializados
• Papel de la Ingeniería de
Procesos durante el Arranque.
Discusión:
• Tópicos
seleccionados
asociados con tu Proyecto y su
Arranque
• Ejercicio de planificación de un
Arranque..
Tercer día
EN EL CAMPO
Inspección de la Construcción:
• Porqué?
• Quién?
• Cómo?
• Cuándo?
• Estableciendo los Estándares
de Calidad
• Fuerza
hombre
para
la
Inspección y su adiestramiento
• Técnicas de Inspección en
Campo.
Finalización de la Construccióncomienzo del Arranque:
• Cronogramas de Construcción
vs. Necesidades del Arranque
• Finalización de la Construcción
mediante Sistemas de Prueba
• Arranque mediante Sistemas
• Definición de los Sistemas
• Traspaso de roles – La
interfase entre la construcción
y las operaciones.
“Commissioning” – El corazón del
Arranque:
• Desarrollando la secuencia de
“Commissioning”
• Recursos
requeridos
y
procedimientos
• Técnicas de “Commissioning”
y simulacros de operación
• Preparación
de
la
Instrumentación
• Chequeo de los Lazos
Discusión:
• Ejemplo
de
situaciones
durante el “Commissioning” y
la Detección de Fallas.
•
Comunicación
dentro
del
Equipo de Trabajo
• Cooperación.
Solución de problemas:
• Encontrando soluciones
• Probando una hipótesis
• Evitando gastos “resolviendo”
• Evitando
ineficiencias
“resolviendo”
• Accediendo a las soluciones
• Implementando cambios
• Requerimientos de Ingeniería
y estándares utilizados para
los cambios a realizarse en el
campo.
Ejecución de las pruebas:
• Preparación
• Testificación
• Garantías
• Celebración.
Operaciones de Arranque:
• Ejecución de las actividades
iniciales
• Manteniendo los momentos
anticipados
• Logrando el éxito
• Revisión.
S
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Cuarto día
DETECCION DE FALLAS EN EL
ARRANQUE
Visión General:
• Eventos
• Consecuencias
• Definición de las vías hacia el
éxito.
Retos:
• Retos de Gerencia
• Reconociendo los problemas
• Trampas comunes en el
Arranque
• Fallas que suceden
•
Instrumentación
•
Razones de las fallas
• Seguridad.
Aspectos Técnicos:
• Secretos de un profesional
encargado de la Detección de
Fallas
•
Mentiras,
Asunciones
y
Lecturas de los Instrumentos
• Respuestas en Retroceso
• Respuestas Dinámica’
Recolección de Información Cero:
• Fuentes
de
Datos
y
reconciliación
• Historia vs. Histeria
Los participantes deberán presentarse a las 7:30 a:m el primer día del curso. Sin
embargo para el programa del curso se han previsto sesiones que duran todo el día,
siguiendo un horario de 8:00 a:m a 5:00 p:m, con un receso de 15 minutos en la
mañana, uno de 90 minutos al mediodía y uno de 15 minutos en la tarde.
Director del Curso:
Chris Wallsgrove ha trabajado como Ingeniero/Gerente de Arranque para algunos
de los mayores Contratistas Internacionales y recientemente ha finalizado su
asignación en el arranque de una instalación Petroquímica de rango mundial,
ubicada en el Medio Oriente.
Mr. Wallsgrove l se ha concentrado en los aspectos de Ingeniería relacionados con
el Arranque de Plantas, incluyendo el diseño, planificación, adiestramiento,
operaciones de Arranque y la detección de fallas. “El ha participado en el arranque
de cinco Plantas de Etileno de rango mundial y más de diez Plantas mayores de
Petróleo, Petroquímica y especialidades Químicas.
Mr. Wallsgrove es miembro de la AIChE y ha presentado artículos técnicos,
adiestramiento y detección de fallas a nivel mundial en el tema Arranque de Plantas
y una amplia variedad de asuntos técnicos.
Este evento es producido por:
SIMPSA – (Sistemas Integrales para el Mejoramiento Profesional), S.A., R.I.F.: J-29492517-0.
Calle Arismendi, # 20, Edf. DALY, Piso 3, Oficina 3-6, Sector Centro, Puerto La Cruz, Anzoátegui, 6023,
Venezuela
Teléfonos: +58 (281) 2656928, (281) 2673150, (281) 4197865, (416) 4460124, / Fax: +58 (281) 2651127.
Correo electrónico: [email protected]
Para información adicional sobre Adiestramiento de Ingeniería, visite la siguiente dirección
Web: http://www.petrolero.net
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John Butler has over forty years of experience managing the
effective design and operation of process plants, including all
second,
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start-up
and troubleshooting. Mr. Butler has been
responsible for a number of technology-driven world-scale
hydrocarbon processing projects from beginning to successful
seco
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Texts
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set records for minimum
timeOther C
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on-stream time in the initial production run. He is Past Chairman of
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Chris Wallsgrove is Manager of the Process Engineering group
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HiddenReading
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with Middough Inc., an engineering and consulting company in
people shortages; Staff buildup example;
Plant personnel involvement
Start-Up Trouble Shooting
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