What are the most effective practices for gas plant shutdown and start-up?

2 Follow the shutdown procedure

Once the plan is ready, you need to follow the shutdown procedure according to the instructions and specifications. The procedure should be performed in a systematic and controlled manner, avoiding abrupt changes in pressure, temperature, or flow that could cause damage or instability. The procedure should also be monitored and documented by the operators, who should report any deviations or issues to the supervisors. The procedure should be completed when the gas plant is in a safe and stable condition, ready for maintenance or inspection.

3 Conduct maintenance and inspection

During the shutdown period, you need to conduct maintenance and inspection activities to ensure the integrity and performance of the gas plant equipment and systems. Maintenance and inspection activities include cleaning, repairing, replacing, testing, and calibrating the components and instruments, as well as checking for corrosion, erosion, cracks, leaks, or other defects. Maintenance and inspection activities should be done according to the standards and regulations, as well as the manufacturer's recommendations. Maintenance and inspection activities should be recorded and verified by the qualified personnel.

4 Prepare a start-up plan

Before starting up a gas plant, you need to prepare a comprehensive plan that covers all the aspects of the operation, such as the scope, objectives, schedule, resources, risks, and contingencies. The plan should also include the sequence of actions to fill, pressurize, heat, and start the equipment and pipelines, as well as the safety measures and precautions to prevent hazards, such as fire, explosion, or leakage. The plan should be communicated and reviewed with all the stakeholders, such as the operators, maintenance personnel, contractors, and regulators.

5 Follow the start-up procedure

Once the plan is ready, you need to follow the start-up procedure according to the instructions and specifications. The procedure should be performed in a gradual and controlled manner, avoiding sudden changes in pressure, temperature, or flow that could cause damage or instability. The procedure should also be monitored and documented by the operators, who should report any deviations or issues to the supervisors. The procedure should be completed when the gas plant is in a normal and steady condition, ready for production.

6 Optimize the production

After starting up a gas plant, you need to optimize the production to achieve the desired quality and quantity of the gas products, as well as the efficiency and reliability of the gas plant equipment and systems. Optimization activities include adjusting, tuning, and regulating the parameters and variables, such as pressure, temperature, flow, level, and composition, as well as analyzing, evaluating, and improving the performance and operation. Optimization activities should be done according to the best practices and benchmarks, as well as the customer's requirements and expectations. Optimization activities should be recorded and reported by the operators.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?