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Chemical and Process Plant Commissioning Handbook
A Practical Guide to Plant System and Equipment Installation and Commissioning
1st Edition - September 27, 2011
Author: Martin Killcross
Paperback ISBN:
9 7 8 - 0 - 0 8 - 1 0 1 5 1 1 - 7
Hardback ISBN:
9 7 8 - 0 - 0 8 - 0 9 7 1 7 4 - 2
eBook ISBN:
9 7 8 - 0 - 0 8 - 0 9 7 1 7 5 - 9
The Chemical and Process Plant Commissioning Handbook, winner of the 2012 Basil Brennan Medal from the Institution of Chemical Engineers, is a guide to converting a newly… Read more
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The Chemical and Process Plant Commissioning Handbook, winner of the 2012 Basil Brennan Medal from the Institution of Chemical Engineers, is a guide to converting a newly constructed plant or equipment into a fully integrated and operational process unit. Good commissioning is based on a disciplined, systematic and proven methodology and approach that achieve results in the safest, most efficient, cost effective and timely manner.
The book is supported by detailed, proven and effective commission templates, plus extensive commissioning scenarios that enable the reader to learn the context of good commissioning practice from an experienced commissioning manager. It focuses on the critical safety assessment and inspection regimes necessary to ensure that new plants are compliant with OSHA and environmental requirements. Martin Killcross has brought together the theory of textbooks and technical information obtained from sales literature, in order to provide engineers with what they need to know before initiating talks with vendors regarding equipment selection.
- Unique information from a respected, global commissioning manager: delivers the know-how to succeed for anyone commissioning new plant or equipment
- Comes with online commissioning process templates that make this title a working tool kit as well as a key reference
- Extensive examples of successful commissioning processes with step-by-step guidance enable readers to understand the function and performance of the wide range of tasks required in the commissioning process
Chemical and process engineers. Industrial and plant engineers
Acknowledgment
Introduction
What is Commissioning
Safety and Environmental Considerations
A Simplified Commissioning
Intent and Use of the Handbook
The Commissioning Approach
Chapter 1. Commissioning Phase One – Prepare
Appointing the Commissioning Manager
Commissioning Scope and Contracts
Contracts
Budget Estimation
Prioritized Asset Systemization
Support Design
Develop an Initial Commissioning Plan or Philosophy
Appointment, Composition of the Commissioning Team, Roles, Responsibilities and Organization Chart
Documentation and Sign-Off Requirements, the Library and Electronic Filing
Devise Assignment Details, Site and Office Requirements, Consumables and Procure Commissioning Chemicals
Create Commissioning Documents and the System File
Control, Instrument, Electrical Commissioning Document Preparation
Mechanical Commissioning Document Preparation
Develop Training Materials
Develop Standard Operating Procedures (SOPs)
Develop Commissioning Schedule
Devise Handover Procedure
Devise Commissioning Tagging System
2. Commissioning Phase Two – Implement
Factory Acceptance Testing
Check Construction and Quality of Build
Tracking Progress and System Status
Cleaning Procedures and Drying
Pre-Commissioning Procedures
Vessel Check Sheets
Instrument Loop, Electrical and Control System Testing
Commissioning Punchlisting
Handover from Construction to Commissioning
Introduction of Safe Chemicals
Pre-Commissioning HAZOP Studies or Pre-Start-Up Safety
Commissioning Leak Testing
Commissioning and Initial Start-Up Plus Procedures
Handover to Operations
3. Commissioning Phase Three – Close-Out
Close Out Reservations
Complete Commissioning Documentation
Complete Training and Update Documents to “As Commissioned”
Update Operating Procedures to “As Commissioned”
Assist Continued Operation, Troubleshooting and/or De-bottlenecking Projects
Close Down the Commissioning Team
Complete Close-Out Hazard Study
Chapter 4. The Commissioning System File, a Full Catalogue of Blank Commissioning Documents
Commissioning System File
Commissioning System File System
1. System P&IDs
2. Decontamination Procedure and Isolation Register
3. System Cleaning Checklist and Procedures
4. Hazard Study Actions
5. Equipment Check Sheets, Off- and On-Site Checks
6. System Punchlists
7. Action Upon Alarm Sheet
8. Handover Certificate Construction to Commissioning
9. Project Documentation Check Sheet Prior to Introduction of Safe Chemicals
10. Safe Chemical Commissioning Authorization and Pre-Commissioning Procedures
11. Leak Test Check List and Procedure
12. Instrument Check Sheet
13. Motor Check Sheet
14. Interlock Check Sheet
15. Emergency Shut-Down Check Sheet
16. DCS Sequence Test Procedure
17. Relief Stream Check Sheets
18. Critical Insulation Checks
19. Critical Gasket Checks
20. Lubrication Check Sheet
21. PSSR and Plant Check-Out Prior to Introduction of Hazardous Chemicals
22. Documentation Requirements for Ongoing Maintenance Group
23. Authority to Introduce Process Chemicals, Check Sheet and Certificate
24. Commissioning Procedures
25. Standard Operating Procedures (SOPs)
26. Commissioning to Operations Handover Certificate
Glossary of Terms
Appendix 1. Commissioning Team Meeting Agenda
Appendix 2. Commissioning System Documentation Validation Matrix
Appendix 3. Control System Fault Log
Appendix 4. Loop Test Sheet
Appendix 5. Worked Example of a Knowledge-Based Training Package
Appendix 6. Appendix
Appendix 7. Example Labels and Tags
Appendix 8. Worked Example of a Vendor Shop Inspection Report
Appendix 9. Commissioning System Status Chart
Appendix 10. Steam Blow Target Plate Configuration
About the Author
Index
- No. of pages: 312
- Language: English
- Published: September 27, 2011
- Imprint: Butterworth-Heinemann
- Paperback ISBN: 9780081015117
- Hardback ISBN: 9780080971742
- eBook ISBN: 9780080971759
MK
Martin Killcross
Current Manager of Commissioning in the UK energy sector, a world scale Nuclear Deconversion Project (circ £1B) which is in the final commissioning stages. With over 41 years in the Chemical, Nuclear and related business sectors, 38 of those years specifically commissioning, de-commissioning and operating assets world-wide, including 25 years with ICI, subsequently working in both the client and contracting commissioning leadership capacities. The author has commissioned most unit operations and handled many hazardous chemicals. Since the publication of the 1st edition of this book, the author has presented at conferences and training events worldwide
Affiliations and expertise
Commissioning Manager, URENCO ChemPlants, UK