Chemical and Process Plant Commissioning Handbook
A Practical Guide to Plant System and Equipment Installation and Commissioning
- 2nd Edition - March 13, 2021
- Imprint: Butterworth-Heinemann
- Author: Martin Killcross
- Language: English
- Hardback ISBN:9 7 8 - 0 - 1 2 - 8 2 4 0 4 9 - 6
- eBook ISBN:9 7 8 - 0 - 3 2 3 - 8 5 1 4 1 - 1
Chemical and Process Plant Commissioning Handbook: A Practical Guide to Plant System and Equipment Installation and Commissioning, Second Edition, winner of the 2012 Basil Bre… Read more
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Request a sales quoteChemical and Process Plant Commissioning Handbook: A Practical Guide to Plant System and Equipment Installation and Commissioning, Second Edition, 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. The book is supported by detailed, proven and effective commission templates and includes extensive commissioning scenarios that enable the reader to good commissioning practices. Sections focus on the critical safety assessment and inspection regimes necessary to ensure that new plants are compliant with OSHA and environmental requirements.
Martin Killcross has comprehensively brought together the theory of textbooks and technical information obtained from sales literature to provide engineers with what they need to know before initiating talks with vendors regarding equipment selection.
- Outlines how to organize and commission a process plant
- Includes extensive examples of successful commissioning processes with step-by-step guidance that enables readers to understand the function and performance of the wide range of tasks required in the commissioning process
- Offers an understanding of supplementary factors of commissioning such as risk and hazard management
- Reviews commonly asked commissioning questions
- Includes the basis of the commissioning paperwork system
Process Engineers, Project Managers, Operations personal, Commissioning Engineers and Managers. Possible textbook for university courses/supplementary text
- Cover image
- Title page
- Table of Contents
- Copyright
- About the author
- Acknowledgments
- What is commissioning?
- Dry commissioning
- Wet commissioning
- Inactive commissioning
- Active commissioning
- HSE advice on commissioning
- Main phases of commissioning
- Safety and environmental considerations
- A simplified commissioning logic
- Intent and use of the handbook
- The commissioning approach
- The commissioning phases
- Section 1: Commissioning phase one—Prepare
- Introduction
- Commissioning Terminology Capturing Lessons Learnt
- 1: Appointing Commissioning Manager
- Abstract
- Main attributes of a Commissioning Manager
- Main responsibilities of a Commissioning Manager
- Main qualifications of a Commissioning Manager
- Key points
- 2: Commissioning scope
- Abstract
- Commissioning scope development—The client Commissioning Manager
- Commissioning scope development—Contracting Commissioning Manager (not client employed—delivering a contractual commissioning scope of work)
- Key points
- 3: Contracts
- Abstract
- Contract considerations for completion and handover from construction to commissioning
- Contract considerations for commissioning delivery
- Contract considerations for training
- Contract considerations for roles and responsibilities
- Key points
- 4: Commissioning in highly regulated industries—A guide
- Abstract
- Office of Nuclear Regulation guidelines on commissioning
- 5: Budget estimation
- Abstract
- Commissioning budget estimation—Key elements
- Key points
- 6: Prioritized asset systemization
- Abstract
- Guidelines for commissioning systemization
- Hypothetical highlighted P&ID showing system identification
- Key points
- 7: Support design
- Abstract
- Commissioning considerations at a hazard study
- Commissioning considerations at layout reviews
- Commissioning considerations at P&ID reviews
- Commissioning considerations at 3-D model reviews
- Commissioning considerations while reviewing isometric drawings
- Commissioning considerations of risk assessments and Hazards during Construction
- Commissioning considerations for control systems
- Commissioning considerations for action upon alarm reviews
- Key points
- 8: Develop an initial commissioning plan, philosophy, and strategy
- Abstract
- Commissioning philosophy or plan
- Commissioning strategy
- Key points
- 9: Commissioning risk management
- Abstract
- Safe execution of commissioning activities—Point of work and specific risk analysis
- Procedural assessment of risk
- Safety system testing
- General commissioning risk evaluation and management—The commissioning contribution to project-related risk
- Key points
- 10: Appointment and composition of the commissioning team, roles, responsibilities, organization chart, and interview considerations
- Abstract
- Descriptions of typical commissioning team roles and responsibilities
- Roles and responsibilities matrix
- Stakeholder management
- Interview considerations—Questions useful in the selection of commissioning staff
- Key points
- 11: Suitably Qualified and Experienced Personnel (SQEP) for commissioning
- Abstract
- Job description
- Resume or curriculum vitae
- Induction process
- SQEP assessment
- Authority to commission certificate
- Key points
- 12: Documentation and sign-off requirements required for commissioning preparation
- Abstract
- Documentation sign-off
- Key points
- 13: Devise assignment details, site and office requirements, consumables and procure commissioning chemicals
- Abstract
- Common considerations when developing foreign commissioning assignments
- Site and office requirements
- List of commonly used commissioning consumables
- List and procure commissioning chemicals
- Key points
- 14: Create commissioning documents and the system file
- Abstract
- Commissioning documents
- The commissioning system file
- Commissioning file structure
- Key points
- 15: Control, instrument, and electrical commissioning document preparation
- Abstract
- Electrical, control, and instrumentation documents prepared during commissioning
- Key points
- 16: Mechanical commissioning document preparation
- Abstract
- Mechanical documents prepared during commissioning
- Key points
- 17: Develop training materials
- Abstract
- Typical engineering documents utilized during drafting of training packages
- Operator knowledge training—Classroom
- Operator knowledge training—Vendor presentation
- Operator practical training—“On The Job”
- Maintenance personnel knowledge training—Classroom
- Maintenance and operator personnel equipment-related training—Workshop and classroom
- Management training—Classroom
- Control system, operator training—Classroom with control system simulation
- Control system, systems engineer training—Typically control system vendor location (potentially site-based)
- Key points
- 18: Develop Standard Operating Procedures (SOPs)
- Abstract
- From the Health and Safety Executive (HSE)—Commissioning guidelines
- Title of procedure manual Standard Operating Procedure
- Table of contents descriptions Standard Operating Procedure
- Typical considerations for commissioning documents required after a major overhaul or turnaround
- Key points
- 19: Developing commissioning schedules and contingency plans
- Abstract
- Stage 1—Level 2
- Stage 2—Level 3
- Commissioning execution plans
- Considerations for inclusion in a commissioning execution plan
- Tracking commissioning progress
- Commissioning logic diagrams and normal durations
- Key points
- 20: Determination of commissioning readiness and team audits
- Abstract
- Guide words for consideration in a commissioning readiness review
- Commissioning audits
- Key points
- 21: Devise handover procedure
- Abstract
- Handover criteria
- Phased system handover approach
- Safe systems of work at handover
- Handover documentation
- The review process prior to handover
- Key points
- 22: Devise commissioning tagging system
- Abstract
- Location of tie-in points
- Location of commissioning system battery limit isolation
- A punchlist item
- Leak point found during leak test
- System LIVE
- Item under construction control—Refers to an electrical item
- Item under commissioning control—Refers to an electrical item
- General commissioning label
- Commissioning area sign
- 23: Commissioning terminology
- Abstract
- 24: Capturing lessons learnt
- Abstract
- Section 2: Commissioning phase two—Implement
- Introduction
- 25: Factory acceptance testing
- Abstract
- Modular construction
- Things that can go right!
- Key points
- 26: Check construction and quality of build
- Abstract
- Key points
- 27: Tracking progress and system status
- Abstract
- 28: Fault management
- Abstract
- Raising a fault
- Acceptance and categorization
- Solution
- Design assessment
- Solution acceptance
- Change and document implementation
- Fault retest
- Close out
- Key points
- 29: Temporary commissioning defeat systems
- Abstract
- General information
- Key points
- 30: Simultaneous construction and commissioning considerations
- Abstract
- Key points
- 31: Cleaning procedures and drying
- Abstract
- Cleaning
- Types of cleaning methods
- Procedural steps
- Drying
- Key points
- 32: Pre-commissioning procedures
- Abstract
- List of example pre-commissioning procedures
- Key points
- 33: Logs, reports, and dashboards
- Abstract
- Logs
- Reports
- Headings to base commissioning logs, reports, and dashboards
- Dashboards
- Key points
- 34: Vessel check sheets
- Abstract
- Key points
- 35: Instrument loop, electrical, and control system testing
- Abstract
- Key points
- 36: Commissioning punch listing
- Abstract
- Key points
- 37: Handover from construction to commissioning
- Abstract
- Key points
- 38: Project documentation check sheet prior to the introduction of safe chemicals
- Abstract
- Typical Hazard Study guide word list for safe chemical commissioning
- Key points
- 39: Introduction of safe chemicals
- Abstract
- Typical checks prior to safe chemical and initial energy introduction
- Key points
- 40: Pre-commissioning HAZOP studies or pre-start-up safety
- Abstract
- Typical commissioning hazard guide words for hazardous chemical introduction
- Key points
- 41: Commissioning leak testing
- Abstract
- Test (a): Service test
- Test (b): Safe chemical leak test
- Test (c): Vacuum test
- Test (d): Toxic testing
- Test (e): Helium leak testing
- Key points
- 42: Commissioning and initial start-up plus procedures
- Abstract
- Utilities and services
- Water commissioning
- Commission and initial start-up of the plant with process chemicals
- Key points
- 43: Recommissioning of plant after an event or delay in commissioning activities
- Abstract
- Key points
- 44: Laboratory analysis
- Abstract
- Laboratory design phase
- Equipment
- General
- Samples and analysis
- Key points
- 45: Handover to operations and transition of ownership
- Abstract
- Key points
- Section 3: Commissioning phase three—Closeout
- Introduction
- 46: Close out reservations
- Abstract
- 47: Complete commissioning documentation
- Abstract
- 48: Complete training and update documents to “as commissioned”
- Abstract
- 49: Update operating procedures to “as commissioned”
- Abstract
- 50: Assist continued operation, troubleshooting, and/or de-bottlenecking projects
- Abstract
- 51: Close down all commissioning temporary defeats, commissioning faults, and modification paperwork systems
- Abstract
- 52: Closing down of the commissioning team
- Abstract
- 53: Complete close-out hazard study
- Abstract
- Section 4: The commissioning system file, a full catalog of blank commissioning documents
- Introduction
- Commissioning System File
- Commissioning System File System
- Appendix 1: Commissioning team meeting agenda
- Appendix 2: Commissioning system documentation validation matrix
- Hypothetical process plant
- Appendix 3: Control system fault log
- Control system fault log
- Appendix 4: Loop test sheet
- Appendix 5: Worked example of a knowledge-based training package
- Plant X
- Contents
- Introduction to training process
- The training process
- Appendix 6: Optimal operational values sheet
- Appendix 7: Example labels and tags
- Appendix 8: Worked example of a vendor shop inspection report
- Sketch of test rig
- Trial 1
- Trial 2
- Appendix 9: Commissioning system status chart
- Appendix 10: Steam blow target plate configuration
- Appendix 11: Additional labels
- Appendix 12: Example documentation structure for the Commissioning Group
- Appendix 13: Example of a Commissioning Dashboard
- FAQs and answers
- The questions
- Glossary of terms
- Index
- Edition: 2
- Published: March 13, 2021
- Imprint: Butterworth-Heinemann
- No. of pages: 534
- Language: English
- Hardback ISBN: 9780128240496
- eBook ISBN: 9780323851411
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, UKRead Chemical and Process Plant Commissioning Handbook on ScienceDirect