Chemical and Process Plant Commissioning Handbook

A Practical Guide to Plant System and Equipment Installation and Commissioning

Martin Killcross

• Publisher: Butterworth-Heinemann
• Year: 2011
• ISBN:
  9780080971759
• Topic: Technology & Engineering
• Subtopic: Chemical & Biochemical Engineering
• Index: Technology & Engineering

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

Chapter 1

Commissioning Phase One – Prepare

Chapter Outline

Appointing the Commissioning Manager

Attributes

Responsibilities

Qualifications

Key Points

Commissioning Scope and Contracts

The Client Commissioning Manager

Contracting Commissioning Manager (Not Client-Employed)

Contracts

Commissioning Scope and Contracts – “Things That Can Go Wrong”

Key Points

Budget Estimation

Prioritized Asset Systemization

Hypothetical Highlighted P&ID Showing System Identification

Prioritized Asset Systemization – “Things That Can Go Wrong”

Key Points

Support Design

Hazard Study

Layout Reviews

P&ID Reviews

The Process

Mechanical Issues

Control, Instrument and Electrical Issues

General Issues

3-D Model Reviews

Isometric Drawing

Risk Assessments and Hazards During Construction

Control Systems

Action Upon Alarm Review

Support Design – “Things That Can Go Wrong”

Key Points

Develop an Initial Commissioning Plan or Philosophy

Table of Contents

Purpose of the Commissioning Plan

Commissioning Overview

Project Scope of Work

Key Project Objectives and Aims

Commissioning Team Roles

Commissioning Methodology

Initial Commissioning Systems

The Commissioning System File

Commissioning and Start-up Challenges

Appointment, Composition of the Commissioning Team, Roles, Responsibilities and Organization Chart

The Commissioning Manager

Commissioning System Engineer

Control/Electrical/Instrumentation Commissioning Engineer

Mechanical Commissioning Engineer

Standard Operating Procedure Group – If Not in Scope of the Commissioning Engineer

Training Group – If Not in Scope of the Commissioning Engineer

Key Points

Documentation and Sign-Off Requirements, the Library and Electronic Filing

Documentation Sign-Off

Key Points

Devise Assignment Details, Site and Office Requirements, Consumables and Procure Commissioning Chemicals

International Assignment

Site and Office Requirements

General Commissioning Consumables

List and Procure Commissioning Chemicals

Key Points

Create Commissioning Documents and the System File

Commissioning Documents

The Commissioning System File

Table of Contents

Create Commissioning Documents and the System File – “Things That Can go Wrong”

Key Points

Control, Instrument, Electrical Commissioning Document Preparation

Main Electrical Installation, Switchgear, Transformers, Motor Control Centers (MCC) and Power Cables

Lighting

Control Systems (DCS and/or PLC)

Various Instrument and Electrical Cabling

Instrument Calibration and Instrument Range Consistency

Existing Equipment Sanity Check

Loop Test Paperwork Development, Checking and Testing

Motor Checking and Testing

Software Interlock and Emergency Shut-Down Testing, Both “Dry” and “Wet”

DCS/PLC Sequence Checking and Testing

Specialist Vendor Installation

Training

Control, Instrument, Electrical Commissioning Document Preparation – “Things That Can Go Wrong”

Key Points

Mechanical Commissioning Document Preparation

Isometric Drawing to P&ID Sanity Check

Pipeline Cleanliness Checks and Procedures

Construction and Installation Checks

Vessel and Equipment Checks (Off and On Site)

Mechanical Documentation Check

Vendor and Proprietary Equipment Check-Out

Lubrication

Training

Mechanical Commissioning Document Preparation – “Things That Can Go Wrong”

Key Points

Develop Training Materials

Operator Knowledge Training – Classroom

Operator Knowledge Training – 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)

Develop Training Materials – “Things That Can Go Wrong”

Key Points

Develop Standard Operating Procedures (SOPs)

From the Health and Safety Executive (HSE)

Status of Guidance

Operating Procedures

Title of Procedure Manua

Table of Contents

Table of Contents Descriptions

General Description of System

Safety, Health and Environmental Considerations

Pre-Start Checks

Valve Positions for Start-Up

Initial Start-Up Procedures

Normal Start-Up

Normal Operation Including Optimal Operational Values

Normal Shut-Down Procedures

Emergency Shut-Down Procedures

Fault-Finding Guide, Consequences of a Deviation and Corrective Action Plan

Loss of Utility Emergency Procedures

Temporary Operating Procedures

Action Upon Alarm Sheets

Regular System Routines

Decontamination Procedures

Re-commissioning Procedures Post a Major Overhaul or Turnaround

Key Points

Develop Commissioning Schedule

Stage 1 – Level 2

Stage 2 – Level 3

Key Points

Devise Handover Procedure

Handover Criteria

Phased System Handover Approach

Safe Systems of Work at Handover

Handover Documentation

The Review Process Prior to Handover

Devise Handover Procedure – “Things That Can Go Wrong”

Key Points

Devise Commissioning Tagging System

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

The tasks on the following bulleted list are, at a minimum, those that must be considered during the preparation phase of process plant commissioning; they are in chronological order and consistent with the required flow of activities during this initial phase.

• Appointing the commissioning manager

• Commissioning scope and contracts

• Budget estimation

• Prioritized asset systemization

• Support design

• Develop an initial commissioning plan or philosophy

• Appointment and 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

• Develop Commissioning Schedule

• Devise handover procedure

• Devise commissioning tagging system.

Appointing the Commissioning Manager

Po...