Chemical and Process Plant Commissioning Handbook

A Practical Guide to Plant System and Equipment Installation and Commissioning

Martin Killcross

• Publisher: Butterworth-Heinemann
• Year: 2021
• eBook ISBN: 9780323851411
• Edition: 2
• Topic: Technology & Engineering
• Subtopic: Chemical & Biochemical Engineering
• Index: Technology & Engineering

Chemical 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

Table of contents

• Cover
• Front Matter
• Table of Contents
• Copyright
• About the author
• Acknowledgments
• What is commissioning?
• Safety and environmental considerations
• A simplified commissioning logic
• Intent and use of the handbook
• The commissioning approach
• List of Illustrations
• List of Tables
• Introduction
• 1 : Appointing Commissioning Manager
• 2 : Commissioning scope
• 3 : Contracts
• 4 : Commissioning in highly regulated industries—A guide
• 5 : Budget estimation
• 6 : Prioritized asset systemization
• 7 : Support design
• 8 : Develop an initial commissioning plan, philosophy, and strategy
• 9 : Commissioning risk management
• 10 : Appointment and composition of the commissioning team, roles, responsibilities, organization chart, and interview considerations
• 11 : Suitably Qualified and Experienced Personnel (SQEP) for commissioning
• 12 : Documentation and sign-off requirements required for commissioning preparation
• 13 : Devise assignment details, site and office requirements, consumables and procure commissioning chemicals
• 14 : Create commissioning documents and the system file
• 15 : Control, instrument, and electrical commissioning document preparation
• 16 : Mechanical commissioning document preparation
• 17 : Develop training materials
• 18 : Develop Standard Operating Procedures (SOPs)
• 19 : Developing commissioning schedules and contingency plans
• 20 : Determination of commissioning readiness and team audits
• 21 : Devise handover procedure
• 22 : Devise commissioning tagging system
• 23 : Commissioning terminology
• 24 : Capturing lessons learnt
• Introduction
• 25 : Factory acceptance testing
• 26 : Check construction and quality of build
• 27 : Tracking progress and system status
• 28 : Fault management
• 29 : Temporary commissioning defeat systems
• 30 : Simultaneous construction and commissioning considerations
• 31 : Cleaning procedures and drying
• 32 : Pre-commissioning procedures
• 33 : Logs, reports, and dashboards
• 34 : Vessel check sheets
• 35 : Instrument loop, electrical, and control system testing
• 36 : Commissioning punch listing
• 37 : Handover from construction to commissioning
• 38 : Project documentation check sheet prior to the introduction of safe chemicals
• 39 : Introduction of safe chemicals
• 40 : Pre-commissioning HAZOP studies or pre-start-up safety
• 41 : Commissioning leak testing
• 42 : Commissioning and initial start-up plus procedures
• 43 : Recommissioning of plant after an event or delay in commissioning activities
• 44 : Laboratory analysis
• 45 : Handover to operations and transition of ownership
• Introduction
• 46 : Close out reservations
• 47 : Complete commissioning documentation
• 48 : Complete training and update documents to “as commissioned”
• 49 : Update operating procedures to “as commissioned”
• 50 : Assist continued operation, troubleshooting, and/or de-bottlenecking projects
• 51 : Close down all commissioning temporary defeats, commissioning faults, and modification paperwork systems
• 52 : Closing down of the commissioning team
• 53 : Complete close-out hazard study
• Introduction
• 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 : Optimal operational values sheet
• 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
• Appendix 11 : Additional labels
• Appendix 12 : Example documentation structure for the Commissioning Group
• Appendix 13 : Example of a Commissioning Dashboard
• FAQs and answers
• GENERIC-TITLE
• Index
• A