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.