Chemical and Process Plant Commissioning Handbook. A Practical Guide to Plant System and Equipment Installation and Commissioning

Front matter
Copyright
Contents
About the author
Acknowledgments
What is commissioning?
Safety and environmental considerations
A simplified commissioning logic
Intent and use of the handbook
The commissioning approach
Section 1. Commissioning phase one—Prepare
	1. Appointing Commissioning Manager
		Main attributes of a Commissioning Manager
		Main responsibilities of a Commissioning Manager
		Main qualifications of a Commissioning Manager
		Key points
	2. Commissioning scope
		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
		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
		Office of Nuclear Regulation guidelines on commissioning
		5. Budget estimation
		Commissioning budget estimation—Key elements
		Key points
	6. Prioritized asset systemization
		Guidelines for commissioning systemization
		Hypothetical highlighted P&ID showing system identification
		Key points
	7. Support design
		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
		Commissioning philosophy or plan
		Commissioning strategy
		Key points
		9. Commissioning risk management
		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
		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
		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
		Documentation sign-off
		Key points
		13. Devise assignment details, site and office requirements, consumables and procure commissioning chemicals
		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
		Commissioning documents
		The commissioning system file
		Commissioning file structure
		Key points
	15. Control, instrument, and electrical commissioning document preparation
		Electrical, control, and instrumentation documents prepared during commissioning
		Key points
	16. Mechanical commissioning document preparation
		Mechanical documents prepared during commissioning
		Key points
	17. Develop training materials
		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)
		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
		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
		Guide words for consideration in a commissioning readiness review
		Commissioning audits
		Key points
	21. Devise handover procedure
		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
		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
	24. Capturing lessons learnt
Section 2. Commissioning phase two—Implement
	25. Factory acceptance testing
		Modular construction
		Things that can go right!
		Key points
	26. Check construction and quality of build
		Key points
	27. Tracking progress and system status
	28. Fault management
		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
		General information
		Key points
	30. Simultaneous construction and commissioning considerations
		Key points
	31. Cleaning procedures and drying
		Cleaning
		Types of cleaning methods
		Procedural steps
		Drying
		Key points
	32. Pre-commissioning procedures
		List of example pre-commissioning procedures
		Key points
	33. Logs, reports, and dashboards
		Logs
		Reports
		Headings to base commissioning logs, reports, and dashboards
		Dashboards
		Key points
	34. Vessel check sheets
		Key points
	35. Instrument loop, electrical, and control system testing
		Key points
	36. Commissioning punch listing
		Key points
	37. Handover from construction to commissioning
		Key points
	38. Project documentation check sheet prior to the introduction of safe chemicals
		Typical Hazard Study guide word list for safe chemical commissioning
		Key points
	39. Introduction of safe chemicals
		Typical checks prior to safe chemical and initial energy introduction
		Key points
	40. Pre-commissioning HAZOP studies or pre-start-up safety
		Typical commissioning hazard guide words for hazardous chemical introduction
		Key points
		41. Commissioning leak testing
		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
		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
		Key points
	44. Laboratory analysis
		Laboratory design phase
		Equipment
		General
		Samples and analysis
		Key points
	45. Handover to operations and transition of ownership
		Key points
Section 3. Commissioning phase three—Closeout
	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
Section 4. The commissioning system file, a full catalog of blank commissioning documents
	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
Glossary of terms
Index