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.
1. Introduction - p. Page xvii 2. 1 : Appointing Commissioning Manager - p. Page xvii 3. 2 : Commissioning scope - p. Page 7 4. 3 : Contracts - p. Page 12 5. 4 : Commissioning in highly regulated industries—A guide - p. Page 17 6. 5 : Budget estimation - p. Page 21 7. 6 : Prioritized asset systemization - p. Page 26 8. 7 : Support design - p. Page 34 9. 8 : Develop an initial commissioning plan, philosophy, and strategy - p. Page 43 10. 9 : Commissioning risk management - p. Page 55 11. 10 : Appointment and composition of the commissioning team, roles, responsibilities, organization chart, and interview considerations - p. Page 63 12. 11 : Suitably Qualified and Experienced Personnel (SQEP) for commissioning - p. Page 80 13. 12 : Documentation and sign-off requirements required for commissioning preparation - p. Page 86 14. 13 : Devise assignment details, site and office requirements, consumables and procure commissioning chemicals - p. Page 90 15. 14 : Create commissioning documents and the system file - p. Page 96 16. 15 : Control, instrument, and electrical commissioning document preparation - p. Page 112 17. 16 : Mechanical commissioning document preparation - p. Page 133 18. 17 : Develop training materials - p. Page 146 19. 18 : Develop Standard Operating Procedures (SOPs) - p. Page 153 20. 19 : Developing commissioning schedules and contingency plans - p. Page 164 21. 20 : Determination of commissioning readiness and team audits - p. Page 181 22. 21 : Devise handover procedure - p. Page 185 23. 22 : Devise commissioning tagging system - p. Page 191 24. 23 : Commissioning terminology - p. Page 196 25. 24 : Capturing lessons learnt - p. Page 198 26. Introduction - p. Page 200 27. 25 : Factory acceptance testing - p. Page 200 28. 26 : Check construction and quality of build - p. Page 212 29. 27 : Tracking progress and system status - p. Page 215 30. 28 : Fault management - p. Page 219 31. 29 : Temporary commissioning defeat systems - p. Page 225 32. 30 : Simultaneous construction and commissioning considerations - p. Page 229 33. 31 : Cleaning procedures and drying - p. Page 233 34. 32 : Pre-commissioning procedures - p. Page 247 35. 33 : Logs, reports, and dashboards - p. Page 256 36. 34 : Vessel check sheets - p. Page 256 37. 35 : Instrument loop, electrical, and control system testing - p. Page 262 38. 36 : Commissioning punch listing - p. Page 267 39. 37 : Handover from construction to commissioning - p. Page 277 40. 38 : Project documentation check sheet prior to the introduction of safe chemicals - p. Page 277 41. 39 : Introduction of safe chemicals - p. Page 282 42. 40 : Pre-commissioning HAZOP studies or pre-start-up safety - p. Page 286 43. 41 : Commissioning leak testing - p. Page 290 44. 42 : Commissioning and initial start-up plus procedures - p. Page 306 45. 43 : Recommissioning of plant after an event or delay in commissioning activities - p. Page 320 46. 44 : Laboratory analysis - p. Page 325 47. 45 : Handover to operations and transition of ownership - p. Page 325 48. Introduction - p. Page 334 49. 46 : Close out reservations - p. Page 334 50. 47 : Complete commissioning documentation - p. Page 334 51. 48 : Complete training and update documents to “as commissioned” - p. Page 334 52. 49 : Update operating procedures to “as commissioned” - p. Page 334 53. 50 : Assist continued operation, troubleshooting, and/or de-bottlenecking projects - p. Page 334 54. 51 : Close down all commissioning temporary defeats, commissioning faults, and modification paperwork systems - p. Page 334 55. 52 : Closing down of the commissioning team - p. Page 334 56. 53 : Complete close-out hazard study - p. Page 334 57. Introduction - p. Page 334 58. Appendix 1 : Commissioning team meeting agenda - p. Page 417 59. Appendix 2 : Commissioning system documentation validation matrix - p. Page 417 60. Appendix 3 : Control system fault log - p. Page 417 61. Appendix 4 : Loop test sheet - p. Page 417 62. Appendix 5 : Worked example of a knowledge-based training package - p. Page 417 63. Appendix 6 : Optimal operational values sheet - p. Page 441 64. Appendix 7 : Example labels and tags - p. Page 444 65. Appendix 8 : Worked example of a vendor shop inspection report - p. Page 446 66. Appendix 9 : Commissioning system status chart - p. Page 449 67. Appendix 10 : Steam blow target plate configuration - p. Page 452 68. Appendix 11 : Additional labels - p. Page 452 69. Appendix 12 : Example documentation structure for the Commissioning Group - p. Page 459 70. Appendix 13 : Example of a Commissioning Dashboard - p. Page 462 71. FAQs and answers - p. Page 462 72. GENERIC-TITLE - p. Page 484 73. Index - p. Page 486
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.
1. Introduction - p. Page xvii 2. 1 : Appointing Commissioning Manager - p. Page xvii 3. 2 : Commissioning scope - p. Page 7 4. 3 : Contracts - p. Page 12 5. 4 : Commissioning in highly regulated industries—A guide - p. Page 17 6. 5 : Budget estimation - p. Page 21 7. 6 : Prioritized asset systemization - p. Page 26 8. 7 : Support design - p. Page 34 9. 8 : Develop an initial commissioning plan, philosophy, and strategy - p. Page 43 10. 9 : Commissioning risk management - p. Page 55 11. 10 : Appointment and composition of the commissioning team, roles, responsibilities, organization chart, and interview considerations - p. Page 63 12. 11 : Suitably Qualified and Experienced Personnel (SQEP) for commissioning - p. Page 80 13. 12 : Documentation and sign-off requirements required for commissioning preparation - p. Page 86 14. 13 : Devise assignment details, site and office requirements, consumables and procure commissioning chemicals - p. Page 90 15. 14 : Create commissioning documents and the system file - p. Page 96 16. 15 : Control, instrument, and electrical commissioning document preparation - p. Page 112 17. 16 : Mechanical commissioning document preparation - p. Page 133 18. 17 : Develop training materials - p. Page 146 19. 18 : Develop Standard Operating Procedures (SOPs) - p. Page 153 20. 19 : Developing commissioning schedules and contingency plans - p. Page 164 21. 20 : Determination of commissioning readiness and team audits - p. Page 181 22. 21 : Devise handover procedure - p. Page 185 23. 22 : Devise commissioning tagging system - p. Page 191 24. 23 : Commissioning terminology - p. Page 196 25. 24 : Capturing lessons learnt - p. Page 198 26. Introduction - p. Page 200 27. 25 : Factory acceptance testing - p. Page 200 28. 26 : Check construction and quality of build - p. Page 212 29. 27 : Tracking progress and system status - p. Page 215 30. 28 : Fault management - p. Page 219 31. 29 : Temporary commissioning defeat systems - p. Page 225 32. 30 : Simultaneous construction and commissioning considerations - p. Page 229 33. 31 : Cleaning procedures and drying - p. Page 233 34. 32 : Pre-commissioning procedures - p. Page 247 35. 33 : Logs, reports, and dashboards - p. Page 256 36. 34 : Vessel check sheets - p. Page 256 37. 35 : Instrument loop, electrical, and control system testing - p. Page 262 38. 36 : Commissioning punch listing - p. Page 267 39. 37 : Handover from construction to commissioning - p. Page 277 40. 38 : Project documentation check sheet prior to the introduction of safe chemicals - p. Page 277 41. 39 : Introduction of safe chemicals - p. Page 282 42. 40 : Pre-commissioning HAZOP studies or pre-start-up safety - p. Page 286 43. 41 : Commissioning leak testing - p. Page 290 44. 42 : Commissioning and initial start-up plus procedures - p. Page 306 45. 43 : Recommissioning of plant after an event or delay in commissioning activities - p. Page 320 46. 44 : Laboratory analysis - p. Page 325 47. 45 : Handover to operations and transition of ownership - p. Page 325 48. Introduction - p. Page 334 49. 46 : Close out reservations - p. Page 334 50. 47 : Complete commissioning documentation - p. Page 334 51. 48 : Complete training and update documents to “as commissioned” - p. Page 334 52. 49 : Update operating procedures to “as commissioned” - p. Page 334 53. 50 : Assist continued operation, troubleshooting, and/or de-bottlenecking projects - p. Page 334 54. 51 : Close down all commissioning temporary defeats, commissioning faults, and modification paperwork systems - p. Page 334 55. 52 : Closing down of the commissioning team - p. Page 334 56. 53 : Complete close-out hazard study - p. Page 334 57. Introduction - p. Page 334 58. Appendix 1 : Commissioning team meeting agenda - p. Page 417 59. Appendix 2 : Commissioning system documentation validation matrix - p. Page 417 60. Appendix 3 : Control system fault log - p. Page 417 61. Appendix 4 : Loop test sheet - p. Page 417 62. Appendix 5 : Worked example of a knowledge-based training package - p. Page 417 63. Appendix 6 : Optimal operational values sheet - p. Page 441 64. Appendix 7 : Example labels and tags - p. Page 444 65. Appendix 8 : Worked example of a vendor shop inspection report - p. Page 446 66. Appendix 9 : Commissioning system status chart - p. Page 449 67. Appendix 10 : Steam blow target plate configuration - p. Page 452 68. Appendix 11 : Additional labels - p. Page 452 69. Appendix 12 : Example documentation structure for the Commissioning Group - p. Page 459 70. Appendix 13 : Example of a Commissioning Dashboard - p. Page 462 71. FAQs and answers - p. Page 462 72. GENERIC-TITLE - p. Page 484 73. Index - p. Page 486
