Chemical and Process Plant Commissioning Handbook

Table of contents

1. Cover image
2. Title page
3. Table of Contents
4. Copyright
5. Acknowledgment
6. Introduction
7. What is Commissioning
8. Safety and Environmental Considerations
9. A Simplified Commissioning Logic
10. Intent and Use of the Handbook
11. The Commissioning Approach
12. Chapter 1. Commissioning Phase One – Prepare
    1. Appointing the Commissioning Manager
    2. Commissioning Scope and Contracts
    3. Contracts
    4. Budget Estimation
    5. Prioritized Asset Systemization
    6. Support Design
    7. Develop an Initial Commissioning Plan or Philosophy
    8. Appointment, Composition of the Commissioning Team, Roles, Responsibilities and Organization Chart
    9. Documentation and Sign-Off Requirements, the Library and Electronic Filing
    10. Devise Assignment Details, Site and Office Requirements, Consumables and Procure Commissioning Chemicals
    11. Create Commissioning Documents and the System File
    12. Control, Instrument, Electrical Commissioning Document Preparation
    13. Mechanical Commissioning Document Preparation
    14. Develop Training Materials
    15. Develop Standard Operating Procedures (SOPs)
    16. Develop Commissioning Schedule
    17. Devise Handover Procedure
    18. Devise Commissioning Tagging System
13. Chapter 2. Commissioning Phase Two – Implement
    1. Factory Acceptance Testing
    2. Check Construction and Quality of Build
    3. Tracking Progress and System Status
    4. Cleaning Procedures and Drying
    5. Pre-Commissioning Procedures
    6. Vessel Check Sheets
    7. Instrument Loop, Electrical and Control System Testing
    8. Commissioning Punchlisting
    9. Handover from Construction to Commissioning
    10. Introduction of Safe Chemicals
    11. Pre-Commissioning HAZOP Studies or Pre-Start-Up Safety
    12. Commissioning Leak Testing
    13. Commissioning and Initial Start-Up Plus Procedures
    14. Handover to Operations
14. Chapter 3. Commissioning Phase Three – Close-Out
    1. Close Out Reservations
    2. Complete Commissioning Documentation
    3. Complete Training and Update Documents to “As Commissioned”
    4. Update Operating Procedures to “As Commissioned”
    5. Assist Continued Operation, Troubleshooting and/or De-bottlenecking Projects
    6. Close Down the Commissioning Team
    7. Complete Close-Out Hazard Study
15. Chapter 4. The Commissioning System File, a Full Catalogue of Blank Commissioning Documents
    1. Commissioning System File
    2. Commissioning System File System
    3. 1 System P&IDs
    4. 2 Decontamination Procedure and Isolation Register
    5. 3 System Cleaning Checklist and Procedures
    6. 4 Hazard Study Actions
    7. 5 Equipment Check Sheets, Off- and On-Site Checks
    8. 6 System Punchlists
    9. 7 Action Upon Alarm Sheet
    10. 8 Handover Certificate Construction to Commissioning
    11. 9 Project Documentation Check Sheet Prior to Introduction of Safe Chemicals
    12. 10 Safe Chemical Commissioning Authorization and Pre-Commissioning Procedures
    13. 11 Leak Test Check List and Procedure
    14. 12 Instrument Check Sheet
    15. 13 Motor Check Sheet
    16. 14 Interlock Check Sheet
    17. 15 Emergency Shut-Down Check Sheet
    18. 16 DCS Sequence Test Procedure
    19. 17 Relief Stream Check Sheets
    20. 18 Critical Insulation Checks
    21. 19 Critical Gasket Checks
    22. 20 Lubrication Check Sheet
    23. 21 PSSR and Plant Check-Out Prior to Introduction of Hazardous Chemicals
    24. 22 Documentation Requirements for Ongoing Maintenance Group
    25. 23 Authority to Introduce Process Chemicals, Check Sheet and Certificate
    26. 24 Commissioning Procedures
    27. 25 Standard Operating Procedures (SOPs)
    28. 26 Commissioning to Operations Handover Certificate
16. Glossary of Terms
17. Appendix 1. Commissioning Team Meeting Agenda
18. Appendix 2. Commissioning System Documentation Validation Matrix
19. Appendix 3. Control System Fault Log
20. Appendix 4. Loop Test Sheet
21. Appendix 5. Worked Example of a Knowledge-Based Training Package
22. Appendix 6. Appendix
23. Appendix 7. Example Labels and Tags
24. Appendix 8. Worked Example of a Vendor Shop Inspection Report
25. Appendix 9. Commissioning System Status Chart
26. Appendix 10. Steam Blow Target Plate Configuration
27. About the Author
28. Index