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Chemical and Process Plant Commissioning Handbook

Name: Chemical and Process Plant Commissioning Handbook
Author: Martin Killcross
ISBN: 9780080971742

by Martin Killcross

September 2011

Intermediate to advanced

312 pages

English

Elsevier Science

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Cover image
Title page
Table of Contents
Copyright
Acknowledgment
Introduction
What is Commissioning
Safety and Environmental Considerations
A Simplified Commissioning Logic
Intent and Use of the Handbook

The Commissioning Approach
Chapter 1. Commissioning Phase One – Prepare
Appointing the Commissioning ManagerCommissioning Scope and ContractsContractsBudget EstimationPrioritized Asset SystemizationSupport DesignDevelop an Initial Commissioning Plan or PhilosophyAppointment, Composition of the Commissioning Team, Roles, Responsibilities and Organization ChartDocumentation and Sign-Off Requirements, the Library and Electronic FilingDevise Assignment Details, Site and Office Requirements, Consumables and Procure Commissioning ChemicalsCreate Commissioning Documents and the System FileControl, Instrument, Electrical Commissioning Document PreparationMechanical Commissioning Document PreparationDevelop Training MaterialsDevelop Standard Operating Procedures (SOPs)Develop Commissioning ScheduleDevise Handover ProcedureDevise Commissioning Tagging System
Chapter 2. Commissioning Phase Two – Implement
Factory Acceptance TestingCheck Construction and Quality of BuildTracking Progress and System StatusCleaning Procedures and DryingPre-Commissioning ProceduresVessel Check SheetsInstrument Loop, Electrical and Control System TestingCommissioning PunchlistingHandover from Construction to CommissioningIntroduction of Safe ChemicalsPre-Commissioning HAZOP Studies or Pre-Start-Up SafetyCommissioning Leak TestingCommissioning and Initial Start-Up Plus ProceduresHandover to Operations
Chapter 3. Commissioning Phase Three – Close-Out
Close Out ReservationsComplete Commissioning DocumentationComplete Training and Update Documents to “As Commissioned”Update Operating Procedures to “As Commissioned”Assist Continued Operation, Troubleshooting and/or De-bottlenecking ProjectsClose Down the Commissioning TeamComplete Close-Out Hazard Study
Chapter 4. The Commissioning System File, a Full Catalogue of Blank Commissioning Documents
Commissioning System FileCommissioning System File System1 System P&IDs2 Decontamination Procedure and Isolation Register3 System Cleaning Checklist and Procedures4 Hazard Study Actions5 Equipment Check Sheets, Off- and On-Site Checks6 System Punchlists7 Action Upon Alarm Sheet8 Handover Certificate Construction to Commissioning9 Project Documentation Check Sheet Prior to Introduction of Safe Chemicals10 Safe Chemical Commissioning Authorization and Pre-Commissioning Procedures11 Leak Test Check List and Procedure12 Instrument Check Sheet13 Motor Check Sheet14 Interlock Check Sheet15 Emergency Shut-Down Check Sheet16 DCS Sequence Test Procedure17 Relief Stream Check Sheets18 Critical Insulation Checks19 Critical Gasket Checks20 Lubrication Check Sheet21 PSSR and Plant Check-Out Prior to Introduction of Hazardous Chemicals22 Documentation Requirements for Ongoing Maintenance Group23 Authority to Introduce Process Chemicals, Check Sheet and Certificate24 Commissioning Procedures25 Standard Operating Procedures (SOPs)26 Commissioning to Operations Handover Certificate
Glossary of Terms
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. Appendix
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
About the Author
Index

Content preview from Chemical and Process Plant Commissioning Handbook

Appendix 5 Worked Example of a Knowledge-Based Training Package

Plant X

Knowledge Training Package

FIG. 44

FIG. 45

1 Introduction to Training Process

The process of operator training addressed in this package incorporates sections on basic system knowledge; it includes all the materials concerned with underpinning knowledge for the ammonia addition system.

This process uses a series of logical steps to build up an individual’s underpinning knowledge of the process, including the equipment, process flow and control, and how ...

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Chemical and Process Plant Commissioning Handbook

by Martin Killcross

Appendix 5

Worked Example of a Knowledge-Based Training Package