Chemical and process plant commissioning handbook : a practical guide to plant system and equipment installation and commissioning / Martin Killcross.

Format:

Book

Author/Creator:

Killcross, Martin, author.

Language:

English

Subjects (All):

Chemical plants--Design and construction--Standards.

Chemical plants.

Building commissioning--Handbooks, manuals, etc.

Building commissioning.

Physical Description:

1 online resource (536 pages) : illustrations

Edition:

2nd ed.

Place of Publication:

Oxford, England ; Cambridge, Massachusetts : Elsevier, [2021]

Summary:

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.

Contents:

Intro

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

Copyright

Contents

About the author

Acknowledgments

What is commissioning?

Dry commissioning

Wet commissioning

Inactive commissioning

Active commissioning

HSE advice on commissioning

Main phases of commissioning

Safety and environmental considerations

A simplified commissioning logic

Intent and use of the handbook

The commissioning approach

The commissioning phases

Prepare

Implement

Closeout

Section 1: Commissioning phase one-Prepare

Chapter 1: Appointing Commissioning Manager

Main attributes of a Commissioning Manager

Main responsibilities of a Commissioning Manager

Main qualifications of a Commissioning Manager

Key points

Chapter 2: Commissioning scope

Commissioning scope development-The client Commissioning Manager

Commissioning scope development-Contracting Commissioning Manager (not client employed-delivering a contractual commissioni ...

Commissioning scope-``things that can go wrong´´

Chapter 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

Chapter 4: Commissioning in highly regulated industries-A guide

Office of Nuclear Regulation guidelines on commissioning

Chapter 5: Budget estimation

Commissioning budget estimation-Key elements

Chapter 6: Prioritized asset systemization

Guidelines for commissioning systemization

A sample prioritized commissioning system list

Hypothetical highlighted P&amp

ID showing system identification.

Prioritized asset systemization-``things that can go wrong´´

Chapter 7: Support design

Potential plant issues identified at design reviews are as follows:

Commissioning considerations at a hazard study

Commissioning considerations at layout reviews

Commissioning considerations at P&amp

ID reviews

The process

Mechanical issues

Control, instrument, and electrical issues

General issues

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

Support design-``things that can go wrong´´

Chapter 8: Develop an initial commissioning plan, philosophy, and strategy

Commissioning philosophy or plan

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

A sample table of contents for a commissioning system file

Commissioning and start-up challenges

Commissioning strategy

Introduction

Prioritized systems list

Scope of Factory Acceptance Testing (FAT)

Pre- and wet-commissioning phases

Simulated commissioning

Process fluid commissioning

Performance testing

Temporary equipment

Consumables

Vendor and licensor commissioning

Assumptions

Other considerations

Chapter 9: Commissioning risk management

Safe execution of commissioning activities-Point of work and specific risk analysis

Commissioning point of work Risk Assessment guide word considerations

Procedural assessment of risk.

Safety system testing

General commissioning risk evaluation and management-The commissioning contribution to project-related risk

List of considerations in compiling a Commissioning Risk Register

Chapter 10: Appointment and composition of the commissioning team, roles, responsibilities, organization chart, and inter ...

Descriptions of typical commissioning team roles and responsibilities

The Commissioning Manager

Commissioning System Engineer/Area Commissioning Manager

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

Commissioning Safety Adviser

Commissioning Planner

Building Services Engineer

Integration Manager

Operations/Maintenance Liaison

Vendor Coordinator

Roles and responsibilities matrix

Stakeholder management

Interview considerations-Questions useful in the selection of commissioning staff

Typical interview questions for commissioning staff

Chapter 11: Suitably Qualified and Experienced Personnel (SQEP) for commissioning

Job description

Resume or curriculum vitae

Induction process

SQEP assessment

Authority to commission certificate

Chapter 12: Documentation and sign-off requirements required for commissioning preparation

Typical list of documentation commonly stored in the commissioning team library.

Typical list of documentation commonly used by the commissioning team.

Documentation sign-off

Chapter 13: Devise assignment details, site and office requirements, consumables and procure commissioning chemicals

Common considerations when developing foreign commissioning assignments

Site and office requirements.

Commissioning office requirements

List of commonly used commissioning consumables

List and procure commissioning chemicals

Typical list of first fill commissioning chemicals and lubricants

Chapter 14: Create commissioning documents and the system file

Commissioning documents

Engineering documents used by the commissioning team

Typical topics for consideration when drafting commissioning procedures

Considerations for civil's commissioning

General System File

HSE guidance (United Kingdom) on commissioning documentation considerations

Description of contents in a typical commissioning documentation system file

Table of contents

Commissioning file structure

Create commissioning documents and the system file-``things that can go wrong´´

Chapter 15: Control, instrument, and electrical commissioning document preparation

Electrical, control, and instrumentation documents prepared during commissioning

Main electrical installation, switchgear, transformers, motor control centers (MCC), and power cables

Lighting and small power

Control systems (DCS and/or PLC)

Various instrument and electrical cabling including identification labels and tags

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 including vendor package checks including ``as installed´´ paperwork and drawings

Protocol for change management through the commissioning effort

Air conditioning (HVAC) for various rooms and cabinets

Training.

Final checkout and lockdown protocols for all control and electrical systems prior to start-up

Attendance of and paperwork check of all C/E/I-related Site Acceptance Tests (SAT)

Earth leakage testing or protective conductor current testing

Earthing or grounding packages

Control, instrument, electrical commissioning document preparation-``things that can go wrong´´

Chapter 16: Mechanical commissioning document preparation

Mechanical documents prepared during commissioning

Isometric (ISO) drawing to P&amp

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 checkout

Lubrication

Alignment checks

Preservation checks

Training

Stores

Mechanical commissioning document preparation-``things that can go wrong´´

Things that can go right!

Chapter 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)

Develop training materials-``things that can go wrong´´

Chapter 18: Develop Standard Operating Procedures (SOPs)

From the Health and Safety Executive (HSE)-Commissioning guidelines

Status of guidance

Operating procedures.

Title of procedure manual Standard Operating Procedure.

Notes:

Includes index.

Description based on print version record.

Description based on publisher supplied metadata and other sources.

ISBN:

0-323-85141-X

OCLC:

1243542627