Chemical and Process Plant Commissioning Handbook
A Practical Guide to Plant System and Equipment Installation and Commissioning
By- Martin Killcross, In the area of 'Commissioning' Martin Killcross has considerable operational experience, experience of managing plant overalls and or turnarounds and of the organisation of training programs
The Chemical and Process Plant Commissioning Handbook is a must have for engineers in the chemical process and process plant sectors, or for those refreshing their skills in this area. It provides a guide and reference to preparing a systematic methodology for converting a newly constructed plant, as well as streamlining equipment into an operational process unit. Includes downloadable commissioning process checklists that comply with industry standard best practice which readers can use and adapt for their own situations.
The reference focuses on the critical safety assessment and inspection regimes necessary to ensure that new plants are compliant with OSH(A) and environmental requirements. Martin Killcross has brought together the theory of textbooks and technical information obtained from sales literature, in order to provide engineers with what they need to know before initiating talks with vendors regarding equipment selection.
Commissioning files can be found here; http://www.elsevierdirect.com/companion.jsp?ISBN=9780080971742.
Audience
Chemical and process engineers. Industrial and plant engineers
Hardbound, 312 Pages
Published: September 2011
Imprint: Butterworth Heinemann
ISBN: 978-0-08-097174-2
Reviews
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"This handbook for new and experienced commissioning engineers, project managers, and operations managers offers a methodology for commissioning chemical and process plants, which can be used when commissioning a new plant, or for modified equipment in an existing facility, or in a turnaround or overhaul scenario. The handbook takes the approach that commissioning is a series of checks and counter-checks to confirm that the newly constructed chemical plant is fit for purpose and suitable for ongoing operation. The book is divided into sections on preparation, implementation, and close-out, with much information in bullet list format. For each step of the process, the handbook offers worked examples, checklists, and guidance on paperwork. The book also includes about 70 pages of sample blank documents, which can be used to creation commissioning manuals, plus 40 pages of schematics and engineering drawings especially designed to illustrate info in the handbook. Killcross is a commissioning consultant."-- Reference and Research Book News, October 2012
Contents
Introduction 6
What is commissioning? 9
Safety and Environmental Considerations 12
A simplified commissioning logic 14
The commissioning approach 15
Commissioning Phase One - PREPARE 18
Appointing the Commissioning Manager 20
Commissioning Scope and Contracts 24Budget Estimation 35
Prioritized asset Systemization 38Support Design 45
Develop Initial Commissioning Plan or Philosophy 52Appointment and composition of the Commissioning Team, roles, responsibilities and organisation chart 54
Documentation and sign off requirements, the library and
electronic filing 63Devise assignment details, site and office requirements, consumables and procure commissioning chemicals 66
Create commissioning documents and the System File 70Control, Instrument, Electrical commissioning document
Mechanical commissioning document preparation 100
preparation 82Develop Training Materials 107
Develop Standard Operating Procedures 113Develop Commissioning Schedule 120
Devise Handover Procedure 124Devise commissioning tagging system 127
Commissioning Phase Two - IMPLEMENT 129
Factory Acceptance Testing & Modular Construction 131
Check Construction and Quality of Build 138Tracking Progress & System Status 140
Cleaning procedures and drying 143Pre-commissioning procedures 152
Vessel Check Sheets 160Instrument Loop, Electrical and Control system testing 164
Commissioning Punch listing 166Handover from construction to commissioning 173
Introduction of Safe Chemicals 174Pre-commissioning HAZOP Studies or Pre Start-Up 178
Commissioning Leak Testing 181Commissioning and initial Start-up plus procedures 195
Handover to operations 207Commissioning Phase Three - CLOSEOUT 211Close out reservations 213Complete Commissioning Documentation 213
Complete Training and update documents to "as commissioned" 213Update Operating Procedures to "as commissioned" 214
Assist continued operation, troubleshooting and or
debottlenecking projects 214Close Down Commissioning Team 215
Complete close out Hazard Study 215The Commissioning System File, a full catalogue of blank commissioning documents 216Index 283Glossary of Terms 287Appendices 288About the author 323
