Chemical and Process Plant Commissioning Handbook: A Practical Guide to Plant System and Equipment Installation and Commissioning
312
Chemical and Process Plant Commissioning Handbook: A Practical Guide to Plant System and Equipment Installation and Commissioning
312eBook
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Overview
The Chemical and Process Plant Commissioning Handbook, 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. Good commissioning is based on a disciplined, systematic and proven methodology and approach that achieve results in the safest, most efficient, cost effective and timely manner.
The book is supported by detailed, proven and effective commission templates, plus extensive commissioning scenarios that enable the reader to learn the context of good commissioning practice from an experienced commissioning manager. It focuses on the critical safety assessment and inspection regimes necessary to ensure that new plants are compliant with OSHA 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.
- Unique information from a respected, global commissioning manager: delivers the know-how to succeed for anyone commissioning new plant or equipment
- Comes with online commissioning process templates that make this title a working tool kit as well as a key reference
- Extensive examples of successful commissioning processes with step-by-step guidance enable readers to understand the function and performance of the wide range of tasks required in the commissioning process
Product Details
| ISBN-13: | 9780080971759 |
|---|---|
| Publisher: | Elsevier Science |
| Publication date: | 09/27/2011 |
| Sold by: | Barnes & Noble |
| Format: | eBook |
| Pages: | 312 |
| File size: | 9 MB |
About the Author
Read an Excerpt
Chemical and Process Plant Commissioning Handbook
A Practical Guide to Plant System and Equipment Installation and CommissioningBy Martin Killcross
Butterworth-Heinemann
Copyright © 2012 Elsevier Ltd.All right reserved.
ISBN: 978-0-08-097175-9
Chapter One
The tasks on the following bulleted list are, at a minimum, those that must be considered during the preparation phase of process plant commissioning; they are in chronological order and consistent with the required flow of activities during this initial phase.• Appointing the commissioning manager
• Commissioning scope and contracts
• Budget estimation
• Prioritized asset systemization
• Support design
• Develop an initial commissioning plan or philosophy
• Appointment and composition of the commissioning team, roles, responsibilities and organization chart
• Documentation and sign-off requirements, the library and electronic filing
• Devise assignment details, site and office requirements, consumables and procure commissioning chemicals
• Create commissioning documents and the system file
• Control, instrument, electrical commissioning document preparation
• Mechanical commissioning document preparation
• Develop training materials
• Develop Standard Operating Procedures
• Develop Commissioning Schedule
• Devise handover procedure
• Devise commissioning tagging system.
Appointing the Commissioning Manager
Potentially it may be that you obtained a copy of this handbook having been selected to a position of significant responsibility, charged with the organization and delivery of the commissioning aspect of a processing asset. In this scenario this section may be of little interest because you are already there! However, the guidance provided here will highlight the general attributes required of the person a project manager or head of operations may wish to consider in the appointment of a commissioning manager for a project.
From a fundamental perspective the responsibility of a commissioning manager is to specify, schedule and directly oversee the implementation of the procedures and practices necessary for commissioning of a given process plant, to enable the equipment and systems within the asset to be safely and reliably brought into operation and handed over to the plant production organization for ongoing production at correct design rates and product specification.
The commissioning manager is obviously a main project role, the incumbent becoming responsible for selecting and appointing the actual commissioning team. The systems of work the individual must then lead, develop and implement are best executed based on the practices and methods explained in this handbook. The commissioning manager will also become the main pivotal role and principal interface between the various disciplines comprising the project team, with particular emphasis generally being focused on the construction to commissioning and commissioning to operations group interfaces and handovers.
It is vital the commissioningmanager is able to fully understand and comprehend how each facility, system or process unit within the asset, including specific main plant items and their ancillary processes, is designed to operate, can be controlled and also maintained. Once this understanding is gained, the commissioning manager then needs to correctly sequence the systemization and as importantly prioritization of the various systems that make up the plant; this will then allow the procedures, check sheets and other commissioning documents to be written, which will address the following main process activities and major process operations:
• Pre-commissioning
• Commissioning
• Start-up
• Normal shut-down
• Emergency shut-down
• Decontamination.
It cannot be stressed highly enough the need to allow sufficient time for the commissioning manager to become totally familiar with the intended process design and the operation thereof as it has such a fundamental impact on the future effective and efficient planning of the commissioning of the process plant that is to be made operational.
Below are listed the main key attributes and responsibilities due for consideration in the selection of a commissioning manager. Most of the skill set, qualities and level of qualification desired in a suitable commissioning manager will lay the foundation for the recruitment of members and thereafter within the commissioning team to be formed.
Attributes
• Adaptable and flexible approach to work
• Sound knowledge of safety, health and environmental, especially with regard to risk, safe systems of work, statutory and regulatory requirements
• Readily able to become familiar with process design
• Experience and knowledge of commissioning process plant
• Knowledge of a "systemized" approach to commissioning
• Experience of commissioning new equipment within an existing operational asset including:
• Experience of project commissioning within the management of a major overhaul or turnaround
• Proven record of working to strict budget and schedule limitations
• Experience of technical problem solving in an operational environment
• Working within the constraints of a highly active and fluid operational environment
• Ability to successfully manage within the constraints of fast-track projects
• Knowledge of control, electrical and instrumentation systems and the commissioning and check-out thereof
• Knowledge of mechanical package equipment and the commissioning thereof.
Responsibilities
• Agree and develop with the project organization the scope of the commissioning team
• Develop the various commissioning schedules required throughout the life of a project
• Ensuring any enabling or preparatory work such as existing equipment decontamination is considered and documentation suitably prepared
• Management of the check-out of new equipment and systems to ensure installation is as per design, proven methodology and approach to punch listing
• Ensuring the design of the new plant or equipment and its commissioning, as far as can be reasonably practicable, has no adverse effect on safety or the environment
• Ensuring tests are carried out to confirm equipment and systems work safely and correctly
• Ensuring equipment is not brought into service until registration and documentation have been completed
• Ensuring suitable isolation standards are incorporated in design for both commissioning and ongoing operations
• Ensuring that all commissioning documentation is handed over to the operating plant manager post completion of commissioning activities
• If required lead and/or complete the requirements of Hazard studies, Management of Change (MOC) paperwork, Authorization to Introduce Safe and Process Chemicals and Pre Start-up Safety Review (PSSR) documentation. In addition ensure all relevant Hazard study, MOC and PSSR actions are completed and closed out prior to start-up
• Management of the development and incorporation into the main project of an acceptable commissioning estimate and budget
• Management of the development of off-site vendor inspections and factory acceptance checks
• Establishing and management of the training program for a competent commissioning, operating and maintenance team
• Clarify the operations/project/commissioning handover and responsibility philosophy
• Manage the production of specific written commissioning procedures for each system and/or each item of equipment, covering all aspects of the commissioning process
• Overall responsibility for the commissioning process, including safe operation and compliance with statutory requirements
• Establishing and management of an appropriate commissioning organization, providing leadership for the execution of the commissioning procedures and plans in conjunction with those of the project and construction teams
• Provide a commissioning manual, outlining the specific methods of commissioning to be used on the project
• Attend design and project reviews as agreed with the project manager supporting the design process as required. Ensure that relevant standards pertinent to the operation are upheld throughout the design phase, particularly when the project or modification is substantial
• Participate in all coordination, scheduling, safety and progress review meetings
• Ensuring all instrument and electrical tests and check-out are completed per commissioning system, including checkout of new computer control systems, interlocks and shut-down systems
• Update all assigned commissioning documentation post start-up
• Management and organization for the potential of shift work patterns and working of long unsocial hours.
Qualifications
• Bachelors Chemical Engineering Degree Education þ 10 years' process plant experience
• Suitable experience in a chemical or oil and gas process industry
• Suitable experience of at least 2 years in the commissioning of industrial process plants. The preceding skill sets are to ensure:
• Suitable documentation and organizational preparation
• Suitable checkout of systems including individual plant items to ensure the asset is ready for operation
• The asset can be made operational ensuring all statutory, safety and legislative procedures have been completed
• The asset is safely commissioned and can operate to full design capability and within product specification.
Key Points
• The commissioning manager is to specify, schedule and directly oversee the implementation of the procedures and practices necessary for commissioning of a given process plant, to enable the equipment and systems within the asset to be safely and reliably brought into operation and handed over to the plant production organization for ongoing production at correct design rates and product specification
• Pivotal project role especially between the construction and operations organizations
• Obtain overall process familiarity and organize system and delivery prioritization accordingly.
Commissioning Scope and Contracts
It is the responsibility of the commissioning manager to undertake and agree with the client operations, project and construction management, the detailed scope of the commissioning aspect of the project. The resultant scope can then be documented within the Commissioning Manual.
There are typically two perspectives to view the commissioning scope:
1. From the client commissioning manager viewpoint
2. From the view of the contracting commissioning manager.
Here are the key points from either perspective.
The Client Commissioning Manager
The client commissioning manager will be very much interested in agreeing with the project management and the ongoing operations management where the key milestones and deliverables for the commissioning scope are. The client commissioning manager will not be as interested in the contract as a contracting commissioning manager. The milestones will include the evaluation of the following points, confirming their inclusion within the scope of the commissioning activities is a positive must for the commissioning manager:
• Is the production and delivery of training packages in the commissioning team scope?
• Is the production of operating procedures in the commissioning team scope?
• To what extent will the commissioning organization check out the construction group activities?
• Witness all flushing and blowing of pipe work, if not what percentage?
• Witness all instrument loop tests, if not what percentage will they witness?
• Witness all motor rotation checks, if not what percentage?
• Determination of what equipment vendor inspections and Factory Acceptance Tests will be attended by commissioning team personnel?
• When can the commissioning team produce a punch list and at what stage in construction (typically after 80% of the build is complete) can this take place?
• How to hand over from the construction group to allow for commissioning activities to start?
• Will the detailed commissioning schedules be incorporated within the main project schedule, or just main milestone activities and dates?
• What design reviews should the commissioning team attend?
• Will the commissioning organization procure the initial fill of process chemicals?
• What safe systems of work will there be, including permit to work and confined space entry systems, and who will administer these processes?
• Determine with the project group the method of communicating prominent status changes; introduction of safe chemicals and initial energy import and introduction of process chemicals
• Will a commissioning budget estimate be required?
• Hand over deliverables to the operations group including confirmation of:
1. The design feed rate
(Continues...)
Excerpted from Chemical and Process Plant Commissioning Handbook by Martin Killcross Copyright © 2012 by Elsevier Ltd.. Excerpted by permission of Butterworth-Heinemann. All rights reserved. No part of this excerpt may be reproduced or reprinted without permission in writing from the publisher.
Excerpts are provided by Dial-A-Book Inc. solely for the personal use of visitors to this web site.
Table of Contents
Introduction
What is Commissioning?
Safety and Environmental Considerations
A Simplified Commissioning Logic
Intent and Use of the Handbook
The Commissioning Approach
Commissioning Phase One – PREPARE
Commissioning Phase Two – IMPLEMENT
Commissioning Phase Three – CLOSE-OUT
The Commissioning System File, a full catalogue of blank commissioning documents
What People are Saying About This
Provides the most extensive and practical description of plant commissioning available