Chemical and Process Plant Commissioning Handbook

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. The book is supported by detailed, proven and effective commission templates and includes extensive commissioning scenarios that enable the reader to good commissioning practices. Sections focus on the critical safety assessment and inspection regimes necessary to ensure that new plants are compliant with OSHA and environmental requirements. Martin Killcross has comprehensively brought together the theory of textbooks and technical information obtained from sales literature to provide engineers with what they need to know before initiating talks with vendors regarding equipment selection.

Current Manager of Commissioning in the UK energy sector, a world scale Nuclear Deconversion Project (circ £1B) which is in the final commissioning stages. With over 41 years in the Chemical, Nuclear and related business sectors, 38 of those years specifically commissioning, de-commissioning and operating assets world-wide, including 25 years with ICI, subsequently working in both the client and contracting commissioning leadership capacities. The author has commissioned most unit operations and handled many hazardous chemicals. Since the publication of the 1st edition of this book, the author has presented at conferences and training events worldwide

1. Appointing the Commissioning manager 2. Commissioning Scope 3. Contracts 4. Commissioning in highly regulated industries 5. Budget Estimation 6. Prioritized asset Systemization 7. Support design 8. Develop Initial Commissioning Plan, Philosophy and Strategy 9. Commissioning Risk Management 10. Appointment and composition of the Commissioning Team, Roles, responsibilities, organisation chart and interview considerations 11. Suitable, Qualified and Experienced Personnel (SQEP), for commissioning 12. Documentation and sign off requirements, required for commissioning preparation 13. Devise assignment details, site and office requirements, consumables and procure commissioning chemicals 14. Create commissioning documents and the System File 15. Control, Instrument, Electrical commissioning document preparation 16. Mechanical commissioning document preparation 17. Develop Training Materials 18. Develop Standard Operating Procedures 19. Developing Commissioning Schedules and Contingency plans 20. Determination of Commissioning Readiness and Commissioning Team Audits 21. Devise Handover Procedure 22. Devise commissioning tagging system 23. Commissioning Terminology 24. Capturing Lessons Learnt 25. Factory Acceptance Testing 26. Check Construction and Quality of Build 27. Tracking Progress and System Status 28. Fault Management 29. Temporary Commissioning Defeat systems 30. Simultaneous Construction and Commissioning considerations 31. Cleaning procedures and drying 32. Pre-commissioning procedures 33. Logs, Reports and Dashboards 34. Vessel Check Sheets 35. Instrument Loop, Electrical and Control system testing 36. Commissioning Punch listing 37. Handover from construction to commissioning 38. Project Documentation Check Sheet Prior to Introduction of Safe Chemicals 39. Introduction of Safe Chemicals and Simulant Testing 40. Pre-commissioning HAZOP Studies or Pre-Start-Up Safety 41. Commissioning Leak Testing 42. Commissioning and initial Start-up plus Procedures 43. Re-commissioning of plant after an event or delay in commissioning activities 44. Laboratory analysis 45. Handover to operations and transition of ownership 46. Close out reservations 47. Complete Commissioning Documentation 48. Complete Training and update documents to "as commissioned” 49. Update Operating Procedures to "as commissioned” 50. Assist continued operation, troubleshooting and or debottlenecking projects 51. Close down all commissioning temporary defeats commissioning faults and modification paperwork systems 52. Close Down Commissioning Team 53. Complete close out Hazard Study