Chemical and Process Plant
Commissioning Handbook
A Practical Guide to Plant System
and Equipment Installation
and Commissioning
Martin Killcross
EngTech TIChemE
AMSTERDAM •
BOSTON •
HEIDELBERG • LONDON
NEW YORK •
OXFORD •
PARIS • SAN DIEGO
SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO
ELSEVIER Butterworth-Heinemann is an imprint of Elsevier
Contents
Acknowledgment ix
Introduction xi
What is Commissioning? xiii
Safety and Environmental Considerations xvii
A Simplified Commissioning Logic xix
Intent and Use of the Handbook xxi
The Commissioning Approach xxiii
1. Commissioning Phase One -
Prepare 1
Appointing the Commissioning Manager 5
Commissioning Scope and Contracts 9
Contracts 11
Budget Estimation 22
Prioritized Asset Systemization 24
Support Design 29
Develop an Initial Commissioning Plan or Philosophy 37
Appointment, Composition of the Commissioning Team, Roles,
Responsibilities and Organization Chart 39
Documentation arid Sign-Off Requirements, the Library and
Electronic Filing 44
Devise Assignment Details, Site and Office Requirements,
Consumables and Procure Commissioning Chemicals 48
Create Commissioning Documents and the System File 52
Control, Instrument, Electrical Commissioning Document
Preparation 63
Mechanical Commissioning Document Preparation 80
Develop Training Materials 86
v
vi Contents
93
Develop Standard Operating Procedures (SOPs)
100
Develop Commissioning Schedule
Devise Handover Procedure 104
Devise 107
Commissioning Tagging System
2. Commissioning Phase Two -
Implement 109
Factory Acceptance Testing 111
Check Construction and Quality of Build 117
and System Status 119
Tracking Progress
Procedures and Drying 121
Cleaning
Pre-Commissioning Procedures 129
Vessel Check Sheets 136
Instrument Loop, Electrical and Control System Testing 137
Commissioning Punchlisting 141
Handover from Construction to Commissioning 147
Introduction of Safe Chemicals 149
Pre-Commissioning HAZOP Studies or Pre-Start-Up Safety 152
155
Commissioning Leak Testing
Commissioning and Initial Start-Up Plus Procedures 166
Handover to Operations 176
3. Commissioning Phase Three -
Close-Out 181
Close Out Reservations 181
182
Complete Commissioning Documentation
and Documents to "As Commissioned" 182
Complete Training Update
Update Operating Procedures to "As Commissioned" 183
Assist Continued Operation, Troubleshooting and/or
183
De-bottlenecking Projects
Close Down the Team 183
Commissioning
Close-Out Hazard 184
Complete Study
Contents vii
4. The Commissioning System File, a Full Catalogue of
Blank Commissioning Documents 185
Commissioning System File 186
Commissioning System File System 186
System P&IDs 187
Decontamination Procedure and Isolation Register 187
System Cleaning Checklist and Procedures 189
Hazard Study Actions 191
Equipment Check Sheets, Off- and On-Site Checks 191
System Punchlists 207
Action Upon Alarm Sheet 211
Handover Certificate Construction to Commissioning 212
Project Documentation Check Sheet Prior to Introduction of Safe
Chemicals 213
Safe Chemical Commissioning Authorization and
Pre-Commissioning Procedures 216
Leak Test Check List and Procedure 219
Instrument Check Sheet 221
Motor Check Sheet 222
Interlock Check Sheet 223
Emergency Shut-Down Check Sheet 224
DCS Sequence Test Procedure 225
Relief Stream Check Sheets 226
Critical Insulation Checks 227
Critical Gasket Checks 228
Lubrication Check Sheet 229
PSSR and Plant Check-Out Prior to Introduction of Hazardous
Chemicals 230
Documentation Requirements for Ongoing Maintenance Group 235
viii Contents
Authority to Introduce Process Chemicals, Check Sheet and
236
Certificate
237
Commissioning Procedures
239
Standard Operating Procedures (SOPs)
240
Commissioning to Operations Handover Certificate
243
Glossary of Terms
245
Appendices
About the Author 281
Index 283
