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

By Martin Killcross

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.

• Outlines how to organize and commission a process plant
• Includes extensive examples of successful commissioning processes with step-by-step guidance that enables readers to understand the function and performance of the wide range of tasks required in the commissioning process
• Offers an understanding of supplementary factors of commissioning such as risk and hazard management
• Reviews commonly asked commissioning questions
• Includes the basis of the commissioning paperwork system

• Language: English
• Publisher: Elsevier Science
• Release date: Mar 13, 2021
• ISBN: 9780323851411

Martin Killcross

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

Book preview

9780323851411_FC

Chemical and Process Plant Commissioning Handbook

A Practical Guide to Plant System and Equipment Installation and Commissioning

Second Edition

Martin Killcross

Table of Contents

Cover image

Title page

Copyright

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

Section 1: Commissioning phase one—Prepare

Introduction

Commissioning Terminology Capturing Lessons Learnt

1: Appointing Commissioning Manager

Abstract

Main attributes of a Commissioning Manager

Main responsibilities of a Commissioning Manager

Main qualifications of a Commissioning Manager

Key points

2: Commissioning scope

Abstract

Commissioning scope development—The client Commissioning Manager

Commissioning scope development—Contracting Commissioning Manager (not client employed—delivering a contractual commissioning scope of work)

Key points

3: Contracts

Abstract

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

Key points

4: Commissioning in highly regulated industries—A guide

Abstract

Office of Nuclear Regulation guidelines on commissioning

5: Budget estimation

Abstract

Commissioning budget estimation—Key elements

Key points

6: Prioritized asset systemization

Abstract

Guidelines for commissioning systemization

Hypothetical highlighted P&ID showing system identification

Key points

7: Support design

Abstract

Commissioning considerations at a hazard study

Commissioning considerations at layout reviews

Commissioning considerations at P&ID reviews

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

Key points

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

Abstract

Commissioning philosophy or plan

Commissioning strategy

Key points

9: Commissioning risk management

Abstract

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

Procedural assessment of risk

Safety system testing

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

Key points

10: Appointment and composition of the commissioning team, roles, responsibilities, organization chart, and interview considerations

Abstract

Descriptions of typical commissioning team roles and responsibilities

Roles and responsibilities matrix

Stakeholder management

Interview considerations—Questions useful in the selection of commissioning staff

Key points

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

Abstract

Job description

Resume or curriculum vitae

Induction process

SQEP assessment

Authority to commission certificate

Key points

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

Abstract

Documentation sign-off

Key points

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

Abstract

Common considerations when developing foreign commissioning assignments

Site and office requirements

List of commonly used commissioning consumables

List and procure commissioning chemicals

Key points

14: Create commissioning documents and the system file

Abstract

Commissioning documents

The commissioning system file

Commissioning file structure

Key points

15: Control, instrument, and electrical commissioning document preparation

Abstract

Electrical, control, and instrumentation documents prepared during commissioning

Key points

16: Mechanical commissioning document preparation

Abstract

Mechanical documents prepared during commissioning

Key points

17: Develop training materials

Abstract

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)

Key points

18: Develop Standard Operating Procedures (SOPs)

Abstract

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

Title of procedure manual Standard Operating Procedure

Table of contents descriptions Standard Operating Procedure

Typical considerations for commissioning documents required after a major overhaul or turnaround

Key points

19: Developing commissioning schedules and contingency plans

Abstract

Stage 1—Level 2

Stage 2—Level 3

Commissioning execution plans

Considerations for inclusion in a commissioning execution plan

Tracking commissioning progress

Commissioning logic diagrams and normal durations

Key points

20: Determination of commissioning readiness and team audits

Abstract

Guide words for consideration in a commissioning readiness review

Commissioning audits

Key points

21: Devise handover procedure

Abstract

Handover criteria

Phased system handover approach

Safe systems of work at handover

Handover documentation

The review process prior to handover

Key points

22: Devise commissioning tagging system

Abstract

Location of tie-in points

Location of commissioning system battery limit isolation

A punchlist item

Leak point found during leak test

System LIVE

Item under construction control—Refers to an electrical item

Item under commissioning control—Refers to an electrical item

General commissioning label

Commissioning area sign

23: Commissioning terminology

Abstract

24: Capturing lessons learnt

Abstract

Section 2: Commissioning phase two—Implement

Introduction

25: Factory acceptance testing

Abstract

Modular construction

Things that can go right!

Key points

26: Check construction and quality of build

Abstract

Key points

27: Tracking progress and system status

Abstract

28: Fault management

Abstract

Raising a fault

Acceptance and categorization

Solution

Design assessment

Solution acceptance

Change and document implementation

Fault retest

Close out

Key points

29: Temporary commissioning defeat systems

Abstract

General information

Key points

30: Simultaneous construction and commissioning considerations

Abstract

Key points

31: Cleaning procedures and drying

Abstract

Cleaning

Types of cleaning methods

Procedural steps

Drying

Key points

32: Pre-commissioning procedures

Abstract

List of example pre-commissioning procedures

Key points

33: Logs, reports, and dashboards

Abstract

Logs

Reports

Headings to base commissioning logs, reports, and dashboards

Dashboards

Key points

34: Vessel check sheets

Abstract

Key points

35: Instrument loop, electrical, and control system testing

Abstract

Key points

36: Commissioning punch listing

Abstract

Key points

37: Handover from construction to commissioning

Abstract

Key points

38: Project documentation check sheet prior to the introduction of safe chemicals

Abstract

Typical Hazard Study guide word list for safe chemical commissioning

Key points

39: Introduction of safe chemicals

Abstract

Typical checks prior to safe chemical and initial energy introduction

Key points

40: Pre-commissioning HAZOP studies or pre-start-up safety

Abstract

Typical commissioning hazard guide words for hazardous chemical introduction

Key points

41: Commissioning leak testing

Abstract

Test (a): Service test

Test (b): Safe chemical leak test

Test (c): Vacuum test

Test (d): Toxic testing

Test (e): Helium leak testing

Key points

42: Commissioning and initial start-up plus procedures

Abstract

Utilities and services

Water commissioning

Commission and initial start-up of the plant with process chemicals

Key points

43: Recommissioning of plant after an event or delay in commissioning activities

Abstract

Key points

44: Laboratory analysis

Abstract

Laboratory design phase

Equipment

General

Samples and analysis

Key points

45: Handover to operations and transition of ownership

Abstract

Key points

Section 3: Commissioning phase three—Closeout

Introduction

46: Close out reservations

Abstract

47: Complete commissioning documentation

Abstract

48: Complete training and update documents to as commissioned

Abstract

49: Update operating procedures to as commissioned

Abstract

50: Assist continued operation, troubleshooting, and/or de-bottlenecking projects

Abstract

51: Close down all commissioning temporary defeats, commissioning faults, and modification paperwork systems

Abstract

52: Closing down of the commissioning team

Abstract

53: Complete close-out hazard study

Abstract

Section 4: The commissioning system file, a full catalog of blank commissioning documents

Introduction

Commissioning System File

Commissioning System File System

Appendix 1: Commissioning team meeting agenda

Appendix 2: Commissioning system documentation validation matrix

Hypothetical process plant

Appendix 3: Control system fault log

Control system fault log

Appendix 4: Loop test sheet

Appendix 5: Worked example of a knowledge-based training package

Plant X

Contents

Introduction to training process

The training process

Appendix 6: Optimal operational values sheet

Appendix 7: Example labels and tags

Appendix 8: Worked example of a vendor shop inspection report

Sketch of test rig

Trial 1

Trial 2

Appendix 9: Commissioning system status chart

Appendix 10: Steam blow target plate configuration

Appendix 11: Additional labels

Appendix 12: Example documentation structure for the Commissioning Group

Appendix 13: Example of a Commissioning Dashboard

FAQs and answers

The questions

Glossary of terms

Index

Copyright

Butterworth-Heinemann is an imprint of Elsevier

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This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein).

Notices

Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary.

Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.

To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein.

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About the author

Having started work with the Imperial Chemical Industries (ICI) in 1978, the author operated various production plants, the latter of which subjected him to process plant commissioning, and this experience had a fundamental effect on him and the commissioning discipline then became the basis and foundation of his ongoing career.

In the late 1980s, he made the transition to a full-time commissioning team role on the world’s first refrigerant 134a facility in Runcorn, Cheshire, United Kingdom. He later spent 4 years in the United States on a major uprate project to the 134a facility built there. After returning to the United Kingdom, a thermal oxidizer process was successfully commissioned along with a major chlorine cell room refurbishment; in 2001, he then parted ways with the INEOS Chlor group, to spend some time as a Principal Senior Commissioning Engineer with MW Kellogg, working on Liquefied Natural Gas (LNG) projects. Two years later, he re-joined the INEOS Group as Technical and Commissioning Manager responsible for the successful and safe delivery of several new projects in their Silica business in Warrington, United Kingdom and Joliet, Illinois, United States.

Between 2006 and 2013, the author made a move to work extensively back in the United States, which in turn demanded him to commission numerous projects across several business units worldwide. In 2013, he became the Commissioning Manager of a multibillion-dollar Mega Project in Louisiana, United States, before returning to work in the United Kingdom on a significant project in the Nuclear business sector. Overall he has taken on more and more senior roles in both the client and contractor commissioning sectors and the establishment of robust commissioning systems and methodologies has been at the forefront of his day-to-day working life, wherever he has worked.

His commissioning experience spans a huge variety of diverse chemical, oil and gas, utility, and nuclear processes, including chlorine and its derivatives, fluorine-based processes, refrigerants, LNG, solvents, polymers, fertilizers, sulfuric acid, silicas and thermal oxidation.

Operational sectors commissioned and operated are numerous and include reaction, thermal oxidization, extrusion, distillation, packing plants, storage and feed systems, refrigeration and compression, vaporization, cooling water circuits and utility systems, distributed control systems (DCS), evaporators, drying and scrubbing systems, kilns, mills, and turbines.

During his career to date, he has amassed significant operating and commissioning management experience on high hazard chemical processes, including the preparation of overhaul and turnarounds with an operational bias and general management of the assets that he had been involved with.

Since the publication of the first edition of the book, the author has presented at conferences and training events worldwide, in 2012, he was awarded the Brennan Medal for the first edition book being voted the most outstanding IChemE publication.

His knowledge of plant commissioning grows each day, this second edition is a testament to that experience growth.

Sharing a robust commissioning methodology continues to be a passion…

Acknowledgments

This book is written with the intent to pass on to those who will follow in the field of Process Plant Commissioning the pearls of wisdom and advice that I have received in over 40 years of working within the discipline.

To those of you who have worked with me, helped, advised, guided, encouraged, and supported me, a very special and grateful thank you. There are many individuals who have inspired me, some now sadly not with us, most of you know who you are and I shall forever be indebted to you.

I offer particular thanks to Dr. Alan Dowan, Mr. Justin O’Doherty, Mr. Brian Chalmers, Mr. Don Maneval, Mr. Steve Garbutt, Mr. Richard Brink, and Mr. Neil Greenwood for their support and guidance throughout the creation of the original work and this second edition, and their continued help through my career.

There is one who however remains most deserving of special mention, my wife Angie. Without her unquestioning support, absolute understanding, and constant belief in me, I would just simply not have had the success in my commissioning efforts that I have been fortunate enough to have experienced.

Therefore, this second edition remains dedicated to you Angie, thank you!

To those of you considering commissioning for the first time or indeed have been thrust into the role (and you are not the first…), welcome. Please reference, hopefully learn and enjoy, but most importantly stay safe and happy commissioning to you all, I hope you are smitten by the experience just as much as I.

What is commissioning?

Commissioning—A structured, methodological, and systematic approach to proving newly constructed plant meets the design intent of the equipment and systems

It is logical that we should start with a basis of just what commissioning is.

It is apparent over a number of years of actual commissioning on various types of chemical and nuclear plant processes and in various countries throughout the world that commissioning is often viewed in different terms. I believe commissioning is best described when broken into three categories; all three compose the whole and total commissioning effort.

1.Precommissioning, activities carried out during construction that prepare and enable a system to move to the main commissioning phase. The range of precommissioning activities can include: installation of filters, packing of distillation columns, filling a reactor with catalyst, cleaning pipes and equipment, vendor and factory acceptance testing, punch listing and instrument, electrical and motor loop testing.

2.Commissioning, here the various systems and items of equipment are first put into initial operation. Utility systems, Instrument Air, Cooling Water, and General Purpose Water are made live and the core process systems are first made operational typically with safe chemicals, air, or water. The unit is leak tested, started up, shut down, distillation columns, and scrubbing columns put into use, all to gain the confidence that when process chemicals are introduced the plant will operate as designed and as intended.

3.Start-up, The plant is brought into actual operation.

There are also various commissioning terms that are readily used which require explanation and inclusion in this chapter.

Dry commissioning

Tests and procedures that are conducted where there is no process or safe chemicals yet introduced to the plant. Examples of these activities would be interlock and emergency shutdown tests, control system sequence checks, and potentially initial running of major motors and/or equipment and ancillary systems such as compressor oil lubrication systems, uncoupled from the turning mechanism.

Wet commissioning

Water or some other relatively safe medium has been introduced to the process and initial commissioning of the system and its major plant items can be undertaken, putting the process through its operating scenarios to replicate in the most suitable manner possible the normal operation of the unit.

Inactive commissioning

A nuclear or related industry term that combines elements of both wet and dry commissioning and proves the design intent of plant and system without the introduction of radioactive material. This stage of commissioning can also be adjusted to suit segregation of lower and higher hazard chemical introduction into the process; for example, Caustic Soda up to 20%–25% could be acceptable but, say, Chlorine not and its introduction deferred until later.

Active commissioning

Phase where Uranic or higher hazard chemicals are introduced into the systems and process.

Turning to the team and actual execution of commissioning, it is correct to state that the general commissioning team for a project can be made of two completely separate parties. All precommissioning and some commissioning can be done by the general contractor commissioning personnel, while most commissioning and start-up would be managed by the client commissioning team with help from the contractor commissioning personnel as and when required. A suitable and clear handover must be developed so all members of the combined team know the boundaries of each separate group to facilitate a safe and coherent effort.

Countless projects have demonstrated that the start-up and ongoing successful operation of a newly built chemical plant has a direct relationship with the quality and effort of the work performed during the precommissioning, initial commissioning, and start-up phases (inactive and active phases also). A complete, well planned, and accurately documented commissioning effort is one of the key factors that can contribute to a trouble free start-up and smooth transition to a production unit manufacturing to full design rate and within product specification.

This handbook will give complete and detailed descriptions of each commissioning activity. It provides a methodology of working which will give optimal potential to bring the new plant into beneficial operation, manufacturing to full process specification and capacity in the most efficient and effective way possible. The detail within this handbook can also be utilized and considered when commissioning new plant or modified equipment within an existing facility, or items and systems being started up from perhaps a turnaround or overhaul scenario. The handbook defines a proven methodology for commissioning developed over many years and projects which should be adapted appropriately to the technologies within the actual project being undertaken, taking due consideration of the hazards and risks associated within its processes.

The HSE website (within the Operating Procedures section) in the United Kingdom gives an indication of what constitutes commissioning activities; these fall into the following key headings and a brief explanation of what each section means is provided within the accompanying text.

HSE advice on commissioning

•System Configuration Check

•Instrumentation System Check—Verification of Alarms and Trips

•Flushing and Cleaning of Lines and Vessels with Water

•Assessment of Ancillary Equipment

•Calibration of Vessels and Instrumentation

•Start-up Protocol

•Shutdown Protocol

•Chemical Trials

•Handover

It is to the advantage of any commissioning team to visit your home countries Health and Safe Executive website and research their expectations in relation to commissioning and follow their guidance in the preparation and execution of commissioning. The Nuclear industry is regulated in the United Kingdom by the Office of Nuclear Regulation (ONR); the requirements set forth by this body are reviewed in a later chapter of this book.

It is my hope that all sections mentioned on the UK HSE website will clearly be explained in full during the course of this handbook and indeed form the very basis of its methodology.

Chemical plant commissioning has developed significantly and at some pace over the last 25 years, as the constraints of primarily cost and schedule bore heavily on project management teams. A methodology had to be developed that no longer had the luxury of distinct and separate construction, commissioning, and handover to the operations group phases. This book therefore explains the guidelines, based on current known best practice, of how the commissioning function can be best integrated within the greater project, to fulfill the aim of always achieving an on-time successful plant start-up.

Having described above what commissioning is, hereafter this handbook will approach the topic of delivering of the actual commissioning process in three distinct stages.

Main phases of commissioning

Unlabelled Image

Although the stages are depicted in a continuous flow path, many of the subtle steps within each section overlap and potentially run in parallel to each other.

Each stage, to be described later in the book, has been well used and tested. All the steps within each stage should be considered for any project, of any size, to ensure all of the commissioning activities required are included in the management system, thus generating the best opportunity of a timely and successful plant start-up.

Commissioning of a chemical plant is fun and wherever possible should be treated as such. It is busy, bordering on hectic, and at certain times is an all-consuming activity; however, there are few other project disciplines that give their personnel the self-satisfaction and reward commissioning offers. Witnessing and, more importantly, being part of a successful commissioning and start-up team is, to me, the most rewarding of occupations.

Safety and environmental considerations

Safety in commissioning—No commissioning activity is important enough that it CANNOT be undertaken safely.

The safe and environmentally friendly commissioning of any new asset should always be of the highest priority and integral with every check sheet and procedure written during the preparation and execution of the commissioning process. The safety of personnel plus the environmental implication must always be the first considerations of any commissioning activity and as such the documentation therefore must address and satisfy all the safety and environmental aspects at all times.

While not aligned directly with safety, it is worth mentioning that good safe commissioning procedures also give considerable consideration to the protection of newly installed plant items during the commissioning phases and hence also have a high priority. A clear understanding of the commissioning logic required to start especially package type equipment must be obtained from the equipment vendor, and their attendance at the initial commissioning is usually a consideration and therefore has to be accounted for in the commissioning cost estimate.

Schedules must be considered and created in such a way that sufficient time is allocated to each and every commissioning activity, as in the intensity of the commissioning and start-up phases, for it is at this, the most critical phase in a project, when safety implications can be neglected and therefore need to be strictly adhered to and enforced.

As construction develops, commissioning systems transfer to the commissioning team and equipment and plant energization commences. Therefore, various process areas must be clearly identified and clear communication made with all the project, especially the construction and operations groups, prior to initial commissioning and testing of the equipment. This move is required to clearly make known the change of status and the new safety implications to the now simultaneous construction and commissioning site.

Simultaneous construction and commissioning activities on a project are always a topic that raises concerns for safety of all personnel. As such, considerations to manage this process are considered in its own chapter within this book.

Areas must be taped off, barricaded (commissioning teams should consider a barricade of a different color to the rest of the project groups, to clearly distinguish an area under the control of the commissioning team), and tagged appropriately, dated, with a commissioning responsible person named and clearly identifying the nature of the activities ongoing in the area. Sufficient commissioning staff must be made available to correctly inform adjacent personnel and thereafter police areas that are being energized. All electrical items at field devices and motor control centers (MCC) must be clearly labeled, locked out, and tracked in a safe and sound manner with an agreement clearly defined between the construction and commissioning organizations, with regard to who is in control of the permitting and key management systems; it can and does vary from project to project.

The commissioning team must undergo all relevant training required by the site at which the project is being worked, hence permitting the team members to safely and diligently discharge their normal duties during the commissioning and start-up activities.

Safe systems of work should be integral to all commissioning activities and procedures. The utmost care must be given to avoid a loss of process containment or environmental incident. The commissioning organization should be robust enough to establish or contribute to the development of safe systems of work at the work location if not already established. These safe systems of work may include permit to work systems, confined space entry permits, and hot work permits. Information on the establishment of such safe systems of work can be found on governmental websites such as the Health and Safety Executive (HSE—United Kingdom) or the Occupational Safety and Health Administration (OSHA) in the United States.

The commissioning team, AT ALL TIMES, should strictly adhere to either the procedure they are executing and/or the stipulations of a specific Permit To Work either issued directly to them, or for an activity the commissioning team is involved with, e.g., the rotation check of a motor. Commissioning personnel are by their nature individuals who want to move the project forward, but team members MUST ALWAYS strictly adhere to the requirements of the procedure and/or permit to work and should never add scope to the work that has not been considered and adequately risk assessed. Unfortunately, there are many examples across the industry, where incidents have occurred when work has been undertaken outside of the initial intent of a test or check.

Provision should be made to establish Control of Substances Hazardous to Health (COSHH) arrangements with the accompanying control and display of all Material Safety Data Sheets (MSDS). Further information and guidelines should be sought from the Health and Safety Executive of the particular area where the project is situated. Clarification should also be made if the commissioning element of the project is confined to a brownfield site, with established plant operation on the periphery of the commissioning area. This action is required to ensure control of the COSHH substances is always maintained and chemical introduction is managed within the site operating rules.

Commissioning personnel must make themselves familiar with all site regulatory procedures and works instructions that they may have to consider during the execution of their activities at a particular jobsite. These could include environmental impact assessments, job safety analysis, major job reviews, job method statements, pre task planning, safe and unsafe acts audits; there are many others. The commissioning manager must ensure that the commissioning team is actively involved with any audit regime that the project has instigated for the purposes of safe construction and commissioning phases. The introduction of specific team safety auditing should also be considered; these could include regular checks of Safe Plan of Actions, Risk Assessment compliance, COSHH management, etc. While considered in more detail in Chapter 10 of this book, a Commissioning Safety Manager is vital to ensure not only day-to-day commissioning is being undertaken in a safe manner, but also management of the team audit protocols, commissioning related toolbox talks, and compliance with site rules and regulations.

Discussions must take place between the contracting and site client personnel to ensure no transgression or site violation takes place within the act of initially commissioning the new facility; examples of these activities are opening process valves potentially from an existing operating area, starting electrical equipment, and manipulation of new graphic pages on an existing control system. The findings from the discussions must be fully documented within the commissioning manual and subsequent commissioning procedures and strictly adhered to during the actual commissioning activities.

The commissioning team must uphold and actively enforce all site safety regulations with regard to transportation, personnel movements, and restricted areas, as well as the use of personnel protective equipment. All implications from the above activities must be included in the relevant individual commissioning procedures.

It is common for the commissioning team to be requested to attend various safety studies; examples of these are Hazard and Operability Studies (HAZOP) in various company formats, Safety Integrity Level (SIL) analysis of protection systems, and Layer of Protection Analysis (LOPA). It is advisable for the commissioning manager to become familiar with the safety studies the team will participate in during the various project stages and arrange formal training for those commissioning team members who are in need of the specific guidance or refresher training if required.

The commissioning manager should also consider, as a prerequisite to joining the commissioning team, that all personnel must attend a formal safety related and accredited safety training course, to provide a baseline expectation and understanding of the safety standards expected while on the commissioning team. The commissioning manager, along with the Health and Safety department of the company where the project is taking place, should consider suitable organizations to provide this training. The commissioning manager has a duty of care to ensure that the whole team are briefed on safety related matters, especially emerging issues that are industry related. All team meetings should commence with a safety topic and the commissioning manager should, at all inductions of new commissioning team members, set a very clear expectation of the safety standards he or she expects while in the team; the message should be personalized.

Commissioning teams typically work long hours; however, the commissioning manager should establish a time tracking system such that the working hours directives in whatever location the project is in is considered and staff given sufficient time to rest and recuperate.

As stated earlier, environmental considerations should be considered and treated very seriously. In many instances, the environmental permits in a location change as a project moves from construction to commissioning; water, for example, generated, say, in hydrostatic testing of pipe (by construction) could be treated differently than water used by commissioning during leak tests. The commissioning manager should work closely with the Environmental Manager for the project to ensure that all regulations are considered and the commissioning team remain compliant until the handover to operations. Specific project related training packages should be drafted and given to the whole commissioning team.

In certain regions where water management is very regulated, the commissioning team should prepare waste water management plans and utilize water conservatively. While considering these plans, consider scenarios that challenge the normal water management plan so contingency can be built into arrangements (this could mean systems not coming to commissioning in the normal required order, so intersystem water transfers could be interrupted). Ensure also that water disposal is considered in the commissioning budget forecast.

The commissioning team at all times should comply with the waste management plan of the project and/or site and suitable training should be given to the team to assist their compliance with all waste regulations and site or project rules.

Noise is also a consideration that should be accounted for and suitable PPE and other precautions made, collated, and stored.

A simplified commissioning logic

Unlabelled Image

Intent and use of the handbook

Handbook intent—To give even the most inexperienced commissioning practitioner, the information required to plan and deliver a successful commissioning effort.

This work is meant to be used as a Handbook to the key stages that must be considered throughout the various steps needing to be undertaken when commissioning process plant; it is not therefore particularly intended as a reading book.

The content varies from the basic, of significant benefit to the novice commissioning engineer, through to detailed specific information that could be of use to the most experienced commissioning practitioner. The second edition of the Handbook also includes reference to commissioning practices within the Nuclear Industry and offers a different perspective and content to that of the normal chemical commissioning process. There is also much useful information incorporated within the various sections that a Project Manager and Operations Manager in fact any senior project discipline lead may find of significant use.

This book is written with the full intent to provide basic, practical knowledge on how commissioning should be structured, documented, and executed. The author offers no apology for a direct, perhaps ineloquent writing style of the subject material, as the sole and driving intent is to offer simple, to the point advice, with a view to assisting planning and delivery of commissioning activities, undertaken safely on any application and in any location.

The Commissioning Phases section is the heart of this handbook and the required topic or section should be referenced directly to obtain the guidance required.

Each new chapter begins with the author’s view of a definition of the topic being discussed.

Within each of the Commissioning Phases explained within this handbook, there are bulleted lists which have been developed to assist in the explanation and therefore delivery of the stage being discussed. The lists are not totally inclusive and indeed as commissioning is a dynamic discipline, these bullet points are revised constantly as new lessons are learnt in the workplace. Therefore, the bullet point lists are meant to be informative guides for consideration in the execution of any commissioning activity.

Worked examples of actual commissioning procedures and check sheets to provide evidence and guidance to the paperwork system required to successfully manage the commissioning process are provided within each step. The procedures and check sheets are based on real documents utilized on many projects, but obviously for confidentially reasons, all possible reference to the actual projects used has been removed.

This handbook in addition offers a full package of blank forms that can be utilized in the formation of commissioning manuals required for any application, and they can be found in the blank commissioning documents section. Where applicable and relevant, sections within this handbook also address brief relevant "things that can go wrong" and key chapter points to further give clarity for the section discussed and importantly share lessons learned between commissioning practitioners.

Several chapters of this handbook include totally hypothetical process schematics depicting crude engineering drawings including