Chemical Plant Commissioning Handbook: A Practical Guide

Chemical and Process Plant
Commissioning Handbook
A Practical Guide to Plant System
and Equipment Installation
and Commissioning
Martin Killcross
EngTech TIChemE
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Acknowledgment
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 I have received in my 30 plus years of
working within the discipline.
To those of you who have worked with me, helped me, 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 know who you are and I shall be forever in your
debt.
I offer particular thanks to Dr Alan Down, Mr Justin O’Doherty, Mr Brian Chalmers, and
Mr Don Maneval, for their support and guidance throughout the creation of this work and
indeed through my career.
There is one who, however, is 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 I have been fortunate enough to have
experienced.
Therefore this book is 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.
ix
Introduction
I wish to stress from the outset of this explanation of chemical plant commissioning that it is
my intent in this handbook to offer a very practical and comprehensive “what do I really have
to do” approach to turning an assortment of pipes, tanks, reactors, valves, instruments, cables,
control systems, pumps, fans, compressors, the process, into a fully operational production
unit designed for whatever purpose devised.
As such, perhaps some more detailed and specific points pertinent to, say, the consideration of contracts will not be found in great detail. This is very much a how to handbook
written to help those who need to gain access to a direct path for getting something operational, from something that is a mass of “pots and pans”, in the most effective and efficient
way possible.
Commissioning within the family of disciplines that compose a project team has, in my
experience on various occasions in the past, been brandished as something of a “black art”.
This for many projects may have been a fair assessment; this being said I have always been of
the opinion that “you get out what you put in” and if your preparation to the commissioning
of a new asset is sloppy, without research, unprepared and unplanned, the resultant start-up
will be fairly much the same. I have personally witnessed much “re-inventing of the wheel”
where new commissioning teams have scrambled for the paperwork from some dim and
distant project from the past to base their commissioning documentation on. I will, within the
pages of this handbook, dispel this myth. It has been my quest for a number of years now to
pull together documents that fulfill the flow of paperwork required to systematically and in an
orderly fashion manage the commissioning process. You will find the basis of this work laid
before you in these pages in a manner that can truly assist you through your commissioning
quest.
The science of commissioning is an interesting one. There are few, if any, formal qualifications specific to the discipline. Its managers and engineers come from all manner of
different backgrounds, process engineers, chemists, mechanical engineers and craftsmen,
piping engineers, electrical engineers and technicians, and in my personal case plant operations. Commissioning experts, in general, are a diminishing band of practitioners. I have had
the recruitment of future numbers of commissioning teams described to me by my second
commissioning manager (back in the late ‘80s) as “looking for hen’s teeth” and there are not
many of those! Unfortunately what foresight he had. In the UK, where there has been an
unprecedented demise of the chemical industry, there has been a significant loss of excellent
commissioning personnel. I cannot believe this to be sustainable; there will be a need to build
new process plant in the future and it is my hope that this handbook, both in the UK and also
throughout the world, will help and enable those who will need to rise to the forthcoming
commissioning challenges to be successful. Many other areas of the world are on the reverse
scenario to the UK, witnessing a significant growth in process plant build; this handbook will
be of great assistance to those charged with the commissioning of those assets also.
With all the above being stated, I want to stress one vitally important starting position
about commissioning before we move to the detail; this is to categorically state, that to be
a critical factor to the success of a project.
xi
xii
Introduction
… Commissioning is
NOT just turning up the
day after construction is
complete and pressing
the
BIG GREEN BUTTON !
Commissioning is the use of a disciplined, systematic and professional methodology, to
convert newly constructed process plant into a fully integrated and operational unit in the
most safe, efficient, cost-effective and timely of manners, to achieve start-up and production
targets whilst, where at all possible, conforming with the ideal of getting it “right first time”.
Fundamentally commissioning is a series of checks and counter-checks that confirm
newly constructed chemical plant is fit for purpose and suitable for ongoing operation, these
checks being made at all stages of a project’s life, not just after construction is complete.
So let the journeys commence. Follow this methodology and the steps explained within
this handbook on all manner of projects, irrespective of size, and your journey within
commissioning should be made that much simpler.
What is Commissioning?
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 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, commissioning:
1. Pre-commissioning, activities carried out during construction that prepare and
enable the unit to move to the main commissioning phase. The range of precommissioning activities 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 intended.
3. Start-up, the plant is brought into actual operation.
There are also two commissioning terms that are readily used which require explanation
and inclusion in this section:
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 lubrications 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.
It is correct to stress here that the general “commissioning team” for a project can be
made up of two completely separate parties. All pre-commissioning and some commissioning
xiii
xiv
What is 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 that 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 pre-commissioning, initial commissioning and
start-up phases. 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 UK gives indication of
what constitutes commissioning activities. These fall into the following key headings and
a brief explanation of what each section means is given within the text:
•
•
•
•
•
•
•
•
•
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
Shut-down protocol
Chemical trials
Handover.
It is my hope that all sections mentioned above 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 document 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 delivery of the actual commissioning process in three distinct stages:
What is Commissioning?
PREPARE
IMPLEMENT
xv
CLOSE OUT
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 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 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 its 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
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.
Whilst not aligned directly with safety, it is worthy of mention 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 must and therefore has to be accounted for in the commissioning
cost.
Schedules must be considered and constructed in a way that sufficient time is allocated
to each and every commissioning activity, as in the heat and intensity of the commissioning
and start-up phases, this is the most critical time when safety implications can be neglected
and therefore need to be strictly adhered to and enforced.
As construction develops, commissioning systems and potentially individual items of
equipment will take place and introduction of energy to the plant will start. The various
process areas must be clearly identified and clear communication made with them all,
especially the construction and operations groups, prior to operation and testing of the
equipment to make known the change of status and the new safety implications to the
construction and commissioning site. Areas must be taped, barricaded or fenced off and
tagged appropriately, clearly identifying the nature of the activities about to commence 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 to 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 will 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
xvii
xviii
Safety and Environmental Considerations
found on governmental websites such as the Health and Safety Executive (HSE – UK) or the
Occupational Safety and Health Administration (OSHA) in the United States.
The 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.
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), to name but a few. 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.
A Simplified Commissioning Logic
Overview of Commissioning Stages
Obtain a clear
definition of Scope
and actual
requirement of the
commissioning team
Appoint Commissioning Manager
Pertinent to Documentation format, initial commissioning, Startup, Normal Operation, Shut-down, Training and Standard
Operating Procedures
PREPARE
Plan
Check Build
IMPLEMENT
Establish format for check-out with construction
Factory Acceptance Testing
Cleaning
Punchlist
Fit internals & packing (pre-commissioning)
Handover and Change
Control Systems
From Construction To Commissioning Team
Manage Change to Scope
Test New Equipment
Complete Dry Checks
Leak Test
Commission on Safe Chemicals
Train
Complete HAZOP & Pre Start Up Safety
reviews
Start-Up
CLOSE-OUT
Size and make-up of commissioning team
Develop team activities
Develop training program
Document preparation, commissioning and
Standard Operating Procedures,
Commission on Process Chemicals with Vendors if necessary
Train Operations and Maintenance personal
Verify Plant and
Products
against Design and
Quality Parameters
Process
Equipment
Product
Handover to Plant
Plant has met acceptance criteria
Handover Commissioning Documentation to Plant
Re-train personnel, re-issue Operating Procedures to
“as commissioned” status
xix
Intent and Use of the Handbook
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. There is also much useful information incorporated within the
various sections that a project manager, operations manager, in fact any senior project
discipline lead, may find of significant use.
The Commissioning Phases section is the heart of this handbook and should be referenced directly to obtain the guidance required.
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 intended to be 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 confidentiality
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; 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 points to further
give clarity for the section discussed and importantly share lessons learned between
commissioning practitioners.
Several sections of this handbook include totally hypothetical process schematics
depicting crude engineering drawings including Piping and Instrument Diagrams (P&ID) and
Process Flow Diagrams (PFD). The various drawings are used to demonstrate the information
contained within the section. Although entirely fictitious and drawn by myself to assist in
explanation of the information, they are a realistic depiction of how a process flow could be
designed. Technical and pertinent engineering information may be missing from the drawings, but to reinforce the intent is purely one explanation of a discussed point. Any reference to
any actual process globally is entirely coincidental and no replication of any existing process is
intended.
xxi
The Commissioning Approach
This commissioning handbook will discuss the subject of commissioning any chemical plant
asset with the fundemental approach devided into three main stages.
The Commissioning Phases
Prepare
Activities to be taken to set commissioning up, gather information, select the commissioning
team, develop the schedule and create documentation.
Implement
This phase, traditionally perceived as “commissioning”, examines the facets that address the
installation, checking and start-up of the new equipment.
Close-out
The final stage of the commissioning process and the one most neglected, ensuring that all
paperwork systems and trials are complete, and that the plant or equipment has met its
acceptance criteria, enabling the plant to be handed to the ongoing operations group.
The commissioning team will then be closed down.
This is a very widely utilized commissioning approach and is the basis of most
commissioning applications used worldwide today. It is the approach I have very successfully
used over many years and projects.
Within each of these stages mentioned above, this handbook will discuss the subtle steps
held within each phase in some considerable detail to help you create a mental picture of the
path and approach best suited for a successful commissioning process in the application you
require. As stated in the intent of this handbook, the work is meant to be a reference material,
the required information and section being directly sorted; however, the nature of the
handbook is written such that an inexperienced commissioning engineer could review the
handbook from cover to cover to gain an initial understanding of the overall commissioning
process.
The handbook is written in a logical and chronological order; each step should be
addressed in turn and action plans put in place before moving forward.
The main activities associated and conducted within each of the three commissioning phases are tabled below and will be the basis on which this handbook will be
presented.
xxiii
xxiv
The Commissioning Approach
Phase
Activities
PREPARE
Appoint the Commissioning Manager
Define the commissioning scope
Systemize the plant utilizing the project Piping and Instrument Diagrams (P&IDs) and other relevant
documents including layout drawings and mechanical flow diagrams, into commissioning systems
Integrate commissioning systems into the engineering documents, line tables, instrument index, P&IDs,
equipment lists and procurement plans
Input to design:
The commissioning team upon agreement with the Project Manager and Commissioning Managers will
attend the following reviews:
P&ID, Piping isometric, Plant Layout, Constructability, 3-D model, Schedule, SIL, LOPA and action upon
alarm
Compile the Commissioning Schedule
Compile the Commissioning Estimate/Budget
Agree interface/handover procedure with project, client and construction groups
Obtain pertinent and relevant documents and establish electronic libraries
Attend Hazard Study
Compile Initial Commissioning Plan
Set-up site base and compile commissioning consumables list
Determine initial fill chemicals, simulants and procure
Create Commissioning Manual
Compile Standard Operating Procedures (SOPs)
Compile training packages
Agree Safe Systems of Work with all interested parties
Compile Commissioning Procedures
Give input as required to the User Requirement Specification (URS) for a Distributed Control System (DCS)
Compile Decontamination Procedures
Attend factory equipment acceptance and pre-delivery tests
Computer Hardware Factory Acceptance Tests (HFAT), Software Factory Acceptance Tests (SFAT), review
Functional Design Specification (FDS) for the DCS
Attend Site Acceptance Tests (SAT) for a DCS control system
Be involved with management and decommissioning and/or decontamination of existing plant if
required
Check construction progress and quality
Start commissioning log
Test and clean pipe work
Punch list
Commence training of plant and maintenance personnel
Manage handover construction to Commissioning and/or Operations
Attend and/or manage pre-start-up safety checks
Complete all leak testing
Pre-commission the systems
IMPLEMENT
(continued)
The Commissioning Approach
xxv
Phase
Activities
IMPLEMENT
Manage post-start-up modifications
Manage the introduction of safe and process chemicals
Move team to shift management role if required
Issue first draft of the Standard Operating Procedures (SOPs)
Start-up plant
Validate plant performance with the Quality Team
Update to “as commissioned” all commissioning documents and Standard Operating Procedures
Manage post-start-up modifications
Update to “as commissioned” training documents
Run and manage plant to pre-determined design production rates and initial output for the required
duration
CLOSE-OUT
1
Commissioning Phase One – Prepare
CHAPTER OUTLINE
Appointing the Commissioning Manager ........................................................................................... 5
Attributes ........................................................................................................................................... 6
Responsibilities................................................................................................................................... 7
Qualifications ..................................................................................................................................... 8
Key Points........................................................................................................................................... 8
Commissioning Scope and Contracts ................................................................................................... 9
The Client Commissioning Manager................................................................................................ 9
Contracting Commissioning Manager (Not Client-Employed) .................................................... 10
Contracts ............................................................................................................................................... 11
Commissioning Scope and Contracts – “Things That Can Go Wrong” ...................................... 11
Key Points......................................................................................................................................... 22
Budget Estimation................................................................................................................................ 22
Prioritized Asset Systemization .......................................................................................................... 24
Hypothetical Highlighted P&ID Showing System Identification ................................................. 28
Prioritized Asset Systemization – “Things That Can Go Wrong” ............................................... 29
Key Points......................................................................................................................................... 29
Support Design..................................................................................................................................... 29
Hazard Study.................................................................................................................................... 30
Layout Reviews ................................................................................................................................ 32
P&ID Reviews.................................................................................................................................... 32
The Process ................................................................................................................................... 33
Mechanical Issues.......................................................................................................................... 33
Control, Instrument and Electrical Issues ....................................................................................... 33
General Issues ............................................................................................................................... 34
3-D Model Reviews .......................................................................................................................... 34
Isometric Drawing ........................................................................................................................... 34
Risk Assessments and Hazards During Construction .................................................................... 34
Control Systems ............................................................................................................................... 34
Action Upon Alarm Review ............................................................................................................ 35
Support Design – “Things That Can Go Wrong”.......................................................................... 35
Key Points......................................................................................................................................... 35
Develop an Initial Commissioning Plan or Philosophy..................................................................... 37
Table of Contents.......................................................................................................................... 37
Purpose of the Commissioning Plan .............................................................................................. 37
Chemical and Process Plant Commissioning Handbook, DOI: 10.1016/B978-0-08-097174-2.10001-5
Copyright Ó 2012 Elsevier Ltd. All rights reserved.
1
2
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Commissioning Overview .............................................................................................................. 38
Project Scope of Work................................................................................................................... 38
Key Project Objectives and Aims ................................................................................................... 38
Commissioning Team Roles ........................................................................................................... 38
Commissioning Methodology........................................................................................................ 38
Initial Commissioning Systems ....................................................................................................... 38
The Commissioning System File..................................................................................................... 38
Commissioning and Start-up Challenges ....................................................................................... 39
Appointment, Composition of the Commissioning Team, Roles, Responsibilities and
Organization Chart............................................................................................................................... 39
The Commissioning Manager......................................................................................................... 40
Commissioning System Engineer.................................................................................................... 41
Control/Electrical/Instrumentation Commissioning Engineer...................................................... 42
Mechanical Commissioning Engineer ............................................................................................ 43
Standard Operating Procedure Group – If Not in Scope of the Commissioning Engineer ...... 43
Training Group – If Not in Scope of the Commissioning Engineer ............................................ 44
Key Points......................................................................................................................................... 44
Documentation and Sign-Off Requirements, the Library and Electronic Filing ............................ 44
Documentation Sign-Off................................................................................................................. 47
Key Points......................................................................................................................................... 48
Devise Assignment Details, Site and Office Requirements, Consumables and Procure
Commissioning Chemicals ................................................................................................................... 48
International Assignment ............................................................................................................... 49
Site and Office Requirements ........................................................................................................ 49
General Commissioning Consumables........................................................................................... 50
List and Procure Commissioning Chemicals .................................................................................. 51
Key Points......................................................................................................................................... 52
Create Commissioning Documents and the System File.................................................................. 52
Commissioning Documents............................................................................................................. 52
The Commissioning System File ..................................................................................................... 56
Table of Contents ............................................................................................................................ 58
Create Commissioning Documents and the System File – “Things That Can go Wrong”........ 62
Key Points......................................................................................................................................... 63
Control, Instrument, Electrical Commissioning Document Preparation ......................................... 63
Main Electrical Installation, Switchgear, Transformers, Motor Control Centers (MCC)
and Power Cables................................................................................................................................64
Lighting ......................................................................................................................................... 65
Control Systems (DCS and/or PLC) ................................................................................................. 65
Various Instrument and Electrical Cabling...................................................................................... 66
Chapter 1 • Commissioning Phase One – Prepare
3
Instrument Calibration and Instrument Range Consistency............................................................ 67
Existing Equipment Sanity Check................................................................................................... 68
Loop Test Paperwork Development, Checking and Testing ........................................................... 69
Motor Checking and Testing .......................................................................................................... 73
Software Interlock and Emergency Shut-Down Testing, Both “Dry” and “Wet”..................... 73
DCS/PLC Sequence Checking and Testing...................................................................................... 74
Specialist Vendor Installation ......................................................................................................... 74
Training ............................................................................................................................................ 75
Control, Instrument, Electrical Commissioning Document Preparation – “Things
That Can Go Wrong” ...................................................................................................................... 79
Key Points......................................................................................................................................... 79
Mechanical Commissioning Document Preparation ......................................................................... 80
Isometric Drawing to P&ID Sanity Check ...................................................................................... 80
Pipeline Cleanliness Checks and Procedures ................................................................................. 80
Construction and Installation Checks............................................................................................. 83
Vessel and Equipment Checks (Off and On Site).......................................................................... 83
Mechanical Documentation Check ................................................................................................ 84
Vendor and Proprietary Equipment Check-Out ........................................................................... 84
Lubrication ....................................................................................................................................... 85
Training ............................................................................................................................................ 85
Mechanical Commissioning Document Preparation – “Things That Can Go Wrong”.............. 86
Key Points......................................................................................................................................... 86
Develop Training Materials................................................................................................................. 86
Operator Knowledge Training – Classroom ................................................................................... 90
Operator Knowledge Training – Presentation................................................................................ 90
Operator Practical Training – “On The Job”................................................................................... 90
Maintenance Personnel Knowledge Training – Classroom ............................................................ 91
Maintenance and Operator Personnel Equipment-Related Training – Workshop and Classroom .. 91
Management Training – Classroom............................................................................................... 91
Control System, Operator Training – Classroom with Control System Simulation.......................... 91
Control System, Systems Engineer Training – Typically Control System Vendor Location
(Potentially Site-based) .................................................................................................................. 92
Develop Training Materials – “Things That Can Go Wrong”...................................................... 92
Key Points......................................................................................................................................... 93
Develop Standard Operating Procedures (SOPs) .............................................................................. 93
From the Health and Safety Executive (HSE) ................................................................................ 94
Status of Guidance........................................................................................................................ 94
Operating Procedures.................................................................................................................... 95
Title of Procedure Manual.............................................................................................................. 96
4
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Table of Contents.......................................................................................................................... 96
Table of Contents Descriptions ...................................................................................................... 97
General Description of System ...................................................................................................... 97
Safety, Health and Environmental Considerations ......................................................................... 97
Pre-Start Checks ............................................................................................................................ 97
Valve Positions for Start-Up ........................................................................................................... 97
Initial Start-Up Procedures ............................................................................................................. 98
Normal Start-Up ............................................................................................................................ 98
Normal Operation Including Optimal Operational Values .............................................................. 98
Normal Shut-Down Procedures ..................................................................................................... 98
Emergency Shut-Down Procedures................................................................................................ 98
Fault-Finding Guide, Consequences of a Deviation and Corrective Action Plan ............................. 99
Loss of Utility Emergency Procedures ............................................................................................ 99
Temporary Operating Procedures .................................................................................................. 99
Action Upon Alarm Sheets ............................................................................................................ 99
Regular System Routines ............................................................................................................... 99
Decontamination Procedures......................................................................................................... 99
Re-commissioning Procedures Post a Major Overhaul or Turnaround............................................ 99
Key Points....................................................................................................................................... 100
Develop Commissioning Schedule ................................................................................................... 100
Stage 1 – Level 2 ............................................................................................................................ 100
Stage 2 – Level 3 ............................................................................................................................ 101
Key Points....................................................................................................................................... 104
Devise Handover Procedure.............................................................................................................. 104
Handover Criteria .......................................................................................................................... 104
Phased System Handover Approach ............................................................................................ 105
Safe Systems of Work at Handover ............................................................................................. 105
Handover Documentation ............................................................................................................ 105
The Review Process Prior to Handover ........................................................................................ 106
Devise Handover Procedure – “Things That Can Go Wrong”................................................... 106
Key Points....................................................................................................................................... 107
Devise Commissioning Tagging System .......................................................................................... 107
Location of Tie-in Points ............................................................................................................... 107
Location of Commissioning System Battery Limit Isolation....................................................... 107
A Punchlist Item............................................................................................................................. 108
Leak Point Found During Leak Test............................................................................................. 108
System LIVE .................................................................................................................................... 108
Item Under Construction Control – Refers to an Electrical Item............................................... 108
Item Under Commissioning Control – Refers to an Electrical Item .......................................... 108
Chapter 1 • Commissioning Phase One – Prepare
5
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
6
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
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 commissioning manager 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
Chapter 1 • Commissioning Phase One – Prepare
7
•
•
•
•
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
8
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• 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
Chapter 1 • Commissioning Phase One – Prepare
9
• 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?
10 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• 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
2. The design production rate
3. The product meeting full specification
4. Production of a pre-specified amount of product
• Support for “on the job” training of the operations team. If Turn Key contracts are to be
put in place on the project, what interface with the commissioning group will there be?
Contracting Commissioning Manager (Not Client-Employed)
It is common in these days of corporations reducing their manpower for a client to enlist
the services of an engineering company to manage construction, pre-commissioning and
initial commissioning of a new plant. Below is described the typical role of a contracting
company commissioning manager and the considerations that should be made with
regard to the scope of the team and the contractual obligations they are required to
consider.
The contract commissioning manager has a somewhat different perspective than the
client commissioning manager; however, it is good practice to consider all the key points
discussed within the previous sections on any project being undertaken.
The single most important item that must be instigated is to understand exactly what
the commissioning team is responsible to deliver with regard to the contract. No early
activity in the commissioning phase should be given as much emphasis as allocating the
right amount of hours to read through the contract comprehensively and gain a full
appreciation of the implications, seeking clarity on potentially questionable areas, so all
parties are fully aware of the scope and the boundaries of responsibility of the
commissioning organization. To avoid difficulties later in the project, this step must be
completely undertaken. Where at all possible a contract engineering company should
involve their commissioning manager in the development of the contract to facilitate
further understanding and knowledge of the considerations laid out in this section of the
handbook.
It is typically, but not always, the case that the contracting commissioning team
will manage all work associated with check-out of construction, punch listing, handover
from the construction group, point-to-point continuity loop check-out (including
confirmation of valve movement), and motor bump tests, of all commissioning systems.
Chapter 1 • Commissioning Phase One – Prepare
11
Introduction of chemicals to the utility systems (air, water and possibly nitrogen) is
commonly undertaken by contract commissioning teams, but steam and condensate
commissioning and introduction of chemicals into all core process systems is usually
undertaken by the client operations group, with the contract commissioning team supporting and assisting where and when required (and having been detailed in the
contract!). The contract commissioning team will usually also assist with all activities
associated with ongoing commissioning of these systems, leak testing, actual interlock
and shut-down tests and process commissioning of the systems/plant, upon the request
of the client operations group.
When a firm agreement is made between the contract commissioning manager and
the client project team as to the full scope of the contract commissioning team’s
involvement, the findings are commonly documented in the commissioning manual.
Ensure all parties understand the logic written within the commissioning manual and
importantly sign off on the manual in case confusion prevails at the point of handover.
It would be in the best interests of all parties to clearly define and document where the
actual responsibility for operation of valves and equipment is and where transfer will
occur, identifying as such on the commissioning schedule and other related documents,
typical identification examples being:
CTTC – Contract team to commission
RFCC – Ready for client commissioning
RFSU – Ready for start-up.
Useful at the initial kick-off meeting by either the client or contracting commissioning
manager with the project or operations team is the guide shown in Fig. 1. The example
taken is from an actual project. It is also useful as the basic agenda for commissioning
team meetings thereafter. A blank form can be located in Appendix 1.
Contracts
It is common for both the client and contracting commissioning manager to be involved
with the development of the commissioning section of a contract. Consideration to the
inclusion and explanation of the key points shown in Fig. 2 is advised in any commissioning section of a contract document.
Commissioning Scope and Contracts – “Things That Can Go Wrong”
Without doubt, the main driver for confusion within commissioning teams are poorly
defined scope, insufficient detail or badly worded descriptions within a contract.
Whilst occurrences tend to be relatively rare, poor scope definition can result in
difficulties during the handover phase of a project, or specific project systems. For
example, a client may not want to adopt a system deemed to be ready for handover if
he/she cannot agree that all activities within the system have been completed. This can
12 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Chapter 1 • Commissioning Phase One – Prepare
FIG. 1 Ă
13
14 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Chapter 1 • Commissioning Phase One – Prepare
FIG. 1—Cont'dĂ
15
16 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Chapter 1 • Commissioning Phase One – Prepare
FIG. 1—Cont'dĂ
17
18 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
FIG. 1—Cont'dĂ
Chapter 1 • Commissioning Phase One – Prepare
19
FIG. 2 Ă
20 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Chapter 1 • Commissioning Phase One – Prepare
FIG. 2—Cont'dĂ
21
22 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
occur when a client changes his/her mind even though all of the actions defined in the
commissioning manual can be demonstrated to have been completed satisfactorily. The
safeguard, in this case, is to ensure that both contractor and client have signed off
the commissioning documents to indicate their understanding and acceptance of the
document’s contents. Failure to complete this simple step can result in difficulties for
both parties if the documents have to be revised and re-agreed. Beware: disagreements
at this point can have sufficient impact for inclusion in any project “lessons learnt”
report.
A clearly defined and agreed scope of work, accurately documented in the contract or
commissioning manual, is imperative to ensure a smooth handover when the commissioning activities have been completed.
Key Points
• Understand fully and completely the commissioning scope
• Clearly understand and define the contract and remove ambiguity
• Ensure all interested parties understand and sign on to the relative scope within the
commissioning manual
• Define responsibility and document accordingly.
Budget Estimation
During the early stages of commissioning development and preparation the
commissioning manager will usually be asked by the project manager or project
finance controller to provide a budget estimate of the cost of the activities associated
within the total commissioning effort. The estimate can be assimilated on a simple
spreadsheet and will vary in duration from the actual projected commissioning
phases up to and including support of the initial operation for a designated period. I
am not aware of any specific commissioning cost estimation software and have not
used any.
Below are considerations for inclusion within most commissioning estimates:
Clear explanation of all assumptions used in the estimation process, including cost of
the various commissioning disciplines (managers, engineers and technicians) and
rates for travel (air fare, hotels, car rental and living expenses) must be given.
• Manpower
Direct commissioning team resources
Project resources required (typically process engineers, electrical, instrument and
control engineers)
Installation contractor resource requirements (support craftsmen and technicians
for punch list rectification and commissioning modification implementation)
Specialist vendors
Chapter 1 • Commissioning Phase One – Prepare
•
•
•
•
•
•
•
•
•
•
•
•
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•
•
•
•
•
•
•
•
•
•
•
•
•
•
23
Independent specialists such as water chemists, laboratory services and equipment
surveillance (use of radioactive detection of flow and level)
Specialist cleaning services (pigging and chemical cleaning)
Cost of existing site services (water, power, effluent treatment)
Team-building events
Professional institution fees
Commissioning spares
Contingency for engineering of commissioning modifications
Initial fill of process chemicals and lubrication
Design support for commissioning
Commissioning temporary buildings and accommodation (cabins, refurbishment
of existing buildings)
Computers and communication (radios, telephones, landlines and mobile phones)
Office equipment (photocopy hire, printers)
General consumables
Commissioning team personal protective equipment (PPE)
Stationary, various types from pens to folders, the list is long! Do not forget
specialist type stationary such as printing of proprietary Permit to Work books
Commissioning instrumentation requirements (temperature, flow meters and
pressure indicators)
Commissioning camera and photography (if the project is of a very high profile and
regularly shared with a large audience, it could be of advantage to consider the
installation of a high level, time-lapse camera to document build progress)
Signs and barricades
Plant entry signage
Safety equipment
Operational equipment (hoses and fittings)
Various labels including pipe work types
Training and team education needs
Travel – Local for vendor visits, inspections and Factory Acceptance Checks.
Consider the viability of long-term vehicle hire as apposed to daily vehicle rental?
Incorporate vehicle mileage allowance in the estimate
Travel – International (consider average flight cost, hotel cost, foreign rental car
cost and daily living costs)
Relocation of personnel considerations and costs if required
Cost of relocation or assignment per diem (daily living and lodging allowance)
Consultants
Regulatory charges (COMAH, IPC)
Professional fees (for commissioning team).
Each project is obviously different in type, complexity and process. This being said, the
project management team and indeed a particular company will have an “expectation” of
24 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
what the total commissioning cost will be. The typical percentage of, or the “norm” for
commissioning services for, a chemical plant process is to be estimated at 3.5% of the
total capital investment.
In addition to the above percentage estimate, the break-down of the total commissioning cost will be approximately 70% manpower; the balance (30%) should be
consumable expenditure. If expensive and/or a large initial fill of chemicals is required
within the process, these will obviously tip the estimate away from this normal
percentage.
Some engineering contracting companies will typically weigh their commissioning
“norms” based on the complexity of the asset to be built; in these instances the
percentage of commissioning cost per capital expenditure will vary from 3.5 (simple
build) to 25% in a really technically challenging process. For normal chemical process
applications, I have also found the 3.5% stated above to be an adequate and acceptable
estimating figure.
Prioritized Asset Systemization
Once the commissioning scope of the project has been defined and initial key project
documents (P&IDs, layout drawings, plot plans and mechanical handling drawings)
have been drafted and issued then commissioning systems can be identified in priority
order. This is the first and one of the most important activities the commissioning
team will undertake as it gives the structure for all the other organization the team will
then perform, sets the priority for document and check-out management and helps
assist in the efficient initial plant commissioning and start-up in the most effective and
timely way.
It is of the highest importance that the overall approach to constructing and
commissioning the new plant has START-UP being the driving force and key objective and
is the ethos of this handbook.
Great difficulty in execution of the project will be experienced if the systemized
approach is not supported by the project engineering team and construction team as the
probability of an effective start-up will certainly be minimized. Therefore it is essential
that the commissioning manager solicits buy-in from the project and construction teams
to the concept that a timely start-up will be the principal project objective. Therefore the
correct systemization of the process, being correctly prioritized, will provide the required
project focus and direction to deliver the commissioning and start-up of the new asset in
the most effective way.
Do not underestimate the difficulty in obtaining this buy-in. Construction organizations will typically be much bigger both in budget and manpower than commissioning organizations and hence from a project level will have more power.
Construction will want to attack the project from an area perspective, which initially is
highly acceptable as main items of equipment, large-bore pipe runs and structures
Chapter 1 • Commissioning Phase One – Prepare
25
need to be assembled in the most effective way possible. However, the close-out of
construction to allow commissioning is always a challenge; investing the time to
establish that the start-up of the facility is always of the highest priority is well worth
the commissioning manager doing as it gives the whole organization direction during
the final construction phase.
Commissioning systems are identified by highlighting principally the P&IDs, clearly
marking the boundaries of the system. In cases where systems are of a typically material
handling (storage facilities) nature, then identifying systems on mechanical and layout
drawings is also acceptable. The systemized P&IDs will then become the commissioning
engineers’ bible; they are the document that the engineers will use to check the
construction against. The P&IDs are the road map of how the design process engineering
perceived the plant to operate.
It is worth confirming that the P&IDs will become the primary commissioning checkout document. To avoid confusion during the punch list generation phase, where
potentially other project disciplines are expecting commissioning to utilize other engineering documents, the piping isometrics are an example where a descriptive of the use
of P&IDs for principal commissioning check-out purposes should be incorporated in the
commissioning manual.
Electrical and control systems are typically identified by highlighting “one-line”
diagrams and control system architectural drawings.
Clear boundaries enable tight control of later commissioning activities such as leak
testing where one system may be energized whilst another is still under construction.
Once the list of systems has been identified, prioritization can take place. Starting at
the first system required, number the systems in the turnover or handover sequence
needed from construction so that the final system is the one needed at the end of the
start-up phase of the project.
To reaffirm, it is most important that the construction team and their mechanical and
electrical subcontractors have embraced the commissioning system approach. At
a significant point in the construction phase, typically 80% completion, the construction
group will need to adopt a change in build philosophy from the “area” approach to that of
a commissioning system close-out.
Each system is given a specific identification tag and system name. Once these
identifications are created they can then be incorporated into engineering documents
such as the piping line tables and instrument indexes and considered for entry onto the
line identification tags on the P&IDs. Attaching the commissioning system identification
to other engineering documents allows for easy sorting and grouping, especially when the
project nears the turnover or handover stage to the client or operations group. Be
prepared to incorporate client stores system entity numbers in the commissioning
identification numbering if so desired.
This is an important point to consider. It is common that engineering in general
embraces the commissioning system approach and incorporates the system numbering
26 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
into their documents. It is also important for the procurement group to also be advised of
the commissioning systems so items of equipment can be purchased and delivered to the
job-site in the correct timing and sequence required.
The full set of P&IDs and other documents used to systemize the asset should be
highlighted. Following on from this, each individual system should be identified on all the
P&IDs that the system figures; this method of further identification is of great use in
quickly addressing specific enquiries within the system.
Depending upon the size of the project the systems are then divided between the
commissioning engineers allocated to the project. The commissioning engineers will
then “own” the system through construction, commissioning, start-up and handover
to the client or operations group, ensuring that all checks are completed and documented in the “system file.” The system file will be discussed at length later in this
handbook. It is typical for each commissioning engineer to be allocated up to four core
process systems (at various time intervals through the project), and up to three utility
or enabling systems again spread as evenly as possible throughout the construction
window.
Asset commissioning systemization is based on the following guidelines:
• Utilize a backwards approach.
• Do not prioritize a commissioning system that when completed adds no
immediate value as it may remain unutilized until other systems have been
pre-commissioned.
System order:
•
•
•
•
•
•
•
Power, lighting
Control systems, DCS, PLCs, data highways
Utilities, air, water
Product storage, stock tank systems and loading
Core process units, reaction, distillation
Raw materials feeds
Raw materials storage.
A system and priorities list from a hypothetical process is provided in Fig. 3. Although
fictitious it proves to demonstrate the required system list layout and more importantly
chronological flow of systems an ideal start-up would demand.
Following on and taken from the systems list in Fig. 3 are two hypothetical P&IDs
(Figs 4 and 5), suitably highlighted with the system identification code and colored
accordingly. These drawings serve to demonstrate the style of how P&IDs are marked up
to indicate the systems allocated.
As a reminder please note the general intent of the systems with priorities list is that
commissioning is organized so that a natural flow is established where any preceding
system being complete sets the sound foundation for an efficient and ideal plant start-up
scenario.
Chapter 1 • Commissioning Phase One – Prepare
FIG. 3
27
28 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Hypothetical Highlighted P&ID Showing System Identification
To Steam Generation
To Hot Oil System
Water
Mains In
LIC
1
FO
1
To By-Product
Acid Storage
To Product
Distillation
Instrument
Air
Shower
Water
Tank
Shower
Water
Pump A
To Reaction
To Feed A System
Shower
Water
Pump B
Shower detail
Commissioning Systems Legend
IA - Instrument Air
WM - Water Mains
SW – Shower Water
FIG. 4
FIG. 5
Shower Water Process and Instrument Diagram
Showing Commissioning Systems
Chapter 1 • Commissioning Phase One – Prepare
29
Prioritized Asset Systemization – “Things That Can Go Wrong”
Without doubt one of the key aspects that has contributed to inefficient delivery of the
final construction and subsequent commissioning facet of projects has been the
unwillingness of adopting the systemized approach. Two unrelated examples are worthy
of explanation:
1. At the start of a significant project, the client requested a small but significant
modification to a tank feed system be brought on line early in the commissioning
phase as it enabled some inter-tank transfers and some operational benefit was
gained. The system was duly highlighted and given priority 1 on the systems list. All
engineering disciplines incorporated this except the procurement team, who did not
promptly order a key component. The result was that the system came LIVE very late
in the start-up process which the client did not appreciate and potential operational
benefit was not materialized.
2. On occasion construction groups can choose not to adopt the systemized approach,
and an area build concept is maintained. This can manifest into difficulties at the
close-out of construction, prior to construction to commissioning handover, where
mechanical and instrument/electrical teams will be concentrating on the installation
and testing of equipment not within the required early systems to be handed over;
impetus is lost for the greater good of the start-up philosophy and much hard work is
required on behalf of the commissioning team to re-focus effort and the ultimate
conclusion of systems to aid start-up effectiveness.
Systems give direction and focus to what needs to be done to close out construction,
a very key element in the efficient delivery of multi-discipline project teams.
Key Points
• Sound process systemization and prioritization will lay the foundation to an effective
and efficient start-up
• A systemized approach will give the project teams close-out focus
• Key to obtain project buy-in to systemized approach
• Utilize a backwards approach to prioritization, power and control, utilities, storage,
core process and feed system order.
Support Design
As the plant design develops key reviews are conducted which will involve the
commissioning group; these reviews will typically include Hazard study, Layout reviews,
P&ID reviews, 3-D model reviews, Isometric drawing reviews, Risk assessments and
Hazard during construction reviews (Hazcon).
A commissioning team representative should attend the reviews, especially if no
operations representation is present. The commissioning engineer will visualize how
30 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
the equipment will look when it is built and anticipate expected problems, examples
being:
•
•
•
•
•
insufficient drainage
isolations for maintenance
initial commissioning issues
start-up
shut-down.
Quite simply expressed in terms of cost alone, the price of redrawing a P&ID or reconfiguring the 3-D model during the design phase of a project is obviously significantly
more cost-effective than redesigning a poorly installed section of pipe or piece of
equipment when actually constructed in the field.
For substantial modifications and retrofits, commissioning is called upon to ensure
that any redundant equipment is included in the scope for removal from the plant. It is
unfortunate that in many projects it is common for redundant plant to be left in situ post
remedial work, which will in time become both an eyesore and potentially a safety hazard
as it degrades and becomes unstable. Where cost permits, commissioning should
encourage the project to remove old plant.
At some point towards the completion of detailed design, the commissioning and
process engineering groups should meet to consider all alarms, interlocks and trips. This
is to ensure that potential nuisance alarms and plant trips are removed. Action Upon
Alarm sheets are a common method of managing this process; a blank form is included
within the commissioning documents section of this handbook.
Here are observations, from the commissioning perspective, one should be aware of
and be considering during the various reviews:
Hazard Study
The Hazard and Operability Study (HAZOP) process referred to in this section of the handbook centers on the Hazard Study 3 format, pioneered within the full suite of Hazard Study
processes (covering all aspects within a project), created by Imperial Chemical Industries
(ICI) during the 1960s. Through time all companies have developed their own approach to
this particular section of the hazard appreciation process; terms vary and include Safety Desk
Review, What If Analysis and HSE 3, but all companies use the same principles. The process is
broken down into “nodes” on a “P&ID by P&ID” basis with potentially several nodes per
P&ID. Each node will be examined under the direction of a number of guide words: low flow,
high flow, no flow, reverse flow, low pressure, the list goes on.
As the study unfolds, some guide words will become specific to commissioning and
the greater hazard study team will expect the commissioning members to give unique
input when discussing. The guide words will incorporate:
• Start-up
• Shut-down
Chapter 1 • Commissioning Phase One – Prepare
•
•
•
•
•
•
•
•
•
•
•
•
•
31
Control sequence
Testing
Maintenance
Venting
Draining
Drying
Isolation
Spares
Leak testing
Cleaning
Vacuum testing
Interlock and alarm testing
Sampling.
Commissioning team members who will be involved with the hazard study process are
encouraged to make a detailed pre-check of the P&IDs prior to the actual study, utilizing
the guide words above to ensure their contribution to the process is prepared, meaningful
and constructive.
Following on the commissioning team therefore should add to the discussion where
relevant but their main considerations should be:
• Can the unit be started up correctly; is everything in place for it to be carried out
safely?
• Can the unit be shut down correctly; is everything in place to allow the activity to be
conducted safely?
• Can the equipment be adequately drained, typically for maintenance, although there
may be specific applications to consider?
• Can the equipment be isolated?
• Is anything specifically required to allow initial commissioning of the unit?
• Is there sufficient instrumentation; is there pressure, temperature, level or flow indication that could be incorporated that will assist the start-up?
• Are the control loops adequate, will they create any potential problems operating the
plant?
• Are there sufficient vents and drains to allow the filling and draining of systems?
• Has a siphon situation been created that requires a vacuum break?
• Is provision adequately considered that allows for ease of system leak testing and
drying out if required?
• Typically for the commissioning and blowing clean of steam systems are there
adequate and suitable vents (even if temporary) incorporated into the design?
• Challenge sample systems for their practicality and safety (transportation of hazardous
chemicals from plant to a laboratory, for example).
• Fully understand mechanical interlock systems and their application to the process
being studied.
32 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
“What If” analysis is another process hazard tool for deduction of risk to a process plant.
Here, prior to the use of formal guide words, the hazard study team will view the process
from a systematic perspective rather than a line-by-line approach.
A general team discussion will be facilitated by the hazard study leader where the team
will brainstorm what if scenarios for the process (examples being what if – the pipe
ruptures, what if – the tank overflows). Post scenario gathering the team will then:
•
•
•
•
•
Ascertain cause
Determine the consequence
Rank the risk
Determine the safeguards
Make reservations and allocate the actions for remediation.
At the end of this process it is normal for a set of guide words to then be considered to
further assist the review of risk to a particular process.
It would be very prudent for all commissioning personnel not familiar with Hazard
Study to attend a formal training course to appreciate the methodology and become
suitably prepared for the role they are to undertake.
Layout Reviews
Layout reviews access the overall plot plan of the asset for optimal placement of major
items of equipment, vessels, pip runs and escape routes.
During a layout review, the commissioning team should be vigilant to ensure proper
consideration has been made to the location of:
• Utility stations
• Safety equipment, showers, fire extinguishers
• Ingress and egress; ensure there are no restrictions, support steel, stairways, pipes that
obstruct the ability to get in and out of the unit
• Stairways and access ladders; ensure reverse “stepping off” from access ladder support
pads does not create a tripping or stumble hazard
• Major isolation valves
• Instrument stands and motor start/stop buttons.
P&ID Reviews
The commissioning team must take the reviews of P&IDs very seriously. The P&ID is the
major project document the team will use, they will be an integral part of all document
and procedure preparation and final check-out of any constructed system within the
asset. The P&IDs must, where at all possible, be right and the commissioning team must
invest sufficient time to appraise and constructively comment on the P&IDs through all
stages of their development. Quality time invested at the review stage can only help the
commissioning team’s total effectiveness throughout the project.
Chapter 1 • Commissioning Phase One – Prepare
33
It is typical for the P&ID review to be multi-disciplined.
Here are typical points that commissioning should consider during a P&ID review;
again it would be of benefit if the commissioning team personnel have pre-reviewed all
P&IDs prior to the review process itself.
The Process
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Operating temperature and pressure – Normal and extreme
Control under normal operation and turndown
Instruments required, level, temperature, pressure?
Instrument locations, local or DCS?
Isolation of instruments, bypass, maintenance, testing, control valve air-fail action
Analysis – Location and method
Start-up
Shut-down – Emergency and planned
Abnormal operation, high/low pressure, temp, backflow
Isolation – Process equipment, process systems
Venting/draining – System, equipment
Maintenance – Access, entry, cleaning
Commissioning requirements – Testing, cleaning, vents, drains
Relief philosophy – Is all relief equipment suitably documented on the P&ID?
Is all process direction of flow indicators correct?
Is the line color coding for new, existing, and demolition correct?
Mechanical Issues
•
•
•
•
•
•
•
•
•
•
Material of construction transition point is clear (one material to another)?
Line numbering correct and consistent with design requirement?
P&ID inter-page cross references are OK?
Important elevations are evident
Relief stream pressures, instruments and stream numbers are correct
Vessel data – Mechanical details (nozzles, man ways)
Mechanical to instrument interface
Break-in points with existing plant
Vessel trim and numbering correct?
Are all vendor packages clearly defined with suitable battery limit points identified
with suitable isolations?
Control, Instrument and Electrical Issues
• Instrument loop identification correct?
• Control system or DCS loop identification correct?
• Emergency shut-down (ESD) loop identification correct?
34 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• Do all inter-page control and ESD loop circuits correspond?
• Are all references to control sequences correct?
General Issues
•
•
•
•
Are all notes relevant and current?
Are all hold points relevant and current?
Is all vendor package information correct?
Are all equipment information tables complete?
3-D Model Reviews
These reviews are absolutely invaluable in identifying potential build issues at a relatively
early stage in the design effort. Many poorly placed valves, inadequate access issues, and
potential for non-draining pipeline low points can be recognized in the office and
rectified well before construction commences.
Please follow the guides for Hazard Study and P&ID for these reviews. It is always best
to follow each line through the model; doing a general overview is much less effective.
Isometric Drawing
Process engineering designs the plant to P&IDs, construction build to isometric drawings
(typically). It is important that commissioning review the isometrics against the P&IDs
prior to construction to ensure the documents are consistent and that when built and
punchlisted there are no conflicting issues that will need to be corrected in the field; this
is costly and can have a detrimental effect on the overall schedule.
Risk Assessments and Hazards During Construction
It is typical that the commissioning teams are requested to attend risk assessments and Hazard during Construction (HAZCON) meetings to give operational
input and to ensure that commissioning activities are considered and given suitable attention.
Control Systems
It is common for the commissioning system engineers to become involved with the
development of a new DCS control system, having specific input into the User
Requirement Specification (URS), development in such areas as graphic page design,
formation of layout, set-up of specialist pages and trend pages. Once the URS is issued to
the DCS manufacturer, the Commissioning Team will usually be involved with the review
of the Functional Design Specification (FDS) when issued from the vendor, this document then being the basis of the DCS system build.
Chapter 1 • Commissioning Phase One – Prepare
35
Action Upon Alarm Review
The action upon alarm review is interesting as the basis challenges both the design
process engineer and the commissioning and potentially the operations personnel to
evaluate the justification for any alarms, their activation points and the action required of
an operator in the event of an alarm. The review can take place post start-up when initial
operational experience has been gained.
The process has two major advantages:
1. Correctly documented alarm review sheets, when located in the control room, will aid
the operations personnel manage the process in the event of infrequent alarms.
2. The review itself will help identify and eliminate nuisance alarms; those which have
a low priority can often repeatedly alarm in the control system.
A worked example is provided here, taken from the hypothetical reactor drawing in the
Prioritized Asset Systemization section of this handbook.
Support Design – “Things That Can Go Wrong”
Two separate instances of the same unrelated issue have caused delay to the commissioning phase of projects. On both occasions the commissioning team’s attendance at
neither the P&ID nor the 3-D review was considered and the same problem resulted.
A steam distribution system was installed, two completely different processes, in fact
in different parts of the world. On both occasions the commissioning team was late on the
project and due to the haste of document, procedure and check sheet preparation no
specific sanity check was made of the P&IDs. Fire-fighting mode kicked in and all efforts
were directed at rapid preparation and initial implementation of commissioning
activities.
As construction materialized, most steam system equipment having been installed, it
became evident that there were no piping low-point steam traps to remove condensate
from the rising steam main, feeding utility stations on each ascending floor of the plant.
The issue was duly reported to the construction group, who then instigated rapid
rectification design and procurement activities to retrospectively install the steam traps
required.
In both cases had the commissioning team, based on the checks documented in this
section, been involved at the review stage, the issue would not have manifested in the
field and resulting time and cost would have been saved.
Key Points
• Ensure the commissioning team are present at all project Hazard studies, P&ID and
3-D model reviews
• Ensure the commissioning team review the documents and P&IDs prior to the actual
reviews
36 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
ALARM ACTION SHEET
Alarm Title:
Reactor Outlet temperature
Settings:
High = 200°C
Low = 100°C
Response time
Loop Number:
P&ID Number:
TIC 3
N/A
Purpose of Alarm
Gives indication of a high or low Reactor outlet temperature
High & Low – Within 3 minutes
POSSIBLE RESPONSES
High – Check instrumentation for malfunction of control and LIC 3.
Check control valve LV 3 for mal-operation
Check FEED systems for mal-operation
Check all other Reaction instrumentation for control issues within the system
Low – Check instrumentation for malfunction of control and LIC 3.
Check control valve LV 3 for mal-operation
Check all is operating normally on the steam condensate system
Check FEED systems for mal-operation
CONSEQUENCES OF A FAILURE TO RESPOND
High – An uncontrolled temperature will lead to a high temperature and a shut-down of the system
via SD 1
Low – Loss of Reaction and product and quality issues
Operational instability
START-UP/SHUT-DOWN IMPLICATIONS
Low – A low temperature at start up is normal. SD1 has a low temperature timed by-pass to allow
reset of SD1 in a start-up situation.
The low temperature by-pass will deactivate once a temperature of 50°C is reached, SD 1 is then
operational
Author:
Validated by:
Date
FIG. 6
• Commissioning should give key input to plant layout
• Consider action upon alarm reviews and document findings in the control room for
continued operations use.
Chapter 1 • Commissioning Phase One – Prepare
37
Develop an Initial Commissioning Plan or Philosophy
Once the commissioning scope has been determined, a prospective commissioning plan
or philosophy of both generic and project-specific commissioning activities and general
timings can be developed and issued. The aim of this level of plan is to identify the key
commissioning project aims, objectives, activities, and general philosophy. The initial
commissioning plan is most often utilized where a contracting commissioning organization is appointed to a project and it may be the first indication to the client project
management, operations and engineering teams how the commissioning will be planned
and the activities managed.
The document should state the approach to commissioning and the basis of its
methodology. There should be some mention of specifics related to the project; however,
detailed information will typically be found later within the Commissioning Manual.
It is the responsibility of the commissioning manager to develop the initial commissioning plan.
A typical table of contents for the initial commissioning plan should be based on that
below:
Table of Contents
1 Purpose of the commissioning plan
2 Commissioning overview
3 Project scope of work
4 Key project objectives and aims
5 Commissioning team roles
6 Commissioning methodology
6.1 Prepare
6.2 Implement
6.3 Close-out
7 Initial commissioning systems
8 The commissioning system file
9 Commissioning and start-up challenges.
Key points for each section are:
Purpose of the Commissioning Plan
State here the commissioning methodology intended for the project based on the
Prepare – Implement – Close-out principle. Phrases such as “The methodology describes
a flow of commissioning stages and considerations which, when considered and utilized,
can aid delivery of the commissioning facet of the project to the very highest standards”
should be adapted accordingly. State why and how the new asset is going to be
commissioned.
38 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Commissioning Overview
Consider replicating the simple flow of commissioning stages as described in the
commissioning logic section of this book.
Project Scope of Work
Insert in the initial commissioning plan a description of the project scope particularly
pertinent to the commissioning group.
Key Project Objectives and Aims
It is important to invest time with the project manager and project sponsors to
understand the key aims and objectives of the project and the implication and guide this
will have on the commissioning team and its activities. Document clearly within this
section.
Commissioning Team Roles
Make an assessment and estimate of the size and make-up of the team (what disciplines
the team will need) and describe their roles here. Typical team member roles will be
described later in this handbook for further guidance.
Commissioning Methodology
Write a description of the key commissioning stages here, based on the activities the
project will demand and the commissioning team will need to perform.
Initial Commissioning Systems
Take the time to review the project P&IDs and drawings then offer an initial breakdown of
the number, description and priority of the commissioning systems for the project. It is
understood that these may change, but it gives those other project disciplines who will
work with the commissioning team an early understanding of how the team plan to
approach the start-up of the unit. Remember it is key within the scoping of the
commissioning team role to obtain buy-in from all disciplines associated with the project,
that start-up of the new asset should be the focal point of all groups and teams unified
together with the common aim of the most effective, efficient and problem-free
commissioning phase possible.
The Commissioning System File
Much will be made of the commissioning system file later in this handbook. It is sufficient
to state that here within the initial commissioning plan the need for a brief description of
how the team will manage the many check-out sheets and procedures required to
effectively pre-commission and commission the process.
Chapter 1 • Commissioning Phase One – Prepare
39
Commissioning and Start-up Challenges
Review the project and process and make an evaluation of any key challenges that the
Commissioning Team may face and offer potential solutions to the opportunities.
Appointment, Composition of the Commissioning
Team, Roles, Responsibilities and Organization Chart
The commissioning team will be composed of a number of various craft personnel; the
size, complexity and nature of the project determines the final team’s number and will
finally be resolved once a full understanding of the process is gained and the commissioning scope of the project is established. A description of typical roles and responsibilities of a successful commissioning organization is the basis of this section. Please note
on smaller projects and commissioning teams some of the positions will not be directly
filled, but their activities will need to be considered and incorporated according to the
duties of the resultant team’s remit.
On a general note it is worth taking the time and consideration to try to obtain
a balanced commissioning team with various levels of experience and discipline skills.
Typically it is advantageous to obtain process engineering skills, operations experience,
and instrument/control and electrical knowledge. If these skill sets are not directly on the
team, assistance with these disciplines from the “home office” engineering department
should be organized, sanctioned by the project manager, be readily available as and when
required, and the strategy fully documented in the commissioning manual.
It is very common for the client operations and maintenance organizations to require
a significant presence on the commissioning team. This is to ensure that all learning
gained through the construction and pre-commissioning phases is retained by the
ongoing operations group.
Initially a commissioning manager will be appointed; this has been discussed at some
length earlier. The incumbent, of course, will in due course be supported by a number of
commissioning engineers who will have responsibility for the day-to-day management
and delivery of the commissioning systems. The total commissioning systems and their
complexity will determine how many commissioning engineers will make up the team,
but normally a commissioning engineer will manage no more than seven commissioning
systems. On major large projects it may be necessary for the commissioning engineers to
have assistants appointed to them who will help in the delivery of the activities associated
within the associated systems.
If a commissioning team is made up solely of contractor personnel, a representative
from the client organization must be identified as a liaison between the contractor
commissioning team and the client operations, maintenance and project organizations.
The individual/individuals must work closely with the commissioning team to ensure
total effectiveness of the commissioning process, especially at handover. Client liaison
personnel typically take control of the management of all chemical introduction to the
40 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
new process if the source of the supply is from an existing asset; the importance of this
role is key to an effective commissioning implementation phase.
The number of commissioning electrical, control and instrument (E/C/I) engineers
will be determined by the size of the project. This team will ensure checkout and documentation of all commissioning system electrical items such as lighting, motors and
power, control systems, field instrumentation and the unification, where applicable, of all
three disciplines.
Mechanical activities will be managed by the commissioning mechanical engineer,
who will check and document pipe and equipment testing and cleanliness for the full list
of commissioning systems. He will also manage the mechanical commissioning and
testing of major vendor equipment, package units and vessels.
Both the E/C/I and mechanical commissioning engineers should work closely with the
client plant area engineers to ensure the plant maintenance department is made fully
aware of the nature of the project, have input to checkout and are made aware of system
status. The maintenance organization should be discouraged from making late submittals of their own punch lists as this can cause significant delay to progress and can create
an additional workload to the project commissioning team.
In addition to those mentioned above, other members of the client operations
personnel and potentially members of the client maintenance teams plus vendor
equipment specialists can supplement the commissioning team as and when required,
especially through the start-up phases.
Three particular areas that on occasion can cause confusion and misunderstanding
are those of the client witnessing of various tests, cleanliness procedures and leak tests,
and the handover from the commissioning team to the ongoing operations team. It is of
the utmost importance that the commissioning manager seeks common understanding
and approval for the success of these two areas with all interested parties and all
agreements are clearly documented in the commissioning manual.
Most large projects demand close co-ordination between those responsible for delivering the commissioning function; this is a key factor in the overall success of the team.
Successful commissioning teams are built on the foundations of trust, respect and
mutual understanding for the unique contribution that they bring to the task given them.
Other project teams are not as diverse as that of the commissioning group; this helps to
contribute to the special atmosphere a first-class commissioning team can generate.
A good commissioning team is absolutely key to any successful project.
The main roles and responsibilities of each commissioning team member are now
highlighted. These descriptions are most useful when drafting job descriptions in the
team recruitment process.
The Commissioning Manager
Reports to: Project or construction manager
Background: All typical engineering or operations disciplines
Chapter 1 • Commissioning Phase One – Prepare
41
Function: Responsible for the management of commissioning activities; systemization, planning, pre-commissioning, loop checking, leak testing, introduction of
chemicals, commissioning, start-up and validation testing of the plant
Typical duties: Organize, supervise and direct all commissioning activities and personnel.
Organize team accommodation and consumables including IT equipment (usually
with assistance of construction manager)
Draft commissioning manual
Systemize the plant into commissioning systems to affect the most efficient plant
start-up, allocate commissioning systems to the commissioning system engineers
Manage development and validation of commissioning procedures and check sheets
Ensuring the commissioning team is adequately trained as required for their duties
Ensuring all site-related training and inductions are organized for the team
Manage and direct all commissioning and start-up activities
Participate in all coordination, scheduling, safety and progress review meetings
Ensuring all instrument and electrical checkout and tests are completed
Ensure all commissioning activities run to cost and schedule
Management of Change Control System
Ensuring checkout of new computer control systems, through design and installation including interlocks and shut-down systems
Update of all commissioning documentation post start-up; if required direct and/or
participate in all pre start-up Safety Reviews and pre start-up Hazard Study activities
Attend design review meetings as required, i.e. HAZOP, P&ID reviews, 3-D Model
reviews, DCS SFAT and SAT.
Commissioning System Engineer
Reports to: Commissioning manager
Background: Process engineering and operations, but any other discipline could be
considered if the individual is adaptable and shows interest and aptitude
Function: Responsible for the execution of all commissioning activities, input as
required into systemization and system planning, direct and or execute precommissioning, leak testing, introduction of chemicals, commissioning, start-up and
validation testing of the allocated systems; assist as required with loop, motor and
interlock checking
Typical duties: Organize and execute all commissioning activities within responsible
systems
Input into systemization of the plant
Create all commissioning documentation and check sheets for assigned systems
If required prepare Standard Operating Procedures
If required prepare and deliver training packages
Punchlist allocated systems
Carry out all commissioning and start-up activities safely and to schedule
42 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Assess all activities associated within the commissioning systems allocated to the
individual and present justified training requirements for commissioning manager
approval
Participate in all coordination, scheduling, safety and progress review meetings
Administer Change Control System
Ensure and assist as required that all instrument and electrical tests are complete
Ensure and assist as required in the design and checkout of new computer control
systems, interlocks and shut-down systems
Ensure that the newly built asset is suitably labeled both for process pipe and
equipment and instrumentation and electrical items
Update all assigned commissioning documentation post start-up
Attend design review meetings as required per assigned systems, i.e. HAZOP, P&ID
reviews and Model reviews.
NOTE: Assistant commissioning engineers will help in the delivery of all activities
documented above.
Control/Electrical/Instrumentation Commissioning Engineer
Reports to: Commissioning manager
Background: Control, instrument and/or electrical engineer or senior technician
Function: Responsible for the execution of all electrical, control and instrumentation
checkout and documentation thereof
Typical duties: Organize, execute, witness and document all electrical, control and
instrumentation checkout ensuring it is to schedule; obtain agreement from all interested operations, maintenance and client personnel for witnessing of all tests completed
Devise and obtain agreement on the format of all loop testing and electrical
documentation and check sheets
Devise and/or ensure standard is upheld on all instruments, instrument cables,
motors, motor cables, junction box, panel labeling
Create and complete all documentation such that all loop testing, interlock testing,
shut-down testing and electrical and motor checkout is completed and the plant is
ready for process commissioning
Create and complete all documentation such that all Computer Control Systems
are checked out and tested such that the system is ready for commissioning Attend
all Hardware Factory Acceptance Tests (HFAT), Software Factory Acceptance Tests
(SFAT) and Site Acceptance Tests (SAT)
Prepare specific personal training plans as determined by the equipment to be
approved by the Commissioning Manager
Document and track testing of all applicable lighting, heating, ventilation and
air-conditioning systems (HVAC), plus general heating and electrical trace heating
systems
Ensure all communication systems are installed and tested; create documentation
accordingly
Chapter 1 • Commissioning Phase One – Prepare
43
Participate in all coordination, scheduling, safety and progress review meetings
Administer Change Control System
Work with ongoing operational engineering teams to establish the spares system
Work closely with the ongoing Instrument/Electrical Group on the layout and fit
out of the Instrument electrical workshop, specifying ongoing test equipment
requirements
Attend design review meetings as required, i.e. HAZOP, P&ID reviews and Model
reviews.
Mechanical Commissioning Engineer
Reports to: Commissioning manager
Background: Mechanical engineer, piping engineer or senior mechanical technician
Function: Responsible for the execution of all mechanical checkout, testing and
documentation thereof
Typical duties: Organize, execute and witness all mechanical inspections on pipe
work, vessels and equipment
Create and complete all documentation such that all hydro testing, pipe work
cleaning, vessel installation and equipment installation and initial run-in is
completed to schedule and the plant is ready for process commissioning
Liaise with the Construction Group that no vessel is finally closed up prior to the
inspection and approval of the Commissioning Team
Organize for all vendor package commissioning personnel to be on site in a timely
manner in accordance with the overall schedule
Evaluate and specify specialist additional equipment or vendor-related training
requirements for approval by the Commissioning Manager
Work closely with the various project and site organizations to ensure that plant
spares systems are created and populated with required data
Administer Change Control System
Work with Project and Construction Groups in assimilation of commissioning and
ongoing operational spares
Assist in the establishment of stores systems including layout and fit-out of the
stores
Participate in all coordination, scheduling, safety and progress review meetings
Attend design review meetings as required, i.e. HAZOP, P&ID reviews and Model
reviews.
Standard Operating Procedure Group – If Not in Scope of the
Commissioning Engineer
Reports to: Commissioning manager
Background: Process engineering and/or operations
Function: Responsible for the creation of all Standard Operating Procedures (SOP)
44 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Typical duties: Write operating procedures to the desired company standard taking
into account all Safety Health and Environmental legislation for the production of
such documents
Complete the production of the procedures in the systemized manner required by
the commissioning manager or client to comply with the overall schedule
Complete a draft copy of the procedures as required so that the procedures are
available for training and Hazard Study purposes
Attend design review meetings as required, i.e. HAZOP, P&ID reviews and Model
reviews.
Training Group – If Not in Scope of the Commissioning Engineer
Reports to: Commissioning manager
Background: Process engineering and/or operations
Function: Responsible for the creation and delivery of all training for the new plant
including classroom-related and on the job modules
Typical duties: Write and/or propose training packages to the desired company
standard. This may also include computer training for the control system. It is usual to
write operator training and maintenance training packages
Complete compilation of the training packages in the systemized manner required
by the commissioning manager and/or the client to satisfy the project schedule
Plan training sessions taking into account shift patterns, vacation days; devise
duration of each training session
Deliver classroom training to personnel as required
Coach and administer on the job training post start-up
Attend design review meetings as required, i.e. HAZOP, P&ID reviews and Model
reviews.
Key Points
• Magnitude and complexity of the project will determine the size of the Commissioning
Team
• Discipline balance of the team is key
• Consider integration and roles of the client operations personnel
• A good commissioning team is absolutely key to any successful project.
Documentation and Sign-Off Requirements, the Library
and Electronic Filing
To effectively discharge their responsibilities, the commissioning team will require
a variety of technical documentation, which must be up-to-date and to the required
document number and specification. All commissioning procedures and checklists will
Chapter 1 • Commissioning Phase One – Prepare
FIG. 7 Ă
45
46 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
be developed utilizing many of these documents so the latest revision must be available
to the team in either paper or electronic format. It is the responsibility of the individual
system engineer to confirm the revision date before selecting a document for use.
It is common for a member of the commissioning team to be given the responsibility
by the commissioning manager for the set-up and updating of a commissioning library
for both the electronic and paper copies. It is normal for a specific area to be set aside on
company intranet systems to allow storage of all commissioning documents. Headings
that must be considered for set-up of electronic libraries are:
•
•
•
•
•
•
•
•
•
•
General Commissioning Information
General Project Information
Commissioning Schedules
Systemized Commissioning P&IDs
Commissioning System Files
Vendor Operating and Installation Manuals
Tie Point and Main Interface and Battery Limit information
Commissioning Photograph Library
Operating Procedures
Training Manuals.
Project-related documents, examples being process data sheets, vessel and equipment
drawings, process flow diagrams and control and operating philosophy reports will
normally be kept in one specific area of the project electronic file; as such the commissioning team will need sufficient project authorization to access these key areas to review
and utilize the information for commissioning procedure and check sheet production.
Filing cabinets will need to be procured and sufficient files obtained to house the
documents. A drawing rack will also be required to conveniently hang large copies of
drawings should the text on the documents be hard to read at A3 or Ledger size (11” 17”).
All project-related documents not owned by the commissioning team should be clearly
marked with “UNCONTROLLED” or some other project-wide key phrase, to identify that
the document in question has a “MASTER” copy held by another project department.
Many projects have a confidential aspect, so all document storage should be configured to be lockable should there be a need. All documents should be kept under the strict
confidential arrangements of the project and managed accordingly. All paperwork will be
identified with a suitable title, “commercial in confidence” and “restricted” are examples,
to reflect the level of secrecy associated with the documents. The commissioning team
will also produce documents of a sensitive nature and the group must uphold all confidentiality clauses established.
It is worthy of note that the construction group are usually the custodians of the latest
revision of the P&IDs as the project moves to site operations, so close communication
must be engaged to ensure any commissioning changes agreed with the project group are
incorporated on these drawings. In the engineering phase all documents are owned by
the relative discipline.
Chapter 1 • Commissioning Phase One – Prepare
47
The commissioning manager must liaise with the project engineer and/or the document controller so that the project document distribution matrix is updated with the
paperwork required by the commissioning team and who will receive the copies.
The following list is indicative of what is required:
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•
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•
Piping and Instrument Diagrams (P&ID)
Process Flow Diagrams (PFD)
Relevant Engineering Standards
Vendor Installation, Operating and Maintenance Manuals (IOM)
Basis of Design Documents
Functional Design Documents by discipline
Insulation and Painting Standards
Instrument Function-Testing Procedures
Instrument Loop Drawings
The Equipment List
Pipe Line Tables
All Engineering Data Sheets, including Instrument Data Sheets
Electrical Distribution Drawings
Electrical One Line Diagrams
Functional Logic Diagrams
User Requirement Specification (URS) for DCS Control Systems
Shut-down, Interlock and Alarm Summaries and Matrices
Detailed Equipment Manufacturers Drawings
Detailed Vessel Internals Drawings
Lubrication List and Schedule
Material Safety Data Sheets (MSDS)
Specific Procedures for Simulation Testing
Control Narrative
Cause and Effect Diagrams/Schedules
Functional Design Document (FDS) for Control Systems
Copy of all completed Hazard Studies
Relevant Management of Change documents (MOC).
Documentation Sign-Off
During the front-end and detailed engineering design phases of a project, documentation
is produced which within certain companies will require the commissioning manager to
sign for the acceptance of the document, with particular emphasis on the commissioning
activities perspective. The commissioning manager must be prepared for this and ensure
all the commissioning team review their related documents and feed back comments to
the commissioning manager for inclusion at any review process prior to the actual
acceptance and sign-off. The following list of potential inclusions will not include any
48 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
commissioning-specific documents which will be created as a matter of course during
the normal discharge of the commissioning team duties.
• P&IDs – isolations are in place, commissioning water and initial chemical import and
commissioning can be conducted, leak and dryness testing can be performed and
equipment can be maintained
• Hazard Study Methodology – ensure the role and objectives for the Commissioning
Team are incorporated in the document
• Battery Limit and Termination Point Schedules – isolation points adhere to the project
standard (single isolation, double isolation and bleed, removal spool piece)
• Pipe Inspection and Testing Documents – cleaning of pipework can be completed
including flushing with water, blowing with air, specialist cleaning examples being
chemical clean and/or the use of a pneumatic “pig”. The cleaning witness methodology, which group will witness and to what percentage of the cleaning procedures
carried out, will require inclusion in this document
• Site Layout Plans – overall layout is acceptable and logical
• Inspection, Testing and Quality Documents – vendor factory acceptance checks
ensuring all commissioning witness points are incorporated within the documents
• Control System User Requirement Specification – configuration of graphic pages is
adequate, trend facility considerations have been made and commissioning team
witnessing of testing has been incorporated.
Key Points
• Always use the latest revision of engineering documents in the preparation of
commissioning procedures
• Set up paper and electronic commissioning libraries and ensure the electronic data are
saved daily to a safe company-maintained system
• Update project documentation distribution matrix with commissioning team
requirements.
Devise Assignment Details, Site and Office
Requirements, Consumables and Procure
Commissioning Chemicals
Consideration will need to be made for the organization of the team should relocation or
an assignment be required; this will include location and set-up of commissioning offices
at the job-site and personnel matters. Most companies will have a system in place to
manage these scenarios; however, those points for confirmation when any assignment
and/or relocation to site are pending should be considered by the commissioning
manager for his team.
Chapter 1 • Commissioning Phase One – Prepare
49
The examples are divided into three categories: International Assignments, Site and
Office Requirements and Commissioning Consumables. It is necessary to address all
three of these groups in the evaluation of the commissioning team relocation and set-up,
from an engineering office to operational site environment.
It is of course important that any consideration having to be implemented on the
project be fully integrated into the commissioning section of the project budget estimate
and approved and accounted for accordingly.
International Assignment
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Visa and/or work permits
Passport availability
Foreign consular information
Medical requirements and proof of inoculation
International healthcare plans
International and domestic travel insurance including company and rental cars
Emergency medical kit
Relocation considerations (to be worked with Human Resources) including familyrelated matters such as schools, banking and mail services
Gather key personnel documents, marriage and birth certificates, and professional
certificates
Foreign climate considerations
Clarify all income and foreign tax considerations
Transportation, cars, trucks and vans
Driving license requirements
Emergency evacuation policy
Staff accommodation and dietary needs
Information pack on local customs, culture and location of amenities
Home relocation considerations including storage of possessions
Hours of work
Lone working policy
Overtime considerations
Rest time policy
Air and group travel policies
Job-site-specific training and induction requirements
Entry to site requirements such as Transportation Workers Identification Credential
(TWIC) cards and Oil Passports.
Site and Office Requirements
It would be unusual for the commissioning organization to be actually establishing
an office at site; this is usually the responsibility of the construction team. However, it is
not uncommon for the commissioning group to require further office space within the
50 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
construction compound and so the following list of requirements must be considered to
facilitate a smooth transition of the team to the site location:
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Office accommodation, rent, lease or purchase
Power, water and toilet/shower facilities
Site power regulations and other policies that will need to be adhered to
Portable on-site toilet facilities
Parking facilities and general walkways, are there requirements for paved areas?
General security, need for 24-hour security guards, fencing requirements
Desks, chairs, tables, drawing racks, drawing boards
Filing cabinets and shelving
Computer systems, including internet set-up and access
Liaise with relevant IT groups for space on the network to allow commissioning
documents to be safely stored
Landline telephone and mobile/cell phone set-up
Photocopy machine
General office supplies
Cleaning services, when, who, how many times per week?
Vehicular access to site
Waste disposal and the regulatory impact.
General Commissioning Consumables
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Various labels including – “LIVE”, basic chemicals, water, instrument air, steam, etc.
Waterproof wallets, to protect signs and warning tags
Cable ties for various uses
Locks
Chains
Gang-hasps or multilock hasps
Lock out, tag out and electrical energy isolation labels
Gloves, various including: cloth, rubber, thermal protection
Hard hat
Goggles
Safety glasses
Harness and life lines
Hoses; air, water, nitrogen, plus connectors
Marker pens
Pens/pencils, black and colored
Paper: legal, ledger, A3, A4, flip chart
Files to put paperwork in, various paper sizes
Leak test rigs (see leak test section)
Hose clips in appropriate and various sizes
Chapter 1 • Commissioning Phase One – Prepare
51
• Slip blinds or pancakes, number off per area, and size to be determined during
commissioning preparation
• Blanks or blind flanges
• Gaskets, for slip blinds and pancakes
• Poster tack, blue tack or drawing pins
• Signs! PLANT LIVE!, KEEP OUT, LEAK TEST
• Bags, various types for rubbish, bagging off the ends of wet or contaminated equipment
• Flash lights, battery and rechargeable and a number of sizes
• Live tape (wrap around pipe being put into service)
• Leak test bottles
• Leak test soap solution
• Sample bottles, equipment
• Rules, highlighters, note paper (for training)
• Printer paper.
List and Procure Commissioning Chemicals
It is very important that the decision of who will procure initial fill chemicals is determined by the engineering and potentially client project personnel. What actual process
and service chemicals that need procuring will then need to be established. The
commissioning manager must ensure that all chemicals he/she will procure have been
included within the commissioning budget estimate.
Initial fill chemicals to a new process unit will include:
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Lubrication (oils and greases)
Catalysts and other important process media
Water addition chemicals
Surfactants and anti-foam agents
Steam boiler treatment chemicals
Heat exchanger service fluids, including hot oil
Initial charge of refrigeration and chiller unit chemicals
Commissioning chemicals required for one-off or simulant use
Potential procurement of the final product for use in initial system pressurization and
vacuum break
Scrubbing and/or acid drying chemicals
Compressed air (cylinders, bottle banks and tanker deliveries)
Laboratory chemicals
Gases, including nitrogen, hydrogen and helium (cylinders, bottle banks and tanker
deliveries)
Filter media, including carbon filtration and desiccant dryer chemicals.
Suitable arrangements for all those chemicals which will fall under the jurisdiction of the
commissioning team to supply will need to be considered, the materials ordered and duly
52 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
scheduled to arrive on site in a timely manner prior to the required commissioning date.
Temporary storage of these chemicals also needs to be thought out if chemicals are of
a hazardous nature and/or if the area of use/storage is still regularly frequented by
construction personnel at the time of delivery.
During the procurement of all chemicals bought by the commissioning team,
consideration needs to be made along with the ongoing operations group, for the
establishment of ongoing contracts for the supply of the chemicals required by the
process as they are exhausted.
Once all initial fill chemicals have been established, the commissioning team will need
to integrate into the relative commissioning procedures to be drafted, how each chemical
will be introduced to the commissioning system. Any temporary equipment that will be
required to introduce the chemicals to the process will also need to be purchased along with
associated hardware, including hoses, special fittings, bolts and gaskets.
Key Points
• All commissioning assignment and consumable items must be correctly accounted for
in the project budget
• Determine and procure all commissioning consumables well in advance of their need
on the project
• Review commissioning team requirements for any foreign assignment, site location
set-up and day-to-day commissioning team consumables
• If the initial fill of chemicals is to be procured by the commissioning organization,
a complete check of what chemicals are required and the due delivery date must be
established.
Create Commissioning Documents and the System File
Addressing the subject of the commissioning of chemical plant, this section on the
creation of the specific documents and filing system thereof is of some significance. The
suite of commissioning documents produced provides the demonstration and security
that all has been done by the commissioning team to check and counter-check the constructed plant, being then able to deliver the project to design specification in the most
safe, effective and timely of manners, to the best possible standard, backed up by correct,
prudent and accurately composed documentation, completed and signed off in full.
Commissioning Documents
Once the commissioning team is in place and the commissioning systems identified, then
the commissioning manager will allocate to each commissioning system engineer the list
of those commissioning systems they are responsible to deliver. As a reminder from
a previous section, depending on the complexity of the process, the average system
Chapter 1 • Commissioning Phase One – Prepare
53
allocation to each system engineer would be four systems, the most assigned would be
seven systems. There must be some evaluation by the commissioning manager to allocate
commissioning systems adhering to the individual strengths of the members of his or her
team, therefore ensuring the quality required in the preparation of the documents
required for each system.
Utilizing the agreed filing system for the commissioning documentation, both on
paper and electronically, all documents are securely created and the team must become
regular in the practice of saving their documents to the security of the intranet or
company computer system. Soon many very important procedures will have been
produced and the overall productivity of the team cannot be compromised by documents
having to be re-written due to being lost into the ether from a local USB or flash drive.
As the plant installation progresses, mass documentation preparation starts to decline
and the commissioning engineers become ever more involved with field activities; this is
the point where system files in their entirety should be printed off to hard copies and filed
accordingly. As the execution pace of the commissioning activities gathers, from this
point all documents will be completed and signed off by hand, including editing the
documents as to how procedures were actually completed, as time is limited and electronic completion of documents will become increasingly hard to achieve. Some explanation of this statement is required. During the preparation phase, commissioning
procedures are produced with all the best intent based on documents available at the
time of document creation (this is why the most relevant revision of an engineering
document is so important to use whilst composing the procedures). The procedure must
go with the commissioning engineers to the field for execution of the activity. How the
commissioning actually was completed must be accurately documented on the procedure and all revisions clearly identified on the document, by hand. As such, a complete
and accurate record is maintained for each commissioning activity undertaken.
A previous section has detailed the amount of engineering documentation required by
the commissioning team but documents most commonly used in the preparation of
commissioning procedures are:
• P&IDs – How to isolate a process, de-isolate a process, allow safe and/or process
chemicals to be introduced into the process, use and management of instrumentation,
alarms, interlock, shut-down systems and control valves, routes for process flows,
information on vessel detail and specific mechanical interfaces, examples being
interlock systems, non-return valves and lockable valves
• Process Flow Diagrams (PFD) and Mass Balance Information – Information on process
flow, temperature, level, pressure, chemical characteristics and composition, plus the
normal quantities and location of the plant chemical inventory
• Process Engineering Descriptions – For basic fundamental description of how the
process is designed to work, start up and shut down in both a normal and emergency
manner. Details of irregular activity are included, an example being the conditioning of
a catalyst or purging sequence
54 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
•
•
•
•
Control Philosophy Documents – How the plant is designed to be controlled
Piping Line Tables – Design criteria of the pipework
Instrument Data Sheets – Instrument calibration data, ranges and alarm details
Interlock and Shut-down Descriptive – Details of how interlock systems are designed
to operate including emergency shut-down systems
• Vendor Installation, Operation and Maintenance Manuals – Equipment-specific
information related to unloading, transportation, start-up and shut-down of the
equipment
• Process Engineering Equipment List – Equipment-specific details including performance, design rating and specific unique information.
It is always prudent to stress the importance of the commissioning systems and their
priorities being shared with the construction group, as later in the process the handover
of these systems will be needed in the correct sequential order laid out in the systems list
to facilitate an effective and efficient start-up.
The detailed procedures and check sheets that will be generated to manage the
actual commissioning of the plant or equipment, through all its various stages,
including safe and hazardous chemical commissioning, will be reviewed in some
detail through the various sections of this manual, but in essence must reflect the
following:
• How the plant is pre-commissioned, columns and towers packed, reactors filled with
catalyst, filter media installed, mechanical interlocks checked
• Methods developed, procedures and tracking schemes for pipework cleaning written
• System leak testing procedures compiled
• Interlock and emergency shut-down system-testing procedures, no chemicals in the
plant (dry commissioning check)
• Control sequence test procedures, no chemicals in the plant (dry commissioning
check)
• How equipment is initially filled, vented and made ready for commissioning
• Initial commissioning (typically with safe chemicals)
• Interlock and emergency shut-down system testing procedures, safe chemicals in the
plant
• Control sequence test procedures (safe chemicals in the plant)
• Test procedures for the system from a loss of service, instrument air, cooling water,
nitrogen or power
• Process chemical commissioning procedures
• Shut-down in a controlled manner
• Shut-down from in an emergency scenario
• Interlock and emergency shut-down system-testing procedures, with process
chemicals
• Procedures to fully decontaminate full systems and major items of equipment.
Chapter 1 • Commissioning Phase One – Prepare
55
If a specialist piece of equipment is being installed, a full and complete understanding of
how that equipment is operated MUST be established, through investigation of vendor
documentation, verbal communication and site visits to ensure a procedure is created
which enables a safe and successful commissioning. Vendor attendance at the actual
commissioning of complicated equipment is advised, but a check must be made that the
cost of vendors actually attending commissioning activities is included both in the project
and commissioning team budget.
Along with detailed procedures, simple documents should be produced that check
such items as lockable valves, internal fitting of non-return valves, correct pipe fall
direction, rotation of motors, alignment and lubrication of plant items and mechanical
interlock systems.
All commissioning procedures should be produced well in advance of the proposed
commissioning and a validation process created to check the documents once
completed. The validation process of the procedures written will consist of:
1. Document created by the discipline commissioning engineer
2. Document checked by peer commissioning engineer from a different process system
3. Approval by commissioning manager.
Appendix 2 provides a commissioning document validation matrix, based on the hypothetical process systems set out in the table within the Prioritized Asset Systemization
section of this handbook.
The commissioning procedures, once written, should then be included in the detailed
commissioning schedule.
Consideration should be given to printing large (A3 or Ledger size) copies of selected
system-specific check sheets and posting on the commissioning office walls to aid
tracking the completion progress during the actual commissioning implementation
window. The lists that should be considered for wall mounting are:
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•
•
•
•
•
Pipe cleanliness check sheets
Instrumentation loop check sheets
Motor rotation check sheets
Relief valve check sheets
Lubrication check sheets
Alignment check sheets.
Once the sheet is fully completed and signed off, the check sheets must be taken down
and again returned to the master commissioning system file.
Control, electrical and instrumentation commissioning engineers should also draft
procedures which test alarms, interlock and hard-wired shut-down systems, electrical
components, motors, switch gear, and lighting.
Mechanical commissioning engineers will address and compile procedures to consider
cleanliness of pipe work, vessel and equipment check out and final closure of vessels, and
the initial commissioning of major items of equipment and their ancillary systems.
56 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
There are a significant number of checks carried out throughout the period from
mechanical completion to beneficial operation; these checks are the proof that everything possible has been completed to ensure the plant has the best opportunity for a safe
and successful start-up.
Preparation of target values – As the completion of procedure preparation draws to
a close, DCS screen pages can be printed off and marked up accordingly showing what
each instrument should indicate in a normal running scenario. These sheets will help the
commissioning and later operations personnel understand how a system is designed to
operate when obtaining flow sheet operational conditions. Target value sheets can
additionally be developed for other particular operations, for example regeneration of
a catalyst bed, or any other regular but non-operation-specific activity.
Further detailed information on commissioning procedures can be found in the
Commissioning and initial start-up plus procedures section within the Implement section
of this handbook.
The Commissioning System File
Tracking all the checks, tests and procedures for a commissioning system is a major
undertaking; the methodology explained in this handbook utilizes the creation of
a commissioning system file per commissioning system to successfully manage the
paperwork process, ensuring success in the delivery of any new asset. Without such
a structured approach, organization of all the checks required within a system would
become a logistical documentation nightmare!
For any size of project the typical contents of the file, given later in this section, should
be considered and those sections not required excluded. The contents of the system
file index will then be reviewed, revised and adjusted accordingly for each and every
process commissioning system created for the project. It is not common to create
a system file for DCS control and electrical systems; however, completed DCS and
electrical project documentation can be held within a section of the commissioning
system file if desired.
The commissioning manager will confirm the content of the general commissioning
system file with relevant client and project personnel approval. The commissioning team
will then compile the documents required within each individual system file, the
commissioning system engineer being responsible for the overall content and completion of his/her systems.
A table of contents from an example system file is provided in this section. The content
has explanation to the section and indication of which commissioning team member will
create the documents to be held within that section and who will then manage the
execution of the procedures and witness the checks in the field. If not available due to
illness or annual leave, a suitable deputizing organization must be compiled by the
commissioning manager to ensure no inefficiency is introduced to the project installation
phase due to absence of any member of the commissioning staff.
Chapter 1 • Commissioning Phase One – Prepare
57
In smaller projects the number of commissioning team members will be reduced and
not all the discipline roles may be filled, so the lead in system file preparation and
management of the activities associated with each potential section will be allocated to
the actual team to deliver the commissioning facet of the project irrespective of their
normal discipline, an example being all vessel and equipment check sheets will be
compiled and completed by the commissioning system engineer in the absence of
a mechanical engineer being on the team.
In simple terms the commissioning system file is the home for all commissioning
documentation created within the system; it is a live manual from initial writing until
close out of the project and it is the home of all the signed and completed commissioning
checks and procedures carried out for the project.
Descriptions and templates of how the paperwork could be reproduced and the detail
that should be included within the documents are given within relevant sections of this
handbook; gathered together, these documents make up the commissioning system file.
The HSE in the UK does give some guidance with regard to what should be included in
commissioning procedures. These guide words are given below:
• Commissioning Procedures document: A logical progression of steps necessary to
verify that installed plant is fully functional and fit for purpose. A general sequence of
steps in commissioning may typically include:
• System Configuration Check: The purpose of this activity is to trace all pipework and
connections to verify the system configuration, and to visually inspect items of
equipment to ensure that they are clean, empty and fit-for-purpose as appropriate
prior to undertaking water trials.
• Instrumentation System Check – Verification of Alarms and Trips: The purpose of this
activity is to ensure that all instrumentation, alarm settings, microprocessor signals
and hardwire trips pertaining to the installation are functional. This will also check that
signals from the field instrumentation are displayed locally and are being correctly
relayed to the computer interface rack, as well as to the computer system.
• Flushing and Cleaning of Lines and Vessels with Water: The purpose of this activity is
to clean all items of pipework and the vessels that make up the installation. This task
shall also ensure that there are no obstructions, blockages or any potential contaminants in any of the process lines or vessels that may have resulted from materials being
left inside the system from the construction phase. If chemicals incompatible with
water are to be used, it is important that the pipelines and equipment are thoroughly
dried prior to introduction of the chemicals. This is normally done by passing dry air
through the plant.
• Assessment of Ancillary Equipment: The main aim of this assessment is to verify the
performance of all ancillary equipment. This may include pumps, fans, heat
exchangers, condensers.
• Calibration of Vessels and Instrumentation: The purpose of this activity is to check the
calibration and performance of all vessels and instrumentation pertaining to the
58 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
installation. To a certain extent this will be carried out in conjunction with the system
pre-checks to ensure that the correct set points and alarm points have been established for use in the water trials.
• Start-Up Protocol: The purpose of this procedure is to provide guidance for bringing
the installation online, starting from an empty non-operational system.
An example commissioning system file table of contents is provided below. After each
heading a description provides the detail of what constitutes the documents contained
within that section. A full blank copy of the documents constituting the commissioning
system file is provided within the The Commissioning System File, a full catalogue of blank
commissioning documents section of this handbook.
Table of Contents
System P&IDs – Commissioning system engineer
Highlighted copy of all system P&IDs so a record is maintained of what actually
constituted the system.
Decontamination procedure and isolation register – Commissioning system engineer
Procedure that describes how all existing plant can be safely decontaminated and the
isolation strategy executed and managed, in the event of an existing asset being the
focus of the project.
Hand over Certificate Commissioning to Construction/Maintenance – Commissioning system engineer
If the commissioning team have been responsible for making ready a system or major
plant items within a system (per the decontamination and isolation procedure above)
this certificate must be completed to formally hand over the items to the construction
group, clearly detailing the standard of isolation and cleanliness achieved.
System cleaning procedures – Commissioning mechanical engineer
Procedures and check sheets to manage the cleaning of pipe work via various
methods, flushing, blowing (including steam blows), chemical cleaning, the use of
a pneumatic “pig” and mechanical cleaning.
HAZOP and actions – Commissioning system engineer
During the Hazard Study process a number of actions will have been assigned to the
commissioning team, a copy of all completed actions associated with a commissioning system is to be included in the system file.
Equipment Check Sheets, off- and on-site checks – Commissioning system engineer
in conjunction with the commissioning mechanical engineer
Each item of equipment will have a check sheet created that documents key factors of
the equipment that the commissioning team will check, including cleanliness, test
installation of vessel internals and suitability for transportation.
System Punch lists – Whole team led by the commissioning system engineer
All completed punch lists, preliminary and final drafts will be placed in this section of
the manual.
Chapter 1 • Commissioning Phase One – Prepare
59
Action upon Alarm Sheet – Commissioning system engineer and commissioning
C/E/I engineer
All copies per commissioning system of completed and signed off action upon alarm
sheets to be included in this section.
Instrument Check Sheet – Commissioning C/E/I engineer
All instrument loops when finally tested are marked as complete on this sheet by either
the commissioning system engineer or the C/E/I commissioning engineer, whoever
actually witnessed the final loop test. Highlighting loop completeness on a check sheet
as such gives clear indication of outstanding loops needing checking when chasing
the close out of a system.
NOTE: The actual loop testing document belongs to the construction group and will
reside in the overall project turnover package.
Motor Check Sheet – Commissioning C/E/I engineer
Each motor will undergo a number of tests. Formal paperwork detailing the various
tests will be created and managed by the construction organization; this check sheet,
as in the instrument check above, will capture when tests have been carried out and
importantly, at handover time, which tests still need to be completed and hence
chased to close out in the field.
Handover Certificate Construction/Maintenance to Commissioning – Commissioning system engineer
Formal handover certificate detailing status of a system upon construction
completeness; indicates responsibility that the day-to-day management of the system
now resides with the commissioning organization.
Project documentation check sheet prior to introduction of chemicals – Commissioning mechanical engineer
Certain plant items will require statutory paperwork to be completed before they can
be put into service; this document details those requirements and a sign-off box
indicates when the document has been obtained.
Hazard Study 4 – Commissioning manager leads review
In the suite of Hazard Studies created by ICI in the 1960s, Hazard Study 4 (or a company’s equivalent) is conducted to ensure all paperwork systems are in place prior to
energy being introduced into a system. Hazard Study 4 can be combined across
several systems if prudent to do so. The guide words and completed Hazard Study 4
report including signed off actions are to be inserted in this section.
Safe Chemical Commissioning Authorization – Commissioning system engineer
Introducing safe chemicals is a key stage-gate in the life of any project commissioning
phase; due care and attention must be given at this milestone and the correct
appreciation suitably documented via a check sheet; it is documented within the
system file here.
Pre-commissioning Procedures – Commissioning system engineer
All completed pre-commissioning procedures, a proportion of which can be
completed during the construction phase, are filed here.
60 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Leak Test Checklist and Procedures – Commissioning system engineer
Post construction activities, the system will have been broken into sections and
checked for mechanical integrity which will include a leak test. However, certain key
flanges will have remained untested for various reasons and as such a complete system
leak test needs to be conducted. The pre-leak test check sheet and associated procedures are documented here.
Interlock Check Procedures – Commissioning system engineer in conjunction with
the commissioning C/E/I engineer
Procedures to facilitate a full pre-introduction of chemicals test on all control system
interlocks are compiled here. If certain elements of the interlock system cannot be
operated in a “dry” condition (no process or safe chemicals are present in the system),
an example being a pump that cannot be run dry, then the control system software
engineer should consider simulation of the motor operation to fully check out the
performance of the interlock being checked. The test procedure must clearly highlight
and explain such occurrences.
Emergency Shut-Down System Check procedures – Commissioning system engineer
in conjunction with the commissioning C/E/I engineer
Emergency shut-down system can differ from software interlock systems included
within the control system hard wired completely independent of the control system.
A full “dry” test of each and every emergency shut-down trip within the system should
be undertaken prior to introduction of safe or process chemicals.
DCS sequence test procedures – Commissioning system engineer in conjunction with
the commissioning C/E/I engineer
Certain aspects of any chemical process may be considered suitable for the control to
be directly manipulated by the DCS system. These control mechanisms are typically
referred to as “sequences”; however, some proprietary control system manufacturers
may have a different trade name.
As with interlock and emergency shut-down tests, any control sequence must be
tested prior to introduction of safe chemicals, then again with safe chemicals to ensure
a suitable degree of confidence has been gathered prior to the sequence being actually
put in operation, that the control functionality is correct.
The sequence may have equipment integrated within it that cannot be operated “dry”,
therefore the DCS software engineer should simulate the operation of such equipment
as and when demanded by the control sequence and documented as such in the
sequence test procedure.
Dry and safe chemical sequence checks should be compiled here and also process
chemical sequence tests if it is determined they are required.
Relief Stream Check Sheets – Commissioning mechanical engineer
Inspection and witness of the installation of process relief devices must be coordinated by the commissioning mechanical engineer incorporating company statutory
requirements as required. This check sheet must clearly demonstrate relief devise
installation completeness within a system.
Chapter 1 • Commissioning Phase One – Prepare
61
Critical Insulation Check Sheet – Commissioning mechanical engineer
Post handover from construction, some handover reservation items could include the
completion of insulation. In certain applications, the complete installation of insulation should not hinder the progression of initial commissioning activities, for
example leak testing. However, where very hot surfaces can be generated later during
the commissioning activities, the list generated here must be completed and insulation fully installed prior to heating operations commencing.
Critical Gasket Installation Checks – Commissioning mechanical engineer
During the document preparation phase, certain key flanges and their associated
gaskets will have been identified that are of significant importance, due to the
inability to sufficiently isolate the flange in the event of a leak, that the installation
of the gasket must be witnessed by a designated engineer as a mitigation step to
avoid a loss of containment. The check sheet will document those gaskets chosen
and include appropriate sign-off boxes. An example of this type of gasket would be
the first flange to first isolation valve at the bottom of a high hazard material storage
tank.
Lubrication Check Sheet – Commissioning mechanical engineer
Each item of equipment that requires greasing or lubrication, including potentially
who will provide the lubricant, will be documented here on this check sheet.
Motor Alignment, (Hot and Cold) Check Sheets – Commissioning mechanical
engineer
All motors that require alignment to the drive mechanism, both cold then hot post an
agreed initial run-in period, will have a check sheet created and suitably completed, in
this section of the system file to track progress.
Hazard Study 5 – Commissioning manager leads review
In addition to the Hazard Studies already completed to date on the project, Hazard
Study 5 (or a company’s equivalent) is conducted to ensure that, prior to the
introduction of process chemicals, the asset is ready for ongoing operation. The
Hazard Study 5 process will incorporate the appraisal of guide words in conjunction
with a site tour of the system being studied. As with Hazard Study 4, several systems
may be combined into one study if prudent to do so. The guide words and
completed Hazard Study 5 report including signed off actions are to be inserted in
this section.
Pre Start-Up Safety Review (PSSR) and/or Introduction of Process Chemicals,
Check Sheet and Certificate – Commissioning system engineer
As with the introduction of safe chemicals, hazardous chemical introduction is a major
milestone in the development of a project and all due care must be taken to correctly
appraise the system prior to introducing process media. Depending on the organization owning the new asset, the approach to the introduction of chemicals will be
slightly different; however, the guide questions will be of the same type. The chosen
management method for process chemical introduction will be documented in this
section of the system file.
62 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Commissioning Procedures – Commissioning system engineer
All procedures based on the information provided in this section are placed in this
section of the system file.
Standard Operating Procedures – Commissioning system engineer
If the commissioning team are responsible for the production of Operating Procedures, final copies, updated to “as commissioned” status, are placed in the completed
commissioning system file.
Training Package – Commissioning system engineer
All training packages that are produced for the commissioning system in question,
post update to “as commissioned” status, must be placed for completeness in the
system file.
Commissioning to Plant Handover Certificate – Full commissioning team
At the point when all commissioning procedures, tests and check sheets have been
completed, operating procedures and training packs updated to reflect initial operational experiences and all documentation has been signed off, then the handover
certificate and accompanying associated documents are collated into a commissioning team to operations team handover package with certificate, and the care and
custody of the system transfers to the operations team.
Create Commissioning Documents and the System File – “Things That
Can go Wrong”
As suggested earlier in this handbook, one of the fundamental principles that underpins
a successful commissioning effort is the degree of checking and counter-checking that is
developed, documented and dutifully signed off during the installation and initial startup of a new asset. The basis for this level of detail and commitment in preparing this
documentation is so the commissioning group, if unfortunately things do go wrong, can
clearly demonstrate through the detail of their preparation and tracking processes used
during the execution of all the tests, check sheets and procedures in any commissioning
system file, that every possible action has been taken and checks duly performed to
deliver the equipment to the highest standard and to the full process design intent.
Those individuals who have delivered the commissioning facet of a project before will
also know that there is an element of frustration in the detailed preparation of
commissioning documents; this statement is worthy of some further explanation.
A project had been duly delivered to the client, the commissioning documentation had
been well thought through, was precise and the implementation had gone very well. The
plant started up and the commissioning organization duly disbanded with a formal handover of completed documentation, including the full suite of commissioning system files.
Some significant months later the commissioning manager returned to the same
client to assist in the delivery of a new project and was given the existing office to establish
the commissioning base. The commissioning system files from the original project were
found in exactly the same location left by the first commissioning team; it was apparent
no-one had utilized the files in the intervening time.
Chapter 1 • Commissioning Phase One – Prepare
63
This is not uncommon based on the fact that a well-planned and documented
commissioning preparation, backed up by excellent delivery in the field, will inevitably
lead to commissioning documents thereafter seldom being used; in fact this very action is
indication of a good job well done by the commissioning team.
However, a word of warning here! Never allow the standards of the preparation and
delivery of commissioning to be compromised by the potential that the documents
produced will never thereafter be used; excellently prepared and executed procedures are
key to the successful delivery of a project and must be diligently prepared for any
commissioning effort, for any size of project.
A project had a system installed that incorporated an electrically powered heat
exchanger, to warm air prior to the use of the air in a mill. During the pre-commissioning
phase all instrument loops, alarms, electrical tests, interlock and control system tests
were conducted and duly signed off on the appropriate construction and commissioning
documentation. Post initial start-up during the early operational period, the exchanger
was found to have overheated to the point where the insulation has started to smoke,
although there was no evidence of fire. The system was shut down in a controlled manner
and an investigation was conducted to the root cause. An internal high-temperature cutoff device was found to have failed and the investigation team requested all test paperwork be provided to confirm all possible tests had been carried out. As the documentation
was available and completed in full, the cause was deemed to be a failure post
commissioning; had the completed test documentation not been available and no
evidence found that confirmed tests had been done, the commissioning team would have
had some difficult explaining to do to justify their actions.
Key Points
• Suitably allocate systems to the commissioning system engineers and establish
a secure electronic file location for the documents created. Print off the system files
prior to implementation of the procedures in the field
• As implementation activities are conducted, the paper copies of the procedures are
edited by hand to reflect the actual actions taken per each procedure
• Commissioning procedures must address all potential scenarios within the operation
of a total system and key items of equipment contained within
• Incorporate specialist equipment vendor information within the procedures produced
• The commissioning system file is the home for all commissioning documentation
created within the system and provides an orderly management structure for all
procedures and check sheets created.
Control, Instrument, Electrical Commissioning
Document Preparation
As discussed in the previous section, all members of the commissioning team will make
a documentary contribution to the commissioning system file. This section will appraise
64 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
the documents that the control, instrument, electrical commissioning engineer will
ensure gets produced. Depending on the components and complexity of the system there
may be omissions from these lists, but the basis for the detail held within the C/E/I
checkout and test procedures will consider the following main criteria:
• Main electrical installation, switchgear, transformers, Motor Control Centers (MCC)
and power cables
• Lighting
• Control systems, (Distributed Control Systems – DCS, and or Programmable Logic
Controllers – PLC)
• Various instrument and electrical cabling
• Instrument calibration and instrument range consistency
• Existing equipment sanity check
• Loop test paperwork development, checking and testing including Alarm tests
• Motor checking and testing
• Software Interlock and Emergency Shut-down testing, both “dry” and “wet”
• DCS/PLC sequence checking and testing, both “dry” and “wet”
• Emergency, hard-wired checking and testing, both “dry” and “wet”
• Specialist vendor installation
• Air conditioning (HVAC) for various rooms and cabinets
• Training to the requirements of all project groups including fellow commissioning
team members, operations personnel and maintenance teams.
The C/I/E commissioning engineer should organize the documents to be created such
that they are consistent (where practicable) with the other members of the commissioning team and the chosen paperwork format. The documentation should be stored in
hard and electronic format in the same system file.
The C/I/E commissioning engineer should also make a check of all engineering
documentation including the instrument index and instrument data sheets to ensure
consistency with P&IDs, specific equipment and control system calibration and ranges.
Relevant points for the key criteria are:
Main Electrical Installation, Switchgear, Transformers, Motor Control Centers (MCC)
and Power Cables
The commissioning C/I/E engineer will need to address what specialist vendors will be
required and then organized in conjunction with the construction and project teams to
deliver most aspects of this group of activities. Suitable documentation should be created
to confirm all installation and checkout is correct and ready for ongoing commissioning. It
would be common to co-ordinate most of the installation in this group of services with
senior engineering personnel within the site of plant organization. Strict adherence to
permit regulations must be built into all work practices for this group of subjects. Attendance at all factory acceptance tests by the commissioning engineer should be encouraged.
Chapter 1 • Commissioning Phase One – Prepare
65
Lighting
The C/E/I commissioning engineer must champion the cause for lighting installation and
prompt illumination to be as high on the installation priority list as is reasonably practicable. It is unfortunately common for lighting to be one of the latter systems delivered
by construction teams, which is not a good or safe consideration, for commissioning in
the dark or via a “daisy chain” of temporary lights with all the hazards associated,
especially miles of cabling, is not a safe practice.
Liaise with the system commissioning engineers to ensure that the lighting installation
is considered to be in the correct location and co-ordinate a lighting survey in the hours of
darkness post commissioning of the lights to ensure suitability. Manage the change
procedure through to new installation of any additional lights required.
Ensure suitable checkout documentation is created and signed off for all light
installation.
Control Systems (DCS and/or PLC)
The C/I/E commissioning engineer should become extremely familiar with the control
system, usually to the extent that they attend a training course such that basic configuration of the control system can be readily conducted by the individual (examples being
changing instrument tag names and relocation of data on a graphic page). It is advisable
that the C/E/I commissioning engineer is also able to tune and troubleshoot control
loops. In the event that during the fine tuning of control loops a control parameter,
interlock trip setting or alarm activation point requires reconfiguration, the final setting
must be set via the standard use of the site or project change control procedure.
The individual responsible for C/E/I commissioning should be very familiar and
indeed should have contributed to the contents of the control system User Requirement
Specification (URS) and he/she will be part of the team to sign off on the Functional
Design Specification (FDS).
Close co-ordination with the rest of the team commissioning engineers should be
undertaken so that all of the group have input to the graphic page design, set-up of trend
and special activity pages (examples being specific start-up page and clean-out operations), such that they can be suitably incorporated into the system design.
Where possible the C/I/E commissioning engineer should have input to the design
and layout of all DCS/PLC wiring marshalling panels to ensure that a correct and sensible
layout, including access for wiring adjustment of the termination blocks, is designed and
built into the cabinets. Attendance at the hardware factory acceptance test should be
encouraged. Clear and precise cabinet layout drawings should be reviewed and accepted
by the commissioning engineer post engineering design and the engineer must then
ensure the completed termination drawings are clearly displayed within the completed
marshalling cabinets.
DCS/PLC software acceptance tests (SFAT) should be attended by the commissioning
engineer who, with the equipment vendor, should create clear and detailed check sheets
66 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
so all tests conducted at the SFAT are documented. A control system log and punchlist of
all system faults should now be started; this should be carried forward to the site
installation and thereafter continually managed by the C/I/E engineer, so all who operate
the system can document issues with the operating environment, which will then be
resolved by the software engineers. This fault log should be maintained until handover to
the final operations group.
A worked example is given in Fig. 8 of a simple control system fault log utilized on an
actual project. A blank control system log sheet can be found in Appendix 3.
The C/I/E engineer must be party to the witnessing of all unpacking of delivered
hardware to the site to ensure the system has received no damage during the delivery
process.
Site Acceptance Tests (SAT) will be attended to by the commissioning C/E/I engineer and all agreed test procedures witnessed and signed off by the individual. Of
particular importance during the SAT is the organization of the initial power-up of the
hardware, as this activity is typically carried out by different engineers to the software
specialists and to avoid inefficiency during the site acceptance program, the commissioning C/E/I engineer must ensure the correct coordination of all parties to the initial
system start-up.
The C/E/I commissioning engineer must also ensure an interlock defeat management
system is instigated, that clearly gives indication of what interlock system has been
defeated, why, and which senior manager has given authority to the interlock being overridden.
A similar system must also be put in place to manage the adjustment and silencing of
alarm set points during the commissioning window. It is common for authority to silence
alarms to be at commissioning manager level, due to the importance of the operating
system; this authority may be duly designated to the commissioning system engineer.
Various Instrument and Electrical Cabling
The main consideration in this area is to ensure that all labeling and signage for the
electrical and instrument cables and wiring conforms to the standards required of the
operational site. Therefore a sound understanding of the various plant cable identification standards is essential.
This includes:
•
•
•
•
•
•
Labeling of junction boxes
Motor cables
Field instrument device cables
Motor control centers and switch gear
Control panel marshalling cabinets
It is also important that an understanding and subsequent instigation of any temporary portable equipment cable inspection standard is incorporated and managed for
the duration of the commissioning team’s activities.
Chapter 1 • Commissioning Phase One – Prepare
67
Instrument Calibration and Instrument Range Consistency
A plan for all instrument calibration should be devised in conjunction with the
construction installation group by the C/E/I commissioning engineer and documented
accordingly. The individual should make a sanity check between field device and
control system to ensure all instrument ranges and standard units are consistent. Use
of the instrument data sheets is vital to this activity. During the consistency check
special attention must be given to complicated control systems, such as variable speed
drives (VSD), as these items need to be correctly set-up both within the individual
motor control cabinet but also within the corresponding loop within the control
system.
FIG. 8
68 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
FIG. 8—Cont'd
Existing Equipment Sanity Check
On a project where a new control system is being installed to replace an existing system,
or modifications to an original system need to take place, it is highly advisable to ensure
all loops on the existing system operate fully and normally. Any loops that are found
within the sanity check to not fully function will need to have rectification work conducted prior to the project work commencing, to avoid a slowing down of the check-out
Chapter 1 • Commissioning Phase One – Prepare
69
process within the new system, due to troubleshooting of existing system loop problems.
There is a cost implication to the correction of existing equipment malfunction, so it is
most important that the operational sanity check of all loops to be handed over to the
commissioning team for inclusion of the new control scheme is undertaken before
handover.
Loop Test Paperwork Development, Checking and Testing
This typically is the most important activity the C/E/I commissioning engineer will
become involved with and certainly one which can create the most confusion and
organizational issues for the team. From the outset of their involvement on the project
the C/E/I commissioning engineer will need to assist in devising and creating (along
with the installation engineering company and potentially the construction group) a loop
test sheet that incorporates all testing and checkout a loop will require.
An excellent format to follow would be to have the loop diagram on one side of the
loop check sheet with all the relevant test and check sheet data on the reverse. It is
important to note that all loop testing should be organized to coincide with the priority
delivery of the various commissioning systems as per the systems list mentioned in
a previous section. A worked example of a loop test sheet is provided in Fig. 9; a blank
form can be found in Appendix 4.
There are many subtle stages to loop testing but the final test, from field device to
DCS/PLC operator work station, is the most important one and the activity that MUST be
witnessed by the C/I/E engineer.
The scope of a typical loop test is shown in Fig. 10.
A loop testing team will be established. Each team will consist of a mimimum of the
following personnel, each from diferent departments of the instrument project team:
•
•
•
•
The instrument installation technician
Commissioning C/E/I engineer
Control system specialist
Potentially client technicians or a further instrument installation technician.
During the actual loop test the team will typically position themselves in the following
locations:
•
•
•
•
Instrument technician at the field device
Control engineer at the DCS/PLC operator workstation
Installation technician to troubleshoot problems found, normally at the field location
All graphic pages, alarm and interlock functionality and sequence control logic should
be tested
• Operations personnel and/or commissioning systems engineer witnessing the test.
The make-up of this team is such that it can diagnose any part of the loop should an issue
become evident during the actual test. Post the test, the loop test sheet is signed off by the
commissioning engineer and if required operations and/or client personnel.
70 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
FIG. 9
If the loop testing schedule has potential to impact on the normal operation of an asset
(much radio communication causing a distraction to the operations staff) during the
commissioning of a new section of an existing plant, the loop test activities at the
Chapter 1 • Commissioning Phase One – Prepare
71
FIG. 10
operator workstation may be conducted in a temporary area such as a motor control
center room, or an engineering station, remote from the main control room, equipped
with a temporary operator interface. Consideration must be given to this important point
during the planning of the loop test program.
It is important to stress that the loop test is a construction group activity and hence the
commissioning team are only party to it, not the directors. However, ensuring instrument
loops operate effectively and to design intent at the actual time of commissioning the
system, it is imperative that the loop works and time is not lost rectifying problems during
valuable process commissioning time. The best insurance that efficient loop testing is
conducted is to have a commissioning team member embedded on the loop testing team.
It is common for several teams to be established to simultaneously test instrument
loops; if this is so, the commissioning team must be flexible enough to attend to all
eventualities and support the tests, hence not negatively affecting the schedule.
Construction groups will often set up two teams to test loops, keeping a third team in
reserve as a rectification squad for troublesome loops, allowing the initial two teams to
keep moving forward with the test schedule. This type of set-up is dependent on the
project and/or system size. Issues found during the loop test and duly rectified will be
documented on the loop test sheet.
In conjunction with the loop test the commissioning engineer should devise test
procedures to check all alarms, interlocks and shut-down systems and liaise with the
ongoing operations and maintenance personnel which loops, interlocks and emergency
shut-down systems will need regular testing and sign-off post commissioning and then
guide and/or assist with the development of the ongoing statutory interlock or emergency
shut-down system test procedures.
Consideration should be made of how alarms are to be tested as ‘injecting’ false
signals to the field device should be a last resort to the test procedure. An example for the
testing of a temperature alarm at 10 C could be via immersing the element into iced
72 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
water. Other similar methods should be considered and implemented where valid and
applicable and suitably addressed for safety aspects.
Close communication will need to be maintained between the various system
commissioning engineers and the commissioning manager so an updated list is generated and completed regularly, showing what instruments have and have not been loop
tested within a system. These lists of all instruments within a system should be clearly
displayed within the commissioning office so all can evaluate what needs to be
concentrated on and which need attension to close within a commissioning system. Post
completion of all loop tests within a system, the completed and signed off list will be
removed from the wall and placed in the appropriate section of the system file.
FIG. 11
Chapter 1 • Commissioning Phase One – Prepare
73
A worked example of an instrument check sheet is given in Fig. 11. A blank copy
appears in the The Commissioning System File, a full catalogue of blank commissioning
documents section of this handbook.
Motor Checking and Testing
A test of each motor is required, usually with the motor uncoupled from the drive
mechanism. It is important to test that all stop/start activation points are checked and
that the motor rotates in the correct direction.
The C/I/E commissioning engineer should witness all tests and be aware of all other
interested parties wishing to witness the check, especially client personnel.
A worked example of a motor test check sheet is shown in Fig. 12, again these check
sheets should be highly visible in the commissioning office, to enable a quick and easy
status check to be made of the motor test completion campain.
Software Interlock and Emergency Shut-Down Testing, Both “Dry”
and “Wet”
Test procedures for all software interlocks and emergency shut-down systems will need
to be written and completed in the field for every appropriate application on the project.
FIG. 12
74 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Consideration should be given to the test methods and activation of all trip indicators and
the test procedure written up accordingly.
System interlock and emergency shut-down test procedures fall under the responsibility of the commissioning team and sufficient resources to assist in troubleshooting of
any issues found in the test must be considered and intergrated into the team during this
time. This will include software engineers, instrument and electrical technicians, and
proprietory vendor commissioning personnel.
Procedures will be written to test the interlock and emergency shut-down systems
in a “dry” environment, no chemicals present, and then again in a safe “wet” chemical
condition (with typically water in the system). In the dry test scenario, considerations
must be made to ensure no damage is done to specific equipment (e.g a pump that
cannot be ran dry), to either uncouple the drive of the item, or to simulate operation
in the control system, the software engineer being able to witness the appropriate
signal coming in from the field. A complete “wet” test conducted typically with water
during the appropriate stage of the commissioning process gives full indication,
prior to introducing hazardous chemicals, of the full functionality of the protection
system.
DCS/PLC Sequence Checking and Testing
Should the unit be controlled via any DCS or PLC logic, full tests should be written that
check each stage of the sequence and more importantly that the sequence will default to
a safe position in a fault situation (its HOLD status). Full failure monitoring (every
potential to stop the sequence) and the complete testing thereof should be written into
the sequence test procedures.
The sequence test procedures could be written with the co-ordination and
involvement of the appropriate system commissioning engineer. Each sequence should
be tested in a safe senario where no chemicals are present (dry commissioning) and
then again when safe chemical procedures (wet commissioning) are being conducted.
This is a very relevant point, as these tests are time-consuming and sufficent time
should be allocated within the commissioning and master project schedule for these
activities. As in the interlock test scenarios, where equipment, due to the potential
of damage, cannot be ran, the software engineer should simulate unit operations to
test the sequence as far as can be practicable and documented accordingly in the
procedure.
A worked example of an interlock test procedure and an uncompleted DCS sequence
test procedure are provided in Fig. 13; all blank forms will be in the system file section of
this handbook.
Specialist Vendor Installation
Where specialist proprietary equipment is being installed, the C/I/E commissioning
engineer will need to become familiar with the proposed installation and commissioning
Chapter 1 • Commissioning Phase One – Prepare
75
FIG. 13
such that plans and check documentation can be written to safely and efficiently manage
the process.
Training
Where specialized equipment is being commissioned, organization of training for pertinent commissioning team, maintenance and operations personnel should be arranged in
co-ordination with the commissioning system engineers.
76 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
DCS sequence test procedure
TITLE: The dry sequence operational test of the Milling Feed System
Ref: MF-1
sequence.
Project: The New Mill Project
System: MF – Mill Feed System
Line & Vessel numbers: All equipment in the Mill
P&ID’s covered: 123-2001, 2002
Feed System
Author: M Killcross
Date: June 2005
Page 1 of 3
PLEASE NOTE: Prior to completing this procedure a check with all Vendors, Construction and
Operations team MUST BE MADE to ensure that the equipment can be safely test run. Check with all
Electrical, Instrument and Mechanical discipline leads also.
Electrically LOCK-OUT all equipment that cannot be run in conjunction with this procedure and be
prepared to forward the sequence when a motor cannot be started.
Ensure all alarms, shut-down systems and warning lights are all operational (please consult with the
commissioning E/C/I engineer).
STEP
ACTION
METHOD
1
Setting of all Starts
to AUTO
Go to the Mill graphic page on the
DCS and select AUTO on the
following drives
Electrically LOCK-OUT
all equipment that
cannot be run.
1. Select C-2106.
Switch to AUTO.
2. Select C-2012.
Switch to AUTO
3. Select C-2109.
Switch to AUTO
4. Select F-2203.
Switch to AUTO
5. Select C-2201.
Switch to AUTO
F-2602 (the Cooling
Fans) are in another
system, ensure if they
cannot be ran they are
electrically isolated.
2
Confirm all
interlocks are clear
I-21 – The Vent System Interlocks
are not inhibited and are all
HEALTHY
3
Confirm all
instrument trips are
clear and operation
can start
Confirm all instruments are in
normal state with no alarms on the
DCS.
4
START sequence
Attend and reset any alarm which is
activated and should not be
(confirm with commissioning
Instrument Engineer).
Please ensure no personnel are
in the area for this test run
SEQUENCE START, MF-1
FIG. 14
Comments
These items of
equipment may not be
able to start within the
scope of this system –
Please clarify the
position with the Mill
System Engineer
Confirm with Vendors all
equipment in this
sequence can be test run
“Dry” (no product load)
DO NOT START without
Signed
Date
Chapter 1 • Commissioning Phase One – Prepare
Go to the Mill Feed Control Screen
on the DCS and locate sequence
Start Push Button, HS-2100
Vendor permission
Open the button HS-2100, double
click to START
Sequence then (please confirm)1 – T-2202 is NOT high level –
LAH-2201 NOT high
2 - T-2606 is NOT low level – LAL2104 NOT low
3 – Feed Conveyer, C-2109
STARTS
4 – LT-2901 OK
5 – Cooling Water Pump
P-2602
STARTS
In another system, confirm
good start signal
6 – Cooling Water Fan
F-2602
STARTS
7 – Feed Screw
C-2201
STARTS
4
(cont)
START sequence
8 - Feed Cooling Fan
F-2203
STARTS
When all alarms confirmed good
5
Test run
6
STOP sequence
9 – Cooler Conveyer
C-2106
STARTS
Consult with Vendor, Operations
and Construction discipline
Engineers and agree test run
duration
SEQUENCE START, MF-1
Go to the Mill Feed Control Screen
on the DCS and locate sequence
Stop Push Button, HS-2200
Open the button HS-2200, double
click to STOP
Sequence confirms:1 – The Mill Feed sequence
STOPPED
FIG. 14—Cont'd
NOTE – All timers may
need adjustment during
commissioning
77
78 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
2 – Feed Conveyer C-2109 is
STOPPED
Allow the timer to elapse
Timer duration TBC…
3 – C-2106 the Cooler Conveyer
STOPS
HS-0102 timer to elapse
Timer duration TBC…
8 – Feed Cooling Fan
F-2203
STOPS
4 – F-2602 then
STOPS
5 – P-2602
STOPS
6 – C-2109 the Feed Conveyer
STOPS
7
8
9
Timer to elapse
Timer duration TBC…
Failure monitoring:
The Mill Feed sequence should not
start if all motors are not in AUTO
Confirm no START
with at least 1 motor state.
not in AUTO
With the sequence in OFF mode,
go to the DCS page and select
AUTO for all motors except
P-2602
Attempt START
START sequence
sequence
Confirm sequence will not start due
to P-2602 not being in AUTO mode
Confirm action of
motors upon a
failure
Continue to retest START with all
other subsequent motors selectively
NOT in AUTO
Re-start the sequence and then
STOP a selective motor
Record what happens to the
sequence
Assumes that sequence
will stop all downstream
motors, upstream
motors to stay running
Restart sequence and confirm
motor restart is as per design. All
stopped motors restart in order
Record findings
Continue with this step until all
motor stops have been tested
Procedure to test of start, stop and failure monitoring of the MF-1 sequence has been completed.
Signed:
Date:
FIG. 14—Cont'd
Chapter 1 • Commissioning Phase One – Prepare
79
Control, Instrument, Electrical Commissioning Document Preparation –
“Things That Can Go Wrong”
Things that can go wrong during this phase of the commissioning element of
a project manifest most significantly during the implementation and actual testing
phase.
During a significant project comprised of many systems, a decision was taken not to
witness any final loop tests; the commissioning team were not charged to prepare
instrument loop test sheets or procedures to ensure loops were working correctly prior
to the handover of the systems from the construction group to the commissioning
team. Post handover and leak testing, at the point of actual execution of safe chemical
commissioning procedures, many loops were found to not operate fully, alarms did not
latch correctly, control valves did not operate when requested and much time was lost
in rectification of instrument loop issues that should and could have been identified
prior to the handover from construction to commissioning.
Another large project took the decision to track all loop testing on an electronic
spreadsheet rather than on pre-prepared loop sheets, an overall check sheet (as identified earlier in this section) thereafter being hung on the commissioning office wall.
Although appearing to be rather antiquated, utilizing the actual completion of visible
sheets is a much more effective method in managing loop testing progression within
a system. The spreadsheet method caused significant issues at the point of handover
from construction to commissioning as testing activities had become so hectic many
completed loop tests had not been entered onto the spreadsheet and much re-testing
had to be done to ensure the test was actually completed prior to the handover to the
commissioning team.
Both examples indicate the issues that can arise if suitable organization and methodology is not put into the preparation of an adequate control, instrument and electrical
preparation phase; more examples of things that can go wrong with loop testing will be
discussed later in this handbook.
Key Points
• The C/E/I commissioning engineer will be very familiar with and involved in the
development of the instrument loop testing scheme, schedule to witness all final loop
tests, field instrument to operator workstation
• Develop suitable paperwork to document and schedule the witness of all motor checks
• Develop, with system commissioning engineer, procedures to test interlocks, emergency shut-down systems and control system software control sequences
• The C/E/I commissioning engineer will also set up sanity checks to ensure existing
equipment to be utilized in a newly commissioned facility is fully operational prior to
handover to the project team
• Ensure that all labeling of cables, panels and junction boxes is adequate and meets all
specification.
80 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Mechanical Commissioning Document Preparation
The mechanical commissioning engineer will formulate documentation systems to be
performed on the following list of activities. Please be aware if a mechanical commissioning engineer is not appointed to the team, these same actions will need to be
addressed by the commissioning system engineers as the activities will still need to be
incorporated into the total commissioning effort:
•
•
•
•
•
•
•
•
Isometric drawing to P&ID sanity check
Pipeline cleanliness checks and procedures
Construction and installation checks
Vessel and equipment checks (off and on site)
Mechanical documentation check
Vendor and proprietary equipment check-out
Lubrication
Training.
Suitable check sheets and procedures will need to be created and later completed during
the implementation phase to capture the activities and progress of these steps.
Isometric Drawing to P&ID Sanity Check
It is not uncommon post the production of the piping isometric drawings for the drawings to not fully comply and match the configuration of pipeline items and equipment as
set out on the P&ID. A check therefore should be made of each isometric to its corresponding location on the P&IDs to ensure consistency. All differences must be resolved
with the process engineering and piping group, with the isometric and/or P&ID being
updated accordingly. This early documentation check will help resolve potential
punchlist issues later in the construction phase when plant gets installed and is not
consistent with the layout on the P&ID, which is always the document the commissioning
group will use as their template for how the process must be constructed.
Pipeline Cleanliness Checks and Procedures
The P&ID will need to be studied along with the line table and a list of all pipelines within
a commissioning system created detailing the type of cleanliness method used and
incorporating a sign-off box. This will facilitate tracking and progress of all pipelines to be
cleaned. Full detail on cleaning pipelines and the various types of cleaning techniques
that can be used will be discussed in a later section of this handbook.
The mechanical commissioning engineer should become familiar with the type of
cleanliness procedure required for each pipeline (flush, blow, pig or mechanical) and if
required and applicable write clearly defined cleaning procedures to safely manage the
actual cleaning process. In most applications the procedure on how to actually clean
a pipeline post an integrity test will be written by the construction group but the
Chapter 1 • Commissioning Phase One – Prepare
81
commissioning team should be prepared to document cleanliness methods when and if
required. Cleanliness procedures will be written with the collaboration of the commissioning system engineer responsible for the system in question. The elements that must
be included within a cleanliness test procedure are:
• Where inter-system isolation is positioned and what type of isolation is required
(blinds or removal of spools), clearly identified on the relevant P&IDs
• What type of cleaning medium should be used, air, water, steam or use of a pneumatic
pig
• The point of energy input and how the energy will be introduced
• The point of energy discharge and the type of valve used, including a vent pipe to a safe
location if required
• Protection requirements for personnel and other equipment
• Clearly defined list of what equipment will need to be removed, restrictor orifice plates,
control valves, instrumentation, filters and delicate valves including non-return or
check valves
• Full reinstatement schedule of when all in-line items have been refitted
• Full description and step-by-step guide to the actual cleaning procedure.
Cleanliness procedures are written utilizing not only the relevant system P&IDs but also
the isometric drawings as these will give key information, an example being elevation, to
ensure in the instance of flushing with water, the flush of construction and installation
debris is always from the top of a system down and out of the low point. The same
philosophy is also true of a pneumatic blowing and must be incorporated where possible
in that application also.
Where possible the cleaning procedure will need to take place post the construction
integrity test procedure, so the mechanical commissioning engineer will need to work
closely with the mechanical installation group to ensure the cleaning procedures are
incorporated within the integrity test packages. This activity will save a significant
amount of time in the overall project schedule.
The installation group must be made aware of the requirements that the mechanical
commissioning engineer has appertaining to the procedures he/she must witness
throughout all the cleaning process and these witness points must be incorporated within
the construction test packages.
A completed worked example of an actual Pipeline Cleanliness Check Sheet is
provided in Fig. 15; within the Cleaning procedures and drying section of this handbook
can be found actual worked copies of cleaning procedures. A blank document can be
found in the system file section of this handbook.
It is always advisable to post on the walls of the commissioning office copies of the
pipeline check sheets so a status can be visibly made, when diligently completed, of
what outstanding pipelines need to be tested and cleaned to close out the pipe cleanliness function, thus contributing to overall system handover from the construction
team.
82 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
FIG. 15
Chapter 1 • Commissioning Phase One – Prepare
83
Construction and Installation Checks
The mechanical commissioning engineer will initiate, from a suitably relevant point in
the construction phase, a daily walk-around of the systems of interest. The engineer will
identify and initiate via reporting to the construction manager rectification of any errors
in the installation. Points that will present issues of inconsistency and requiring correction are:
•
•
•
•
•
•
•
•
•
•
•
•
Correct installation, orientation leveling and grouting of vessels
Use of correct gaskets and incorrect installation thereof
Installation of correct valve types
Orientation of valve types, have pinch points or tripping hazards been introduced?
Potential pipe clashes
Introduction of required piping low points
Pipelines not running on a level plain, or the fall does not correspond to the correct
direction of flow
Correct installation of piping special items including filters and strainers
Identification of correct installation of all non-return valve internals
A check that all valves have been installed in the correct direction of process flow
Correct installation of supports
Correct use of materials of construction.
Early identification and rectification of installation issues is a key activity in ensuring an
effective and efficient transition from construction to commissioning as significant time
will be lost if all rectification is corrected post the commissioning pre-handover punchlist
phase.
Vessel and Equipment Checks (Off and On Site)
Complete vessel installation check sheets will need to be developed for each item of
equipment within each system. A comprehensive list of vessel check sheets can be found
later in the commissioning system file section of this handbook.
A study will need to be made of each vessel drawing and Installation and Operating
Manual (IOM), to ensure the check sheets consider all the items to be addressed at both
the off-site and on-site inspection stages. Those items of equipment that are considered
to be of suitable importance, due to their key involvement in the process, are inspected at
the vendor shop location prior to transportation to site and will have an off-site vessel
inspection check sheet drafted. This check sheet will address items such as cleanliness
and internal component test fitting. Off site, vendor shop inspection can have a significant positive cost and schedule implication as finding errors at the job-site can be
a considerable undertaking and expensive to correct.
The mechanical commissioning engineer should also understand who will be required
to witness the final closure of vessels from all parties other than the commissioning team.
An individual from the commissioning team MUST witness the final closure of all process
84 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
equipment; no vessels should be closed without the consent of the commissioning system
engineer. This important point must be clearly explained to the mechanical installation
subcontractor and highlighted as a HOLD point on their documentation. It is probable that
client operations and engineering staff will also want to witness the closure of equipment;
those individuals relevant must also be included on the list to witness vessel close up.
This important step minimizes the potential for process upset of equipment damage
during early commissioning due to debris being left inside equipment post installation
activities.
Worked examples of vessel check sheets will be located in the Vessel Check Sheets section
of the Implementation phase of this handbook; all blank forms are located in the The
Commissioning System File, a full catalogue of blank commissioning documents section.
Mechanical Documentation Check
Checks will be made and suitable questions asked of the site engineering group and the
project engineering team to ascertain which formal statutory paperwork systems have to
be available and in place prior to any new equipment being put into service. The
following equipment and systems have formal documentation that will need to be signed
off and available to all parties prior to the commissioning activities taking place:
•
•
•
•
•
•
•
•
Pressure vessels
Non-pressure vessels
Relief streams
Special pipelines (e.g. chlorine)
General pipework systems (test packs, weld maps)
Major machines and critical equipment
All statutory inspection certificates
Civil and structural paperwork where there is a seismic implication.
The mechanical engineer should compile these lists of documents and ensure those
responsible sign off appropriately. It is vital that these documents are collated and fully
closed out prior to any pre start-up safety review or Hazard Study 4 to ensure there is no
delay in commencement of commissioning.
An appropriate blank mechanical document check sheet can be found in the system
file section of this handbook.
Vendor and Proprietary Equipment Check-Out
A complete understanding of any vendor-installed package will need to be gained such
that knowledge is obtained and suitable documentation created to manage:
• Removal of transportation bracing
• Preservation of equipment (protective coatings)
• Temporary lubrication.
Chapter 1 • Commissioning Phase One – Prepare
85
This information can be obtained via e-mail, verbal communication and study of the
Operating and Installation Manual.
The mechanical commissioning engineer should work closely with the relevant system
commissioning engineer to ensure all commissioning procedures for any vendor or
proprietary equipment are considered and written into the documentation.
An understanding of all project contracts is required and if vendor assistance at
commissioning is included, the mechanical commissioning engineer should be involved
with the co-ordination of the vendor commissioning personnel so their timely appearance at site is organized.
Lubrication
A complete understanding of what type, manufacturer and who will actually install
lubrication to all equipment that requires it should be developed and progress tracked
per system of a lubrication check sheet; please refer to the worked example in Fig. 16.
FIG. 16
Training
Where specialized equipment is being commissioned organization of training for pertinent personnel should be arranged in co-ordination with the commissioning system
engineers.
86 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Mechanical Commissioning Document Preparation – “Things That Can
Go Wrong”
Many points focused on in this particular preparation phase will be discussed in more
detail in subsequent sections of this handbook; however, there are some lessons that are
pertinent for inclusion here.
A major project being constructed and commissioned in the USA was engineered in
the UK. There was no concerted effort to deduce what statutory paperwork systems were
needed, pre-commissioning activities were being completed and introduction of safe
chemicals for leak testing and initial “wet” water commissioning was imminent. A Hazard
Study 4 process (Pre Start-Up Safety Review) was initiated, during which it was determined all Relief Stream Data Sheets remained unsigned by the senior process engineer.
As there were many, significant time was lost on the schedule whilst all relief paperwork
systems were brought up to the standard required. Had a mechanical document check
been considered and implemented during the preparation phase, this issue would have
been resolved and no time lost on the overall plan.
A significant issue on any project is the topic of lubrication; often who procures the
lubricant and who will actually install the oils and greases is ill-defined in a construction
contract. The point must clearly be defined by the commissioning team well before field
activities start to commence to aid a smooth construction to commissioning handover.
Key Points
• Check that all mechanical isometric drawings comply with the system P&IDs to alleviate punchlist issues during construction if installation does not mirror the process
drawings.
• Working closely with the construction and fellow commissioning team members, draft
cleanliness check sheets and cleaning procedures for all pipe systems. Compile similar
documents to ensure lubrication of equipment is suitably carried out.
• Compile detailed vessel and equipment on- and off-site check sheets after a review of
all vessel drawings. Ensure suitable checks and hold points are incorporated into the
construction program so no equipment is finally closed for operation before
a commissioning team member has inspected the vessel internals and authorizes
closure.
• Regularly monitor construction progress and highlight installation issues early to avoid
later punchlist issues and negative schedule implications.
• Organize a check of and ensure all statutory paperwork is completed on vessels and
piping systems to ensure a smooth transition into the commissioning phases.
Develop Training Materials
Post the decisions made and documented at the commissioning scope review, it will have
been determined if organization, preparation and delivery of training is to be via the
Chapter 1 • Commissioning Phase One – Prepare
87
commissioning organization or by client or operations personnel. It will be assumed here
that training is to be compiled by the commissioning team.
Training can range from simple brief communications and computer software
presentations given to existing experienced plant teams whose plant is perhaps being
upgraded, to creating large in-depth training packages taking several weeks to
develop and equally as long to deliver, for new plant developments and the incorporated operators and maintenance personnel. Prior to the training packages being
written it is vital that a suitable location is created on a secure company computer
system to save the files during writing and the ability to back up the data daily
provided.
In both cases, sufficient validation time must be built into the commissioning
schedule and the correct balance of “classroom” and “on the job” training considered and
importantly integrated into the commissioning program. It is also worth mentioning the
value in incorporating into any suite of training modules the use of 3-D computer models
of the plant, Availability, Reliability and Maintainability (ARM) review software and, if the
training topic is of specific detail and complexity, computer simulators.
The overall package will tend to be tailored to the needs of the operations personnel,
the individuals who will run the asset on a day-to-day basis; however, consideration
and preparation will need to be given to the requirements of the plant management
and maintenance team. It is common however to develop the operator training
package first, followed by hybrid training packages for the remainder of the plant staff
thereafter.
Consideration must be given to schedule, if required, external specialists to be brought
onto site to deliver specific training, examples being fundamental training on a new DCS
control system, and the detailed operation and maintenance of a package unit, examples
being a refrigeration or turbine system.
Many organizations now are combining the training of their operations and maintenance personnel with formal accreditations, as in the case of the UK, an example being
the National Vocational Qualification (NVQ). If this is the case suitable training for the
trainers must be incorporated in the overall training program and a suitable ongoing
validation process established. This route for the training of personnel will obviously have
a significant impact on overall project and commissioning schedule and must be
accounted for appropriately.
As with the commissioning procedures, training documents need to be written well in
advance of the commissioning execution window to allow for proofreading, subsequent
updating, validation of the packages and the detailed scheduling of the sessions to all
parties to be trained.
Operations and maintenance personnel training falls into two main sessions; obviously there are many other subtle sessions that can be convened. The two main areas are:
1. Classroom – here the design basis of the operation is reviewed, what components
the system has, theory of operation and its control and protection philosophy. It is
88 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
common for the training to be sub-divided into the commissioning systems;
however, utility supplies can be consolidated into one volume. Each main
commissioning or process area will have its unique package written and subsequently delivered.
2. On the job – where the actual operation of the plant is learnt and validated. The
training will be divided into packages based on the commissioning system.
Training packages need to be created utilizing the most up-to-date project information at
time of writing. Documents that will be needed to produce training manuals are:
•
•
•
•
•
•
•
•
•
•
•
•
Piping and Instrument Diagrams (P&ID)
Process descriptions and control philosophies
Process Flow Diagrams (PFD)
Vendor Installation, Operating and Maintenance Manuals (IOM)
The Equipment List
Pipe Line Tables
All Engineering Data Sheets, including Instrument Data Sheets
Functional Logic Diagrams
User Requirement Specification (URS) for DCS Control Systems
Shutdown, Interlock and Alarm Summaries and Matrices
Material Safety Data Sheets (MSDS)
Cause and Effect diagrams/schedules.
The delivery of the training needs to be considered, the main points being:
• How will the training be delivered, computer-based, blackboard style?
• What style of training; are the trainees to be subjected to direct instruction, a
self-learning style or a combination of both?
• Duration of the classes and the number of sessions required.
• Location of the training, set out of the room and the booking, if required, of the venue if
remote from the job-site.
• Are the trainees on a shift pattern, do the training sessions need to coincide with that
pattern, perhaps even as part of their shift?
• What level of training is required; all-inclusive operational training, through to an
“appreciation” class to specific groups, potentially given by a principal vendor? Do not
forget that the tutors will then need to consider “on the job” training and being
available to help, coach and validate the operations group through initial plant
production.
• A schedule created to track and plan the various training activities must be produced;
this is an important point as the commissioning engineers could also be busy with the
actual plant commissioning in conjunction with the training activities.
• Ensure training consumables, files, pens, paper are available including any electronic
training aids.
Chapter 1 • Commissioning Phase One – Prepare
Examples of the training session styles are described in Fig. 17.
FIG. 17
89
90 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
The content of the main packages described in the preceding table must at a minimum
contain elements based on the following criteria:
Operator Knowledge Training – Classroom
•
•
•
•
•
•
•
•
•
•
Items of plant equipment and purpose
Theory of equipment operation
Simple flow diagram – core process
Add to the flow diagram – utilities
Add to the flow diagram – instrumentation
Control – give description then add to the flow diagram
Interlocks – give description then add to the flow diagram
Shut-down systems – give description then add to the flow diagram
Sequence control – give description then add to the flow diagram
The validation test.
Operator Knowledge Training – Presentation
•
•
•
•
•
Items of plant equipment and theory of equipment operation
Flow diagram including core process and utilities
Description of instrumentation, control and any operational sequences
Interlocks and shut-down system description
Validation test.
Operator Practical Training – “On The Job”
•
•
•
•
•
•
•
•
•
•
•
•
Plant induction
Plant safety
Process chemical handling, application and hazards
Operator roles and responsibilities
Detailed theory of equipment operation
– Plant item
– Purpose
– Control
– Normal operating parameters
How to complete a start-up
How to normally shut-down
How to conduct an emergency shut-down
Preparation for maintenance
Decontamination of all equipment in a system
Regular routines including, safety shower check, locked valve checks and radio active
source checks
Production validation
Chapter 1 • Commissioning Phase One – Prepare
•
•
•
•
•
91
– Feed rate determination and quality
– Product quality determination
Emergency response
Fault finding
Alarm and interlocks action and response
Shut-down system operation, action and response
Overall training tracking document and validation sheet.
Maintenance Personnel Knowledge Training – Classroom
•
•
•
•
•
Items of plant equipment and description
Theory of equipment operation
Simple flow diagram – core process and utilities
Appreciation of control, interlock and emergency shutdown management philosophy
A validation test if required.
Maintenance and Operator Personnel Equipment-Related Training – Workshop and
Classroom
•
•
•
•
•
•
•
Equipment description
Review of equipment drawings
Appreciation of control, interlock and emergency shut-down management philosophy
Decontamination methods
Dismantling theory and practical demonstration
Spares information
Routine inspection detail.
Management Training – Classroom
•
•
•
•
Items of plant equipment and theory of equipment operation
Flow diagram including core process and utilities
Description of instrumentation, control and any operational sequences
Interlocks and shut-down system description.
Control System, Operator Training – Classroom with Control System Simulation
• Operating system description including interaction with the field instrument and the
control environment
• The system layout and graphic page description
• Logging in and out of the system
• Hierarchy of configuration, who can change what, including alarm set points and
graphic page changes
92 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
•
•
•
•
•
•
•
•
•
•
•
Control of change on the system, authority to change parameters and recipes
Navigation around the system
The overview screen
Description of operating system symbols including ON/OFF, START/STOP, OPEN/
CLOSED and the color thereof
Explanation of system behavior upon an operating feature fault
Operation of various instrument types
– digital inputs
– digital outputs
– analogue inputs
– analogue outputs
– control loops
– discrete control devices
Trending
Alarm management
Screen templates (specific start-up and shut-down screens)
Printing
Operating control system sequences, including practical and simulated operator
interface demonstrations and practice time.
Control System, Systems Engineer Training – Typically Control System Vendor Location
(Potentially Site-based)
•
•
•
•
All of the above
Pertinent specific architecture training for the system
Loop tuning
Basic configuration, including changing alarm set points and small graphic page
changes.
Actual worked example pages from various knowledge-based training packages are
provided in Appendix 5. Obvious editorial and commercial details have been removed,
but it serves to give indication as to the content of a knowledge-based training module.
Develop Training Materials – “Things That Can Go Wrong”
A significant high-profile project took the decision to subcontract the production and
delivery of the training program to a third-party specialist. As time passed, schedule
milestones were consecutively missed by the training group to produce templates and
draft materials for review. A critical meeting was convened to investigate progress, where
it became plain document production was not satisfactory whereupon the project
decided to revoke the subcontract and training material production came within the
remit of the commissioning team. The cost implication as a result of this action was
considerable as new commissioning team members were hurriedly recruited and
Chapter 1 • Commissioning Phase One – Prepare
93
significant overtime had to be worked to enable the training program to proceed, whilst
not compromising the already-busy commissioning schedule.
Setting key delivery dates, monitoring schedule and production of the training
materials must be a priority for any organization prepared to subcontract the production
of important documents, such as training programs, to an independent outsource.
Key Points
• Devise what training is required, where and when it will be delivered and what
presentation style is suitable; this can range from a simple presentation to full-blown
package production and delivery.
• During training package production consider and utilize as appropriate supplementary training aids as the 3-D plant model and specific simulation tools.
• Consider who will need to be trained and what level that training should be for each
specific group.
• Ensure all training packages produced have the correct sections written, created with
the most up-to-date reference material available and cover all key aspects of the
process.
Develop Standard Operating Procedures (SOPs)
As with the topic of training, contracts differ from project to project and as such what
responsibility the commissioning team has in the production of the operating manuals.
This section gives guidance on the production of operating instructions if required by the
commissioning group.
For an existing facility, SOPs may well exist and installation of new equipment will call
for them to be revised and updated. However, on a new facility a format for the procedures may need to be developed and the documents then written. Do not underestimate
the time required to create standard operating procedures for a project of any significant
size; to draft and validate these documents, many man weeks will be expended and these
durations will need to be determined, incorporated and approved within the commissioning budget estimate. Therefore ensure sufficient time and resource are allocated
within the overall commissioning schedule.
It is common for the organization and naming of sections for the operating procedure
documents to take the same format as the commissioning procedures; however, utility
systems may well be included in one section. During the logical progression of documentation preparation by a commissioning team, commissioning procedures are written
first then the initial draft operating instructions taken directly from the commissioning
documents and edited to suit. Post experience and operational knowledge gained from
the first weeks of operation, the first draft operating instructions are then updated to
reflect actual operational practices and understanding.
94 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
On a general but pertinent point, to share learning as the commissioning team develops
it is common for the following strategy to be incorporated in documentation preparation:
• If commissioning procedures are written for allocated systems by a commissioning
system engineer (with assistance from the mechanical and C/E/I engineer)
• The same commissioning systems engineer writes operating procedures from another
commissioning engineers systems
• Writes training programs from yet other system engineers systems.
This may seem complicated but the sharing of documentation preparation does give
excellent potential for full plant understanding, especially for medium- to large-scale
projects.
Due to its nature, specific formal guidance on what should be included in Operating
Procedures is limited; within the HSE website in the UK, the COMAH/Operating Procedures/Technical Measures Document section, some guidelines are given.
From the Health and Safety Executive (HSE)
Status of Guidance
Guidance related to operating procedures tends to be non-specific, i.e. operating procedures are covered in sections of existing guidance. However, no guidance is currently
available that specifically addresses operating procedures and related issues. Consequently, the quality and standard of operating procedures can vary between different
companies, and also within the same company if multi-process plants are in operation.
Comprehensive written operating procedures should be generated where applicable
that address:
•
•
•
•
•
•
•
•
•
•
•
Standard operating procedures and operating philosophy
Abnormal operating procedures
Temporary operating procedures
Plant trials
Emergency operating procedures
Commissioning
Plant start-up
Plant shut-down
Bulk loading and unloading
Process change
Plant change.
These procedures should cover the following:
• Material safety data (COSHH)
• Plant operatives should have an awareness and understanding of material safety data
for raw materials, intermediates, products and effluent/waste
• Control measures and personal protective equipment
Chapter 1 • Commissioning Phase One – Prepare
•
•
•
•
•
•
•
•
•
•
•
95
Location of plant where process is to be undertaken
Roles and responsibilities of individuals involved in plant operations
Plant fit for purpose
The condition of main process plant and equipment (clean, empty, as appropriate)
should be established as being fit for purpose
The condition of ancillary process plant and equipment (clean, empty, as appropriate)
Plant correctly set-up for processing
Process monitoring and recording
Monitoring and recording of key process parameters (temperature, pressure) in plant
logs
Quality
Sampling of raw materials, intermediates, products and effluent/waste
Packaging of final product.
The Occupational Health and Safety Administration (OSHA) in the United States also
stipulates requirements of an SOP. These are:
OSHA’s Process Safety Management (PSM) regulations contain a section (1910.119.f )
dedicated to written operating procedures for processes covered by the PSM
regulations.
The following provides the text of the OSHA regulations for operating procedures.
Operating Procedures
The employer shall develop and implement written operating procedures that provide
clear instructions for safely conducting activities involved in each covered process
consistent with the process safety information and shall address at least the following
elements.
• Steps for each operating phase:
• Initial start-up
• Normal operations
• Temporary operations
• Emergency shut-down including the conditions under which emergency shut-down
is required, and the assignment of shut-down responsibility to qualified operators
to ensure that emergency shut-down is executed in a safe and timely manner
• Emergency operations:
• Normal shut-down
• Start-up following a turnaround, or after an emergency shut-down.
• Operating limits:
• Consequences of deviation
• Steps required to correct or avoid deviation.
96 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• Safety and health considerations:
• Properties of, and hazards presented by, the chemicals used in the process
• Precautions necessary to prevent exposure, including engineering controls,
administrative controls, and personal protective equipment
• Control measures to be taken if physical contact or airborne exposure occurs
• Quality control for raw materials and control of hazardous chemical inventory
levels
• Any special or unique hazards
• Safety systems and their functions.
Operating procedures shall be readily accessible to employees who work in or maintain
a process.
The operating procedures shall be reviewed as often as necessary to assure that they
reflect current operating practice, including changes that result from changes in process
chemicals, technology, and equipment, and changes to facilities. The employer shall
certify annually that these operating procedures are current and accurate.
Due to the very sensitive nature the contents of detailed operating procedures hold, it
is not possible to show a worked example in this handbook. However, listed below are the
minimum requirements an operating procedure manual should incorporate. Following
on from the table of contents is a description of each section.
Title of Procedure Manual
Table of Contents
1.0 General description of system
2.0 Safety, health and environmental considerations
3.0 Pre-start checks
4.0 Valve positions for start-up
5.0 Initial start-up procedures
6.0 Normal start-up
7.0 Normal operation including optimal operational values
8.0 Normal shut-down procedures
9.0 Emergency shut-down procedures
10.0 Fault-finding guide, consequences of a deviation and corrective action plan
11.0 Loss of utility emergency procedures
12.0 Temporary operating procedures
13.0 Action upon alarm sheets
14.0 Regular system routines
15.0 Decontamination procedures
16.0 Re-commissioning procedures post a major overhaul or turnaround.
Depending on the size of the operating manual, as well as being system- or area-specific,
the operating procedure manuals may well be sub-divided into various volumes.
Chapter 1 • Commissioning Phase One – Prepare
97
Table of Contents Descriptions
General Description of System
A high-level process operating description is written here, including basic control
philosophy.
It is also a good practice to include in the general description section, especially
if divided into volumes (therefore Volume 1), the purpose of the operating
procedures.
Safety, Health and Environmental Considerations
Potentially a large section or volume in its own right, sections for inclusion within this
section must include:
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Hazardous or toxic materials, including Material Safety Data Sheets (MSDS)
Explosive hazards
Asphyxiation hazards
Personal safety equipment to be utilized within the system
Permit to Work arrangement including lock-out-tag-out procedures and hot work
practices
Location of safety equipment
Environmental implications
Hot and cold surfaces
Establishment of safe work boundaries including barriers and preparing areas for
decontamination and maintenance
Isolation philosophy for the system.
Pre-Start Checks
A procedure to establish what is required to be in place prior to start up, examples being
availability of feedstocks and product storage.
De-isolation, key insulation is in position (pertinent to very hot and/or cold surfaces),
required specialist equipment available and the position of any locked open/closed
valves are confirmed.
A section within the pre-start checks should clearly document the position (backed up
with clear labeling and signage in the field) of all pipelines feeding the asset in question
including utilities, off-plot to plant raw material pipelines, off-plot product storage
pipelines and drainage systems.
Valve Positions for Start-Up
Full and precise procedure to the set-up and position of all manual valves across the
system, signed off as in the position stipulated on the respective P&IDs.
98 CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Initial Start-Up Procedures
Obviously specific to the project in question, but examples of initial start-up procedures
are:
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Pipeline purging (especially in fuel lines)
Pipeline and equipment evacuation
Pipeline or vessel preparation with an inert gas environment (nitrogen blanket)
Loading procedures (catalyst loading to vessels)
Filling of vessels (with desiccant or filter media)
Initial introduction of chemical procedures
Initial heating or cooling procedures
Procedures to initially condition a catalyst or other specific media.
Normal Start-Up
These procedures detail step-by-step, valve-by-valve, how the total system is brought into
normal operation, divided into as many specific procedures as is required to adequately
describe the process in question.
Normal Operation Including Optimal Operational Values
This section of the operating manual lists the normal operation conditions that the unit
will run under, including all unit operations within the system.
A novel and informative method of portraying optimal operational values for a process
is to print and mark up control system graphic pages including boxes highlighted with
the normal operating parameter for all instrumentation on the screen. These values
could also be written onto P&IDs; both methods are then left in the control room for
operator use.
An example of an optimal operational values sheet based on a hypothetical chemical
process featured in this handbook is provided in Appendix 6.
Normal Shut-Down Procedures
Written for as many applications as required, these procedures detail step-by-step, valveby-valve descriptions of how to safely shut down a process.
Emergency Shut-Down Procedures
Drafted in very simple form these procedures give very direct instruction to the operations team, both in the control room and on the plant, of how to shut down the plant in an
emergency.
Specific procedures will address different emergencies (e.g. loss of containment of
a gas or hazardous liquid or fire) but the procedures MUST be very easy to access and
administer.
Chapter 1 • Commissioning Phase One – Prepare
99
Fault-Finding Guide, Consequences of a Deviation and Corrective Action Plan
These instructions give detail to the operator of the action to take when the process in
question deviates from an acceptable margin of control.
Initially drafted during the documentation preparation phase, sufficient discipline
must be maintained by the commissioning team to update these procedures post initial
operation to preserve the validity and relevance of the documents. This part of the overall
operating procedures is very dynamic as the section should be suitably updated as new
issues are resolved and the lessons learnt incorporated into long-term understanding of
the plant operation.
Loss of Utility Emergency Procedures
This section will address the specific instructions to be written which address the unusual
but potentially dangerous scenario of a loss of services to a production unit.
Temporary Operating Procedures
All chemical processes at some time have to be temporarily modified to accommodate an
unforeseen operational condition. Procedures written to manage these scenarios must be
filed in this section of the system operating manual.
Action Upon Alarm Sheets
For the use of the operations staff all action upon alarm sheets generated during the
documentation preparation phase of the project are filed in this section of the operating
procedure manual (please refer to the Support Design section of this handbook for an
example sheet).
Regular System Routines
The operations staff will have many regular routines to complete on a weekly or monthly
basis. These will include checks of safety shower operation, security of locked open/
closed valves and upkeep of plant housekeeping areas; the check sheets developed to
manage these procedures will be filed in this section.
Decontamination Procedures
Detailed system and where appropriate specific equipment procedures relating to the
safe and effective decontamination of plant are filed here.
Re-commissioning Procedures Post a Major Overhaul or Turnaround
This is a significant section of the Operating Procedure Manual; it details the checks
required to safely and efficiently manage the check-out process plant requires coming out
of a major overhaul or turnaround event.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
The sections that must be addressed are:
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P&IDs marked with system isolations
Decontamination procedures
Isolation register
Handover process
Cleanliness checks
System punchlist
Handover certificates
Leak test procedures
Toxic test procedure
Process chemicals introduction checks
Valve alignment checks
Instrument checks
Shut-down system trip tests
Interlock checks
Authority to introduce chemicals paperwork or pre start-up safety review
System start-up/re-commissioning procedures.
Key Points
• Confirm if the commissioning team are to write the Standard Operating Procedures
• During compilation ensure all required sections of the procedure manual are incorporated; if applicable consult statutory guidance (e.g. HSE and OSHA)
• From a contracting commissioning team perspective, ensure all procedures produced
are in the required format.
Develop Commissioning Schedule
The development of a concise and accurate commissioning schedule of activities is very
important not only to the overall loading of the project schedule, but the plan also
becomes an excellent guide for the commissioning team in the correct prioritization and
execution of the various steps that make up the whole commissioning effort.
Scheduling of commissioning activities should be considered in two separate stages,
often referred to as level 2 and level 3 planning.
Stage 1 – Level 2
This level of commissioning schedule must represent the generic range of commissioning
activities that the team will perform throughout the project and the time it will take to
complete each action. Aimed as a high-level overview, this initial commissioning
schedule will then be integrated into the overall master project schedule. The stage 1 plan
Chapter 1 • Commissioning Phase One – Prepare
101
will be compiled early during the preparation phase of the commissioning effort and will
contribute to the overall total project duration to be determined.
Scheduled activities and timings that must be considered for inclusion within the
phase 1 (level 2) commissioning scope are:
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Agree commissioning scope
Support design at: Hazard Study, P&ID reviews, Layout reviews, 3-D Model reviews
Compile commissioning resource plan
Determine handover philosophy
Determine plant acceptance criteria
Confirm product validation criteria
Compile initial commissioning philosophy
Systemize the plant
Compilation of the commissioning manual
Period for selection and appointment of the commissioning team
Develop detailed commissioning plan
Training period for the commissioning team
Agree operating procedure production requirements by commissioning team
Compile commissioning documentation
Compile training manuals
Compile Operating Procedures.
An example phase 1, level 2 commissioning schedule is provided in Fig. 18.
Stage 2 – Level 3
The objective of this level of commissioning schedule will be to accurately determine
each individual activity the team will perform and its duration.
As the stage 2 (level 3) commissioning schedule concentrates on actual delivery of the
commissioning activities, it is very detailed in composition. The stage 2 plan will
commence after the mechanical completion milestone date per system. Therefore this
level of detailed commissioning schedule cannot be logically completed (activities can be
populated to the schedule), until the construction group has been given a breakdown of
commissioning systems and therefore planned their mechanical completion dates
according to all the factors which the construction team will need to consider; examples
will include delivery of equipment, erecting of steelwork and major pipework systems.
A list of example system activities that must be considered for inclusion in a stage 2
commissioning schedule are:
•
•
•
•
•
Attendance at factory acceptance tests and inspections
Train plant and maintenance operatives
Check construction progress
Test and clean pipe and equipment – per system
Punchlist – per system
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FIG. 18
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Chapter 1 • Commissioning Phase One – Prepare
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103
Loop testing – per devise, per system
Motor rotation checks – per item within a system
Leak testing – per system
Sequence check-out without chemicals
Commissioning on safe chemicals, water commissioning – per system
Loop tuning within a system
Testing of control sequences, interlocks and shut-down systems on safe chemicals
Complete all PSSR paperwork and/or Hazard Studies 4 and 5 – per system
Issue first draft SOPs (milestone)
Start-up procedures
Validation period
Acceptance period
Ramp up of production to design rate period
On the job training of operations
Handover to operations (milestone)
Consolidation period, updating of documentation with best operational knowledge.
Many projects are now being constructed and commissioned to a very fast-track schedule.
This is typically demonstrated as new project and commissioning build within the confines
of an overhaul or turnaround of an existing asset. In these scenarios a very detailed, hourby-hour, procedure-by-procedure commissioning schedule will be invaluable as the
duration of the schedule will be the principal driver to recommence production in an
acceptable manner to maintain the business case. Drafting the commissioning schedule in
this manner facilitates a very accurate duration for the commissioning activities as
a timeframe is planned for each individual commissioning activity.
FIG. 19
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Correct and suitable resource loading of commissioning personnel to the commissioning schedule is very important to add further accuracy to the plan.
Please refer to Fig. 19 for to a worked example from an actual schedule from a recent
project. It is assumed that all projected commissioning procedures will have been
identified to develop this level of detail.
Key Points
• A concise stage 1 plan gives an overall guide to the commission activities to be
undertaken
• A detailed stage 2 commissioning schedule will provide a very accurate duration for all
commissioning activities to be performed.
Devise Handover Procedure
There will be a requirement to clarify, agree and document (in the commissioning
manual) the various handover steps between the range of engineering disciplines within
the project. The handovers are commonly between the construction group to the
commissioning team, then the commissioning team to the operations team (both are
specifically addressed in later sections of this handbook).
In addition where a project is based on an upgrade of existing plant, a formal handover
from the operations group to the construction team will be required to safely manage the
decontamination and isolation of the existing plant that will then be worked on for the
project works to be installed.
It is important to stress that the groundwork for a smooth handover process must be
considered during the preparation phase. What documentation is required and the
acceptance criteria to be met, plus who will accept packages and importantly when they
will need to be considered, as it is common for project contracts to incorporate these
important considerations.
Key elements to a successful and effective handover process are:
•
•
•
•
•
Handover criteria
Phased system handover approach
Safe systems of work at handover
Handover documentation
The review process prior to handover.
Further explanation is provided below.
Handover Criteria
This consideration undertakes what needs to be completed at the point of handover
incorporating documentation and completed activities in the field including installation,
Chapter 1 • Commissioning Phase One – Prepare
105
cleaning, loop testing, electrical and instrument check-out, and control system sofeware
testing.
Phased System Handover Approach
It is vitally important for this type of commissioning methodology to be fully effective,
that the project and construction teams adopt a systemized approach to the final delivery
of the asset on a system-by-system basis. This being established and based on the
number of commissioning team personnel available per project, a phased approach must
be incorporated as many systems being presented for commissioning at the same time
will be an impossible task to successfully manage and overall productivity in the effective
commissioning of the plant systems will be lost.
Based on the prioritized systems list and suitably incorporated into the project and
commissioning schedules the handover criteria will clearly document the phased turnover of systems to the commissioning group, and then if relevant from the commissioning team to the operations group.
Safe Systems of Work at Handover
A very key and important area to any handover procedure is to detail the management
and transition of the isolations in place at the point of transfer of care. These isolations
will include physical isolation in the field (slip blinds, spectacle plates and pancakes),
locked off valves and equipment and electrical isolations all requiring documented
management procedures for custody of care of locks and associated isolation devices
including piping spool pieces.
The handover process will also need to explicitly detail change of any statutory safe
system of work, including permit to work, confined space entry and hot work regulations.
Handover Documentation
Within the commissioning manual, clear lists of all documents to change hands at point
of handover must be specified. These will include:
• Safety Transfer Certificate or “Handover Certificate”
• Copy of the completed Hazard Study 4, with all outstanding items clearly identified,
actions assigned and a schedule of close-out dates specified
• Copy of the completed Hazard Study 5, with all outstanding items clearly identified,
actions assigned and a schedule of close-out dates specified
• Reservation to handover list, agreed with all parties with a clear schedule of rectification drawn up
• Transfer of any outstanding control system rectification works (on control system
punchlist)
• Marked up drawings (P&IDs, PFDs and loop diagrams) at “as-built” status, including
boundary points and boundary isolation points
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• An isolation register of any remaining intersystem isolations (if applicable)
• Termination drawings and/or “cable landing matrix” for all junction boxes, marshalling panels and control panels
• Installation, operations and maintenance (IO&M) manuals
• Design Change paperwork relevant to the system or facility
• All plant labeling in place
• Transfer of relevant method statements
• Up-to-date (to current validation status) Standard Operating Procedures, Maintenance Procedures and Training Manuals (for the system or facility)
• Clear status of related control system hardware and software status
• Stores and management systems suitably updated for the facility to be handed over, all
facility entities entered into the system with designated spares
• Clear location path identified for the quick retrieval of the following (including copies
of relevant certification):
• pressure test certificates (including NDE/weld procedures and qualifications)
• lifting equipment certification
• all completed commissioning documentation
• relief valve test certificates
• pressure system registration documentation
• all statutory inspection data
• isometric drawings
• registered pipe work certificates (if required)
• hazardous area certification
• various control/instrument/electrical documentation as specified by the plant
engineer.
The Review Process Prior to Handover
The handover process can be a very stressful time; the party handing over systems eagerly
wants to discharge responsibility, the accepting party equally wants to push forward with
their ongoing activities. It can be a very frustrating time if all documentation is not
available and/or in place.
It is highly advisable to document in the handover process the establishment of prehandover review meetings to smoothly prepare the documentation preparation, prior to
the actual handover.
Devise Handover Procedure – “Things That Can Go Wrong”
Simply put, an ill-defined and -documented handover procedure will cause serious issues
at handover between parties; without a sound and agreed basis for reference much
argument, debate and discord will inevitably ensue.
Although not particularly “a thing that can go wrong”, much disagreement can
develop over what documentation needs to be transferred with the change of custody. It
Chapter 1 • Commissioning Phase One – Prepare
107
is always advisable to make the list of documentation deliverables as short as is necessary
and practicable, so time is not lost in the overall schedule for documentation review by
the accepter; never underestimate the time required for paperwork appraisal.
Key Points
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Devise the list of actual handovers the commissioning team will be involved with
Develop the list of documents to be available at each specific handover
Agree the phased handover approach
Agree what safe systems of work will transfer between parties.
Devise Commissioning Tagging System
Many tasks will be performed by various engineering and construction disciplines within
the project, simultaneously. The commissioning team must incorporate a sound labeling
or tagging system in conjunction with their activities, to assist in the definition and clarity
of ownership and action identification throughout the pre-commissioning and
commissioning phases.
To assist with various forms of identification at the job-site, especially during the
hectic activities associated with the implementation phase, the commissioning team
must consider the utilization of a series of color-coded tags to signify boundaries, points
of information and general items of clarity.
Tags to consider include:
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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.
Location of Tie-in Points
At the tie-in point of an existing service to the new plant, a label positioned at this point
clearly helps identify the actual location.
Location of Commissioning System Battery Limit Isolation
Vendor-supplied equipment in general has battery limit points where the site ran pipework and instrument/electrical items meet the package equipment. A label positioned at
the battery limit point when installed helps identify the point of transition of responsibility and installation.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
A Punchlist Item
Once a system is at approximately 80% complete the commissioning team will punchlist
the system to identify items constructed which are not consistent with the P&ID. To help
the construction group identify the points for rectification, a tag should be positioned
adjacent or actually on the item to be corrected. The construction group can then mark
the tag when the work is complete to help the commissioning team in check-out of
finished rectification activities.
Leak Point Found During Leak Test
During the system leak test, leaks may occur. Tagging the leak points aids location of the
leak for the construction team, hence speeding up the leak correction process.
System LIVE
Introducing energy into commissioning systems is an activity that must be carefully
managed, especially during the early system commissioning when many construction
personnel may still be present on site (instrument air introduction for leak loop testing is
the classic example). Clearly identifying a system is energized by hanging tags and labels
at regular points across the system will help all site personnel become aware of what
systems are LIVE.
Item Under Construction Control – Refers to an Electrical Item
During motor rotation checking, the electrical isolation will normally be under the
control of the construction team; hanging a label on the actual motor helps to identify
who is in control of the item.
Item Under Commissioning Control – Refers to an Electrical Item
As systems are handed over to the commissioning team, many motors across all systems
will belong to both groups, so labeling motors under the control of the commissioning
team will clearly demonstrate who has responsibility for the motor.
Both the last two points need to be worked in parallel by the construction and
commissioning teams for total project clarity.
Each commissioning system engineer will be responsible for installing and managing
the identification tags within their responsibility.
A check needs to be made with the construction group to ensure that there is no
conflict with any system they intend to employ.
Each tag should be made such that it is water-resistant, can be clearly read and hung in
such a way that the installation of insulation will not hinder it being read.
Example of tags that can be used can be found in Appendix 7.
2
Commissioning Phase Two –
Implement
CHAPTER OUTLINE
Factory Acceptance Testing............................................................................................................... 111
Modular Construction ................................................................................................................... 112
Factory Acceptance Testing and Modular Construction – “Things That Can Go Wrong” ..... 114
Things That Can Go Right! ........................................................................................................... 114
Key Points....................................................................................................................................... 115
Check Construction and Quality of Build ........................................................................................ 117
Check Construction and Quality of Build – “Things That Can Go Wrong” ............................. 118
Key Points....................................................................................................................................... 119
Tracking Progress and System Status .............................................................................................. 119
Cleaning Procedures and Drying ...................................................................................................... 121
Cleaning.......................................................................................................................................... 121
Types of Cleaning Methods .......................................................................................................... 122
Cleaning by Blowing – Rapid Pneumatic Depressurization .......................................................... 122
Cleaning by Steam Blowing (Steam Systems) .............................................................................. 124
Cleaning by Flushing ................................................................................................................... 125
Chemical Cleaning....................................................................................................................... 126
Cleaning Via the Use of a “Pig”................................................................................................... 126
Mechanical Cleaning and Visual Inspection ................................................................................. 126
Drying ............................................................................................................................................. 127
Dryness Level 1............................................................................................................................ 127
Dryness Level 2............................................................................................................................ 128
Cleaning Procedures and Drying – “Things That Can Go Wrong” ........................................... 129
Key Points....................................................................................................................................... 129
Pre-Commissioning Procedures......................................................................................................... 129
Pre-Commissioning Procedures – “Things That Can Go Wrong”.............................................. 133
Key Points....................................................................................................................................... 136
Vessel Check Sheets ........................................................................................................................... 136
Key Points....................................................................................................................................... 137
Chemical and Process Plant Commissioning Handbook, DOI: 10.1016/B978-0-08-097174-2.10002-7
Copyright Ó 2012 Elsevier Ltd. All rights reserved.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Instrument Loop, Electrical and Control System Testing ............................................................... 137
Instrument Loop, Electrical and Control System Testing – “Things That Can Go Wrong” .... 141
Key Points....................................................................................................................................... 141
Commissioning Punchlisting ............................................................................................................. 141
Punchlisting – “Things That Can Go Wrong” ............................................................................. 144
Key Points....................................................................................................................................... 147
Handover from Construction to Commissioning ............................................................................ 147
Introduction of Safe Chemicals......................................................................................................... 149
Introduction of Safe Chemicals – “Things That Can Go Wrong” ............................................. 150
Key Points....................................................................................................................................... 152
Pre-Commissioning HAZOP Studies or Pre-Start-Up Safety........................................................... 152
The Installation and Construction................................................................................................ 153
Main Points ................................................................................................................................. 153
Design and Documentation Requirements ................................................................................. 154
Main Points ................................................................................................................................. 154
Key Points....................................................................................................................................... 154
Commissioning Leak Testing............................................................................................................. 155
Test (a): Service Test ...................................................................................................................... 155
Test (b): Safe Chemical Leak Test................................................................................................. 156
Leak Test Stage 1 ........................................................................................................................ 158
Leak Test Stage 2 ........................................................................................................................ 158
Leak Test Stage 3 ........................................................................................................................ 158
Leak Test Stage 4 ........................................................................................................................ 158
Test (c): Vacuum Test..................................................................................................................... 159
Test (d): Toxic Testing.................................................................................................................... 159
Commissioning Leak Testing – “Things That Can Go Wrong”.................................................. 161
Key Points....................................................................................................................................... 166
Commissioning and Initial Start-Up Plus Procedures ..................................................................... 166
Hypothetical Plant Commissioning Procedures; Explanation of Procedures that will Require
Writing............................................................................................................................................ 168
Utilities and Services .................................................................................................................... 173
Water Commissioning ................................................................................................................. 173
Commission and Initial Start-Up of the Plant with Process Chemicals.......................................... 174
Commissioning and Initial Start-Up Plus Procedures – “Things That Can Go Wrong”........... 174
Key Points....................................................................................................................................... 176
Handover to Operations.................................................................................................................... 176
Handover to Operations – “Things That Can Go Wrong” ........................................................ 179
Key Points....................................................................................................................................... 180
Chapter 2 • Commissioning Phase Two – Implement
111
The following handbook sections are those associated with the Implementation phase of
the commissioning process. The stages are presented in the normal flow in which they are
executed; however, many separate activities across all aspects will run concurrently:
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Factory acceptance testing and modular construction
Check construction and quality of build
Tracking progress and system status
Cleaning procedures and drying
Pre-commissioning procedures
Vessel check sheets
Instrument loop, electrical and control system testing
Commissioning punchlisting
Handover from construction to commissioning
Introduction of safe chemicals
Pre-commissioning HAZOP studies or pre start-up safety
Commissioning leak testing
Commissioning and initial start-up plus procedures
Handover to operations.
Factory Acceptance Testing
Factory acceptance testing (FAT) describes the final check performed on vessels and
major equipment prior to delivery to the job-site. Here the emphasis for the commissioning team is not on the design and fabrication of the unit, but more on its cleanliness,
the test installation of major components and suitability of the equipment to travel.
Sending commissioning team personnel to factory acceptance tests can fall foul of
project budgets, but this strategy must be challenged by the commissioning manager.
Many commissioning hours can be lost to site rectification of issues with equipment and
vessels, costing far more than the price of an air ticket and accommodation to facilitate
the inspection and potential correction of potential problems at source. In the “things
that can go wrong” section, the descriptions there will help demonstrate the benefits of
conducting these checks.
The key points to consider at a vendor shop acceptance test for vessels and package
equipment are:
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Correct finish on flanges as stipulated on the vessel drawings
Is the unit clean, dry and oil-free?
Checks that all internals are secure and open ends are covered for transportation
Are all spare parts, including gaskets and internal components, available for inspection
and present ready to be shipped?
• Can a low-pressure leak test be considered and therefore witnessed?
• Are all temporary hydro-test gaskets removed and service gaskets installed?
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• Witness of any test fit of internal components (tower packing and distribution and
bubble cap trays)
• What is the preservation medium? If the vessel is pressurized, check and log pressure
gauge readings prior to travel
• Overall orientation check against vessel drawing
• Witness any test runs.
Inspection reports must be compiled after the vendor shop visit, a copy sent to all
interested parties and a further copy placed in the commissioning system file. An actual
vendor shop inspection report is provided in Appendix 8.
Significant planning and co-ordination will need to be given to arranging the factory
acceptance tests of control system hardware and software plus emergency shut-down
systems. A complete check on the software within a control system (software acceptance
test, SFAT) is a considerable undertaking; for a large control system this activity can run
into several weeks so the accounting of engineer’s time to attend these checks must be
included within the commissioning budget estimate (accommodation and subsidence
expenditure). The SFAT tests simulate the operation of the plant so all operator interfaces
can be checked out prior to shipping to site. All graphic page, alarm and interlock
functionality should be tested and if configured sequence controllers.
Specialist package assemblies including heaters, conveyers, packing systems and
refrigeration packages will also be tested prior to shipping to site and the commissioning
team must attend these initial run trials.
It is common for the vendor to produce all test paperwork, but the commissioning
team should be prepared to create test and check sheets if required; it is advisable for the
commissioning team to develop simple test sheets prior to attending the factory acceptance tests as this helps the understanding of the operation of the equipment and/or
control system.
Where lined piping spool pieces are being incorporated within the construction, an
inspection of the manufacturer’s test methods and an actual test inspection would be
advised. The consequence of a lined spool piece failing in initial operation can cause
significant commissioning schedule delays and obvious cost implications, therefore the
importance of checking to ensure spool pieces are fit for purpose is essential.
A worked example of a vendor shop vessel and equipment check sheet can be found in
Fig. 20, with further blank examples provided in the commissioning system file section of
this handbook.
Modular Construction
It is now common in the construction of new chemical plant for sections of the asset to be
built in a modular format. Here the plant is sub-divided into realistic sub-sections and
built as pre-assembled units with all vessels, equipment, instrument and electrical items
pertinent to one operating system to be housed in one stand-alone structure designed
and built to be constructed, transported and installed as one unit. This approach can
Chapter 2 • Commissioning Phase Two – Implement
113
positively and significantly impact the overall project build schedule as multiple work
fronts can be constructed simultaneously.
Examples of process systems that can readily be constructed, where all the main
components are housed in one structure, are:
•
•
•
•
•
•
•
•
Scrubbing trains
Distillation systems
Process and product drying packages
Skid mounted refrigeration plant
Compressor packages
Pipe racks
Standby and duty pump skids
Heat exchanger bundles.
To make the process of modular construction even more efficient, the commissioning
team can conduct several activities at the module shop, which when considered, integrated into the module construction schedule and then executed at the vendor site, can
considerably ease the workload of the team and project duration at the job-site when the
modules are delivered. These activities will include:
•
•
•
•
•
•
Monitor construction and installation and identify errors for speedy rectification
Testing and cleaning of pipework
Punchlisting
Initial loop testing
Preservation of vessels (very low-pressure nitrogen pressurization)
Checks to ensure the modules are acceptable for transportation with respect to closing
all openings on pipes and vessels
• Compiling full inventory of all incomplete work.
It is of the utmost importance that a full and concise punchlist is compiled of the final
status of the structures before dispatch, noting all outstanding works and temporary
shipping braces. The commissioning manager must liaise with the project management team to inform them of all incomplete work due now to be completed at the
job-site that was scheduled to be completed at the module shop. As any completion
work may have contract implications, it is critical that the punchlist be complete,
concise and valid.
Some imagination may be required to the commissioning of modular constructed plant,
as in many cases the units can be constructed horizontally and to visualize them in the
vertical can be a challenge. However, the benefits of getting commissioning work done at
the vendor shop can significantly help the schedule and the overall progress of the project.
The inverse of this scenario is also probable where the modules are constructed
vertically then require lowering to the horizontal plane for transportation. In this case the
team should assist with the appraisal of suitable bracing of not only main pipe and
equipment but other equipment including lighting, junction boxes and cable tray. The
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
commissioning C/I/E and mechanical engineers have a key role to perform in this
identification situation.
The commissioning team should be prepared to consider out-of-hours and shift
working in vendor shop module construction as it is common for integrity testing
activities to take place out of hours, in some cases 24 hours a day.
Factory Acceptance Testing and Modular Construction – “Things That
Can Go Wrong”
In this section it is not only important to describe what can go wrong, but also by initiating these checks at the vendor shop what actually can go right which later saves things
from going wrong!
On a major project in the UK to upgrade an existing operating asset, the decision was
taken (on cost grounds) to not send commissioning team personnel to inspect a key
product feed tank at the vendor shop. The vessel was duly delivered to site, set in its
position and fabrication around and to the tank initiated. The commissioning team
insisted the construction group opened the main man-way on the top of the vessel to
facilitate an internal inspection prior to the vessel being put in service. Once opened, the
inside of the vessel was found to have several foreign objects lying in the tank, including
gloves, cardboard and used test gaskets. Schedule and cost implications then ensued as
a confined space entry was required to clear and clean the vessel internally prior to
further commissioning activities.
On a project in the USA a number of product compressors were installed. No vendor
shop inspection and/or leak test was initiated by the project commissioning team or
operations team. Post delivery and pipework and instrument/electrical connection, the
first major activity to commission the compressor train was to subject them to an
operating pressure leak test conducted with nitrogen. One compressor unit significantly
failed the leak test, not even a small pressure being able to be held. A significant schedule
delay then ensued as a vendor engineer had to be called to site to rectify the issue (no
main chamber gasket installed!). This test could have been conducted at the vendor shop,
witnessed by the commissioning team, the problem then being resolved with no lost time
to the commissioning schedule.
On the same project a further compressor failed to start due to a defective lubrication oil
pump. Again, this pump should have been put through a series of tests at the vendor shop,
witnessed by the commissioning team and the problem resolved before shipment to site.
Things That Can Go Right!
This brief section will describe a number of vendor shop inspections conducted by
commissioning team members that identified issues and had them resolved at source,
thus saving valuable time and cost implications back at the job-site.
A stock tank fabricated in the UK was inspected by the commissioning system engineer prior to delivery; transport was waiting to ship the item post the inspection to site.
The duty of the tank would call upon it to work at high pressure (18 barg) within
Chapter 2 • Commissioning Phase Two – Implement
115
a hazardous environment. Upon a request from the commissioning engineer, all transportation blank flanges were removed from all branches and man-ways to enable a full
inspection internally and external to the tank. A nozzle face on the top of the vessel was
found upon inspection to be damaged; a deep impact gouge completely dissected the
flange face. The damage was such that a seal upon pressurization would not have been
possible. The offending flange was re-machined and delivery was postponed for 1 day. If
this vessel was shipped with the nozzle damage uncorrected the schedule and cost
implications of site rectification would have been considerable.
A heat exchanger on a high-pressure (10 barg), highly acidic duty in the UK was
inspected by the commissioning team prior to shipment to site. Full inspection found the
vessel to be acceptable, clean, dry and oil-free. The final test at the vendor shop was to
have a low-pressure (3 barg) leak test conducted with argon gas. The resultant leak test
demonstrated the vessel was unable to hold pressure due to a significant leak on the tube
bundle to body shell flanges. The flange faces on the various faces were re-machined
overnight; the following morning the leak test was successful. This again demonstrates
that if this rectification work had not have been identified at the vendor shop, significant
schedule and cost implications would have arisen at the job-site for the correction works
that would have been required.
A new reactor on a high-pressure (18 barg), hazardous environment process was being
fabricated by a major engineering company in the USA. The reactor had a high-pressure
(12 barg) steam jacket associated with the main body of the vessel. The vessel drawing
called for all flange faces on steam nozzles to be a gramophone finish; upon inspection all
18 flange faces were found to have a smooth mirror finish, completely unacceptable for
high-pressure steam duty. All 18 faces were re-machined prior to shipment. This issue
being identified and resolved at the vendor shop inevitably saved significant downtime
later in the operational life of the vessel, as it is certain many of the steam flanges would
have leaked.
A significant distillation column with numerous bubble cap trays was fabricated in the
USA. The commissioning team was dispatched to witness the test fitting of the internally
installed bubble cap trays, each tray being made up of several sections bolted together. The
design intent was for the trays to be flooded to the overflow and downcomer piece to
maintain an optimum operating liquid level on the tray. After installation of the first tray it
was evident that many significant gaps between the various parts of the trays were evident,
significant enough that a second tray was assembled outside of the vessel to flood the tray
and trial the maintainable level. After the test it was evident that a sufficient liquid level
could not be held on the tray, due to leakage through the unwanted gaps and a tray redesign
was initiated. This again clearly demonstrates the benefit of works testing and the witnessing thereof by the commissioning team, in saving schedule and cost implications at site.
Key Points
• Fully review all major vessels and equipment and document the vendor site checks
required
• Challenge the project if vendor shop test witnessing is not included in the project scope
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• Conduct detailed checks of all equipment at the vendor shop per the vessel and
equipment drawings
• Produce concise inspection and visit reports
• If modular construction is considered, complete as much pre-commissioning activity
at the vendor shop as possible
• Make detailed punchlists of the modules prior to shipment.
Off-Site Inspection Check Sheet
Rotating Machinery
Equipment Title: Blender 10
System : Blending
Project: Y
Shop Location: XXX
Engineering, South Wales.
Author: M Killcross.
Step
1
2
3
Item
Check General cleanliness
Clear of debris:
Dry:
Grease free:
Check all drain plugs are fitted
Check orientation of assembled sections and
pieces of kit, if skid mounted
4
5
Witness casing pressure test
Witness performance trial run
6
Check guards:Location
Security
Effectiveness
FIG. 20
P&ID: 11112
Vessel Drw: 40767
Date: 13th August 2004
Yes
No
N/A
Comments
Sign &
Date
Swarf to be removed
MK 11/8
MK 11/8
MK 11/8
Degrease to be done
MK 11/8
Nozzle C to have burs
removed. (General point
for all of unit)
Nozzle F, Fit door
Nozzle G, Secure door
Nozzle E, Door fitted
but latch required to stop
door swinging closed
Nozzle J, (2 off) Fit
viewing glass
Most of the top panel
securing bolts to be
fitted
MK 11/8
MK 11/8
Ribbon ran for 2
minutes, no sign of
vibration or “wobble”
NOTE: Gearbox
greased, but oil will
need to be filled when
on site
All shaft guards to be
fitted prior to
MK 11/8
transportation.
MK 11/8
MK 11/8
Chapter 2 • Commissioning Phase Two – Implement
7
8
9
Check drive motor:Type
Guard
Numbering
Check drive alignment
Check mounting of Base frame and Flanges
117
MK 11/8
MK 11/8
MK 11/8
MK 11/8
MK 11/8
The blade had still to be chamfered.
All open ends are to be bagged and tapped prior to transport.
Motor/gearbox enclosures to be primed and painted.
A slide valve was test fitted to nozzle B, fit was good
All gaskets for the 4 slide valves will be transported to site with the valves.
The exterior finish (acid clean) to be completed for the unit.
The motor to inspection hatch interlocks are at the fabrication shop, but yet to be fitted.
The unit is due for transportation and delivery to site by 20th August 2004
A request that the center of gravity be marked onto the unit to aid lifting on site was
given to the Vendor
M Killcross.
13th August 2004
FIG. 20—Cont'd
Check Construction and Quality of Build
As construction activities commence, vessels start to be installed and major piping runs
established, it is advisable for the commissioning team to start making regular site visits
to closely monitor and follow the build progress. Any installation issues identified at this
early stage will obviously be quicker, easier and cheaper to correct rather than waiting for
the punchlist process to become established and then for the rectification work to take
place. Therefore it is of the highest importance that a good working relationship is created
with the construction management team so that a common understanding is gained that
the commissioning team, whilst not interfering in any way with the construction progress, does have a vital role to play in early issue identification and therefore efficient
correction work.
The commissioning team will start to become ever more based on the construction
plot as cleaning procedures start to be conducted, but in addition regular inspection of
the plant construction helps establish a sound understanding of the location and build
status of each commissioning system; this will help immensely in the learning process for
the commissioning systems engineer.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
During the construction phase items of equipment do get installed incorrectly.
Examples of this include:
•
•
•
•
•
•
•
•
•
•
•
•
Vessel being installed in the wrong location
Vessel being installed in the wrong orientation (e.g. needs to be turned 180o)
An installed valve handle protrudes into a walkway creating a trip or injury hazard
Pipe runs installed too low (head hazard)
Pipe runs have created a low point which cannot be drained down
Liquid-filled pipe runs installed with no high-point vent
Control valves and non-return valves installed in the wrong orientation for the
required direction of process flow
Pipes to be insulated have been installed too close together and insulation cannot be
fitted
Pipe installed with wrong fall direction (flows away from low point not to it)
Installed insulation covers a valve handle
Metal insulation cladding or fixing bands have sharp edges presenting a cut
hazard
Incorrect gasket material being installed.
Towards the latter stages of the construction effort within a system (to be agreed with the
construction manager but normally ~80% complete) it would be normal practice for the
commissioning team to be invited to compile a “preliminary punchlist”, where the build
is checked against the project P&IDs. Any resultant issues are then captured on the
punch-list to be rectified before mechanical completion of the system.
This scenario is discussed significantly later in the punchlist section of this handbook.
Check Construction and Quality of Build – “Things That Can Go Wrong”
Although not a thing that could go wrong, it is prudent to stress that the methodology
which is the basis of this handbook is based on the premise that the construction
group and the commissioning team work as a cohesive unit, with a shared goal of
delivering the start-up in the most efficient way possible. Projects can be managed
such that the construction group build the asset, then hand over to the commissioning team for them to then systematically dismantle the plant, clean it, and then
punchlist it, returning the list of rectification works back to the construction group for
attention.
This is certainly an approach; however, I have known project schedules be put back
6 months while major changes to the structure and equipment layout have been initiated,
hazard studied and installed due to the requirements of the commissioning team based
on their appraisal of the constructed plant. This is not an approach I endorse; working
with construction groups efficiently with the greater benefit of the project in general has
always been my driving aim and as stated above is the fundamental basis for this
methodology and work.
Chapter 2 • Commissioning Phase Two – Implement
119
Key Points
• The commissioning team must start regular checks of the systems being installed at
a suitable point during construction
• Agreement must be gained with the construction group for the commissioning team to
conduct these build checks; the commissioning team must not hinder the construction activities and progress
• Regular site inspection of progress is an excellent learning tool for the commissioning
team.
Tracking Progress and System Status
The overall management of the documents required to effectively check-out and later
commission a process system incorporated within a project is held within the commissioning system file (reviewed later in this handbook). However, it is advisable to post
clearly in the commissioning office, grouped by system, the following key documents so
that the general progress within each system can be readily seen. This will help in
establishing priorities for close-out, daily actions and activities required to complete
a system and facilitate a system handover from the construction group.
•
•
•
•
•
Cleaning check sheets
Instrument check sheets
Lubrication check sheets
Relief stream installation check sheets
Commissioning schedule (which will need highlighting when activities are
completed).
It is also very important is to produce and display a STATUS chart, which by commissioning system has within the right column a tag which changes status and can be colorcoded in a traffic light format to give further impact. The commissioning team will be very
busy during the latter stages of the construction effort and, throughout all the commissioning phases, it is psychologically beneficial to the team to clearly see their progress
identified in a dynamic chart hung on the wall.
The various identification phrases that can be used in a status chart are:
• Being constructed
• Being commissioned
• SYSTEM LIVE!
An example status chart is provided in Appendix 9.
A tracking chart can also be produced per system which provides sign-off boxes for the
various stages of the commissioning effort; again these should be clearly displayed. A
worked example of a staged commissioning tracking chart is provided in Fig. 21.
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FIG. 21 Ă
Chapter 2 • Commissioning Phase Two – Implement
121
It is also important to clearly post and identify key dates as a reminder to the whole
project, construction and commissioning team of the common goals. It is of most use and
interest if these lists are published in a common meeting room; an example is given below.
FIG. 22
Cleaning Procedures and Drying
Cleaning
Prior to pipes and equipment being put into service, it is important that good cleaning
procedures be conducted to help ensure a successful and trouble-free start-up. Unfortunately it is not uncommon for an initial plant commissioning period to be marred by
foreign materials having been left inside pipework, which find their way to pumps and
other equipment, causing significant damage.
It is also essential for some processes that water be totally removed from the pipework
and equipment due to contamination or a corrosion potential.
The commissioning system and mechanical engineers must document and track the
progression of pipework cleaning and drying within the engineer’s responsibility to ensure
all pipework is processed as required and to enable a check of outstanding procedures to
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
be completed to aid close-out of systems prior to handover. The commissioning team
should work closely with the construction group as the most effective and efficient time to
clean pipework is immediately after the construction proof or integrity test.
Each system will have numerous procedures written, detailing the method for
cleaning all the pipes and equipment within the system in question. The procedures will
incorporate a check sheet that will indicate:
• The type of cleaning (steam, water, rapid pneumatic depressurization with air or
suitable gas)
• The source of the cleaning medium
• Maximum pressures that may be utilized in the procedure
• The cleaning route for continuity
• Temporary equipment necessary for cleaning, for example spools, flexible hoses,
strainers and target plates.
It is standard industry practice to erect pipework using temporary piping spools to
replace any equipment that may prevent successful cleaning and/or will be damaged by
the cleaning process. Examples of this type of equipment are:
•
•
•
•
•
Instrumentation including flow meters, temperature probes and pressure indicators
Modulating control valves
Non-return valves
Filters
Restrictor flow orifice plates.
It is good practice to list these items and check them as reinstalled post the cleaning
procedure and rectification of the pipeline. Marking up of the relevant isometric drawing will
assist in tracking removed items, temporary spools and the installation of any test blinds.
Post the cleaning procedure the commissioning engineer will need to ensure that all
open pipe ends are sealed to avoid ingress of dirt and debris prior to commissioning of the
piping system.
The commissioning team during the detailed design phase could appraise the plant
and organize for commissioning strainers to be procured and installed at the required
plant locations, an example being the inlet of pumps, to ensure during water commissioning and initial operation any potential foreign objects within the piping and vessels are
captured and do not make their way to a place where damage could be done. It is common
practice for commissioning strainers to be removed at a suitable shut-down post start-up.
Types of Cleaning Methods
Cleaning by Blowing – Rapid Pneumatic Depressurization
This method of cleaning utilizes a stored source of energy, typically air or nitrogen within
a pipe system, then rapidly opening a suitable end-of-line valve to quickly depressurize
the system to encourage debris to be blown from the pipeline.
Chapter 2 • Commissioning Phase Two – Implement
123
It is strongly advised that one must not blow into a vessel; the vessel will act as
a knockout pot ensuring debris is accumulated within the vessel and the removal of the
debris could mean a costly confined space entry into the vessel in question.
For tube heat exchangers removal of trapped debris may become impossible. If
therefore the vessel is on a key duty, inspection of the unit prior to the fitting of the tube
bundle at the vessel fabricator shop may be required.
It is highly advisable that a check is made and duly documented on the cleaning
procedure to ensure the exhaust open pipework ends are securely anchored down to
minimize any whiplash from the energy being released from the pipework during the
depressurization phase of the procedure. Erect warning notices and cordon off areas
where flying exhaust debris is possible.
If the pipeline size permits, fit a full bore plug or ball valve to the exhaust end. Pressurize the system to the agreed pressure, isolate the source and rapidly open the exhaust
valve to produce a shock wave that will carry any debris forward. Continue the pressurization and blowing process until the exhaust gas is clear of dust and debris.
Pneumatically driven instrumentation must not be connected to the instrument air
supply and therefore initially operated in the loop testing procedures until all instrument
air lines have been blown clear of debris. Suitable arrangements must be created and put
in place by the commissioning and installation instrument groups to ensure this vital step
is incorporated within the project plans. Failure to correctly clean instrument air pipework, hence potentially causing internal damage to delicate and expensive instrumentation, can cause significant delay to schedule if rectification work is required on
a damaged instrument. When blowing clean instrument air lines and related systems,
make the final blow with a white rag and/or card to ensure the exhaust air is clean.
Consideration may be given to the use of a flimsy diaphragm or strong paper disc
being clamped between two flanges at the exhaust point if a valve arrangement is not
suitable. If a diaphragm is used it may be necessary to find the bursting pressure by
experiment; some knowledge of pipeline design pressures must be incorporated into this
method of pneumatic cleaning and should be used as a last resort if pipeline design
pressures are not readily available.
Positioning of “target plates” on the exhaust port of the line to be blown may be required
on lines that have critically clean criteria. The plate is usually a 1” square bar which is
strategically positioned in the first section of the exhaust pipe from the line to be cleaned.
Steam lines feeding turbines are the classic place where a target blow is required. The target
plate due to its nature will indicate via “pitting” of the surface that debris is resident in the
pipework. Blow and rotate the plates accordingly until the cleanliness standard is met.
PRECAUTIONS
It is common due to the noise involved in this type of cleaning procedure for pneumatic
blows to be conducted outside of normal working hours when the number of people and
their movements are easier to control. The cleaning procedures must be considered, then
prepared well in advance of the actual blow wherever possible. The air or gas source must
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
be clean, dry and oil-free, e.g. instrument air or nitrogen. If the source is from an existing
works system consider the installation of a restrictor orifice limiting the maximum flow
into the cleaning system from the source point so that existing users cannot be affected by
loss of pressure.
If the emission of "flying" debris cannot be controlled or contained by a protective
screen then a collection pot must be fitted to the exhaust end of the pipework.
Cleaning by Steam Blowing (Steam Systems)
The cleaning of steam pipework via blowing of the pipe with the actual steam supply is
required to remove dust, debris and mill scale from the inside of the pipe system,
especially on delicate applications, examples being steam-driven turbines where the
impact could damage the delicate turbine fins and graphite steam exchangers where the
carbon block may be damaged.
A detailed step-by-step valve-by-valve procedure must be written prior to any steam blow
incorporating all the various steps and stages the activity will require. The procedure must be
reviewed, agreed and signed off by all responsible parties prior to the actual activity.
PRECAUTIONS
As steam blowing constitutes a highly dynamic form of gaseous energy release, it is vital
to ensure the open exhaust pipe ends are securely anchored to minimize whiplash within
the pipework incorporated within the cleaning procedure.
The area should be cordoned off and suitable warning signs erected with the area
rigorously policed during the actual blow to ensure all non-necessary personnel are
completely removed from the vicinity.
The fitting of temporary insulation on all exposed pipework for personnel protection
purposes should be undertaken.
Hearing protection must be seriously considered and the wearing thereof incorporated into the preparations, procedures and obviously worn extensively during the actual
steam blows. High-pressure (>600 psi) steam blows reach sonic velocities; the significant
noise generated from these steam releases must be considered, for the optimum timing
with regard to any local community and other workers at the job-site.
PROCEDURAL STEPS
Critical target steam blows are conducted at a certain velocity and pressure to obtain the
sufficient abrasive force required to remove the scale and debris from the pipe wall.
Process engineering should be involved to help calculate the steam flow from pressure
available, the key steps being (please confirm with process engineering):
• Calculate the pressure drop to a point where a vent is attached
• Size vent for sonic velocity at vent pipe exit
• Properties at the discharge is in ratio with “normal” operating conditions of the line
(flow and density) to obtain a correct cleaning ratio
• The ratio should be a value between 1.0 and 1.5 to conduct a targeted blow
Chapter 2 • Commissioning Phase Two – Implement
125
• High temperature (50–100oC) of superheat at steam blow pressure
• Saturation temperature drop not to exceed a suggested 75oF or 24oC during cooling
step
• Repeat blow as required; typical blow should be 3–5 minutes.
Steam blow computer models are also available to calculate the flow required.
As documented in the steam blow procedure, the common steps incorporated in
a steam blow are:
• Prior to commencing any steam blow, the supplier of the source steam should be
contacted and permission to use the steam given.
• Slowly open the steam from source to the pipework system to warm the line; continue
in this manner until all gross condensate has been removed from the pipe. It is
common not to open the steam supply to the steam traps at this point until all debris
has been initially blown from the pipe (avoids blocking of the steam trap).
• Continue to slowly warm until live steam is seen at the furthest open end.
• Open source supply to obtain the correct pressures and flow and blow clean the pipeline.
• Post the initial steam blow allow the pipework to cool as per the required procedural
steps.
• Repeat this cycle at least three times until the expansion and contraction of the pipework causes the internal mill scale to flake off. Repeat the blow until clean white steam is
emitted. Tests for cleanliness can be made if a target plate is fitted to the exhaust end
before blowing; typical surface coatings of the target are copper and/or aluminum.
A typical target plate set-up is given in Appendix 10.
Cleaning by Flushing
As stated in the cleaning by blowing section, it is advisable to avoid flushing into vessels as
debris displaced into the equipment may become very difficult and costly to remove.
Systems may be flushed by connection to a suitable source (always check as some water
can be corrosive to certain pipework), filling the pipe system then draining as required to
cleanse the pipes.
PRECAUTIONS
• Make sure a vent valve is open before draining a filled system to prevent pulling
a vacuum.
• Check for personnel below any drain points, if the flush is high in the plant structure
and remove from the area as required.
• Check plant drainage systems for environmental consent levels of contaminants
allowed to be discharged, examples being oil and suspended solids. Ascertain that
sufficient quantities of water are available and clear before draining. Complete an
environmental risk assessment prior to any flushing series to ensure the flush water is
directed to the correct location.
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• Where required fit temporary commissioning strainers into pumped systems. Agree
post start-up when these strainers are to be removed.
• Ensure that the providers of the water (in the event of large-scale usage) are aware of
the activity and starting time.
Chemical Cleaning
This work, usually undertaken by a specialist contractor, should only be conducted
after consulting a designated project or company specialist. The cleaning organization
will need to know the volume of the pipework to be cleaned, the materials of
construction and the level of cleanliness required post the cleaning procedure. Prior to
the introduction of any chemical used for cleaning a full punchlist should be created to
ensure the system is ready to accept a cleansing agent and a water leak test completed
to ensure no environmental incidents occur in the event of unforeseen chemical
leakage. A full and precise procedure or method statement describing exactly all steps
included in the procedure must be prepared by the organization conducting the work
and thereafter must be approved by the commissioning team prior to the activity being
executed.
Cleaning Via the Use of a “Pig”
As with chemical cleaning, “piging” is usually conducted by a specialist contractor. It uses
the technology of slowly propelling a full-bore abrasive pig down the pipe (usually a foam
device), which is driven by air or nitrogen at source and scours the inner pipe wall as its
cleaning method.
Typical applications are very long lengths of pipe, where the pig can have tagging
devices attached which allow for tracking and traceability should a blockage be identified.
Simple pigs such as a ball with rope attached can be use to prove clear bore, not
necessarily cleanliness on exhaust stacks and vent pipes.
Mechanical Cleaning and Visual Inspection
Manual cleaning and subsequent visual inspection are often the only methods which can
be used in some columns and vessels. The commissioning mechanical or systems
engineer should carry out a final cleanliness inspection post the cleaning prior to closure
of the piece of equipment. All procedures requiring confined space entry for their
execution MUST be strictly adhered to throughout the activity.
In general, larger-sized piping (30" or more in diameter) is manually cleaned. This
cleaning method entails personnel entering the pipe to sweep off and remove dirt or
debris from the pipe walls and welds mechanically with wire brushes or other suitably
abrasive devices. Stringent precautions must be taken to make the task safe. All work
should be subject to the conditions detailed on the method statement and permit to work,
including any confined space entry permit system.
Chapter 2 • Commissioning Phase Two – Implement
127
Drying
It is common for commissioning systems to have an operational requirement to be dry. This
could be for a number of process and mechanical reasons. Examples of these will include:
• For product streams to remain within process specification
• To avoid a chemical reaction (as with water and sulfuric acid)
• On applications where water or moisture cannot be tolerated in the process as is the
case of refrigeration systems where water will freeze and potentially cause blockages
and ineffective instrumentation.
There are therefore two typical levels of “dryness”:
1. Gross water has been removed; however, there may be some moisture
2. No water or moisture present.
A description of how to achieve either state is provided below.
Dryness Level 1
A commissioning procedure will be prepared for this activity and due consideration to the
execution of the activity will be given.
The dryness procedure needs to be completed when all pipework is installed, all
vessels and equipment are ready for service, and all physical isolations removed.
• The first stage of the dryness procedure is a series of pneumatic blows to remove
potential slugs of water in the pipework. Nitrogen is typically used for all procedures
involved with drying as it has a very low dew point and is very dry. Air may be used but
it must be filtered, dry and oil-free. A test of the dew point (at or below –30 C) of the air
supply must be conducted prior to its use in any drying procedure. The drying media
will be connected to a suitable point on the system. Noting the system design pressure,
the pipework and vessels should be pressurized to around 25 psig. If the system design
pressure is lower than 25 psig, use an appropriate pressure for the blow. It is worthy of
note that during any blow-down procedure all unrelated personnel should be out of
the area with barriers and warning signs erected. All operations and construction staff
should be informed of the operation. Please follow the guidelines described in the
cleaning by pneumatic blowing section of this chapter. At a suitable low-point valve,
depressurize the system and look for evidence of water. Repeat blowing at the low
points until there is no sign of water or mist from the exhaust gas.
• After the blow-down step, the second stage is to continually blow the system. Open the
drying source and, from as many low points as possible, purge the system.
Ensure if nitrogen is being used that any outlets cannot allow the collection of nitrogen gas
in enclosed or confined spaces.
Be aware of the source of the drying media and liaise with the controller of the source
to ensure no other user is being depleted by the drying operation.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Purge for typically 12 hours. After this time, sample a low-point purge with a dewpoint meter for moisture. If the reading is greater than –30 C continue to purge. If the
sample reading is at –30 C or lower, stop the purge and reinstate the system.
Purge times can be significantly lowered if it is possible to heat the source with an
external electric or steam heater, or by warming process vessels with the heat source.
Dryness Level 2
This secondary level of dryness is called upon typically for refrigeration or related
applications or for process product specifications where no moisture can be tolerated.
The extra dryness required is achieved by pulling a full vacuum on the system. This
obviously has its implications and during the writing of the evacuation procedure a full
check will need to be made of all pipes, vessels, equipment, instruments and relief
streams to ensure all can withstand a full vacuum. It is common for some instrumentation not to be rated for full vacuum; if so, suitably isolate and capture all isolations made
on the evacuation procedure.
As evacuation pumps are not typically an item readily available within a plant store
system, or commonly used and operated by commissioning personnel, vacuum drying
procedures can be organized and executed by an external contractor with all the correct
equipment.
The steps to achieve dryness level 2 will include:
• For any application, the first stage of dryness level 2 is to follow dryness level 1 to
completeness.
• When dryness level 1 has been achieved, install an evacuation pump to the system.
Ensure a calibrated vacuum gauge is fitted to a suitable position where it can be easily
read. Do not fit the gauge in a location that it is closed off when isolating the vacuum
pump.
• Valve up the system accordingly so all sections can be fully evacuated. Start the
vacuum pump. Monitor:
a) The vacuum pump oil; if it goes milky, moisture is present and the oil will need to
be changed and
b) the exhaust from the pump; a mist will indicate moisture.
• On a dry, leak-tight system the pressure should fall very quickly. If it does not and mist
is seen at the evacuation pump there is air being drawn into the system and
a secondary leak test must be conducted.
• Continue to run the vacuum pump until a pressure of 26–30” Hg is seen on the gauge
and there is no sign of discolored oil or exhaust fumes from the evacuation pump.
• Stop the vacuum pump and disconnect from the pipework. Begin to monitor the
vacuum gauge. If the pressure rises then the system is leaking and a leak test must
again be conducted. If the pressure holds a full vacuum has been pulled and the
system will be dry. Attach a nitrogen source and break the vacuum by pressuring to
atmospheric pressure with nitrogen. If required, break the vacuum with process gases.
• Remove all evacuation equipment and make good for continued commissioning.
Chapter 2 • Commissioning Phase Two – Implement
129
Cleaning Procedures and Drying – “Things That Can Go Wrong”
Taking a very proactive stance on cleaning standards and witnessing protocols is the best
guarantee to ensuring all pipework on any fluid or gas service system will be clean and
therefore predicate things going wrong during the actual commissioning phase. Not
enforcing a stringent cleaning regime can have implications on the commissioning of
a project.
A large circulating hot oil system was pre-commissioned and made ready to be put
into service. All pre-start checks were conducted and oil charged to the system. Electrical
de-isolation and valve alignment were the final steps to allow the system to be circulated
for the first time. No water commissioning had been conducted as moisture could not be
tolerated in the process, and the risks of a process leakage considered and accepted. It was
also considered unnecessary that commissioning strainers be installed.
The circulation system was duly started but ran for only a short period when the
circulation pump stopped and a grinding noise was observed at the pump. A significant
isolation and decontamination procedure was undertaken and the pump dismantled,
whereupon a significant length of wood was found in the pump suction system. The block
of wood had been left in the system, not removed by the cleaning methods and also
therefore not caught by a strainer. A significant cost implication was enforced on the
project to replace damaged parts on the oil circulation pump.
Key Points
• Conduct extensive cleaning procedures to all pipe systems independent of the size and
complexity of the system being cleaned
• Always ensure all design parameters are considered in the preparation of cleaning
procedures and vacuum procedures utilized in the drying process
• Ensure the correct cleaning medium is selected: flushing, blowing, use of a pneumatic
pig, chemical cleaning and/or mechanical mechanisms
• It is highly recommended that all delicate instrumentation and in pipeline items are
removed for the cleaning procedures. Never attach instrument air lines to field devices
until the lines have been suitably blown and proved clean
• Cleaning procedures, especially steam blowing, are noisy and dirty activities that by
their nature create the potential for flying debris. Ensure safety precautions are fully
considered and an integral aspect of the cleaning procedures and completely adhered
to during the cleaning operations.
Pre-Commissioning Procedures
This aspect of the commissioning effort will be conducted throughout the construction
and commissioning phases and will witness the execution of the procedures drafted
during the Prepare stage of the project and initially considered in the Create Commissioning Documents and the System File section of this handbook.
130
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Pre-commissioning procedures are just as important as cleaning documentations and
when diligently and completely executed by the commissioning team demonstrate the
high standards the team are committed to working to.
Pre-commissioning procedures form the basis of the check-out and associated
documentation of the build prior to the introduction of any chemical including water, air
and nitrogen into the system. After carefully reviewing the P&IDs, vendor IOM manuals,
data sheets and other associated engineering documents, a list per system can be drawn
up which details all the checks and inspections that will need to be drafted and later
witnessed and signed off in the field. Close inspection of the P&IDs will give the information required, for example are there mechanical interlocks installed, can these be
checked after initial installation? Are there non-return or check valves in the system, have
these been inspected to ensure that the internal device is present and works and is in the
correct process flow?
Please remember these procedures will need to be written well in advance of the actual
performance of the activity.
Obviously any potential list could be endless and unique to a project but typical
standard pre-commissioning procedure headings are given below:
• Procedure to check spectacle blind installation. NOTE: All slip blinds or spectacle
plates utilized must be given a suitable tail or handle so immediate identification can
be made in the field
• Procedure to check installation of car seal locks
• Procedure to check provision of weep holes in relief stream vent pipework
• Procedure to check installation non-return valve internals
• Procedure to check installation of thermal refractory lining
• Procedure to dry commission, a burner management system and/or PLC
• Mechanical interlock checks
• Fitting of all locks on valves
• Packing of a distillation or scrubbing column
• Packing a reactor with catalyst
• Filling of desiccant into drying tower
• Installation of filter medium and cartridges
• Checks to ensure pipework falls in the correct direction
• Installation of filter bags into a bag house or dust collector
• Procedure to check flexible couplings and bellows are fit for operation
• Filling a mill with beads
• Procedures to check the operation without any chemicals present of a DCS control
sequence.
Example hypothetical drawings of a process plant are provided in Figs 23 and 24. It will
serve to demonstrate, in the case of this fictitious process, which pre-commissioning
procedures will need to be written.
Hypothetical Process Drawing
of a Chemical Plant
Reactor Off
Gas Analyser
FI
3
AI
3
Legend
PZ
3
Instrument relayed to control
system
SD
2
Emergency Shut-Down System
(ESD)
PIC
3
HH
SD
2
PZ
3
A – Analyzer
F – Flow
P – Pressure
T – Temperature
I – Indicator
C – Controller
Z – Trip inpvut (ESD)
H – High (alarm)
L – Low (alarm)
HH – High High trip input (ESD)
SD – Shut-Down
MI – Mechanical Interlock
Process pipe/flow
Instrument signal
TIC
3
H
Reactor Off
Gas Condenser
L
H
Cooling Water
OUT
V-3
Cooling
Water IN
L
Refrigeration
Outlet (Gas)
L
Refrigeration
Inlet (Liquid)
PIC
4
Stripping
Tower
H
TIC
4
LIC
2
H
L
MI
L
FIC
1
H
L
SD
2
Steam
IN
LIC
7
L
H
L
H
Cooling
Water IN
Product
Filter
L
Feed 1
Vaporizer
TIC
1
H
Steam
OUT
L
Electric Hot
Oil Heater
Hot Oil
Recirculation
Pump
Heater
Cooling
Water OUT
Product
Condenser
Stripping
Boiler
Feed 2
From Stock
MI
Product
Compressor
H
FI
4
H
Hot Condensate
IN
L
TI
4a
Reactor Feed
Mixer
Steam IN
Feed 2
Vaporizer
Stripping
Reflux
Pot
H
L
H
L
LIC
6
LI
8
H
Product
Compressor
Suction
Drum
LI
9
H
L
Product
Receiver
Chapter 2 • Commissioning Phase Two – Implement
SD
1
LI
4
FIG. 23 Ă
L
HH
Steam OUT
Feed 1
From Stock
H
TZ3
SD
2
Hot Condensate
OUT
LIC
5
H
Reactor
FIC
2
Stripping
Condenser
131
132
Reactor Off
Gas Analyser
FI
3
AI
3
Legend
PZ
3
Instrument relayed to control
system
SD
2
Emergency Shut-Down System
(ESD)
PIC
3
HH
SD
2
PZ
3
A – Analyzer
F – Flow
P – Pressure
T – Temperature
I – Indicator
C – Controller
Z – Trip input (ESD)
H – High (alarm)
L – Low (alarm)
HH – High High trip input (ESD)
SD – Shut-Down
MI – Mechanical Interlock
Process pipe/flow
Instrument signal
TIC
3
H
H
V-3
Refrigeration
Outlet (Gas)
Stripping
Condenser
Cooling Water
IN
Cooling
Water IN
L
L
SD
1
Precommissioning 1
Packing of
Reactor
H
Refrigeration
Inlet (Liquid)
PIC
4
Stripping
Tower
H
L
LIC
6
Precommissioning 2
Packing of
Stripping Tower
Steam OUT
Reactor Feed
L
Mixer
Feed 2
Vaporizer
LIC
2
H
L
MI
H
L
FI
4
H
L
H
L
SD
2
Feed 2
From Stock
TIC
1
L
4a
FIC
1
Feed 1
Vaporizer
Stripping
Reflux
Pot
H
Product
Compressor
TIC
4
Steam IN
Hot Condensate
IN
H
Steam
IN
Precommissioning 5
Dry test of SD
system
LIC
7
Electric Hot
Oil Heater
Heater
H
L
Cooling
Water IN
Product
Filter
L
Stripping
Boiler
Precommissioning 3
Fitting of Filter
Media
MI
Pre-commissioning
4
Test of mechanical
interlock
H
Steam
OUT
L
Hot Oil
Recirculation
Pump
FIG. 24 Ă
L
HH
LI
4
Feed 1
From Stock
H
TZ3
SD
2
Hot Condensate
OUT
LIC
5
H
Reactor
FIC
2
Reactor Off
Gas Condenser
L
Cooling
Water OUT
Product
Condenser
LI
8
H
Product
Compressor
Suction
Drum
LI
9
H
L
Product
Receiver
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Hypothetical Process Drawing
of a Chemical Plant
Chapter 2 • Commissioning Phase Two – Implement
133
An example of how a pre-commissioning procedure prepared for the hypothetical flow
scheme may be represented is provided below.
To further demonstrate the process being described here, worked examples of actual
pre-commissioning procedures are provided below.
Pre-Commissioning
Procedure
TITLE: Procedure to Install packing into Scrubbing Tower 1
1
2
3
ACTION
Page 1
System: ST
Date: October 2010
Project: X
Author: M Killcross
STEP
Ref: PC2
METHOD
Comments
Check packing support Make an internal inspection of the
grate
packing support grate to ensure it is
secure and fit for operation
Check packing of
Confirm correct packing is available
Tower– 1 packed
Packing is 2” PTFE Pall Rings
section
Pack Tower 1
Confirm with
vessel data sheet
and vendor IOM
manual
Check the required quantity is available 3 m3 required
Signed Date
MK
3/10/10
MK
5/10/10
Transport packing in bags to top manway level
With the top and bottom man-way
access doors open:
3
Pour packing into tower from the bags. 3 m
installed
4
Confirm fill level
5
Fit hold-down plate
6
Confirm packing installed to correct fill Fill point
2.8 m from
point
packing
support grid
Installation
Lay hold-down plate on top of the
witnessed by
packing
commissioning
engineer also
With mechanical technician present
secure hold-down plate
Confirm all internal fittings are installed
as per installation drawings
MK
5/10/10
MK
5/10/10
MK
5/10/10
MK
5/10/10
Procedure to check installation of Tower 1 packing has been completed.
Date: 6/10/2010
Signed by: M Killcross
FIG. 25
Pre-Commissioning Procedures – “Things That Can Go Wrong”
Neglect the importance of rigid preparation and execution of pre-commissioning
procedures with caution; considerable negative implication to the commissioning effort
134
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
FIG. 26
can be generated in this non-chemical stage which will cause a significant issue in the
later commissioning phases.
A hydrofluoric acid (HF) recirculation pump was integral to the operation of a key
operational system on a high-hazard facility. All pre-commissioning checks were conducted and a complete leak test undertaken prior to the system carefully being put into
operation.
The pumped system ran with no adverse operational conditions for a short period,
whereupon the pump stopped although the motor was still running. After some troubleshooting activities it was decided to take the pump out of service, to decontaminate
Chapter 2 • Commissioning Phase Two – Implement
135
FIG. 27
and investigate the issue. At this point, as this was the only pump on this duty (no in-line
spare), the plant was shut down and operation and revenue lost.
Further mechanical investigation found that the impeller of the pump had become
unscrewed from the drive shaft and became detached. The discharge pipeline of the
pump had a non-return valve installed. This had been checked for correct directional
installation for process flow, but no internal check was made to ascertain if the internal
136
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
components of the valve were operational. Upon further investigation of this non-return
valve, the internal device was found to be missing; hence as the pump had stopped during
normal plant operational a reverse flow of product had over time unscrewed the pump
impeller.
It is always advisable to check the operation of control system sequences in the “dry
commissioning” pre-commissioning condition (taking into account those items of
equipment that cannot be operated without process fluids present), as it is much easier
and safer to rectify issues prior to the introduction of process chemicals than with them in
the operational unit.
Key Points
• Study all relevant engineering documents and manuals to ascertain the list of all precommissioning procedures to be conducted
• Conduct pre-commissioning procedures at any suitable stage in the construction and
commissioning phases. Construction management approval must be obtained for all
procedures conducted during the construction phase.
Vessel Check Sheets
Compiled during the Prepare stage of the project by either the system commissioning
engineer or the mechanical commissioning engineer to the requirements of each individual item of equipment, the vessel check sheets provide the data on what has been
checked and which aspects of the vessel construction have been witnessed by the
commissioning team on each unit prior to it being put into service.
Vessel check sheets need to be uniquely compiled for each project; however, examples
of check sheets that are commonly used are:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Vendor shop check – tank or drum
On-site check – tank or drum
Vendor shop check – column or tower
On-site check – column or tower
Vendor shop check – rotating machinery
On-site check – rotating machinery
Auxiliary systems – lube oil, hydraulic systems, HVAC
Vendor shop check – heat exchangers
On-site check – heat exchangers
Conveyer
Mill
Sieve
Pump
Blower or fan
Chapter 2 • Commissioning Phase Two – Implement
137
• Furnace or burner
• Turbine.
The actual vessel check sheet completion will be undertaken at various stages of the
construction, with a main and important sign-off being that of final closure prior to
operation. This is to ensure a final check has been made that the equipment is fit for
purpose, clean, free of debris and all internals having been installed as per the design. It is
important to know which interested parties need to be at the final closure; this will
include commissioning and project team members, plus potentially members of the
ongoing operations team if required.
It is worthy of note that some internal inspection will require entry to the vessel, and
all appropriate safety systems including confined space entry permits must be consolidated and integrated into the commissioning team plans for this activity.
A mechanical engineer or craftsman technician must be actively involved where
practicable with the completion of the vessel check sheets. All vessel check sheets should
be completed and fully signed off prior to introduction of chemicals. It is not uncommon
however for some items of equipment to be re-inspected post an initial operational and
then cleaning procedure; this secondary check should be suitably incorporated into the
vessel check sheet.
Worked examples of vessel check sheets can be found on the following pages. It is
important to note each vessel check sheet is individual to the equipment it is describing
and vessel check sheet compilation must be conducted having reviewed all vendor
manuals and drawings, as such generic checks, inclusions and omissions will be made to
suit an actual vessel within a given project.
A full suite of generic vessel check sheets is provided within the Commissioning System
File, a full catalogue of blank commissioning documents section of this handbook.
Key Points
• Compile vessel check sheets utilizing all vendor drawings and manuals
• Complete the check sheets at the appropriate time during the vessel installation
• Ensure that the correct teams of individuals are present at the time of vessel closure
and the correct personnel have inspected the vessel internally and witnessed the
installation of internal components prior to vessel closure.
Instrument Loop, Electrical and Control System Testing
During the Implement phase of the project, the E/C/I commissioning engineer has
considerable responsibility to ensure all electrical, control and instrumentation systems
have been installed and tested to the required standards. The documentation that will
have been prepared can be found in the Control, intrument, electrical commissioning
document preparation section of this handbook; during the Implement phase the
paperwork now starts to be signed off.
138
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
FIG. 28
The main activities that the E/C/I commissioning engineer will be conducting are:
• Witness to confirm all testing and check-out of instrumentation loops and electrical
equipment.
• Constant auditing of the completion of loop testing documentation to ensure that
a high standard is maintained and that all loops are fully tested with no significant
omissions creating additional testing later in the commissioning phase.
Chapter 2 • Commissioning Phase Two – Implement
139
FIG. 29
• Witness to confirm that the electrical, instrument and control systems function as
designed and all test procedures are signed off and documented correctly.
• Witness that all alarms, interlocks, DCS-controlled sequences and shut-down systems
are installed, configured and tested correctly.
• Witness to confirm that the control, electrical and instrument installation is in
accordance with the required design standards.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Electrical and instrument function testing is executed to demonstrate the instrument
and safeguarding systems and any associated operability of equipment will operate as
the design and basis of safety intent and will include as a minimum the following
elements:
• Operation and calibration of each instrument loop from the DCS operator workstation
to remote field device
• That for all input conditions, the corresponding output actions occur as designed
• The integrity of all safeguarding of the equipment is consistent
• Instrument and control systems are fully commissioned and ready for a plant start-up
• The operation and set-up of each electrical item, an example being a motor, from the
motor control center (MCC) process to field device.
Control system testing is executed to demonstrate the integrity of the entire system. The
tests will confirm design configuration and will include as a minimum the following
elements:
• The system is configured as per the design intent. This is to include a loop-by-loop
check of all graphic interface pages, trend pages and general system navigation. Test
documentation will be completed as evidence of the check-out; these documents will
either be compiled by the E/C/I commissioning engineer or by the DCS vendor with
sign off by the commissioning engineer and other appropriate parties (if required the
site maintenance group).
• All marshalling cabinets are set up, tested and documented correctly.
• The integrity of the system hardware including power up and power down is as per
design.
• To test that the backup procedures that are in place are robust should there be a loss of
part or the whole of the operating system.
• Complete all test procedures to demonstrate full system functionality, including safe
interlock, shut-down and sequence testing including complete failure monitoring; for
example if more than one initiator fails a system, all initiators are checked.
It is common that operational sites will have a complete portfolio of control, electrical
and instrumentation test procedures that can be then incorporated into the commissioning documentation. These procedures would describe the systems and paperwork to
be used in cooperation with the activities detailed above.
During the loop and electrical check-out phase, it is imperative that all work groups,
including all commissioning team personnel, construction and operations teams, work
very closely, as parts of the plant will begin to be energized.
It is advisable to consider suitable signs to warn non-commissioning team personnel
of ongoing loop and safety system checks, backed up where appropriate with barriers and
taped off areas clearly identifying the work being undertaken in the restricted area.
Chapter 2 • Commissioning Phase Two – Implement
141
Instrument Loop, Electrical and Control System Testing – “Things That
Can Go Wrong”
It is of the highest importance that a good system for all instrument and electrical testing
is established prior to the actual field execution activities.
The failure of loops operating correctly when required is a major contributor to
schedule disruption during the commissioning phases, as retrospective correction
activities are undertaken to a control valve not operating in the correct manner, or
a motor not starting during commissioning.
During the commissioning of a significant project in the USA, communication
between the C/E/I commissioning engineer and the installation and testing instrumentation subcontractor broke down and during the loop testing stage no alarms were
checked as the loop was confirmed operational. As the issue was identified during the
actual commissioning of systems, considerable time was lost to schedule as a corrective
plan of testing was established and conducted to allow a smoother execution of the
commissioning phase.
Always ensure all aspects of the loop testing program are identified, roles and
responsibilities clearly defined, and the activities dutifully discharged in the field to
facilitate a smooth testing schedule in this most important area of the commissioning
team’s activities.
Key Points
• Establish the methodology of testing, the how, where and what
• Monitor to ensure a suitably high standard is maintained during the testing phase and
all documentation is correctly completed.
Commissioning Punchlisting
Punchlisting, or snagging as it is sometimes referred, is the name given to the preacceptance, checking and inspecting of new installations by all groups within the project
organization, but will here focus on the effort required by the commissioning team during
this activity.
The record of the checking conducted is compiled into a PUNCHLIST of incomplete
work. The importance of a complete, well-executed and detailed punchlist cannot be
stressed highly enough and is the standard and key indicator that a good commissioning
team will be measured by.
When requested by the construction manager, the commissioning manager will ask
the responsible commissioning system engineer to inspect and check the system when
installation is typically at 80% complete. It is not uncommon for the commissioning
punchlist to be prepared out of normal construction hours to avoid disruption to the
142
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
build effort. This first punchlist is referred to as the PRELIMINARY PUNCHLIST and
should be as comprehensive as possible (potentially itemizing any incomplete items, but
included for completeness, an example would be late delivery equipment such as
a control valve or item of instrumentation).
The preliminary punchlist is compiled after a complete, full and extremely detailed
check of the whole system against the relevant P&IDs, incorporating all P&ID notes,
holds, comments and line description identifiers. The punchlist is not a walk through of
the system and visual inspection. A hands-on punchlist approach must be encouraged
and incorporated on every item on the system, with its surrounding geographical area
also being checked.
Punchlisting is at least a two-man activity (one member will physically check items
including bolt tightness, gaskets present and adequate piping supports), whilst the other
punchlist team member acts as scribe capturing all defects on the P&ID and documenting
exactly what has been omitted from the build and therefore included within the
punchlist. Where possible the commissioning C/E/I and mechanical engineers should
also be present so all the disciplines can check out the system at the same time and hence
the punchlist is the most inclusive it can be. It is common to also have a client representative present if required at the punch list.
Punchlist items could include the following points from obvious glaring errors to
minimal points of note:
• Incorrectly installed valves which present a safety hazard (handle protrudes into
a walkway)
• Valves installed in the wrong direction for the process flow
• Instrumentation installed such that it cannot be easily read by an operator
• Manual isolation valve that is installed out of reach of the operations personnel
• Trip hazard at the base of an access ladder
• Damaged pipework including insulation errors and painting issues
• Loose bolts and valve spindles
• Loosely installed instrumentation
• Inadequate labeling and signage
• Equipment that has not had lubrication installed.
The preliminary punchlist should indicate any equipment that has been removed to
permit testing, cleaning or leak testing and equipment that is missing or incorrectly
assembled according to the vessel and P&ID drawings. If the installation is correct as per
drawings but an alteration is thought desirable for operational or safety reasons, the item
must be listed for discussion (see priority designation below), with the commissioning
manager then submitting a suitable change proposal through the project engineering
change procedure as required and agreed at the job-site between all responsible parties
involved with the project change process.
Chapter 2 • Commissioning Phase Two – Implement
143
Each action should be listed as a separate numbered item, and clearly defined
with a precise location and description. Tagging the location often helps the
understanding of those not involved with the punchlist who later will need to rectify
the defect.
Each action must then be given a priority code and an “action on” column completed
on the punchlist to clarify who has responsibility for resolution of the issue. I advocate
a simplistic approach to punchlist prioritization, the punch list items falling into these
three categories:
1. Complete before handover/start-up
2. Complete after handover/start-up
3. Item for further discussion and clarification.
Other more complicated prioritization systems can be used, but the above has served
good purpose for me over many commissioning campaigns.
Once the on-site preliminary punchlist is complete and before the formal write-up
commences, the commissioning punchlist team must consider all prompts on a “post
punchlist check sheet”, to ensure that all due considerations have been made to the
system being inspected. Any oversight recorded will need to be addressed by
the team with a secondary review incorporating any missed initial checks back on the
job-site.
After the composition of the preliminary punchlist, the commissioning manager will
supply the construction manager with an agreed quantity (copies to all those who require
it), of the punchlist and associated marked up P&IDs for onward distribution to the
construction subcontactors for rectification purposes.
Posting of all system punchlists on a wall within the commissioning office or
trailer for ease of access is encouraged and the set-up of daily meetings to be
convened with the construction group to facilitate quick close-out of the punch list
items. It is also common for the construction group to assign a punchlist rectification
team to the commissioning team to manage as a speedy way to correct all punchlist
defects.
When construction is 100% complete and remedial actions have been taken on all
items shown on the preliminary punchlist, the commissioning team should be
requested to produce a FINAL PUNCHLIST. The author of the list should note any
isolation that may be needed (physical isolation, such as a pancake or slip blind) to
separate the system being punched, from adjacent systems before it can be made live
after handover.
Any final punchlist actions outstanding at handover are reassigned to the handover
reservation section of the handover certificate, and must be closed out at the earliest
possible opportunity.
A worked example section of an actual system punchlist and its corresponding post
punch check sheet can be found in Figs 30 and 31.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
FIG. 30
Punchlisting – “Things That Can Go Wrong”
It is clear: the desired successful outcome of the transition from a construction arena to
an asset being commissioned with ease and efficiency has a significant bearing on the
quality of all the previous commissioning activities but the punchlist phase is quite simply
the most important series of checks to ensure all is in place and the system is fit for
purpose and ready for chemical commissioning.
Chapter 2 • Commissioning Phase Two – Implement
FIG. 31
145
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
FIG. 31—Cont'd
An asset in the United States had progressed through the handover stage and
commissioning activities had actively started. The first major commissioning activity
was to conduct a leak test on a compressor system. Nitrogen was used as the test
medium and was duly connected to the process. The test pressure was 20 barg. The
initial test pressure was 5 barg, where a hold would be incurred and the system soap
tested for leakage. It became apparent 5 barg could not be held and a significant leak
Chapter 2 • Commissioning Phase Two – Implement
147
was found on a drying bed main flange joint. Initially the bolts were tested for tightness,
but the leak could not be stopped. After depressurization it was found that no gasket had
been installed in the flange. The gasket was duly fitted and the system pressured as per
the leak test procedure and passed its leak test. Significant time was lost to the
commissioning schedule which could have been avoided if a more stringent punchlist
had identified the gasket omission.
A large refrigeration system was installed as part of a major chemical plant build in
the USA. Both vendor and client commissioning team personnel had worked together
to check out and punchlist the system and the refrigeration plant was duly
commissioned. The unit ran for a number of hours when it tripped out and
a medium-term shut-down ensued due to a major issue with the actual process
compressor. Upon investigation by the refrigeration plant vendor, a small isolation
blind was found in one of the lubrication oil lines to the compressor intermediate
stages with some limited damage to the equipment requiring rectification work. This
example indicates the intricate depth of punchlist check-out required both by clients
and vendors to highlight potential issues within the system build to avoid scenarios as
described above.
These are simple examples, but over many projects globally, many commissioning
hours have been lost to rectification work which could have been avoided should a more
rigorous punchlisting effort been undertaken.
Key Points
• Complete a preliminary punchlist at 80% construction completion within a system,
having first agreed this timing and when the punchlist will be undertaken with the
construction group
• The punchlist must be a complete check of all aspects of the system, per the P&IDs and
not just a walk around and sight check
• A post punchlist check sheet must be considered after the punchlist is done to ensure
everything possible in the system has been checked
• Clearly identify all punchlist items on the list and tag the defects in the field
• Utilize a suitable priority ranking system for the punchlist items and indicate those
responsible for rectification. Stipulate a completion date for all items to be made
good.
Handover from Construction to Commissioning
At the point in a project where the handover from the construction group to the
commissioning team takes place, the formal documentation created and agreed during
the Prepare phase and documented in the commissioning manual is deployed to manage
the process.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
It is vital good communication be then employed to ensure everyone within the
project and construction groups workforce is told and is aware of the change of
responsibility status and the implications to permit issue, safety and introduction of
energy and related commissioning activities.
A worked example of a handover certificate is provided in Fig. 32; a blank document
will be found in the blank commissioning system file section of this handbook.
FIG. 32
Chapter 2 • Commissioning Phase Two – Implement
149
Introduction of Safe Chemicals
It is common for the phase of the construction and pre-commissioning effort where
utility chemicals need to be introduced (instrument air required for loop testing and
water systems for hydrostatic testing are examples) that the full hazard study and/or prestart safety review (PSSR) process will not have been completed. This may occur because
the commissioning and/or operations group want to hazard study and/or PSSR full
groups of utility systems rather than on a utility-by-utility basis. In the scenario where the
hazard study/PSSR process is not completed, a system must be considered to manage the
introduction of safe, utility chemicals in an effective and well-communicated manner,
clearly indicating who will be in control of the energy source being introduced.
The use of a notification of safe chemical introduction system is a method to manage
the process. The commissioning manager is responsible for completing and issuing the
introduction of a safe chemicals certificate. Prior to submitting the certificate for signing,
the commissioning manager will ensure that (amongst other things) all punchlist items
(see punchlist section, category 1 items) and loop testing procedures have been conducted and suitably signed off before any energy is brought into the system and any
statutory paperwork is in place.
Communication and advertisement of the introduction of safe chemicals to all
interested parties is essential with incorporated barriers and appropriate labels positioned where applicable.
The following is a list of prompts to ensure that all relevant items have been addressed
and are in place before the introduction of safe chemicals. It is to be used in conjunction
with any associated PSSR and other safety-related site paperwork systems.
• Has the system to test been handed over from the construction team?
• Have all flushing and blowing activities been completed and of those remaining have
they been incorporated as part of the safe chemicals trials?
• Hazard studies: Has a hazard study been completed during the design phase and all
actions arising from this study closed out? Has a pre-commissioning hazard study
been completed and have actions that need to be carried out before introduction of
safe chemicals been completed? Is the work being done under a management of
change or modification procedure? Have all resultant actions arising from the hazard
assessment section of the modification form been completed? Has a PSSR been
undertaken for this system?
• Is all statutory paperwork for vessels, pipes and relief streams in place and entered into
the correct registry?
• Have all instruments, interlocks and shut-down systems been tested and witnessed by
the C/I/E commissioning engineer and handed over for process commissioning? Are
the handover documents including loop drawings (to “as built”) available for use?
• Does the plant emergency alarm system work? Is there a system in place to cover this? Do
all communication systems fully operate or, if not, what contingency system is in place?
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• Are there protective commissioning screens and/or filters in place to protect
equipment?
• Punchlist and reservation sheets: Have all items that need to be completed before safe
chemicals are introduced been completed? Is the pipework and equipment adequately
supported?
• Have all construction Permit to Work certificates been signed off so only commissioning personnel can operate the system?
• For leak-testing activities have all leak test procedures been written? Do the activities
have an impact on adjoining construction activities including noise and dust?
• Have any initial commissioning trials been defined? Do people know what the trials are
and what parameters have to be measured? Do log sheets exist to collect the data or do
they still need to be written?
• Has the risk of loss of containment been addressed and its effect on the environment
considered? Are written contingency measures in place should leaks occur? Do people
know what the emergency procedures are should a leak occur?
• Has the whole process been thought through? Where do the safe chemicals go once
they have been through the process? Are they recycled or does effluent removal need to
be arranged?
• The system must be isolated from other systems still under construction control by
positive isolation, spool removal, or slip blind. Locked closed valves should not be
solely used unless agreed with all parties prior to introduction of chemicals. Are these
isolations in place and are they recorded in the isolation register?
• Has the owner of the plant service to be used (water, steam, air or nitrogen) been made
aware of the intention to use the service and does the commissioning engineer have
written approval from the supplier?
• Has the intended date to introduce safe fluids been advertised? It is useful to have
a status board at the plant entrance that indicates which systems are live.
• Have all live pipes been marked up with ‘LIVE’ ID tape in advance of the introduction
of chemicals?
• In the case of steam, have all necessary precautions to protect personnel from injury due
to contact from unprotected hot surfaces been taken? Is critical insulation in place?
• Have all critical valve alignments been checked to ensure they are in the correct
positions, for example on relief streams and interlock systems?
• Is their adequate commissioning cover for any trials? Is 24-h cover organized? Do you
need a separate team to solve technical problems arising during start-up?
Figure 33 offers an example of an introduction of safe chemicals certificate that can be
considered for effective and safe utility chemical introduction.
Introduction of Safe Chemicals – “Things That Can Go Wrong”
It is very important that a clear management system is visible when introducing process
chemicals into a system that has not been subject to a formal chemical introduction
Chapter 2 • Commissioning Phase Two – Implement
151
Introduction of Safe Chemicals
Project:
System : Instrument Air (IA)
th
Author: M Killcross
Date: 27 November
2004
No
Item
P&ID’s covered: 2007, 2008
Authorized
Signature
Date
Person to sign
27/11/04
Commissioning PH
1
System completed as per P&IDs
Engineer
27-11-04
Commissioning MK
Punchlist compiled
2
Manager
All high priority items closed out
27/11/04
Valve Alignment Checks carried out.
Commissioning PH
3
(Including relief stream interlock alignments).
Engineer
All instrument loop testing complete and
C/E/I Comm’s
4
27/11/04
SW
signed off
Engineer
C/E/I Comm’s
5
All Interlock testing complete and signed off
27/11/04
SW
Engineer
All Emergency Shut-down System checks
C/E/I Comm’s
6
27/11/04
SW
complete and signed off
Engineer
Commissioning N/A - None
7
Lubrication checks completed and signed off
Engineer
Pump alignment checks completed and signed Commissioning N/A - None
8
Engineer
off
C/E/I Comm’s
9
Motor rotation checks completed and signed
N/A - None
Engineer
off
Commissioning PH
27/11/04
10
Leak/pressure test procedure written
Engineer
Any Management of Change (MOC) checked Commissioning N/A - None
11
Manager
to ensure compliance
27/11/04
Commissioning PH
12
All safety equipment in position
Engineer
27-11-04
13
All Permits to Work and Confined Space Entry Commissioning MK
permits have been signed off
Manager
27-11-04
All blanks, blinds or pancakes in correct
14
Commissioning MK
positions & isolation register completed.
Engineer
27/11/04
15
All labeling (including temporary labels)
Commissioning PH
completed
Engineer
27-11-04
16
All personnel have been informed of the
Commissioning MK
introduction of chemicals
Manager
Authority is given to introduce: Instrument Air for loop testing, leak testing and pre-commissioning purposes.
The system is under full control of the Commissioning Team
We are satisfied that the general housekeeping/safety standards in the area are satisfactory. We agree the
Date/Time for introduction of process fluids will be : 28th November 2004
Construction Manager B Jones Sign: B Jones Date 27/11/04
Commissioning Manager M Killcross Sign M Killcross Date: 27-11-04
Operations Manager A Black Sign A Black Date: 27.11.04
FIG. 33
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
review. A transparent system must be in place that has addressed all safety and operational checks that have been made on the system and who has control; this is all in the
event of an unfortunate eventuality when things can go wrong.
Key Points
• Establish a robust check sheet and sign-off certificate
• Ensure all site-based safety paperwork for the introduction of safe chemicals has been
considered and incorporated within the introduction system
• Communicate fully the notification and control of the introduction of safe
chemicals.
Pre-Commissioning HAZOP Studies or Pre-Start-Up
Safety
Prior to any introduction of hazardous chemicals a hazard study and/or pre-start safety
review study must be completed. There are various forms of hazardous chemical introduction Hazard Studies that can be used; the hazard study approach created by ICI in the
1960s in the UK, a Hazard Study 4, is an excellent example and can be readily convened
prior to the introduction of the process chemicals. In other parts of the world the PSSR
approach is used; the guide words to be asked at this appropriate time are very similar in
nature in both cases. After the study follow-up meetings will be convened to close out any
of the actions generated.
Hazard Study 4 and/or the pre-start-up safety review can be conducted via a system or
group of systems approach; the studies containing the checks required to ensure all
relevant and pertinent documentation and the plant build in general is in suitable fit for
purpose order prior to any energy introduction to a commissioning system.
The studies will be managed typically by the commissioning manager; however, in the
case of a project where a retrofit of process equipment has taken place. The manager of
operations may take the lead with relevant commissioning team personnel attending
where required.
A pre-start-up safety review or Hazard Study 4 team for this activity would be made up
of the following project and operations personnel:
•
•
•
•
•
•
•
•
Project manager
Mechanical engineer
Electrical engineer
Process engineer
Operations manager
SHE advisor
Commissioning manager
Commissioning engineers.
Chapter 2 • Commissioning Phase Two – Implement
153
Most companies will have a Hazard Study 4 (or equivalent) or pre-start-up safety review
policy and procedure in place; however, below is a general list of items to be considered
for inclusion and review during this process.
The Installation and Construction
Main Points
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
System fully checked against P&ID with all components verified?
All labeling as per specification including vessel hazard identification?
All tripping and head/leg bang hazards identified and mitigating steps initiated?
Correct materials of construction and valve type have been used?
Control and non-return valves plus filters installed for correct direction of flow?
Supports are adequate?
Have any pipeline low points or pockets been introduced?
Stairs, walkways and ladders all installed as per specification?
All lighting adequate and fit for operation?
All exit routes clearly identified and illuminated?
Access for operation and maintenance adequate and suitable for operation?
Instruments all in correct position for operations and maintenance?
Lubrication points suitable?
Guarding of machines and moving parts adequately addressed?
Stop and emergency shut-down buttons and activation points installed and labeled as
per specification?
Fragile pipes and roof spaces correctly labeled with suitable barriers installed?
Hot surfaces suitably insulated or protected?
Lifting beams tested and labeled?
Safety equipment addressed and installed, shower systems tested?
Fire systems installed as per specification?
Control room and motor control centers checked for labeling and suitability for
operation?
Hazardous areas clearly labeled and identified?
Sample and environmental systems as per design and specification?
Housekeeping suitable for ongoing commissioning and operation?
Relief systems correctly installed and documented?
All sharp edges on, supports, bolts, insulation and labels have been considered and
rectified?
All instrumentation and electrical items correctly checked out, including rotation and
fail-safe position verified?
All computer control systems (DCS) completely checked out and documented. Are
personnel suitably trained?
Are there procedures in place to restart a DCS system in the event of a shut-down?
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• All emergency shut-down systems, interlocks, trips, alarms and sequences checked
and ready for ongoing operation?
• Provision in place to safely manage drum handling, skid mounted units, cylinders and
road transit systems?
Design and Documentation Requirements
Main Points
• All previous hazard study and design safety review actions have been signed off and
accepted for ongoing operation?
• All inspections required have been performed and documentation is available?
• Suitable drainage has been considered and installed?
• Suitable consideration made to work at heights?
• Ventilation and HVAC considerations have been met?
• All instrument calibration certificates available and verified?
• Restrictor flow orifice plates verified for correct flow?
• Standard operating procedures and maintenance procedures all written, validated and
in place?
• Current set of P&IDs available for operations and commissioning teams?
• Instrument loop drawings and electrical drawings all in place and available to operations and maintenance?
• Adequate provision considered for spares and the spares system uploaded with new
information?
• Provision of hazardous substances considered and a managing system in place?
• Noise considerations have been met?
• Provisions for site, emergency and plant procedures in place and a system for
managing visitors?
• Radioactive equipment management system in place and or updated?
• Emergency power, communication and services management systems in place?
• Training systems for all personnel written and being executed?
• Management of change system in place?
• Handover systems identified, in place and working?
• A recognized scheme for managing interlock trip defeat systems in place?
Key Points
• Prior to the introduction of hazardous process chemicals a robust safety checking
system must be used
• Utilize the existing site system or one based on best industry practice such as the
original ICI created Hazard Study 4 format
• The system will be managed by the commissioning manager
• The hazard study must take place prior to the introduction of any hazardous chemical.
Chapter 2 • Commissioning Phase Two – Implement
155
Commissioning Leak Testing
The system leak test is typically the first major commissioning exercise after the
compilation of the punchlist and the handover process.
Depending on the gas or fluid within the process pipework and vessels, one of various
types of leak test will take place. Leak testing is carried out system wide; the purpose is to
ensure that no potential leak path, a gasket or seal for example, is passing the test medium
thus reducing the risk of a loss of containment to atmosphere once the process chemicals
are introduced into the system.
The commissioning leak test should not be confused with the construction proof
test. During the construction proof test a section or sections of pipe systems (potentially
from different commissioning systems) are tested to prove the integrity of the pipe
welds and other associated hardware. Some key piping components will have been
removed such as delicate instrumentation and control valves (as typically there is no
instrument air to open them at this stage in the construction phase) and some of the
proof tests may have been conducted off site or in a remote test area. In addition to this
various aspects of a system are different pressures (the suction pipe work may be at
lower pressure, whilst the discharge side of the pump system potentially could be
significantly higher and hence the total system becomes subdivided into several
integrity test packages).
The commissioning leak test captures all potential leak paths within a complete
system with no or limited flanges excluded from the test (typically where isolation blinds
have been installed to physically isolate one system from another). There could be some
flanges that cannot be included in the leak test; these flanges should be identified and
special attention made to their integrity when actually put into service. These flanges
(commonly referred to “golden” or “critical” flanges) will then be witnessed at installation
and make-up of the gasket by the senior plant mechanical engineer.
Care should be taken when preparing leak test procedures to ensure items such as
pumps and seals can withstand any pneumatic or hydraulic pressure and indeed in some
instances can tolerate a temporary loss of hydraulic pressure. In the case that they cannot,
suitable isolation should be put in place to remove the equipment from the test and
a check point included on the leak test and commissioning procedures to ensure at startup any gasket that has had a physical isolation installed does not then leak in normal
operation.
Leak testing can be conducted in various forms.
Test (a): Service Test
The simplest leak test is that associated with a system that is within a service or utility
function with relatively safe chemicals within, examples being utility or instrument air,
utility, potable or cooling water and nitrogen systems. Here, once all paperwork has been
reviewed and signed off and the system is ready to be energized and pressurized, the
utility medium is carefully introduced to the pipework and equipment and allowed to
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
pressurize to the normal operating condition, thus an in-service test is performed. Even in
the event of a service test scenario, a full and precise leak test procedure should be
completed to safely manage the introduction of the process medium.
In the case of a gas system (air or nitrogen) all pipework and vessels should be walked
down and sprayed with a soapy-water solution looking for bubbles to form, hence leak
paths. Common leak points that need to be carefully checked are:
•
•
•
•
Pipe and vessel gaskets and joints
Pump seals
Valve stems and associated packing
Valve bonnet gaskets.
Any leak found must then be tagged to aid identification by the rectification team (see
previous section for examples of tags to be used) and a clear note made on the P&ID used
for the leak test. In the event of a major leak, the system may need to be depressurized and
a re-joint undertaken or if possible the location of the leak isolated and a smaller location
vented or drained down to correct the leak. The safest way to manage the system MUST
be used.
For water tests, more care should be given to ensure the test procedure identifies and
gives instruction on how the system will be bled of air whilst filling; if the air is not vented
the system will not be hydraulically full and a steady test pressure will not be possible to
achieve. After pressurization a full system walk down should be conducted and all leaks
identified and tagged accordingly. Any wet pipe must be dried so identification of any
leak becomes easier to notice. Due to the need for the pipe system to be dry in a hydraulic
test scenario, the test must not be conducted in the rain. Care must be given to a safe
drain point for the test water in case a major leak occurs and the system needs to be
drained down to enable any rectification work to be safely conducted.
After a successful leak test all procedures should be signed off and the system
considered to be left “LIVE”, energized and “in service”. In the interest of safety, a suitable
communication must be considered by the commissioning manager to ensure all
construction, client and project personnel are aware of the change of system status.
Test (b): Safe Chemical Leak Test
By their nature most core process systems contain hazardous chemicals; the introduction
of such chemicals without a prior safe chemical leak test potentially could lead to a loss of
containment which obviously would have environmental implications and as such
should be considered unacceptable.
Each and every system containing hazardous chemicals should have its leak test
carefully and meticulously defined, planned and documented.
Considerations on each test must include:
• Scope of test drawn up on the relevant system P&IDs
• List of all pipelines and equipment to be tested
Chapter 2 • Commissioning Phase Two – Implement
•
•
•
•
•
•
•
•
•
•
•
•
•
157
Clearly identified inter-system isolations
Complete list of valve positions for the test
The test medium – air, water, nitrogen
The test input point
Configuration of the test rig – see example of a typical test rig configuration later
Test pressure
Test pressure indication points to be used
Test depressurization points
Safe locations to drain and vent
Test duration
Clearly identified test pressurization phases and durations
Specific written test procedure
If available (control system is operating?) trend data of the test period to prove no
pressure loss, or to track the pressure over time with explanation of pressure highs and
lows (ambient temperature changes?)
Depending on the size of the system several commissioning personnel should be
considered to perform each test to ensure a complete check is made of every potential
leak path.
After the test the procedure must be signed off to confirm the system is ready for
continued commissioning. Any supporting evidence of the successful test (trend pressure
data from the control system and the log of pressure indication over duration of the test)
included with the test procedure.
Incorporated within the leak test procedure paperwork is a pre-test check sheet. This
must be considered and compiled prior to the test to ensure the correct test media are
used, the correct isolations are in place and most importantly the correct test pressure is
utilized. The leak test procedure itself must be detailed, clearly explaining each stage of
the test.
Leak testing of a large system is a major undertaking and during the Prepare phase
consideration must be made and action put in place to address and account for the
following:
•
•
•
•
•
Is there sufficient air or nitrogen available?
Is an air compressor required?
Is the air output dry and oil free?
Is nitrogen in bottles to be ordered?
Have there been sufficient leak testing soap solution and application bottles obtained?
At the point of pressure introduction a “test rig” must be installed which will enable tight
control of the energy source. It must be equipped with a suitable and certified relief
device and test gauge. The set-up of the rig should be such that an isolation valve with
blow-down point is configured in such a way that the test medium can be vented yet the
test pressure gauge can still be read.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
For guidance purposes the leak test pressure for any given system would be 1.1 times
the normal operating pressure, but a clear and informed check of the particular pressure
and test requirements of any actual system to be tested must be incorporated into the test
procedure.
Prior to pressurization, the final leak test pressure should be divided into three or four
test stages. For example, if the final test pressure is 100 psig, then hold points should be
made at 25, 50 and 75 psig. This builds in a margin of safety for the test allowing for a full
inspection of the system at a lower than final pressure to check for major leakage.
Leak Test Stage 1
Slowly pressurize the system to the first-stage hold pressure. A visual inspection of the
system must take place to ensure there is no major leakage. If not, proceed to the second
stage.
Leak Test Stage 2
At this stage pressure, a FULL leak test using soap solution is conducted. Soap solution is
applied to all parts of the system that are a potential leak path. Tag with suitable labels all
leaks and identify the leak points on the leak test P&IDs. Attend to all leaks found; if
required depressurize the system and isolate accordingly.
Proceed to the third stage and, when at the hold point, walk the system again.
Leak Test Stage 3
Slowly pressurize the system to the third-stage hold pressure. Conduct a visual inspection
of the system to check that a major leak has not been created and then proceed to the final
stage.
Leak Test Stage 4
When at the final leak test pressure, the test rig should be isolated and the test medium
disconnected; the pressure gauge on the test rig must remain within the scope of the
test. Fully soap test each potential leak point and visually inspect the system. If
available utilize a DCS pressure indication and set up a trend of the pressure point to
track pressure fall. Climatic conditions can affect a long-term leak test; as the ambient
temperature falls so will the test pressure and the reverse will apply as the temperature
rises; these pressure swings must be accounted for in the test. Hold the test pressure
for the time specified on the leak test check sheet. If the test is successful, make
a printout of the DCS pressure indication and include with the system leak test
procedure.
Post a successful leak test, safely depressurize the system, reinstate any physical
isolation and organize for temporary test equipment to be returned to store.
An example test rig configuration is provided below.
Chapter 2 • Commissioning Phase Two – Implement
159
Typical Leak Test Test Rig Set-up
Calibrated pressure indicator
System to be leak tested
Suitable calibrated
and tested
Relief valve
Energy source
hose coupling
Blow-down valve
FIG. 34
Test (c): Vacuum Test
In a scenario where the intergrity of a system is of major importance, a vacuum test may
be considered to provide secondary evidence of a leak-tight system. After a successful
leak test and after careful preparation of a vacuum test procedure taking into account
isolation of all system equipment that cannot within full vacuum, the system will have
a vacuum pump attached to a suitable point.
The vacuum pump is started and the system allowed to depressurize to the vacuum
point required as specified on the vacuum test procedure.
The pump can then be stopped and disconnected from the system; the procedure is
very much the same as a leak test procedure although the steps are in reverse.
The negative pressure is then monitored for pressure rise to confirm there is no air
ingress to the system. Shave foam or some other suitable medium can be applied to
flanges to inspect for the material being drawn into the piping or equipment by the
vacuum. A check must be made to confirm this is acceptable.
After the successful hold period has expired, care must be taken to break the vacuum
with the correct medium; as air is not always acceptable, an inert gas can be considered in
applications where air cannot be tolerated or indeed an introduction of process chemicals ensuring all correct chemical introduction paperwork and safety procedures have
been initiated.
Test (d): Toxic Testing
In some scenarios and for process-related reasons a toxic test can be considered. In this
situation again it may not be practical to leak test with air, or a secondary leak test is
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
required or the configuration of the pipework and equipment makes soap testing very
difficult.
An initial leak test pressure is achieved (utilizing the steps in test b) with an inert test
medium. A small quantity of a test chemical gas is injected (a common example would be
Leak Test Procedure
Leak Test 1 – Shower Water System
NOTE: THIS IS A LIVE SEVICE LEAK TEST
Please refer to the marked up P&ID attached to this procedure
Step
1
2
3
4
5
6
7
Operation
Check valves:
Valve 1 – CLOSED
Valve 2 – OPEN
Valve 3 – OPEN
Valve 4 – OPEN
Valve 5 – OPEN
Valve 6 – CLOSED
Valve 7 – CLOSED
Valve 8 – CLOSED
Valve 9 – CLOSED
Valve 10 – CLOSED
Valve 11 – CLOSED
LIC 1 – 0% - CLOSED
Open the water supply at valve 1
OPEN LIC 1 slowly to 50% and fill the
Shower Water Tank.
Monitor LIC 1
Check the pipe work to the Shower Water
Pumps A and B and the Shower Water Tank
for leaks
Fill Shower Water Tank to 40% in level.
CLOSE LIC 1 control valve
Start Shower Water Pump A and circulate
water around the system
Check the pipe work from the Shower Water
Pump A to the Shower Water Tank for leaks
Comments
If a leak on either the tank or
pump pipe work is seen,
CLOSE LIC 1 and attend to
the leak, drain the system if
required
If a leak is seen on the pipe
work STOP Pump A and
attend to the leak, drain the
system if required
The equipment and lines included in this procedure have passed the test as defined above:
Commissioning Engineer: M Killcross Signed: M Killcross Date: 1/2/2010
Plant Representative: A.N Other Signed: A.N Other Date: 1/2/2010
FIG. 35(A)
Signed off
Chapter 2 • Commissioning Phase Two – Implement
161
a known refrigerant gas) and then each potential leak path is tested by “sniffing” the
potential leak points with a hand-held chemical detector specific to the test medium.
Considerable care must be taken when utilizing this method to ensure the test gas
mixture is vented to a suitable and safe location.
Example leak test paperwork systems can be found in Figs 35 and 36 based on the
hypothetical process plant utilized in other sections of this handbook; they address
a service and a safe chemical leak test.
Commissioning Leak Testing – “Things That Can Go Wrong”
Leak testing is a very important activity as it forms the basis that the pipework and equipment incorporated within a system are free from the potential to leak process chemicals to
atmosphere during the commissioning phase and therefore avoids a loss of containment.
A relatively benign chemical operation in the USA formed, as a by-product of the
process, quantities of a hazardous acidic gas. No leak test of the system was conducted as
it was considered unnecessary as the process utilized relatively safe chemicals. Upon
start-up several relief systems within the system leaked and the hazardous by-product gas
was lost to atmosphere. After rectification of the leaks, a low-pressure nitrogen leak test
was introduced which found additional leaks in the system which were able to be
attended to without further loss of containment. It then became standard practice to
adopt this leak test upon re-commissioning of the asset.
6
Water
Mains In
7
FO
1
LIC
1
8
1
9
Shower
Water
Tank
Shower
Water
Pump A
10
4
11
2
E-5
Shower
Water
Pump B
Drain Point
Equipment included in the
service leak test
5
3
Shower Water Process and Instrument Diagram
E-6
Service Leak test
(See procedure at Fig. 32)
FIG. 35(B)
162
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Leak Test Procedure
Checklist
Project: X
System : Reactor
Page 1 of 4
P&ID (which must be attached to this procedure)
MK-0002
Author: M Killcross
Date: December 2010
SUB-SYSTEM - Identify all vessels/lines to be tested:
Reactor, Reactor Off-Gas Condenser and related pipe work and instrumentation
ISOLATIONS - Identify isolations required for test (spades, double block and bleeds)
Slip Plate (SP) isolations installed at (SP-1). Feed 1 at isolation valve 2, (SP-2). Feed 2 at isolation valve 3 and
(SP-3) Product to Stripper Column and Valve 5.
VALVES - Identify valves which need to be opened for test (control valve shutdown valves)
System valves and system for opening and closing will be identified within the procedure and on the P&ID
Test Input Points: Valve 1 on Feed 1 feed line. Signed: M Killcross
Location : Reaction Building and associated Condenser area
Test
Rig Fitted
Medium
Test Pressure Pressure Indication Point -
Water
Air
12 barg
PIC 3 (control system)
Test pressure gas to be released
Release Pressure At from valve 4
N/A
Drain Liquor To
All joints to be soap tested - Yes / No
Other test if not soap test - N/A / No / Yes - Identify:
Expected Test Duration Time:
12 hours
Nitrogen
Other
Yes MK
Actual Test Duration Time:
Rig Removed
Yes MK
14 hours
Pressure drop with time
Initial
Pressure :
25% :
Atmospheric
Final Pressure :
12 barg
3 barg
Leaks Found?
YES / NO
Identify location with tag, and mark on system
P&ID. Done MK
50% :
6 barg
Leak locations:
See P&ID
75% :
9 barg
Remember: Temperature and pressure differential must be considered.
FIG. 36(A)
A major chemical plant in the UK was subject to a significant upgrade to plant capacity
including the installation and commissioning of new operational systems. One major
new system on the plant utilized a circulation salt solution as a medium to remove heat
from the process. The overall system proved very troublesome to leak test and after some
considerable time conducting in-depth leak tests the decision was made to put the
Chapter 2 • Commissioning Phase Two – Implement
163
Leak Test Procedure
Step
1
2
3
4
5
6
7
8
FIG. 36(A)—Cont'd
Operation
Comments
Signed off
Install isolation spades:
With the system depressurized:
SP-1 Install Reactor side of V2
SP-2 Install Reactor side of V3
SP-3 Install Condenser side of V5
Fit Test rig to Nitrogen inlet point at V1
Installed
MK
4/12/10
Installed
MK
4/12/10
Set valves:
V1 – CLOSED
V2 – CLOSED
V3 – CLOSED
V4 – CLOSED
V5 – CLOSED
Pressurise to initial hold pressure:
OPEN nitrogen source to test rig
Slowly OPEN V1 and monitoring PIC 3
Build pressure to 3 barg
Isolate V1
Check for leaks:
Monitor PIC 3 for pressure loss.
Walk the system to ensure there are no major
leaks
Valves set
MK
4/12/10
Pressurized
MK
4/12/10
If leaks are found, identify
the leak with a tag, mark up
the P&ID, depressurize the
system and have the leak
rectified
No major leaks found
MK
4/12/10
Pressurise to 2nd hold pressure:
OPEN nitrogen source to test rig
Slowly OPEN V1 and monitoring PIC 3
Build pressure to 6 barg
Isolate V1
Check for leaks:
Monitor PIC 3 for pressure loss.
Fully soap test the system to ensure there are
no major leaks
Pressurized
MK
4/12/10
If leaks are found, identify
the leak with a tag and mark
up the P&ID. If the leak
cannot be stopped by
tightening flange bolts,
depressurize the system and
have the leak rectified
No major leaks found
MK
4/12/10
Pressurize to 3rd hold pressure:
OPEN nitrogen source to test rig
Slowly OPEN V1 and monitoring PIC 3
Build pressure to 9 barg
Isolate V1
Pressurized
MK
4/12/10
164
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
9
Check for leaks:
Monitor PIC 3 for pressure loss.
Walk the system to ensure there are no major
leaks
If leaks are now found,
identify the leak with a tag
and mark up the P&ID. If the
leak cannot be stopped by
tightening flange bolts,
depressurize the system and
have the leak rectified.
Some leaks now found.
All were corrected by
tightening flanges
MK
4/12/10
10
Pressurize to final hold pressure:
OPEN nitrogen source to test rig
Slowly OPEN V1 and monitoring PIC 3
Build pressure to 12 barg
Isolate V1
Remove the test rig
Check for leaks:
Monitor PIC 3 for pressure loss.
Fully soap test the system to ensure there are
no major leaks
Pressurized
MK
4/12/10
If leaks are found, identify
the leak with a tag and mark
up the P&ID. If the leak
cannot be stopped by
tightening flange bolts,
depressurize the system and
have the leak rectified.
Full leak check
conducted and no
additional leaks found
from step 9.
MK
4/12/10
Hold test:
When all leaks are identified and corrected
and the system is not losing pressure, set up
a control system trend for PIC and start the
12-hour hold period
Pass test:
When 12 hours have passed and the test
pressure is confirmed as holding pressure:Slowly OPEN V 4 and in a controlled
manner vent the system pressure to a safe
location
When at atmospheric pressure, remove SP-1,
SP-2 and SP-3.
Make note of these gaskets that will need to
be checked when the system is presurized
when in service.
Leak test hold period
commenced at 21:00
hrs.
MK
4/12/10
Leak tested held.
MK
5/12/10
11
12
13
The equipment and lines included in this procedure have passed the test as defined above:
Commissioning Engineer: M Killcross Signed: M Killcross Date:5/12/10
All isolations removed and valves returned to normal required position:
Commissioning Engineer: M Killcross Signed: M Killcross Date:5/12/10
Plant Representative: A.N Other Signed: A.N.Other Date: 5/12/10
FIG. 36(A)—Cont'd
Chapter 2 • Commissioning Phase Two – Implement
165
Vent Point
Reactor Off
Gas Analyser
AI
3
HH
SD
2
FI
3
4
PIC
3
PZ
3
TIC
3
H
L
H
L
H
Reactor Off
Gas Condenser
L
HH
SP-3
TZ3
Reactor
5
SD
1
Nitrogen inlet
point
SP - Isolation spade
SP-1
Pipe work within
leak test
Feed 2 IN
Feed 1 IN
Steam IN
1
To Stripper
Column
2
3
SP-2
REACTION SYSTEM
Leak test
(Refer to Procedure at
Fig 33)
Steam OUT
FIG. 36(B)
system into service. The operation ran on process chemicals for a number of hours when
a loss of containment forced the plant to shut down. A leak had occurred as the salt
solution had leaked into the process, the subsequent reaction having corroded plant
items causing the loss of containment.
Although not directly a commissioning leak test issue, the following interesting
example shows the consideration needed during the installation of new equipment
within an existing plant system.
A chemical process in the USA was in the process of a significant upgrade in
production capability; to meet the demands of the new design, a new refrigeration
compressor system was introduced to work in parallel with an existing refrigeration plant.
At the suction of the old machine, new pipework was installed to the common inlet to the
new refrigeration plant. A hydrostatic test to prove pipe integrity was required by the
piping specification and a test procedure duly written. Physical isolation was installed as
laid out in the hydro-test procedure to obviously stop water being fed to both the new and
old refrigeration systems. During the actual initial water fill, prior to the pressurization,
a low-point valve on the old refrigeration system drained water and the filling procedure
was immediately stopped. Upon detailed investigation a small instrument pressure tube
linked from the suction pipe to the main compressor system had been left un-isolated at
166
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
the old refrigeration machine and allowed water to enter the existing compressor.
Although no actual time was lost to the commissioning schedule, there was some
significant cost incurred to clean out and make good the original refrigeration system
prior to commissioning of the upgraded facility.
These scenarios identify the significant hazards chemical processes can pose and the
importance robust leak test procedures play in the safe and successful commissioning of
operational plant.
Key Points
• Select the appropriate type of leak test, a service test, safe chemical operational
pressure leak test, vacuum test or toxic test and draft procedures accordingly
• Diligently complete the procedure accurately documenting all steps and pressures
encountered during the test
• Conduct a leak test on a full system basis will all possible flanges and potential leak
paths included in the test. Document all flanges that could not be included in the test
for close inspection for leakage upon commissioning with hazardous chemicals
• All components within a system that cannot be subject to the test pressure must be
isolated and leak potential checked during commissioning with process chemicals
• Make a very detailed check to ensure all isolations are in place before commencing any
leak test procedure.
Commissioning and Initial Start-Up Plus Procedures
Commissioning procedures, written during the Prepare phase of the project, are the
documents which, in great detail, set out how the plant will be commissioned and then
started up. Of all the procedures created and executed to this point, the commissioning
procedures are the key documents that control how the systems and assets in general will
successfully and efficiently be put into service.
To this point in the logical progression of commissioning within a project, many
procedures already will be executed to enable the asset to come to this stage, the initial
process commissioning. Here, where possible, “safe” chemicals are initially introduced, water, steam and air, to simulate closely the unit in actual operation and to give
an indication of how the plant will probably perform when the process chemicals are
introduced and the main commissioning and start-up event takes place. During the
safe commissioning execution all safety-related systems are rigorously checked,
including:
• Confirmation of alarm activation points via manipulation of the actual process
variable
• Confirmation of the operation of all control system software trip logic via various
means including variability of the process conditions, both manually and via the
control system
Chapter 2 • Commissioning Phase Two – Implement
167
• Confirmation of all hard-wired emergency shut-down systems by various documented
operational means
• Confirmation of the operation and control of all DCS sequences including full testing
of all failure monitoring.
It is common for the commissioning procedures to be written first, the first draft operation procedures then being developed from these documents.
A detailed commissioning procedure should be compiled for each major activity that
the plant will undergo through the start-up. These documents are not check sheets, they
give a detailed descriptive of how the plant is made ready for and then initially started up
and shut down.
Information to draft these procedures is found within various engineering documents,
including P&IDs, PFDs, process descriptions, instrument data sheets, equipment data
sheets, control narratives, interlock and emergency shut-down descriptions, vendor
installation and operating manuals, and most importantly talking with the process
engineering design teams.
Sound commissioning procedures will detail the various logical steps involved, the
method of performing the various steps, any relevant details, comments and observations, and a suitable sign-off box detailing the signatory and the date the procedure was
performed.
Commissioning procedures will be produced which will address numerous scenarios
based on the process concerned. However, the following list highlights many common
key facets faced during the commissioning of process plant:
• Can the system be safely commissioned initially with water, steam, air and nitrogen to
gain an initial operational insight to the unit performance?
• How can the initial fill chemicals be imported to the system? Is the initial fill quantity
known?
• If not initially produced to the required process specification, how is the process
managed to deal with out of specification initial product? Where will the product be
put?
• Are all services available, including instrument air, process water, intermediate
chemicals and the cooling water system?
• How to slowly heat up, cool down, vent non-condensables, control pressure and
introduce and control the level within the process equipment?
• Establish and control various flows, feeds in, product out, scrubbing, recirculation and
reflux flows?
• How to closely manage expected process-related exothermic and endothermic
reactions?
• Procedure to condition a new catalyst
• Set-up of a distillation column for the correct product temperature and pressure
profile including utilization of process variable diagrams on temperature and
pressure
168
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
• Initial set-up and control of a scrubbing column or tower
• Actually (no simulation) introduce alarm conditions to test functionality
• Introduce (no simulation) control system interlock conditions to test operability and
set points
• Describe, manage and test all DCS-controlled sequences
• Perform normal and emergency shut-down scenarios – where applicable and possible
• Establish validation criteria and draft procedures and spreadsheets which capture the
product performance
• Establish, document then commence sampling regime
• Control and manage the system until steady state operation is established
• Introduce a system to ensure non-conformance of the process is suitably addressed to
enable the system to operate as designed
• Draft optimization and proving trials that are to be conducted
• Complete initial performance trials and test that guarantees are met
• Manage modifications to enable stable operation to be established and then progress
documentation to completeness
• Process and product validation commences
• Operate until production quantities are met
• Commence then complete all on-the-job training.
Depending on the size of the project, the commissioning and start-up phase can take
a considerable amount of time. The commissioning team members will also be
migrating onto shift patterns to manage the transition to operating unit plus supporting
the operations staff in understanding the process and managing the on-the-job training
process.
To further demonstrate the detail required in an actual commissioning procedure
random, explanatory procedure sections, selected from various chemical processes and
projects, are provided in Fig. 37.
Utilizing the hypothetical example of a chemical process used in the precommissioning section of this handbook, the process stream is provided in Fig. 38,
review for the potential commissioning procedures and the content of those procedures that will need to be considered for drafting.
Hypothetical Plant Commissioning Procedures; Explanation
of Procedures that will Require Writing
Following the guidelines set out in various sections within this handbook, the commissioning logic for the various systems must be:
•
•
•
•
Utilities and services
Water or safe chemical commissioning
Process chemical commissioning
Start-up.
Chapter 2 • Commissioning Phase Two – Implement
Commissioning
Procedure
Various procedure sections across diverse projects for
explanation purposes
TITLE: Various
Ref: N/A
Project: Numerous
System: Varied
Line & Vessel numbers:
P&ID’s covered:
Author: M Killcross
Date: May 2010
Page 1 of 3
(Example pre-procedure execution) NOTE: Prior to completing this procedure a check with Construction and
Operations needs to be made to ensure that the equipment can be safely run. Check with all Electrical,
Instrument and Mechanical discipline leads also.
– Includes LIVE leak TestSigned
STEP
ACTION
METHOD
Comments
Date
Tank T-607 clean
JK
Ensure that sufficient clean water Tanker at required
deliveries are available, one at the location
job-site to allow commissioning of
this system
JK
Lubrication and greasing
Ensure all lubrication and greasing
complete, witnessed by
checks have been carried out on
commissioning
P-007 and P-008 and the pumps
mechanical engineer.
are ready for ongoing operation
JK
Confirm Tank T-007, is clean, dry
and oil free.
1
Pre-start checks
Ensure that the overflow and vent
on T-007 have been proved clean,
refer to section 3 of this
commissioning manual
Flushed clean
All electrical equipment
Electrically de-isolate both P-008
and P-007 and the Local Control
de-isolated
Panel and associated equipment is
available for the commissioning of
the water pump P-007
The diesel supply is available to
P-006
Diesel storage set up and
filled.
See related procedure in
Ensure a calculation has been made the Diesel System File
to ensure sufficient water has been
ordered to fill the Water Tank
Sufficient Water
available
FIG. 37
JK
JK
JK
JK
169
170
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
6
Fill T-100 to clear
the Low alarm on
LIA-100
Monitor the level of T-100 via
LIA-100 and any level reduction
indication on the supply truck
Fill T-100 until the low alarm has
cleared on LIA-100
STOP Water transfer, CLOSE all
isolation valves
Note level at which alarm sounded
and check against design
Low Alarm Point =
Design =
10
Circulate T-100 via Position operators at pertinent
P-106
points around the system
Start P-106 and circulate water
around T-100
11
Live system Leak
check!
Ensure there are no leaks on the
tank and pipe work system,
including the instrument fittings
LEAK TEST of T-106
The Tank and associated
equipment have been
filled to a normal working
level and is free of leaks,
normal operation can
continue
Signed:
Commissioning
Tare the supply truck on the exit
Signed: A Smith
of the Process Plant Site if required Operations
for accounting purposes
Use the net weight if
required to give an
indication of the level in
the Water Tank for future
reference
FIG. 37—Cont'd
Chapter 2 • Commissioning Phase Two – Implement
15
Test interlock
I-95
High High level of
Oil
Crusher to be
operational but
awaiting product
4
Check Sump level
control and alarms
Outputs
GH-0101 Feeder STOP
GH-0102 Screen STOP
GH-0116 Conveyer STOP
GH-0119 Conveyer STOP
INPUT
LAHH 0101 – Vessel High High
Level activated
All steps conducted as per
Method.
procedure with presence of
1. Start Crusher GF-0101
mechanical commissioning
2. Activate LAHH 0101, by
engineer
overfilling with oil to trip point
3. Confirm STOP of motors above
4. With maintenance engineer
support, drain oil level to normal
operational point
Monitor LA 4418 86A and confirm L clears at 20%
L and LL alarms clear as level rises.
LL clears at 16
REW
2/6/03
DED
25.9.01
When alarms have cleared, isolate
water to VC-1, OPEN drain valve L activated at 20%
and ensureL and LL alarms reLL activated at 15%
activate when required.
6
Check alarms
Close drain and resume fill
Select VG-8 and START
Test L alarm on pump
recirculation, FI 4418-90AL:
On the discharge of VG-8 select a All steps conducted
suitable valve and gradually close as per procedure
until the flow starts to reduce on
FI-90A
Continue to CLOSE until FI-90A L
alarms is activated, SP = 165 m3/h
MK
1/3/19
98
Alarm activates at… 167 m3/hr
Confirm PT 4418-79 also comes
into L alarm
9
FIG. 37—Cont'd
Test LL level in
Allow the sump on VC-1 to drain All steps conducted
VC-1 sump stops
empty, at the activation of the LL as per procedure
recirculation pump alarm, SP = 38%, confirm: 38%
(cont’)
STOP of duty recirculation pump.
Stopped
MK
1/3/19
98
171
172
Reactor Off
Gas Analyser
Legend
PZ
3
15
H
FI
3
AI
3
Reactor Off
Gas Condenser
L
Refrigeration
Outlet (Gas)
3
Instrument relayed to control
system
SD
2
Emergency Shut-Down System
(ESD)
PIC
3
HH
SD
2
A – Analyzer
F – Flow
P – Pressure
T – Temperature
I – Indicator
C – Controller
Z – Trip input (ESD)
H – High (alarm)
L – Low (alarm)
HH – High High trip input (ESD)
SD – Shut-Down
MI – Mechanical Interlock
Process pipe/flow
Instrument signal
PZ
3
H
V-3
TIC H
3
L
8
PIC
4
H
L
e)
LIC
2
FIC
1
H
L
7
Feed 2
From Stock
12
TIC
1
L
FI
4
a), b), c)
L
Cooling
Water IN
Cooling
Water OUT
Product
Condenser
Stripping
Boiler
20
5
MI
1
LI
8
Steam
OUT
Heater
11
H
Product
Filter
L
L
Electric Hot
Oil Heater
Product
Compressor
H
H
H
Hot Oil
Recirculation
Pump
FIG. 38 Ă
18
18
19
17
LIC
7
Steam
IN
SD
2
L
a)
L
13
Feed 1
Vaporizer
8
14
H
Stripping
Reflux
Pot
H
MI
LI
4
6
Feed 1
From Stock
2
L
b)
TI
4a
Reactor Feed
Mixer
Steam IN
LIC
6
H
TIC
4
8
H
Feed 2
Vaporizer
d)
8
10
L
8
Stripping
Tower
c)
SD
1
4
9
L
Refrigeration
Inlet (Liquid)
Steam OUT
Hot Condensate
IN
H
HH
16
SD
2
Hot Condensate
OUT
LIC
5
TZ3
Reactor
FIC
2
Stripping
Condenser
Cooling Water
IN
Cooling
Water IN
L
H
Product
Compressor
Suction
Drum
Commissioning Procedures Required to be written, explanations given on the
following page.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
LI
9
H
L
Product
Receiver
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Hypothetical Process Drawing
of a Chemical Plant
Chapter 2 • Commissioning Phase Two – Implement
173
Therefore titles for commissioning procedures that will need to be written in each of the
phases including any key points are as indicated in Fig. 38.
Utilities and Services
1. Procedure to commission the cooling water system to the product condenser.
2. Procedure to commission refrigerant to the stripping condenser including:
(a) establish a normal working level including venting of non-condensable gases
(b) establish control of LIC 5 including tuning of the loop
(c) Manipulation of the condenser level with actual live testing the low- and high-level
alarms by raising and lowering refrigerant levels.
3. Procedure to commission the cooling water system to the reactor off gas condenser.
4. Procedure to commission condensate to the feed 2 vaporizer including:
(a) establish a normal working level including venting of non-condensable gases
(b) establish control of LIC 2 including tuning of the loop
(c) Follow on from these steps by then manipulating the vaporizer level actually live
testing the low and high alarms via raising and lowering of the vaporizer level.
5.
(a) Fill the hot oil heater with oil
(b) Establish cold oil circulation
(c) Perform initial heating procedure for the hot oil system to drive off water.
Water Commissioning
1. Fill the stripping boiler and base of the stripping tower with water, test low and high
alarms on LI 4 and LIC 7.
2. Commission steam to stripping boiler and warm content of the tower, test accuracy of
TI 4a
(a) Warm contents of the tower, if practical test TIC 4 control and loop tune. Vent
non-condensable gases.
(b) Test if possible the low and high alarms on TIC 4 via manipulation of steam to the
boiler.
(c) Setup PIC 4 loop tests and check validity of the low- and high-pressure alarms on
PIC 4.
(d) Establish a level in the stripping reflux pot, set up and tune LIC 6, test high and
low alarms via manipulation of the level.
(e) Shut down tower, drain water and dry the tower.
3. Assume for this hypothetical process, feed 1 and 2 plus the reactor cannot be subjected
to water, so decision taken to only commission on process chemicals. Therefore full
commissioning of the hot oil system will be conducted later. Make actual tests of the
alarm conditions of TICs across the reactor system by immersing temperature probes
in hot water to test high alarm and cold water or ice for the low alarm.
4. Conduct the test procedure for SD1 and SD2 in the shut-down state to confirm
practicality of the test procedure.
174
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Commission and Initial Start-Up of the Plant with Process Chemicals
1. Commission product compressor on minimum load and hot gas bypass (discharge
gases are fed to the suction to enable the machine to stay on very low load awaiting feed).
2. Establish a level of feed 1 in the vaporizer. Start to heat hot oil and therefore bring
feed 1 to acceptable temperature, test loop TIC 1HL.
3. Establish a level of feed 2 in the vaporizer. Introduce hot condensate and raise the
level in the vessel, test LIC 2HL.
4. Commission the steam jacket to the reactor. Commission and establish feed flows 1
and 2 to the reactor. Raise reactor temperatures, tune loops in the reactor, and
vaporizers 1 and 2.
5. Commission the reactor off gas analyzer and make provision for lab analysis to prove
consistency of unit results.
6. Monitor all flows and start to take regular DCS trend data and hourly readings of key
parameters to establish baseline operational data.
7. Monitor LI 4 gains a working level in the stripping tower.
8. Establish steam to the stripping boiler, heat the tower, establish a reflux pot level and
reflux to the tower. Establish all control loops to automatic control when able and
tune all loops. Start to amass initial operations data.
9. As TIC 4 comes into product specification range, allow product to flow to the
product compressor. Ensure product compressor comes into control as hot gas
bypass is replaced by product. Monitor level in the product receiver and take
samples.
10. Monitor all control parameters and adjust to give stable operation. Take analysis as
required to ensure product is within specification. Ramp plant up to design rates.
Consider high rate trials and determine the plant capacity.
The generic type of commissioning procedure described in this section as indicated
based on the hypothetical process, is created to demonstrate the detailed process of
bringing a chemical plant into initial operation. On actual projects the activities will
obviously be different but the descriptive provided does give indication of the broad
range of thought processes that need to be considered to plan for and make suitable
arrangements for all potential eventualities within a standard commissioning and startup scenario.
It is worth re-emphasizing that the commissioning procedures, although the last
documents to be executed, were one of the first created to give the basis of the initial
operating procedures and training materials.
Commissioning and Initial Start-Up Plus Procedures – “Things That Can
Go Wrong”
If all steps, stages and procedures are followed in this handbook, the common things that
can go wrong at this stage in the process will be those incorporated with design issues,
Chapter 2 • Commissioning Phase Two – Implement
175
hence in this section of this chapter mention must be made to commissioning scenarios
that do not go to plan.
A chemical process in the UK utilized a constant hot air stream to burn deposits from
a catalyst in a vessel specifically designed for the purpose. The air stream was heated by
an electrical induction heater some distance from the vessel where the burning process
was to take place. It became impossible (due to the distance from the heater to the burner
vessel and therefore temperature losses) to achieve the desired burn temperature, so an
additional layer of insulation was applied to the air pipework, the temperature required
was then achieved and the plant initially commissioned. Several hours later the plant was
shut down as the initial layer of insulation (that beneath the new additional layer) ignited
and a small fire ensued. The plant remained shut down until the heater was re-located
close to the burner vessel and the correct process temperatures could be obtained in
a safe and efficient manner. The system was then successfully commissioned.
The main crude distillation column on a major asset in the USA had, during the
upgrading of the facility, the internal packing and associated internal components
changed out from the original random fill type packing to a new form of fixed packing.
Water commissioning provided no evidence of a change in plant operation and the plant
distillation system was duly commissioned. As process feed load was increased, the
column became very susceptible to flooding and the design throughput could not be
achieved. After days of troubleshooting and evaluation of the issue, no remedy or
solution to the problem was found. Consultation with the packing supplier took place
and the system and therefore plant was shut down whilst a change to the column
packing was enforced; a combination of both the new and old types of packing resolved
the issue and design rates then were achieved and a successful commissioning of the
system.
A pressurized vessel used steam as the medium in the batch separation of organic
components in a process stream that was put into initial operation after water
commissioning. All ran well with the unit for several batches until during one operation
high pressure caused the system to trip. Several unsuccessful attempts to restart and
complete the batch were made with much troubleshooting work being undertaken.
Eventually the unit was shut down and isolated to allow internal inspection of the vessel
and vent pipework. Upon investigation the dip pipe on the pressure trip instrument was
found to be blocked with solids created during the batch. A modification procedure was
undertaken with a revised pressure instrument more suitable for the process duty
installed. The system was successfully commissioned with no further issue.
Several feed stocks combined to form the reactants in a chemical process in the UK.
One feed stock (A) was fed to the reactor from a road barrel via a pump. At initial
commissioning of the reaction system, it became apparent feed stock (A) was not being
fed steadily and the first commissioning efforts were frustrated. Troubleshooting found
cooling the inlet pipework to the pump with service water helped and a temporary rubber
water line was hastily installed to enable commissioning of the plant. A suitable pump
inlet cooler was then designed, procured, installed and commissioned to satisfy the
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
requirement of this pumping system, enabling the feed stock (A) system to operate with
no ongoing issue.
An acid scrubbing system removed organic components from a vent stream on
a hazardous chemical process in the UK. The water and initial commissioning of the
acid scrubbing system worked well and the plant was started up. After only a few hours
of operation, significant levels of organics were observed in the vent gas stream and
the plant was shut down. After a small number of re-start attempts the plant was shut
down, the acid scrubbing system decontaminated and a re-design initiated to
construct an acid scrubbing system more robust and suitable for the process duty
required. Three months downtime was incurred whilst the revised acid scrubbing
system was designed, procured and then commissioned. The plant then ran
successfully.
These examples provide some insight into the significant issues that manifest into
things that can go wrong during the initial commissioning of plant. In numerous other
cases smaller matters can give commissioning issues and result in changes to the design
to allow the asset to operate to the design intent, including:
• Undersized and oversized control valves and equipment
• Wrongly configured instrumentation and control systems
• Reconfiguration of piping.
Key Points
• Include in the procedure all possible and credible tests required to fully check out the
operation of the system and its equipment
• Fully check out the full scope of the operation including start-up, shut-down and
emergency shut-down
• The procedure must also check and validate alarm set points and prove the operability
of interlocks, hard-wired emergency shut-down systems and control system sequences
• Sound commissioning procedures will draft the number of steps, the description of the
step, the detail of the step, a comments area and a sign-off box.
Handover to Operations
When all pre-determined performance criteria for a commissioning system (or prearranged group of systems), for example design production rates confirmed, product
specification satisfied and an initial quantity of full specification product has been
produced, a handover certificate will be compiled and the system handed over to the
ongoing operations personnel.
At the point of handover from commissioning to operations, a key point to stress is
that only documents pertinent for the operations team to successfully and with ease carry
on the ongoing production on the plant be handed over. This handover stage gate should
not, where possible, be the point where full project documentation be handed over, as the
Chapter 2 • Commissioning Phase Two – Implement
177
check-out of a whole raft of paperwork could lead to lengthy periods of time being lost in
document checking, which in effect is not valuable to the actual job of running the facility
post the commissioning phase.
To reinforce, due to the hectic nature of the handover phase within a project, the
handover package contents should be kept to a minimum to allow an efficient and
effective handover process, with only the essential documentation exchanging hands.
All non-essential documents pertinent to operating the unit should be included within
the project handover dossier.
Considerations for documentation inclusion in the commissioning to operations
handover package are:
• Copy of the completed HSE 4 or Hazard Study 4 equivalent (UK), with all outstanding
items clearly identified, actions assigned and a schedule of close-out dates
• Copy of the completed HSE 5 or Hazard Study 5 equivalent (UK), with all
outstanding items clearly identified, actions assigned and a schedule of close-out
dates
• Completed pre-start-up safety (USA and other worldwide locations) review paperwork
• Reservation to handover list, agreed with commissioning team with a clear schedule of
rectification drawn up
• Transfer of any outstanding control system rectification works (on control system
punchlist)
• Marked up drawings, P&IDs, loop diagrams and one-line diagrams completed to “asbuilt” status including boundary points and boundary isolation points
• An isolation register of any remaining inter-system isolations (if applicable)
• Termination drawings and/or “cable landing matrix” for all junction boxes, marshalling panels and control panels
• Vendor installation, operations and maintenance (IO&M) manuals
• Pipework and equipment labeling in place
• Transfer of any relevant method statements
• Operation procedures, maintenance procedures and training manuals (for the system
or facility) issued
• Clear status of related DCS or PLC hardware and software status (if required)
• Clear location path identified for the quick retrieval of the following (including copies
of relevant certification, NOTE – not actual documents only a path to electronically
locate them):
•
•
•
•
•
•
•
pressure test certificates (including NDT/weld procedures and qualifications)
lifting equipment certification
relief valve test certificates
pressure system registration documentation
all statutory inspection data
isometric drawings
registered pipework certificates (if required)
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
•
•
hazardous area certification
various control/instrument/electrical documentation as specified by the plant
engineer.
After signing the handover certificate, the commissioning team will now take a step back
from guiding and directing the direct operation of the plant system being handed over
and revert to the final stage in the commissioning process, that of Close-Out.
A completed example handover certificate is provided in Fig. 39.
COMMISSIONING TO OPERATIONS
HANDOVER CERTIFICATE
Project Title: X
No
1
Item
All Project P&IDs available and set in the
Control Room
System Description : Reaction
Organized by
Signature
MK
M Killcross
Date
1/8/10
2
Commissioning Procedures all completed, and
documentation available
MK
M Killcross
1/8/10
3
Reservation Check-list completed
MK
M Killcross
1/8/10
4
All outstanding HAZOP Actions and or
MK
Modifications documented such that it is
acceptable to Operations
All instrument Loop Sheets and electrical one- MK
line diagrams are handed over to maintenance
personnel
Initial draft of the operating procedures handed MK
over to Operations
M Killcross
1/8/10
M Killcross
1/8/10
M Killcross
1/8/10
Initial draft of the training manuals handed over MK
to Operations
M Killcross
1/8/10
5
6
7
The acceptance criteria for this Project, as agreed between the Project Manager, Operations Manager
and Commissioning Manager, are as set out below.
No
1
2
3
4
FIG. 39
Description
A robust punchlisting process has been conducted on
all commissioning systems with the check-out
conducted to the latest revision of the P&IDs
Comments and completed by
Completed
M Killcross 1/8/10
All commissioning procedures to have been
i Completed
completed in full and accurate descriptions of all
M Killcross 1/8/10
findings during the procedures documented
A full and robust Hazards Study conducted prior to
Completed
introduction of safe chemicals and then at introduction M Killcross 1/8/10
of hazardous chemical (known on this project as
Hazard Study 4 and Hazard Study 5)
A full leak test at 1.1% of normal operating pressure to Completed
have been conducted and signed off as witnessed by
the ongoing operations group
M Killcross 1/8/10
Chapter 2 • Commissioning Phase Two – Implement
179
COMMISSIONING TO
OPERATIONS
HANDOVER CERTIFICATE
The above checklist for handover to operations has been completed.
I am satisfied that the system work has been commissioned and it is safe to allow continued operation.
Commissioning Manager M Killcross Print Date 1/8/10
M Killcross Signature
Plant/Operating Manager A. N Other Print Date 1/8/10
Signature
Reservations to Handover
Priority: 1 – Within 1 week, 2 - Within 2 weeks, 3 – Within 1 month (all from Handover date)
Item
No.
Description of Outstanding Work
Touch up paintwork as indicated on the Reaction Punchlist
Complete insulation (protective metal covering) on:
(a) Reactor Product outlet line
(b) Steam to Reactor
The Reactor recycle control valve (FCV 100) was found to be
oversized for duty during water commissioning.
The valve size has been redesigned and a new valve trim
ordered. To be installed upon delivery.
Complete all Hazard Study 4 outstanding actions (see action
sheet)
Complete all Hazard Study 5 outstanding actions (see action
sheet)
Complete all on-the-job training for operations team
Item ID
R1
R2
Action Req.
From
Construction
Construction
Priority
2
1
R3
Process Engineering/
Construction
3
R4
Commissioning
2
R5
Commissioning
3
R6
Commissioning
3
FIG. 39—Cont'd
Handover to Operations – “Things That Can Go Wrong”
The major issue incorporated with handover to operations from the commissioning team
is in the scenarios discussed earlier in this handbook during the Prepare stage where there
is insufficient definition and/or agreement with the handover process. Issues at the actual
handover stage will obviously be alleviated with a clear directive prepared much earlier in
the project.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Key Points
• Include in the handover paperwork a detailed list of all outstanding work, captured in
the handover reservations section
• Only hand over essential documents to facilitate ongoing operation; it would be
advisable to not include all system documentation at this point in the project when
time and effort needs to be concentrated on the commissioning of the asset.
3
Commissioning Phase Three –
Close-Out
CHAPTER OUTLINE
Close Out Reservations...................................................................................................................... 181
Complete Commissioning Documentation ...................................................................................... 182
Complete Training and Update Documents to “As Commissioned” ............................................ 182
Update Operating Procedures to “As Commissioned”................................................................... 183
Assist Continued Operation, Troubleshooting and/or De-bottlenecking Projects...................... 183
Close Down the Commissioning Team ............................................................................................ 183
Complete Close-Out Hazard Study................................................................................................... 184
As the installation, construction and commissioning of systems within a project comes to
a close, the commissioning personnel will remove themselves from the ongoing detail of
running the new operation, their potential shift responsibilities decline and the team will
revert back to regular day operation to complete all paperwork systems and bring general
documentation up to an “as-commissioned” status.
It is common that the commissioning engineers are assigned one or more of the topics
below to follow through to completion and complete the commissioning of the project:
•
•
•
•
•
•
•
Close out reservations
Complete commissioning documentation
Complete training and update documents to “as commissioned”
Update operating procedures to “as commissioned”
Assist continued operation, troubleshooting and/or debottlenecking projects
Close down commissioning team
Complete close-out hazard study.
Close Out Reservations
The commissioning team will now review all hazard study actions compiled during the
various stages of the project, including design (known as Hazard Study or HSE 3), and the
commissioning-related hazard studies documented in this handbook as Hazard Study 4
(pre-introduction of safe chemicals) and Hazard Study 5 (pre-introduction of hazardous
Chemical and Process Plant Commissioning Handbook, DOI: 10.1016/B978-0-08-097174-2.10003-9
Copyright Ó 2012 Elsevier Ltd. All rights reserved.
181
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
chemicals), and also any pre-start-up safety reviews to ensure all outstanding actions are
completed and fully signed off. If the actions are not complete, the commissioning team
will champion the close-out of all outstanding actions and issue the findings as required.
There potentially will have been modifications to the process initiated and conducted
through the commissioning and start-up phases to enable the plant to run effectively and
efficiently to the design intent; these modification procedures must now be diligently
followed through to completion and all sections signed off.
Many punchlist items will have been created, some transferred to the reservations to
handover list and signed off; however, some will be outstanding. These need now to be
pushed to completion by the commissioning team to close this section of the project out.
It is worthy of note that there will not only be punchlist items for mechanical work, but
those associated with the control system also.
Complete Commissioning Documentation
As the team returns to normal day working after weeks of intensive commissioning
periods in the field, followed potentially by shift-working activities leading the operations
team in the start-up of the new asset, some commissioning procedures may have been
left incomplete and not completely signed off, although the procedure has actually been
executed. A trawl through all commissioning documentation now needs to be conducted,
all documents brought up-to-date before finally passing to the client and/or operations
group for archiving.
A review of all electronic files also needs to be completed, updated accordingly and
saved to the appropriate hard drive or site network location for archiving and future use.
It is important that all procedures and revisions of the project P&IDs are correctly and
carefully archived, as in many instances some seldom-performed operations, potentially
in the future operation of the plant, will need reference to the original commissioning
documentation for assistance with the rectification of a process issue.
Complete Training and Update Documents
to “As Commissioned”
Some “on-the-job” training will still need to be conducted to ensure the operations
personnel are fully conversant with their new role and all personnel training procedures,
records and files are completed and importantly validated. This work must be seen
through to full completion.
A complete review of all training materials must also now be undertaken, all sections,
drawings, descriptions and validation questions brought up to the “as commissioned”
status before full revised documents are handed over to the client or operations personnel
for future plant use.
Chapter 3 • Commissioning Phase Three – Close-Out 183
It is of the utmost importance that the commissioning team leave a full and detailed
legacy to the operations group detailing all experience and pratical know-how of how the
new asset operates to full design rates and conditions. Completing in full, to the best
known knowledge and information, the training materials is one of the key steps to
passing on the weath of information gained durting the commissioning to the new
operating plant team.
Update Operating Procedures to “As Commissioned”
With newly gained operational experience, update all operating procedures to reflect the
most up-to-date information available. Issue to the operations group.
If target values have been produced for the operators (typically DCS screen prints with
all instruments shown at their required value), these will need to be updated and reissued to ensure the most up-to-date information is available to the operations team.
The commissioning personnel also have an obligation to assist the project team in
updating plant mechanical, instrument and electrical records, control system (especially
if DCS screens have been changed and logic within sequences) and the spares lists within
the mechanical systems relevant to the plant.
Assist Continued Operation, Troubleshooting
and/or De-bottlenecking Projects
It is not uncommon for the operations group to retain an element of the commissioning
team (typically one or two individuals) to form an ongoing plant technical support
function for the first few months, possibly up to a year of initial operation. If this action is
required, an appropriate selection process to identify the right person from the
commissioning team will need to be made, the personnel then joining the operations
group at the correct time.
The troubleshooting team selected will then help resolve issues that result in the first
operational period. Examples of their work will include:
• systems within the plant not performing to the design intent
• head up and lead any de-bottlenecking (increase in plant throughput) projects
• taking a prominent role in maintenance and/or overhaul events, usually undertaken
after a year’s operation to investigate potential internal wear or corrosion of the
process.
Close Down the Commissioning Team
As all commissioning work gets completed, commissioning team members will gradually
leave the group to new projects; finally the commissioning manager will fully disband the
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
team, hopefully to the next new project. This will leave the commissioning manager with
the final task of organizing a well-earned celebration of the team’s excellent performance
and the overall success of the project!
Complete Close-Out Hazard Study
At a designated time post-beneficial operation (typically 3–6 months after beneficial
production) the commissioning manager must, along with other key plant and project
personnel, conduct this final review of the newly commissioned plant.
Based on the Hazard Study 6 process pioneered by ICI in the 1960s, this study checks
that previous hazard studies have been completed and that early operation is consistent
with the design intent and with the assumptions made in earlier hazard studies. The
hazard study at this point is to identify and record operating and maintenance difficulties
and ensure feedback to the relevant functions responsible for the project for rectification
considerations, and ongoing lessons learnt.
4
The Commissioning System File,
a Full Catalogue of Blank
Commissioning Documents
CHAPTER OUTLINE
Commissioning System File............................................................................................................... 186
Commissioning System File System ................................................................................................. 186
Index ............................................................................................................................................... 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
List of Vessel Check Sheets ........................................................................................................... 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
Pre-Commissioning Procedure List ............................................................................................... 217
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
PSSR and Plant Check Sheet Prior to Introduction of Hazardous Chemicals –
Action Register............................................................................................................................... 234
Chemical and Process Plant Commissioning Handbook, DOI: 10.1016/B978-0-08-097174-2.10004-0
Copyright Ó 2012 Elsevier Ltd. All rights reserved.
185
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Documentation Requirements for Ongoing Maintenance Group ................................................ 235
Authority to Introduce Process Chemicals, Check Sheet and Certificate ..................................... 236
Commissioning Procedures ............................................................................................................... 237
Standard Operating Procedures (SOPs) ........................................................................................... 239
Commissioning to Operations Handover Certificate...................................................................... 240
The whole basis of the commissioning methodology set out in this handbook is based
on a standardized and systemized paperwork system that manages the various activities
that must be undertaken for the successful commissioning of a process plant. Many
worked and demonstrative examples of these documents were provided in the respective
sections of this handbook. Here a full blank master set of all commissioning paperwork is
provided for consideration and use.
Commissioning System File
Project
System
Plant
Prepared By
Checked By
Validated By
Date
Date
Date
Commissioning System File System
Index
1. System P&IDs
2. Decontamination procedure and isolation register
3. System cleaning procedures
4. Hazard study and actions
5. Equipment check sheets, off- and on-site checks
6. System punchlists
7. Action upon alarm sheet
8. Handover certificate construction/maintenance to commissioning
9. Project documentation check sheet prior to introduction of safe chemicals
10. Safe chemical commissioning authorization and pre-commissioning procedures
11. Leak test check list and procedures
12. Instrument check sheet
13. Motor check sheet
14. Interlock check procedures
15. Emergency shut-down system check procedures
16. DCS sequence test procedures
Chapter 4 • The Commissioning System File
187
17. Relief stream check sheets
18. Critical insulation checks
19. Critical gasket installation checks
20. Lubrication check sheet
21. PSSR, plant check-out prior to introduction of hazardous chemicals
22. Documentation requirements for ongoing maintenance group
23. Authority to introduce process chemicals, check sheet and certificate
24. Commissioning procedures
25. Standard operating procedures
26. Commissioning to plant handover certificate
1
System P&IDs
Marked up copies of the systemized P&IDs are included in this section when developed
for a specific project.
2
Decontamination Procedure and Isolation Register
During a project where some or all of the new construction involves upgrading or retrofitting of existing equipment, it may be necessary for the commissioning team to
manage the decontamination and isolation of the old equipment to facilitate a safe
handover to the construction team.
The following documentation will manage that process.
Decontamination
Procedure
Project:
Plant Equipment:
Risk Assessment
Number:
Steps
1
2
3
4
5
6
7
8
9
10
System:
P&ID Ref. :
Associated Permit
Numbers:
Hazardous Substance Classification:
Major Hazard
Hazardous
Low Hazard
Define Work :-
Decontamination method
Date/Time
Complete/
Initials
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
ISOLATION
REGISTER
Project:
Valve
Number
Valve
Position
System:
Area:
Valve isolations/Recommissioning log
Isolation
Recommissioning
Date
Initials
Lock
Lock
Date
Isolated
removed
Number
Isolated
by :
(initials) Open/Closed
Electrical Isolation / Recommissioning Log
Isolation
Item
Reference
Lock No.
Recommissioning
Locked off by: Date isolated
Lock
removed
by:
Date
Trace heating log
Vessel or pipe
work Ref.
Date removed
Signed
Date replaced
Signed
Chapter 4 • The Commissioning System File
189
Positive Electrical Isolation & Re-commissioning Log
Item
Ref.
Fuse
removed
by
Fuse
Cert. No.
Disconnected
by
Date
Reconnected Date reconnected
isolated
by
Physical Isolation Log
Location
Spade, Isolated
Spool
by
or Blank
fitted
Date
isolated
Isolation
removed by
Date isolation
removed
Radio Active Source Isolation
DATE
3
SHUTTER
CLOSED
SOURCE
REMOVED
DATE
SOURCE
REPLACED
SHUTTER
OPEN
System Cleaning Checklist and Procedures
During the construction integrity test commissioning must follow with a cleaning
procedure for the pipe sections included in the test.
The construction group may have the cleaning procedure incorporated within the
integrity test procedure; if this is the case commissioning need to create a list of system
pipelines to track progress.
If required a line-by-line valve-by-valve procedure needs to be written for a cleanliness check; these procedures are to be written utilizing the piping isometrics as
a guide.
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
System list of pipe work to be cleaned
Project:
System:
Page
Author:
P&IDs:
PLEASE NOTE PRIOR TO THE CLEANING :
All open pipe ends MUST be secured to avoid excessive movement.
Always blow away from any vessels.
Position target plates if required, to deflect debris to a safe location and/or use as proof of
cleanliness.
All personnel not associated with the blow are to be removed from the area.
All personnel involved with any high-pressure blow MUST wear ear protection.
After the cleaning process, all open pipe ends MUST be closed to avoid recontamination. If pipe
work is left for a period, after the clean, then a visual inspection of the pipe needs to be done, prior to
its commissioning.
LINE
DESCRIPTION
TYPE OF CLEAN
SIGNED/DATE
Cleaning Procedure
Project:
Pipeline
numbers:
Author:
System:
Procedure Number:
P&IDs:
PLEASE NOTE PRIOR TO THE CLEANING:
All open pipe ends MUST be secured to avoid excessive movement.
Always blow away from any vessels.
Position target plates if required, to deflect debris to a safe location and/or use as proof of
cleanliness.
All personnel not associated with the blow are to be removed from the area.
All personnel involved with any high-pressure blow MUST wear ear protection.
After the cleaning process, all open pipe ends MUST be closed to avoid recontamination. If pipe
work is left for a period, after the clean, then a visual inspection of the pipe needs to be done, prior to
its commissioning.
STEP
ACTION
METHOD
SIGNED/DATE
Chapter 4 • The Commissioning System File
4
191
Hazard Study Actions
Prior to introduction of chemicals the commissioning manager will need to ensure all
Hazard Study actions that have start-up implications are complete and signed off. The
completed paperwork is then included in this section of the file.
5
Equipment Check Sheets, Off- and On-Site Checks
List of Vessel Check Sheets
1. Off-site check – tank or drum
2. On-site check – tank or drum
3. Off-site check – column
4. On-site check – column
5. Off-site check – rotating machinery
6. On-site check – rotating machinery
7. Auxiliary systems – lube oil, hydraulic systems, HVAC, etc.
8. Off-site check – heat exchangers
9. On-site check – heat exchangers
10. Conveyer
11. Mill
12. Sieve
13. Pump
14. Blower
15. Furnace or burner
16. Turbine
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CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Off-Site Equipment Inspection
Check Sheet
Tank or Drum
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
18
19
20
21
22
23
24
25
Equipment Title:
Project:
System:
Shop Location:
Author:
Date:
P&IDs:
Vessel data sheet available? Y/N
Item
Yes
No
N/A
Comments
Check internal cleanliness
Clear of debris:
Dry:
Grease free:
Check nameplate
Check condition of lining
Check position of assembled covers and/or
flanges
Check dip pipes for:
Length
Anti-syphon hole
Lining/Coating
Check internal dip pipe supports
Check for clearance between dip pipes and
moving equipment
Check bottom support/bearing for agitator
(See Rotating Machinery)
Check test joint material
Check internal valve setting and operation
Check vortex breaker
Check baffles or weirs
Check sump
Other internals; demisters, support grids,
weirs
Witness pressure test.
Log all test data in comments section
Witness leak test of assembled vessel
Witness vessel drained and dry and ready
for transportation
Flange finish as per vessel drawing
All branches fitted as per drawing
Ensure all temporary transportation brace
is identified
Sign
Date
Chapter 4 • The Commissioning System File
On-Site Equipment Inspection
Check Sheet
Tank or Drum
Step
1
2
3
4
5
6
7
8
9
10
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13
14
15
16
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18
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21
22
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25
26
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28
29
30
Equipment Title:
System:
Author:
Item
Check vessel level or slope as appropriate
Check vessel bolted down
Check for sliding support assembly
Check saddles/mountings settings
Check corrosion/insulation packing under
vessel
Check vessel and saddle earthing straps
fitted correctly
Witness final closure of vessel
Witness fitting of agitator etc.
Gasket jointing material
Check access platforms conform to
standards
Check vent branches clear
Check vessel name plate details
Check vessel identification painted correctly
Check vessel relief stream inspected
Check vessel relief stream labeled
Check vessel PV number
Check registration documents are on file
Check sight glasses correctly installed
Check vessel adequately illuminated
Check vessel insulation
Witness fitting of joints between vessel and
first isolation valve
Check vessel painting
Check installation of fire cladding
Check that all transportation bracing has
been removed
Yes
No
N/A
Project:
P&ID:
Date:
Comments
Sign
Date
193
194
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Off-Site Equipment Inspection
Check Sheet
Column/Tower
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Equipment Title:
Project:
System :
Shop Location:
Author:
Date:
P&IDs:
Vessel data sheet available? Y/N
Item
Yes No
N/A
Comments
Check internal cleanliness
Clear of debris:
Dry:
Grease free:
Check condition of lining
Check orientation of assembled sections
and covers
Check installation and fitting of
internal components, where applicable
Packing grid supports
Bubbly cap trays
Bubble cap tray weirs
Bubble cap heights
Downcomer position and dimensions
Distributors
Feed nozzles and/or sprays
Check test joint material
Witness pressure test
Witness vessel drained and dry
Witness leak test of assembled vessel
Demister pads fitted correctly
Flange finish as per vessel drawing
All branches fitted as per drawing
Ensure all temporary transportation brace
is identified
Sign &
Date
Chapter 4 • The Commissioning System File
On-Site Equipment Inspection
Check Sheet
Column/Tower
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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18
19
20
21
22
23
24
25
26
27
28
29
30
31
Equipment Title:
System :
Author:
Item
Check vessel is vertical.
Check vessel is bolted down and
appropriate guides fitted, including
insulation and/or anti friction pads.
Check internal Cleanliness, clean, dry and
oil free.
Check condition of any lining, ensure no
holes or tares
Column packing type is:
Column packing quantity is :
Check packing support grids.
Check Bed limiters
Check distributors fitted and level
Check demister installed correctly
Check feed/spray nozzles for fitting and
orientation
Check bubble cap trays fitted correctly and
settings correct
Check downcomers length/height.
Check vent branches clear.
Check drain branches clear.
Check earthing strap if applicable
Check lagging as per specification
Witness vessel closure.
Check painting
Check vessel name plate details
Check vessel identification painted correctly
Check vessel relief stream inspected.
Check vessel relief stream labeled.
Check statutory paperwork is in order
Check access platforms conform to standards
Ensure all transportation bracing removed
Yes No
N/A
Project
P&ID:
Date:
Comments
Sign &
Date
195
196
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Off-Site Equipment Inspection
Check Sheet
Rotating Machine
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Equipment Title:
Project:
System :
Shop Location:
Author:
Date:
P&IDs:
Vessel data sheet available? Y/N
Test certificates available for all pressure retaining parts? Y/N
Item
Yes
No
N/A
Comments
Check general cleanliness
Clear of debris:
Dry:
Grease Free:
Check all drain plugs are fitted.
Check orientation of assembled sections
and pieces of kit, if skid mounted
Witness casing pressure test.
Witness performance trial run
Check guards:Location
Security
Effectiveness
Check drive motor:Type
Guard
Numbering
Rotation
Check drive alignment
Check mounting of Base frame and Flanges
Check all name plate detail
Witness general machine leak test
Check machine is suitable for transport, all
open ends blinded
Check integrity of preservation pressure
Confirm all packing is of the correct type
All couplings are clean and lubricated?
Sign &
Date
Chapter 4 • The Commissioning System File
On-Site Equipment Inspection
Check Sheet
Rotating Machinery
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Equipment Title:
System :
Author:
Item
Check all transportation bracing/packing is
removed
Check special tools available
Check foundations/bolding down
Check laser alignment of drive
Check alignment of belts and tensions
Check direction of rotation
Check alignment of pipework and correct
loading
Check alignment of ducts
Check lubrication
Check all drain plugs are fitted
Check gland seal and packing
Check mechanical seal
Check shaft seal
Check shaft grounding
Check gland flushing
Check machine labeling and identification
Check access for operation
Check access/removal for maintenance
Check position and operation of local
stop/start buttons
Check labeling of stop/start buttons
Check temporary strainer installed
Check for correct fitting of insulation
Check for cooling on bearings and oil
systems
Confirm correct packing and glands installed
Check machine instrumentation
Check/record amps loading
Check vibration
Check noise
Check load settings/calibration
Check machine guarding
Confirm all inlet and outlet pipes are clean
E-Stop easily accessible
Yes
No
N/A
Project
P&ID:
Date:
Comments
Sign &
Date
197
198
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
On-Site Equipment Inspection
Check Sheet
Auxiliary System
Step
1
2
3
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6
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33
34
35
36
Equipment Title:
System :
Author:
Item
Check all transportation bracing/packing is
removed
Check special tools available
Check foundations/bolding down
Check alignment of any drives
Check direction of rotation
Check alignment of interconnecting pipe
work
Check lubrication and greasing
Check all drain plugs are fitted
Check gland seal and packing
Check mechanical seal
Check shaft grounding
Check machine labeling and identification
Check access for operation
Check access/removal for maintenance
Check position and operation of local
stop/start buttons
Check labeling of stop/start buttons
Check temporary strainer installed
Check for correct fitting of insulation
Confirm correct packing and glands installed
Check machine instrumentation
Check/record amps loading
Check vibration
Check noise
Check load settings/calibration
Check machine guarding
Confirm all inlet and outlet pipes are clean
Check all components with design
documents
Ensure system has been flushed and clean
Ensure all cooling systems are ready for
operation
Ensure unit does not create a safety hazard
E-Stop easily accessible?
Yes
No
N/A
Project
P&ID:
Date:
Comments
Sign &
Date
Chapter 4 • The Commissioning System File
Off-Site Equipment Inspection
Check Sheet
Heat Exchangers
Step
1
2
3
4
5
7
8
9
10
11
12
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14
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16
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29
30
Equipment Title:
Project:
System :
Shop Location:
Author:
Date:
P&IDs:
Vessel data sheet available? Y/N
Item
Yes No
N/A
Comments
Check general cleanliness
Clear of debris:
Dry:
Grease free:
Check orientation and fitting of all end boxes
and/or covers
Check test joint material
Check baffles & weirs
Witness pressure test
Witness vessel drained and dry.
Witness leak test of assembled unit
Ensure vessel fit for transportation, no open
ends
Check integrity of preservation pressure
Ensure all temporary transportation bracing
is clearly listed:
Confirm name plate details
Sign &
Date
199
200
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
On-Site Equipment Inspection
Check Sheet
Heat Exchangers
Step
1
2
3
4
5
6
7
8
9
10
11
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13
14
15
16
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Equipment Title:
System:
Author:
Item
Vessel checked for level
Check vessel properly bolted down and if
applicable guides are fitted
Check internals are:
Clear of debris
Dry
Oil free
Check for sliding support assembly
Check saddles/mountings assembly
Check corrosion/insulation packing under
vessel feet/legs
Check vessel & saddle earthing straps
Check bolting
Witness vessel closure
Check jointing
Check vent branches suitable & clear
Check drain branches clear
Check insulation as per specification
Check painting specification
Check vessel name plate details
Check vessel identification painted correctly
Check vessel relief stream has been
inspected and labeled
Ensure statutory paperwork is complete
Check any access platforms conform to
standards
Confirm all transportation bracing has been
removed
Check for pipe high points where air could
be trapped
Yes
No
N/A
Project
P&ID:
Date:
Comments
Sign &
Date
Chapter 4 • The Commissioning System File
On-Site Equipment Inspection
Check Sheet
Conveyor
Equipment Title:
System:
P&ID:
Author:
Date:
Step
Item
1
Check cleanliness
Clear of debris:
Dry:
Grease free:
Hold down bolts installed & secure
Gearbox fitted
Guards fitted (to comply with requirements)
Shaft correctly fitted
Scroll securing bolts locked
Stop start button installed and labeled
Can scroll be removed for maintenance
Is scroll/motor direction correct
Motor fitted
Can scroll be rotated by hand and clear of
obstruction
Correct lubrication and greasing conducted
Belt alignment instrumentation correctly
installed
Safety pull cord/E-Stop correctly installed
and accessible?
All platforms and access ways conform to
correct standards
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Project:
Yes
No
N/A
Comments
Sign &
Date
201
202
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
On-Site Equipment Inspection
Check Sheet
Mill
Equipment Title:
System:
P&ID:
Author:
Date:
Step
Item
1
Check cleanliness
Clear of debris:
Dry:
Grease free:
Hold down bolts installed & secure
Gearbox fitted
Guards fitted, complies to standards
Shaft correctly aligned
Lubrication and greasing completed
Stop/start button installed and labeled
Can key parts be safely removed for
maintenance
Motor rotation correct
Motor fitted
Scalping receiver in position?
All instrumentation installed as per design
and installation manuals and P&ID
Inlet and outlet pipe work clean and ready
for operation
Has the equipment been suitably grounded
E-Stop easily accessible?
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
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23
24
25
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27
28
29
30
Project:
Yes
No
N/A
Comments
Sign &
Date
Chapter 4 • The Commissioning System File
On-Site Equipment Inspection
Check Sheet
Screen
Equipment Title:
System:
P&ID:
Author:
Date:
Step
Item
1
Check cleanliness
Clear of debris:
Dry:
Grease free:
Hold down bolts installed & secure
Gearbox fitted
Guards fitted (to comply with requirements)
Guards fitted, complies to standards
Are additional guards needed to protect
personnel from the sieve rotational
movement
Lubrication and greasing completed
Stop/start button installed and labeled
Can key parts (screens) be safely removed
for maintenance and cleaning
Motor rotation correct
All instrumentation installed as per design
and installation manuals and P&ID
Inlet and outlet pipe work clean and ready
for operation
Has the equipment been suitably grounded
Is an alarm installed required to warn of
equipment starting?
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Project:
Yes
No
N/A
Comments
Sign &
Date
203
204
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
On-Site Equipment Inspection
Check Sheet
Pumps
Equipment Title:
Project:
System:
P&ID:
Author:
Step
Item
Pre-running
1
Motor nameplate in place & correct
2
Glands and mechanical seals in position
3
Check adequate spares available in stores
4
Loose bolts
5
Impeller in position
6
Pump turns freely
Uncoupled
Coupled
7
Alignment checks complete
8
Earthing correct
9
Guarding safe and rigid
10
Bearings greased/oil level OK
11
Inlet pipe clean
12
Relief devices installed and tested to correct
specification
13
Can pump be drained
14
Can pump be easily removed for
maintenance
Running
1
Glands and mechanical seals
2
Direction of rotation correct
3
Post running checks of strainers carried out
4
Running checks
Date & Time:
Suction pressure
Delivery pressure
Flow
Temperature
Ammeter reading
Vibration and noise
Bearing temps
5
Drain valves closed & blanked
6
Lubrication levels OK
Date:
Yes
No
N/A
Comments
Sign &
Date
Chapter 4 • The Commissioning System File
On-Site Equipment Inspection
Check Sheet
Furnace or Burner
Step
1
2
3
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26
27
Equipment Title:
Project
System :
P&ID:
Author:
Date:
Vendor manuals and data sheets must be available
Item
Yes
No
N/A
Comments
Vessel checked for level
Check vessel properly bolted down and if
applicable guides are fitted
Check internals are :Clear of debris
Dry
Oil free
Check for vessel expansion materials are
suitable. Ensure no clashes with steel, pipe
etc.
Ensure weather protection is suitable
Confirm correct location of instrumentation
Check vessel & saddle grounding straps
Check bolting
Witness vessel closure. Ensure inspection
doors are sealed
Check jointing
Check all air dampers operate correctly
Check snuffing connections and equipment
Check insulation as per specification
Fully check burner management system
Check vessel name plate details
Check vessel identification painted correctly
Ensure all purge and coolant air flows are
acceptable
Check all peep holes and flame eyes are
operable
Check any access platforms conform to
standards
Confirm all transportation bracing has been
removed
Check explosion doors if fitted
Check all fuels are isolated at a safe distance
Check suitable location of E-Stop
Check fire fighting equipment in vicinity
Ensure correct installation of all refractories
Sign &
Date
205
206
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
On-Site Equipment Inspection
Check Sheet
Turbine
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Equipment Title:
System :
Author:
Item
Check all transportation bracing/packing is
removed
Check special tools available
Check foundations/bolding down
Check laser alignment of drive
Check lubrication
E-Stop easily accessible
Check the equipment supplied against the
schedule of auxiliary and associated
equipment for correct calibration and
settings
Check for correct functioning and setting of
fuel gas supply system
Check the turbine washing system for
correct operation against the manufacturer's
manual
Check the lube oil mist extractor system
Check the air intake system for cleanliness
and correct operation
On lube and seal oil systems particular
attention should be paid to proper cut-in of
auxiliary/ emergency pumps
Check proper functioning of inlet guide
vanes
Check proper installation of acoustic
enclosure and sealing strips, etc.
Check sealing air system
Check all auxiliary equipment ( i.e. torque
converter, ratchet device, start-up
motors/engines, etc.) for proper installation.
Check all such equipment against specific
items as described in the applicable
paragraphs of the installation
Check that anti-rotation device is
available/installed
Yes
No
N/A
Project:
P&ID:
Date:
Comments
Sign &
Date
Chapter 4 • The Commissioning System File
6
System Punchlists
Punchlist
Punchlist Type: Preliminary/Final
Project
System :
Author:
Page 1 of
P&ID:
Date Requested:
Date Issued:
Priority: 1. Complete before Handover. 2. Complete after Handover. 3. Item for discussion
Pipe,
No.
Action PRIORITY
Action
Description
Vessel,
on
completed
Loop Tag
&
No.
signed
Elec.
off by
Circuit
Tag No.
(Continued)
207
208
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Punchlist
Continuation Sheet
No.
Pipe,
Vessel,
Loop Tag
No.
Elec.
Circuit
Tag No.
Description
Action
on
PRIORITY
Action
completed
&
signed
off by
Chapter 4 • The Commissioning System File
209
Post Punchlist
Check Sheet
PLEASE NOTE: This sheet should be completed post the actual punchlist as an “Aide
Memoir”.
This check sheet should never be used as a substitute to actually physically checking the
system being punchlisted.
No
1
2
3
4
Checked
Description
& signed off
Has this system been totally checked against the relevant P&ID?
Comments
Has the pipeline finish been
fully checked?
Insulation
Painting
Trace heating
Flange covers
Labels
Have potential hazards
Splashing from drains
installation may have created Air blow-off points
been considered?
Potential for water pools
(uneven surfaces)
Trip hazards, kerbs, pipes, etc.
Noise
Headroom
Have all HAZOP actions that have had a construction
implication been considered?
5
Component check
Correct valve type as specified
Correct gaskets in all flanges
All In-line equipment correct
as specified
All bolts checked for tightness
All internals fitted, e.g. filter
elements, NRV internals
Other
6
Have all valves been checked for ease of operation, pinch points
and loose bonnet bolts?
7
Have all control valves been checked that they are fitted
correctly for direction of process flow?
8
Have all filters, non-return valves and other in-line pieces of
equipment been checked that they are fitted correctly for
direction of process flow?
(Continued)
210
9
12
13
14
15
16
17
18
19
20
21
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Have all vents and drains been Safety of location
checked to ensure?
Access
Direction of exhaust
Splashing
Pooling
Space for blind flange removal
and flexible pipe fitting is
adequate
Are there sufficient drains on
pipe including manifolds
Have all grounding straps been checked, no loose connections
or loose bolts?
Have all instruments and
Accessibility
electrical items been checked Can gauges be read
for?
Do impulse lines and cables
create a hazard
Are junction boxes in the way
Are all stop buttons accessible,
labeled and guarded if
necessary
Motor guards checked and
tight, no loose screws
Have all instruments been
labeled in the filed
Have all relief streams been
Exhaust lines clear
checked?
Labeled
Relief valves tested & tagged
Bursting discs fitted and
tagged
Supports appear adequate
Have all pipelines been checked to ensure no visible mechanical
damage has been made?
Has a list of all scaffolding to be removed prior to handover
been made and added to the punchlist?
Have all structures and
Loose bolts
steelwork been checked for? Safety of stairways,
obstructions, etc.
Grouting
Kick plates
Lighting
Handrails (fitted & secure)
Touch up paintwork
Holes in flooring
Have all areas been checked for poor housekeeping, excessive
construction debris and waste
Have all areas been checked to ensure all safety equipment, eye
wash boxes, BA sets etc., safety showers etc. have been installed
and checked
Has all rotating equipment been checked to ensure guards are in
place and secure
Are there any lifting beams? If so are they tested and stamped
with relevant ID markings?
Chapter 4 • The Commissioning System File
7
Action Upon Alarm Sheet
ALARM ACTION SHEET
Alarm Title
Settings
Response Time
POSSIBLE RESPONSES
Loop Number
P&ID Number
Purpose of Alarm
CONSEQUENCES OF A FAILURE TO RESPOND
START-UP/SHUT-DOWN IMPLICATIONS
Author:
Validated by:
Date
211
212
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
8 Handover Certificate Construction
to Commissioning
Construction to Commissioning
Handover Certificate
HANDOVER CERTIFICATE FOR COMMISSIONING SYSTEM………. FROM THE
CONSTRUCTION MANAGER TO THE COMMISSIONING MANAGER
COMMISSIONING SYSTEM REFERENCE:
DATE:
This certificate certifies that the ………. system has been completed and is available for Process
Commissioning. This is subject to any reservations agreed by the Construction Manager and the
Commissioning Manager. It is understood these reservations must be completed in full as soon as is
practicable. These reservations are detailed below.
If no reservations for this system apply, please insert N/A in the boxes.
Reservation Reference Number
Reservation Details
Signatures
System Offered by:
Title & Signature
Date:
System Accepted by:
Title & Signature
Date:
Chapter 4 • The Commissioning System File
9
213
Project Documentation Check Sheet Prior to
Introduction of Safe Chemicals
It is probable that the jobsite or client will have in place a system for checking the new
plant is ready to accept chemicals, this is usually in the form of management of change
procedure (MOC), hazard study process or a pre start up safety review (PSSR) system.
Please use the guide words below to check that the detail within the table is found
within the job or client system. If some of the check words are not found, discuss with the
client and incorporate accordingly. If there is no system in place use this paperwork
system in its entirety.
Documentation check sheet prior to
chemical introduction
Team Members: (Typical listed)
PROJECT
Author
DATE
Project Manager Mechanical Engineer Electrical Engineer Process Engineer Operations Manager SHE Advisor Commissioning Manager No
1
Section
Installation
Guide word
Comments and action
Action On
Has a check of pipe work, valves,
instrumentation configuration and
supports against P&IDs and
isometrics been made?
Check equipment labeling,
insulation and valve numbering,
testing and labeling of stop and
start buttons and isolators
2
Relief systems
3
Interlocks,
shut-down systems
and alarms
Have correct materials of
construction been used
Correctly installed and
documented to approved
company and standards
Schedule of inspections in place
All commissioning checklists and
procedures completed
Interlock and shutdown test
procedures written
Practicality of test methods
reviewed and approved
List of persons responsible for
testing in place
Alarm action review completed
Procedure in place for the control
of interlock and S/D defeats
(Continued)
214
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
4
Restrictor orifices
or other flow
restricting
devices
Are all in place, labeled,
documented and a system
available to sustain
5
Equipment
inspections
Check availability of equipment
manufacturer’s and independent
authorities test certificates
6
HAZOP
Have all requirements and actions
from the HAZOP been
implemented and completed
7
Operating and
maintenance
procedures
Written and validated for
normal operation, start-up,
planned and emergency
shut-downs and
decontamination
Maintenance procedures
compiled
Log sheets developed
General Risk Assessments
written, if applicable
8
Spares
Systems for control of materials
used, e.g. gaskets, valves,
instruments, etc. in place and
has been updated for the new
plant
9
Control of hazardous
substances
Assessments and controls in
place that meet EPA and RCRA
requirements
10
Noise
11
Effluents
Noise assessment carried out?
Ear protection zones marked
Sampling schedules in place,
ownership and responsibilities
defined
Systems for disposal of
samples, spillages, etc. defined
and in place
12
Ionizing radiation
Authorities informed?
Installation and monitoring
system in place
13
Major pipeline
isolations
Accessibility, operability and
labeling of major isolations
checked
System to monitor fitting of
lock set-up
Chapter 4 • The Commissioning System File
14
Emergency power,
services and
communications
Are they satisfactory for
ongoing operation?
15
Training
Program complete, validated
and records in place (should
cover operating and
maintenance personnel)
16
Computer control
systems
Validation and acceptance
checks complete
Test schedules in place
Functional design paperwork
available
17
Management of
change, MOC
MOC generated and complete to
commissioning stage?
18
Drawings
P&IDs updated and indexed
Electrical loop, one-line and
instrument loop drawings
available and issued to
commissioning/operations
19
Site emergency
procedures
Confirm that any necessary
changes have been made to plant,
site or off-site emergency
procedures
20
Other site
procedures
Do other site procedures need to
be modified and has this been
done?
21
External approvals
Are there any external approvals
required for this project
22
Construction
handover
Obtain key documentation
Is the handover procedure in
place?
215
216
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Documentation check sheet prior to safe chemical introduction
Action register
No.
10
Section
Guideword
Comments/Action
required
Action
on
Completed by
Safe Chemical Commissioning Authorization
and Pre-Commissioning Procedures
In some circumstances the project or client may need a procedure in place to clearly
confirm, check and communicate prior to introduction of energy into the system for initial
commissioning activities such as leak testing. This check sheet will manage that process.
Chapter 4 • The Commissioning System File
217
Authorization to
Introduce Safe Chemicals
Project:
Author:
No
1
2
3
4
5
6
7
8
9
10
11
12
13
System:
Date:
Item
System pipe work closed in, all openings have
been fitted with appropriate equipment or
blinds
Page 1 of
P &IDs covered :
Authorisation
Signature
Date
Critical joints witnessed
Punchlist complete, all high priority items
closed out
Critical Valve Alignment Checks carried out
(including relief stream interlock alignments)
Valves lined up for testing
Leak/pressure test procedure written
Any MOC checked to ensure that installation
is per design
All safety equipment in position
All Permits to Work and Confined Space Entry
permits have been signed off
All blanks, blinds or pancakes in correct
positions & isolation register completed
All personnel have been informed of the
introduction of a chemical for testing purposes
Is equipment sufficiently supported?
Has PSSR and documentation check been
completed?
Authority is given to introduce: _____________________________ for leak test and SAFE chemical trials and
commissioning purposes only.
System Name : ______________________
I am satisfied that the general housekeeping/safety standards in the area are satisfactory. We agree the
Date/Time for introduction of process fluids will be :
Commissioning Manager Sign: Date
Commissioning Engineer Sign Date
The following list details examples of pre-commissioning procedures that commissioning can perform potentially during construction.
Pre-Commissioning Procedure List
•
•
•
•
Mechanical interlock checks
Fitting of all locks on valves
Checks to ensure check valves are fitted with internals
Packing of a distillation column
218
•
•
•
•
•
•
•
•
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Packing a reactor with catalyst
Filling of desiccant into drying tower
Installation of filter medium, cartridges, etc.
Checks to ensure pipework falls in the correct direction
Installation of filter bags into a bag house or dust collector
Procedure to check flexible couplings and bellows are fit for operation
Filling a mill with beads
Procedures to check the operation without any chemicals of a DCS control sequence.
These procedures can be numbered such that they can be easily referenced on a detailed
commissioning schedule.
Pre-Commissioning
Procedure
TITLE:
STEP
Ref:
Project:
System:
Line & Vessel numbers:
P&ID covered:
Author:
Date:
ACTION
METHOD
Comments
1
Procedure to …… has been completed.
Signed by:
Date:
Page 1 of
Signed
Date
Chapter 4 • The Commissioning System File
11
Leak Test Check List and Procedure
Leak Test Procedure
Check List
Project
System :
Page 1 of
P&IDs (which must be attached to this procedure)
Author:
Date:
SUB-SYSTEM - Identify all vessels/lines to be tested
ISOLATIONS - Identify isolations required for test (spades, double block and bleeds, etc.)
VALVES - Identify valves which need to be opened for test (control valve, shut-down valves, etc.)
Test Input Points Tick and Sign
Location :
Test
Rig Fitted
Medium
Water
Air
Nitrogen
Other
Test Pressure -
Pressure Indication Point Release Pressure At Drain Liquor/Gas To
All joints to be soap tested - Yes/No
Other test if not soap test - N/A/No/Yes – Identify:
Expected Test Duration Time:
Rig
Removed
Actual Test Duration Time:
Pressure drop with time
Initial
Pressure :
1 hours :
9 hrs :
12 hrs :
3 hours :
Final Pressure :
6 hours :
Leaks Found?
YES / NO
Identify location with tag, and mark on
system P&ID.
Remember: Temperature and pressure differential must be considered.
219
220
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
Leak Test Procedure
Step
Operation
Comments
Signed off
The equipment and lines included in this procedure have passed the test as defined above:
Commissioning Engineer: Signed: Date:
All isolations removed and valves returned to normal required position:
Commissioning Engineer: Signed: Date:
Plant Representative: Signed: Date:
Chapter 4 • The Commissioning System File
12
221
Instrument Check Sheet
Individual loop check sheets will be prepared throughout the course of construction. As
an aid to collating all instrument information per system with handover in mind, the
check sheet below should be compiled and signed off by the C/E/I and/or system
commissioning engineers to signify progress and completion.
Instrument Check Sheet
Project:
Loop No
System:
Description
In position in
field
Tested on DCS & ready
for
commissioning?
Signed/Date
222
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
13
Motor Check Sheet
Individual motor check sheets will be prepared throughout the course of construction. As
an aid to collating all electrical information per system with handover in mind, the check
sheet below should be compiled and signed off by the C/E/I and/or system commissioning engineers to signify progress and completion.
Motor Check Sheets
Project:
Drive
Start
Local
System:
Stop
Local
Start
DCS
Stop
DCS
ESD
Field
ESD
DCS
Rotation Check
Chapter 4 • The Commissioning System File
14
Interlock Check Sheet
Interlock Check Sheet
Project:
Page of
System:
P&IDs covered:
Interlock
Description
Interlock Input Checked
Alarmed?
System trip
initiated?
Stroke Test
SDV
Field
DCS
Alarm
Tested
223
224
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
15
Emergency Shut-Down Check Sheet
Emergency Shut-Down Check Sheet
ESD
Project:
Page of
System:
P&IDs covered:
Description
ESD Input Checked
Alarmed?
System trip
initiated?
Stroke Test
SDV
Field
DCS
Alarm
Tested
Chapter 4 • The Commissioning System File
16
225
DCS Sequence Test Procedure
DCS Sequence Test Procedure
Step
Project:
Page of
System:
P&IDs covered:
Action
Hold checked
Failure monitoring
check
Sign
226
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
17 Relief Stream Check Sheets
Relief Stream Check Sheet
Project:
P&IDs:
System:
Description:
Ensure that all Relief Streams have clear bore, prove via a flush, blow or pig procedure
Relief
Stream
Description
Disc in Place?
Relief Valve in
Position,
exhaust line
clear?
Relief Valve
tested and
tagged?
Relief Stream
Labeled?
Chapter 4 • The Commissioning System File
18
Critical Insulation Checks
Critical Insulation Check Sheet
Project:
P&IDs:
System:
Description:
Please check the following lines; the failure to have less than an initial coat of insulation will
prevent the sections of pipe work from being commissioned, or operated
Line or Equipment Number
Description of cover required, and location
Insulation fitted?
Date and sign
227
228
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
19
Critical Gasket Checks
Critical Gasket Check Sheet
Project:
P&IDs:
System:
Description:
Please check the following gaskets, which if improperly fitted could result in either rework
if they fail a leak test, or a release of the contained fluid/gas being commissioned on a service
leak test
Line or Equipment Number
Description of cover required, and location
Witnessed fitting by:
Date and sign
Chapter 4 • The Commissioning System File
20
Lubrication Check Sheet
Lubrication Schedule
Project:
P&IDs:
Systems: All
Equipment Number
Description
Lubrication installed
to correct
specification
Date and
sign
229
230
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
21
PSSR and Plant Check-Out Prior to Introduction of
Hazardous Chemicals
Pre-introductory checks defined in this section are based on the Hazard Study 4 system as
developed by ICI in the 1960s. These guide words must be considered working in
conjunction with the site- or client-based checking protocol.
Pre-start-up safety review – mandates that a safety review for new facilities and
significantly modified work sites to confirm that the construction and equipment of
a process are in accordance with design specifications; to assure that adequate safety,
operating, maintenance and emergency procedures are in place; and to assure process
operator training has been completed. Also, for new facilities, the PHA (process hazard
analysis) must be performed and recommendations resolved and implemented before
start-up. Modified facilities must meet management of change requirements.
The above is the guideline from OSHA. Most client operations will have a PSSR
procedure in place; however, reference should be made to the guide words found in the
document below and implemented to enhance the client PSSR document as required.
PSSR and Plant Check Sheet Prior to
Introduction of Hazardous Chemicals
Team Members: (Typical listed) Project Manager,
Mechanical Engineer, Electrical Engineer, Process Engineer,
Operations Manager, SHE Advisor, Commissioning Manager
No
Section
1
Visitors
2
2.1
General access
Stairs
2.2
Fixed ladders
2.3
Floor and tripping
hazards
Project:
Guide word
Procedure for management of
visitors in place
Warning notices, indication of
sign in location clearly identified
Required PPE available
Plant induction procedure in place
Regular risers – especially top
and bottom steps
Depth of tread and slope
Continuity of handrails
Rails, guards, access and egress.
Are they acceptable?
Are self-close gates fitted where
required
Unguarded openings in floors.
Pipe slots in the floor sealed?
Holes for pipes, etc., which
require toe rings.
Toe boards, handrails, security
and continuity
Uneven ground, pipe obstructions
at low level
Areas susceptible to water pooling
Raised anchor bolts
Uncovered drains and gullies
Author
Comments and action
Date
Action on
Chapter 4 • The Commissioning System File
2.4
Headroom
2.5
Plant exits
2.6
Fire escape and
toxic refuge
3
Access for
operation and
maintenance
Valves and other
operating controls
Instruments points Accessible for maintenance –
consider frequency and urgency
that will apply and move or
provide access if necessary
Lubrication
If grease nipples are out of reach
fit extension pipes
Has all newly installed equipment
had an initial charge of
lubrication?
Has a “top-up” routine been
established?
Space for operation Consider especially maintenance
and or maintenance activities they usually require
more space than plant operation
Lighting fittings
Can access for maintenance be
improved?
Road and rail
Access to tanker with handrail
tankers
protection if operator has to work
on tank?
Consider: pump glands, coupling
Guarding of
machines
guards, fans and conveyor drives.
Exposed lengths of Are all exposed turning parts
revolving shaft
covered?
Belt drives
Are guards adequate – closed –
fixed?
Inspection
Do they give access to moving
openings
parts? Are they fixed? Should
they be interlocked?
Belt conveyors
Guarding of nips, idle rollers.
Trip wires, inching operations for
maintenance. Guarding for those
underneath. Protection from
splashing underneath
Charging openings Contact with moving parts?
in vessels
Could someone fall in? Is an
interlock needed? Should bars be
fitted?
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
4.5
Minimum headroom on
walkways and normal operation
areas acceptable. Check pipe
work and steel bracing
Are exits marked and adequately
lit? Are safety barriers required
because of vehicular movements?
Are escape routes adequate? Are
they marked and well lit?
Is the safe refuge defined, labeled
and communicated?
Are they out of reach – consider
emergency and frequency of use?
Consider moving, automating or
providing access
(Continued)
231
232
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
5
6
7
8
9
10
11
12
13
13.1
13.2
13.3
13.4
13.5
13.6
13.7
14
A stopping device, suitably
located and identified, should be
adjacent to power driven
machines and motors
Fragile pipes and
Are glass or plastic devices
vessels
protected from damage and
labeled? Are protective screens
required?
Hot surfaces
Are people protected? Do stream
traps drain to a safe location?
Pressure relief
Discharge to a safe location? Are
they labeled?
Flammables
Storage, labeling?
Lifting beams
Safe working load marked.
Labeled? Registered?
Overhead, power
Drivers access to cab and escape
operated cranes
routes? Access for maintenance,
lubrication? Are travel limit
switches required?
Lighting
Adequacy? Access for
maintenance on plant? Roadways,
paths? Emergency lighting
operational and adequate?
Labeled, lighting, access,
Safety equipment
operation, testing, frost
Emergency
protection, bacterial effects
showers
Eyewash
Labeling, notices, lighting,
cleanliness, auditing?
Breathing apparatus Labeling, notices, lighting,
cleanliness, auditing?
Other specialized
protective
equipment
Emergency
Signed, communicated and tested?
assembly point
Adequate?
Emergency alarm
Audible throughout plant with
operations ongoing?
Communication
How will this be done during
emergencies?
Fire fighting equipment – access
Fire
– monitoring?
Fire alarms adequate labeled,
visible?
Stopping devices
Chapter 4 • The Commissioning System File
15
Labeling
16
Collision damage
17
Control room
18
DCS control
systems
19
Eye hazards
20
Health
21
Safety information
22
Housekeeping
23
Sampling points
24
Environmental
25
Outstanding
HAZOP actions
Fire detection – suitable,
appropriate?
Fire walls, sealing of duct pipe
runs
Fire proofing of steelwork?
Access for emergency services?
Valves, pipelines, fragile
equipment, filling connections?
Electrical equipment, vessels,
pumps, roadways etc.
Safety barriers for vulnerable
plant and pedestrians?
Instrumentation clearly labeled?
Ventilation and lighting
adequate? Have all ergonomic
checks been completed? Any
alarms and indicator panels
correct?
All operator interfaces comply
with policy and procedures?
All ergonomic checks carried
out?
Zoned areas marked? Signs in
place? PPE available?
Ventilation systems (including
LEV) – testing – maintenance?
Hazard data sheets, risk
assessments available on plant?
All redundant excess material
removed from site. Roads/ paths
finished to acceptable standard?
Location, drainage, grounding?
Analytical schedules and
laboratory support services?
Monitoring and sample points set
up? Management system in
place? Are sample points
accessible?
Outstanding actions from
previous studies reviewed and
signed off?
233
234
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
PSSR and Plant Check Sheet Prior to Introduction of Hazardous
Chemicals – Action Register
No
FIG. 40
Section
Guide word
Comments
and action
Action
on
Completed by/Date
Chapter 4 • The Commissioning System File
22
235
Documentation Requirements for Ongoing
Maintenance Group
It is common that key documentation that appertains to new pipework, vessels, and
civil installations may not be available at the time of chemical introduction. The table
below provides guide words which should be discussed at the earliest opportunity with
the client maintenance and engineering groups to help insure all paperwork is in
place.
FIG. 41
236
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
23
Authority to Introduce Process Chemicals,
Check Sheet and Certificate
Authorization to
Introduce Hazardous Chemicals
Project:
Author:
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
System:
Date:
Item
Vessel or equipment internally inspected
immediately prior to closure and is free of
debris.
Witness of any critical joints by the Plant
Engineer.
Leak test satisfactorily completed as per
schedule.
All Instrument/Electrical, alarm and interlock
checks carried out and fault corrected.
Shut-Down Tests completed and faults
corrected. All valves associated with impulse
lines are aligned correctly.
Valve Alignment Checks carried out
(including relief stream interlock alignments).
Locked Open/Closed Valves in correct
positions and clearly marked. Security of
locking devices checked and satisfactory.
Equipment dried out/purged as necessary.
P&IDs covered:
Authorization
Commissioning
Engineer
Plant
Engineer
Commissioning
Engineer
Commissioning
C/E/I Engineer
C/E/I &
Commissioning
Engineer
Commissioning
Engineer
Commissioning
Engineer
Commissioning
Engineer
Critical insulation completed as per schedule. Commissioning
Engineer
Commissioning
All necessary Punchlist (excluding
Reservation List) work completed.
Engineer
Commissioning
All Blinds/blanks in correct positions (refer
to Isolation Register).
Engineer
Commissioning procedures complete (e.g.
Commissioning
stroke check valves/look for abnormal
Engineer
readings etc.).
Interlock defreat register signed off.
Commissioning
Engineer
MOC procedure checked to ensure that
Commissioning
installation is as per design.
Engineer
All safety equipment in position.
Commissioning
Engineer
Signature
Date
Chapter 4 • The Commissioning System File
16
Rotating equipment checks carried out.
17
All Permits to Work have been signed off.
18
19
All staging in the vicinity of hot surfaces has
been dismantled or otherwise protected.
Radioactive sources installed as necessary.
20
Handover reservations listed.
21
Statutory paperwork complete.
22
Housekeeping satisfactory.
23
All HAZOP actions complete.
237
Mechanical
Commissioning
Engineer
Commissioning
Engineer
Commissioning
Engineer
Commissioning
Engineer
Commissioning
Engineer
Plant
Mechanical &
Instrument
Engineer
Commissioning
Engineer
Commissioning
Engineer
The above checklist for introducing chemicals has been completed. Yes/No
All shut-down, de-contamination and recommissioning paperwork has been signed off.
System Commissioning Engineer: Date
We are satisfied that the system pre commissioning work has been completed and the general
housekeeping standards and safety in the area are appropriate to allow the introduction of process fluids.
The agreed Date/Time for introduction of process fluids is :
Commissioning Manager: Date:
Responsible E/I Engineer: Date:
Responsible Mechanical Engineer: Date:
Plant Manager: Date:
24 Commissioning Procedures
Commissioning procedures, written during the preparation phase of the project, are the
documents which, in great detail, set out how the plant will be commissioned and started up.
It is common for the commissioning procedures to be written first, the SOPs being
developed from these documents.
A detailed commissioning procedure should be compiled for each major activity that
the plant will undergo through the start-up. These documents are not check sheets, they
give a detailed descriptive of how the plant is made ready for normal operation.
Information to compose these procedures is found within P&IDs, PFDs, process
descriptions, instrument data sheets, equipment data sheets, control narratives, interlock
and emergency shut-down descriptions, vendor installation and operating manuals, and
most importantly talking with the process design teams.
238
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
A good commissioning procedure will detail the step, the method of performing the step,
any detail and any relevant comments and observations.
Common procedures could be:
•
•
•
•
•
•
•
•
•
•
•
•
•
How do we get the chemicals in?
How to slowly heat up, cool down, vent and control pressure and non-condensables
Introduce and control level
Establish and control flow
Manage exotherms and endotherms
Condition a catalyst
Set up a distillation column for profile – diagrams on temperature/pressure curve can
be utilized
Set-up and control of a scrubbing tower
Actually introduce alarm conditions to test operability
Introduce interlock conditions to test
Describe and manage any DCS-controlled sequences
Normal and emergency shut-down – where applicable and possible
Validation criteria and sampling regime.
Commissioning
Procedure
TITLE:
ST
Page 1 of
Project:
Document Title:
System:
P&IDs Covered:
Line Numbers:
Vessel Numbers:
Author:
Date:
ACTION
Procedure to ……….. has been completed.
Signed by:
Comments
Procedure Validated by:
METHOD
Comments
Date:
Sign/Date
Signed
Date
Chapter 4 • The Commissioning System File
25
239
Standard Operating Procedures (SOPs)
It is not uncommon for the commissioning team to be requested to draft the initial SOPs
as most of the key information detailed within will be written during the composition of
the commissioning procedures.
Below are the OSHA (USA) guidelines for the contents of an SOP.
The employer shall develop and implement written operating procedures that provide
clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and shall address at least the following elements:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Steps for each operating phase
Initial start-up
Normal operations
Temporary operations
Emergency shut-down including the conditions under which emergency shut-down
is required, and the assignment of shut-down responsibility to qualified operators to
ensure that emergency shut-down is executed in a safe and timely manner
Emergency operations
Normal shut-down
Start-up following a turnaround, or after an emergency shut-down
Operating limits
Consequences of deviation
Steps required to correct or avoid deviation
Safety and health considerations
Properties of, and hazards presented by, the chemicals used in the process
Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment
Control measures to be taken if physical contact or airborne exposure occurs
Quality control for raw materials and control of hazardous chemical inventory levels,
and
Any special or unique hazards.
240
CHEMICAL AND PROCESS PLANT COMMISSIONING HANDBOOK
26
Commissioning to Operations Handover Certificate
COMMISSIONING TO OPERATIONS
HANDOVER CERTIFICATE
Project Title:
No
1
2
3
4
5
6
7
Item
Project Data or Turnover Book prepared and
available to hand over
All Project P&IDs available and set in the
Control Room
Commissioning Procedures all completed, and
documentation available
Reservation Check List completed
All HAZOP Actions and or MOC completed
such that it is acceptable
All Loop Sheets are handed over to
maintenance personnel
Initial draft of SOPs available
System Description:
Organized by
Signature
Date
The acceptance criteria for this Project, as agreed between the Project Manager, Operations Manager
and Commissioning Manager, are as set out below.
No
Description
Comments and completed by
Chapter 4 • The Commissioning System File
COMMISSIONING TO PLANT
HANDOVER CERTIFICATE
The above check list for handover to plant has been completed.
I am satisfied that the system work has been commissioned and it is safe to allow continued
operation.
Commissioning Manager Print Date
Signature
Plant/Operating Manager Print Date
Signature
Item
No.
Reservations to Handover
Description of Outstanding Work
Item ID
Action Req.
From
Priority
241
Glossary of Terms
ARM
COMAH
COSHH
CR
DCS
E/C/I
ESD
FDS
HAZCON
HAZOP
HFAT
HSE
HVAC
ID
IOM
IPC
IT
LOPA
MCC
MOC
NDT
NFPA
NVQ
OSHA
PC
PFD
PLC
PPE
P&ID
SAT
SFAT
SHE
SIL
SOP
TWIC
URS
VSD
Availability, reliability and maintainability
Control of major accident hazards
Control of Substances Hazardous to Health
Control room – control center for a chemical plant
Distributed control system
Electrical/control/instrumentation
Emergency shut-down
Functional design specification
Hazards in Construction Study
Hazard and Operability Study
Hardware (electrical or control system) factory acceptance test
Health and Safety Executive
Heating, ventilation and air conditioning
Identification
Installation and operations manual
Integrated pollution control
Information technology
Layers of protection analysis
Motor control center
Management of change
Non-destructive testing
National Fire Protection Association
National Vocational Qualification
Occupational Health & Safety Administration
Personal computer
Process flow diagram
Programmable logic controller
Personal protective equipment
Piping and instrument diagram
Site acceptance test
Software (PLC or DCS) factory acceptance test
Safety Health & Environment
Safety integrity level
Standard operating procedure
Transportation worker identification credential
User requirement specification
Variable speed drive
243
1
Appendix
Commissioning Team Meeting Agenda
FIG. 42
245
246
APPENDIX 1
FIG. 42—Cont'd
2
Appendix
Commissioning System Documentation
Validation Matrix
Hypothetical Process Plant
Commissioning System Documentation Validation Matrix
System Owner
and Systems
System Owner 1
Instrument Air
Shower Water System
Utility Water Mains Supply
Out of Specification Product
Storage System
Product Transfer System
Reaction System
System Owner 2
Condensate System
Nitrogen System
Refrigeration System
Condensate Storage System
Product Polishing System
Reactor Feed A
Feed B System
System Owner 3
General Purpose Air
Potable Water System
Cooling Water System
Product Storage System
Product Scrubbing System
Reactor Feed B
Feed A Storage System
System Owner 4
Steam
Hot Oil Circulation System
Seal Water Supply System
By-Product Storage System
Product Distillation System
Feed A System
Feed A Storage System
System
System
System
System
Accepted by
Owner 4
Commissioning
Owner 3
Owner 2
Owner 1
Checked and Checked and Checked and Checked and
Manager
Signed off
Signed off
Signed off
Signed off
Signed off
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
247
3
Appendix
Control System Fault Log
Control System Fault Log
Please Describe in Detail All Issues with the Control System Here
Date
Time
What was the request and
or Last action
What has the DCS done/problem
Comments/Resolution from
Control Engineer
Signed Off
FIG. 43
249
4
Appendix
Loop Test Sheet
Loop test sheet
System:
P&ID:
Loop number
Alarm settings
Actual alarm values
Alarms needing
reset
Project:
Description
L=
L=
LL =
LL =
H=
H=
HH =
HH =
Post test statement
Signed
The loop is installed as shown on the P&ID and loop
diagram
The loop will perform as designed
Field labeling
Motor push buttons
Motors
Control/on–off valves
Instruments and cable
Orifice plates
Junction box
Marshalling cabinet
DCS/PLC panel
Local panels
General electrical wiring
Other
MCC room
Starters and push buttons
Lighting suitable
Accessibility of terminations
Fuse/breaker lock box available
Heating adequate
Cooling adequate
Cabinet air fan acceptable?
Labels on cabinet door correct
Wires labeled
Cables labeled
Other
OK –
N/A
YES
NO
YES
NO
Instrument
Air isolation correct
Accessible
Location correct per loop diagram and
P&ID
Input continuity check
Calibration
Range check with control system
Loop direct/reverse action
Serial number correct
State change OK on control system
Control – on/off valves
Position
0% =
mA =
Position
25% =
mA =
Position
50% =
mA =
Position
75% =
mA =
Position
100% =
mA =
Valve positioner operates correctly
State change OK on control system
Fail position checked
Interlock tested
Documentation
Interlock data on loop and P&ID correct
251
252
APPENDIX 4
DCS and/or I/O room
DCS/PLC panels labeled
Termination panel access suitable
Termination drawing suitable
Fuse in place
Motor
Megged/rating
Rotation
State change OK on control system
Signed for instrument/control/electrical
Signed for process
All loop diagram data correct
Master copy red lines for final mark-up
Control room has copy until as built issued
Date
Date
5
Appendix
Worked Example of a Knowledge-Based
Training Package
Plant X
Knowledge Training Package
FIG. 44
Contents
FIG. 45
1. Introduction to Training Process
The process of operator training addressed in this package incorporates sections on
basic system knowledge; it includes all the materials concerned with underpinning
knowledge for the ammonia addition system.
This process uses a series of logical steps to build up an individual’s underpinning
knowledge of the process, including the equipment, process flow and control, and how
the plant is protected in an adverse operational or emergency situation.
The training is based on a number of tutor-led exercises and self-learning; the program
for each session will be fully described by the training facilitator.
253
254
APPENDIX 5
The steps you will be asked to follow are listed below. You will be taken through the
steps in a formal training plan and assessed at the end of the process. After completing the
training pack a final validation assessment will take place to ensure that the information
has been successfully learnt.
Process steps:
FIG. 46
The tasks required at each step are fully explained both in the pack notes and by
your facilitator. Should you have any questions during the process – ask your
facilitator.
2. The Training Process
Step (1) – Items of Plant
Task
Using the worksheet provided complete a list of the equipment used in the process. Give
a brief description of each item’s duty or purpose. You will need to walk around the area
of plant, if allowed by the construction group.
Visit the plant to get to know the names, positions and uses of the items of equipment.
Do not get into great detail and do not use trade names unless they are commonly used
within the process.
Make a mental note of the positions of individual pieces of equipment; you will need
this information later in this training program.
Purpose
To become familiar with the layout of the plant system and the location/duty of each item
of equipment.
Assessment
Check with your trainer that your information is correct before you move onto the next
stage.
Appendix 5 • Worked Example of a Knowledge-Based Training Package
255
Key Criteria
• 100% accuracy in identification of plant items required.
Step (1) – Worksheet
FIG. 47
Step (2) – Item Drawings and Theory of Operation
Task
On the worksheets provided sketch as accurately as possible the main system equipment
listed in Step (1), including all interconnecting pipelines and connecting ancillary plant
items.
Sketch out the items to represent them graphically on the page. Indicate the shape of
each item and show lines in and out. Concentrate on process lines not those of services
such as gas and compressed air.
Use one worksheet per item – ask for more sheets if required.
Under each sketch give an explanation of the theory behind the operation of the unit.
Purpose
To look at each item of plant individually and understand what feeds in and what product
is coming out. This demonstrates you have gained an appreciation of the construction of
plant vessels, their internals and how they operate.
Assessment
Check with your trainer that your drawings and information are correct before moving
onto the next task.
Key Criteria
• Descriptions and drawings must be completed to ensure competence.
• 95% accuracy expected with drawings – only minor errors allowed.
APPENDIX 5
Plant items
256
Step (2) – Worksheet (A)
Ammonia addition system
Drawing
Process Water
Vent to
Atmosphere
30% Ammonia
Ammonia
Tank
T-208
Users
Ammonia
Pump
P-208
Appendix 5 • Worked Example of a Knowledge-Based Training Package
257
Theory of Operation – Worksheet (B)
Ammonia system
Ammonia is used by various users within plant X, as a pH adjustment medium.
T-208, the ammonia tank, holds a 5% ammonia solution. The tank is made from polypropylene,
and can hold 1.0 m3. It is protected from overfill by an overflow line, which drains to a bunded area,
which in turn drains to the plant effluent system. The ammonia is diluted in T-208 and is supplied
from an adjacent operating unit, plant Y at 30%.
Five percent ammonia batches are made in T-208 via an operator-initiated DCS control
sequence. Once initiated, the make-up of new batches will run automatically to keep T-208 topped
up after user demand. To allow the new batch to be accurately made a certain volume of process
water and ammonia needs to be added to the tank; this volume can only be added if the tank level is
at 80% or less, the finished batch taking the tank level to about 85%. A batch of 5% ammonia is made
up at the ratio of 1 part ammonia to 6 parts water.
When a new batch is required, the DCS sequence calculates the amount of water required, the
amount of ammonia required, based on what is left in the tank from the previous batch, and a fill
volume of 85% of the full vessel.
Process water is allowed to feed the tank the volume counted down on a flow meter, FI 208A. A
block valve, CMXV 308A, closes to stop the water flow. T-208 is then put on re-circulation, all user
valves from P-208 are closed and the re-circulation pump, P-208, is started. P-208 is made of
polypropylene, and can pump at a rate of 18 l/min.
Thirty percent ammonia from plant Y is allowed into T-208 via the opening of block valve CMXV
208B. Pump 96 (plant Y) is started and the pre-calculated amount of ammonia required is counted
down on flow meter FI 208B. Pump 96 is stopped and the block valve closed when the desired
quantity is met.
The contents of the tank are then circulated for typically 30 minutes.
Ammonia at the correct % is then available for use by the upstream users.
Step (3) – Flow Diagram
Task
You are provided with a basic diagram of the process plant system. The task is to ensure
all main process flow connections are present on the diagram, all items of equipment are
present, indicate the correct flow directions for materials and answer the range of
questions given.
In addition you will be asked to ensure any support systems are correctly present on
the diagram including items such as gas and steam supply.
Use the information and knowledge you have gained so far and check the actual plant
to confirm the answers you have given.
Your trainer will provide you with information on the standard symbols used
in drawing a flow diagram. However, when indicating flow directions use heavy
arrowheads.
258
APPENDIX 5
Purpose
To understand the construction and purpose of a process flow diagram and to interpret
the diagram in relation to the actual plant.
Assessment
Your trainer will compare your diagram with a training copy and discuss the diagram
layout, the symbols used and your answers to the various questions.
Key Criteria
• Candidate must identify at least three missing or incorrect flow lines.
• Candidate must identify at least three missing or incorrect critical valves.
• All questions on the sketch must be answered correctly.
Step (3) – Worksheet
XV
208A
User A
Vent to
Atmosphere
Process Water
XV
208B
User B
30% Ammonia
RO
208A
User C
Syphon Break
Ammonia
Tank
T-208
User D
Ammonia
Pump
P-208
Safe drain
S/S
208
Appendix 5 • Worked Example of a Knowledge-Based Training Package
Ammonia Addition System
259
260
APPENDIX 5
Step (4) – Instrumentation
Task
There are two sections to this step:
1. The first worksheet contains a list of all instrumentation on the plant. You need to
complete:
a. Descriptions of the equipment
b. Type of equipment (indicator, controller, recorder, alarm and analysis)
c. Information on normal settings.
2. Utilizing the diagram drawn in Step (3), you need to update the drawing by indicating
where the instruments listed in the first section of this step are located.
Purpose
To understand the different instruments used on the plant and to identify where they are
located in relation to the equipment on the plant.
Assessment
Your trainer will check your completed worksheets and question you on your understanding of this step.
Key Criteria
• Complete all instrumentation information tables.
• Enhance the flow diagram to show all instrumentation.
Step (4) – Worksheet (A)
Appendix 5 • Worked Example of a Knowledge-Based Training Package
FIG. 48 Ă
261
262
Process
Water
XV
208A
APPENDIX 5
Step (4) – Worksheet (B)
FI
208A
XV
208B
30%Ammonia
FI
208B
User B
LI
208
H
Level
Glass
RO
208A
FICZA H
208
L
LAH
208
Safe
drain
User A
Vent to
Atmosphere
User C
Syphon Break
Ammonia
Tank
T- 208
User D
Ammonia
Pump
P-208
PI
208
S/S
208
Appendix 5 • Worked Example of a Knowledge-Based Training Package
263
Step (5) – Plant Control and Protection
Task
Using your flow diagram completed with all equipment, pipelines and instrumentation
up to task 4, add the instrument control loops and shut-down systems based on
knowledge developed in the previous step. In the sections following this answer the
questions about each control loop.
For processing equipment controlled by a PLC, complete the worksheet provided by
your trainer that deals with the understanding of the operation of PLC systems.
Purpose
To learn and understand the control and protection systems of the plant and how they
interact.
Assessment
Your trainer will check the worksheets against the master copy. The control loops should
be correct and your answers accurate, covering the wider implications of process control.
Key Criteria
• Enhance the flow diagram to show all control loops, interlock and shut-down systems
(worksheet A).
• Complete a description sheet for each control loop (worksheet B).
• Complete a description sheet for each emergency shut-down system (worksheet C).
• Complete a description sheet for each interlock system (worksheet D).
• Complete a description sheet for each DCS-controlled sequence (worksheet E).
264
APPENDIX 5
Step (5) – Worksheet (A)
CS
10
Process
Water
I
10
XV
208A
FI
208A
I
10
XV
208B
30%Ammonia
Z
12
FI
208B
I
10
Level
Glass
User B
RO
208A
LI H
208
L
FICZA
208
LAH
208
Safe
drain
User A
Vent
to
Atmosphere
H
L
User C
Syphon Break
Ammonia
Tank
T- 208
User D
Ammonia
Pump
P- 208
PI
208
S/S
208
CS
10
Appendix 5 • Worked Example of a Knowledge-Based Training Package
265
Step (5) – Worksheet (B) Control Loops
FICZA 208 – ammonia flow to users
Plant item
H
FICA
208C
L
Washer
Ammonia
What is Being Measured and Why?
•
Ammonia is the medium utilized in the upstream to raise the pH in the process to the
required 8–8.2 range.
• Ammonia is pumped from the ammonia tank, T-208, to the online user via pump
P-208. A DCS user sequence downloads the required set point of the ammonia flow,
and control valve FCV 208A controls the flow to the SP requirement.
What Happens when these Measurements Vary?
•
The pH of the user will be initially offset (not at pH 8) and some adjustment will be
required by the operator. This will lead to the generation of poor-quality product.
What Effect do Variations have on other Areas of the Plant?
•
Time will be lost in an upstream user cycle (as the pH was not “right first time”) which
could lead to a loss of production and poor-quality product.
Step (5) – Worksheet (C) Shut-Down System
Plant item
Z-12 upstream shut-down
In the event of a trip of Z-12, the upstream users shut-down system, simultaneous actions
occur; the effect on the Ammonia Addition system will be FVC 208 will be forced closed
and the controller FICZA 208 will be given a zero set point.
A reset of the system once the trip Z-12 has cleared will be via the pressing of a local
button in the field.
266
APPENDIX 5
CLOSE FCV
208
Gives0%
Z-12 input
Step (5) – Worksheet (D) Interlocks
Plant item
Ammonia addition system
Below are the system interlocks, controlled within the DCS that govern the ammonia
addition system.
FIG. 49
Step (5) – Worksheet (E) DCS Sequences
Sequence
FIG. 50
Level control and dilution of the ammonia tank, T-208
Appendix 5 • Worked Example of a Knowledge-Based Training Package
FIG. 50—Cont'd
Knowledge Assessment Sheet
Process Operator Questions
FIG. 51
267
6
Appendix
269
7
Appendix
Example Labels and Tags
PUNCHLIST ITEM
System:
System Engineer:
LEAK POINT
System:
System Engineer:
SYSTEM LIVE
Care must be taken when in this area.
Please consult the commissioning engineer below before
any work is carried out on this system
271
272
APPENDIX 7
UNDER COMMISSIONING CONTROL
System:
System Engineer:
UNDER CONSTRUCTION CONTROL
System:
System Engineer:
Tie-In Point
System:
System Engineer:
Battery Limit Point
System:
System Engineer:
8
Appendix
Worked Example of a Vendor Shop
Inspection Report
M Killcross Visit Report.
Client information retained.
Project ——————— —————————.
Pneumatic Dense Conveying trials for Product A and Product B, 22nd October 2003.
Location: XXXXX Materials Handling Ltd.
Upon arrival at XXXXX, an initial meeting was convened to plan the events of the day.
These were classified as:
1. Trial of flow rate.
2. Observe breakdown of material on one pass, and several pass movements.
3. Observation of blockages the materials experienced.
The materials to be trialed were drummed Product A, and bagged Product B.
Product A – a course granular material (confirmed through microscope identification
at XXXXX) was expected to give some transfer difficulties. The expected pipe run of
installation is w24 meters, the pipe test rig at XXXXX was w36 meters. The APS for
Product A is w100.
Product B is spherical in make-up (again confirmed via microscope), which raises less
concerns with the transfer characteristics. Its APS is w40. The expected transfer length
for the project will be w50 meters.
It is worthy of note that all pipework lengths are flanges and jointed, typically with
swept bends.
With there being a concern from the Client of the potential difficulty transferring
Product A, XXXXX made the Client team aware of a feature (to be installed at additional
cost) available which could be installed to pipe runs called the “Density Stabilizer”
system. This method of operation made provision for an air injection system placed at
4-meter intervals on the pipe run to aid the transfer of difficult products.
It was agreed to trial the transfer both with and without the Density Stabilization
system being activated.
The Client personnel were also made aware of a further, more expensive system which
could be purchased, called the “Auto Flow System”, which used “pipe within a pipe”
technology, creating inner pipe turbulence, and hence aiding the transfer of more
difficult materials.
273
274
APPENDIX 8
This system was considered inappropriate for the Client application and was not put
on trial.
Sketch of Test Rig
Hopper
Product A
Air
operated
Air
Blow
Egg
Product B
p1
Trial 1
Product A, source drum.
An air-actuated valve mounted on top of the blow-egg was opened, and the unit filled
via tipping Product A drum into the unit. Nuisance dust was taken away via
an extraction system.
The valve was closed and air applied to the blow-egg.
The density stabilizer (DS) system at this time was off.
The transfer was achieved successfully, with a backpressure on the blow-egg of w0.3
barg.
A sample of virgin Product A was taken prior to the transfer.
The blow-egg was again manually filled from the drum, and a transfer again set up. DS
off.
This time the material blocked several times, and a back pressure of 3 barg (air inlet
maximum pressure) was generated to force the blockage clear and enable the transfer
to be completed.
A concern was obviously generated as the blockage clearing was somewhat violent and
damage to the particles could result.
DS was turned on.
Material was returned to the blow-egg from the hopper and sampled, having been
transferred x1.
Multiple transfers were then completed, blockage free (with DS on), and after
a number of movements samples taken. Average back pressure on the blow-egg,
0.3 barg.
The trial was then halted while analysis was conducted.
Appendix 8 • Worked Example of a Vendor Shop Inspection Report
275
The initial results showed little degradation, although the samples will be returned to
client for analysis on their more reliable equipment.
Trial 2
Product B, source 1te bag
Same test rig.
The blow-egg was manually loaded with scoops from the bag. A virgin benchmark
sample was taken.
With the DS off, the material was transferred to the hopper. Back pressure on the blowegg w0.1 barg, no problems with transfer.
Multiple transfers between material in the hopper/bag and blow-egg then ensued with
no difficulty.
Samples were taken, and analyzed, again indicating little degradation; however, full
analysis will be undertaken at Client Site.
It was noted that the fines tail was reducing as more transfers were made. This was put
down to the extraction system not only removing nuisance dust, but fine particles also.
A solution to this (run without filters on) should be considered for the future Product A
trial.
M Killcross.
23rd October 2003.
9
Appendix
Commissioning System Status Chart
System Status List
FIG. 52
277
278
APPENDIX 9
FIG. 52—Cont'd
10
Appendix
Steam Blow Target Plate Configuration
Typical Target Plate
Configuration
Vent to atmosphere
Target should be
at least 10% of
the vent pipe size
Target Plate
Mirror finished
polished target 4
sided
Pipe coupling
Pipe cap
Steam inlet to vent/
target
279
About the Author
Having started with ICI in 1978, the author operated various production plants, the latter
of which subjected him to process commissioning, which had a fundamental effect upon
him and then became the basis of his 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, UK. He later spent 4 years in
the USA on a major uprate project to the 134a facility built there. After returning to the
UK, a Thermal Oxidizer process was successfully commissioned along with a major
Chlorine Cell Room refurbishment; in 2001 he then parted ways with the then 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 rejoined 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, UK and
Joliet, Illinois, USA.
In 2006 the author made a move to work extensively in the USA and has taken up more
and more senior roles in both the client and contractor commissioning sectors; currently
he is the head of the commissioning services department for an EPC Contractor in
Tampa, Florida, USA, PegasusTSI.
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 overhaul and
turnaround preparation and general management of the assets he has been involved
with. This knowledge of plant commissioning grows each day.
—July 2011
281
Index
A
Action upon alarm worksheet, 30, 36, 99, 211
Appendices, 245–279
Appoint commissioning manager, 5–9
Assignment considerations, 48–52
Authorization to introduce process chemicals,
236–237
B
Budget, 22–24
C
Cleaning, 121, 189
Cleaning chemically, 126
Cleaning mechanically, 126
Cleaning via blowing, 122–124
Cleaning via flushing, 125–126
Cleaning via steam blowing, 124–125
Cleaning with a “pig”, 126
Client commissioning manager, 9–10
Commissioning – what is it?, xiii–xv
Commissioning approach, xxiii–xxv
Commissioning chemicals, 48–52
Commissioning CLOSE OUT, 181
close down the commissioning team,
183–184
close out reservations, 181–182
commissioning document revision, 182
ongoing operation assistance, 183
operating procedure document revision, 183
training document revision, 182–183
Commissioning consumables, 50–51
Commissioning documentation, 52, 182
Commissioning documentation validation, 247
Commissioning IMPLEMENT, 109–180
Commissioning logic, xix
Commissioning organization chart, 39–45
Commissioning plan and philosophy, 37–39
Commissioning phases, 1–108, 109–180,
181–184
Commissioning PREPARE, 1–108, 129, 147,
157, 166
Commissioning procedures, 166–176, 237
Commissioning schedule, 119
Commissioning team meetings, 11, 245–246
Construction – quality of build checks, 118
Contract commissioning manager, 10
Contracts, 11
Control/instrument/electrical
(documentation preparation), 63
Control systems, 65–66
DCS/PLC fault log, 67–68
DCS/PLC sequence testing, 74
Existing C/E/I equipment sanity check, 68–69
Instrument calibration, 67
Instrument loop testing, 79
Instrument/electrical cabling, 66
Interlock testing, 73–74
Lighting, 65
Loop test sheet, 69–72
Motor checking and testing, 73
Typical full loop test diagram, 69–72
Control sequence test sheet procedure, 76–78
D
Decontamination procedure, 58, 99, 187–188
Design support, 29
Documentation checks prior to introduction
of safe chemicals, 213–216
Documentation requirements, 154
Dry commissioning, xiii, 135
Drying, 127–129
E
Electrical checks, 42, 137
Electronic filing of commissioning
documents, 46, 182
Emergency shut down system test sheet/
procedure, 20, 224
Environment issues, 97
283
284
INDEX
F
Factory acceptance testing, 111–116
Inspection check sheet, worked example,
116–117
G
Gasket check sheet, 228
Glossary of terms, 243
H
Handover definition, 104
Handover criteria, 104–105
Handover documentation, 105–106
Phased handover approach, 105
Review process, 106
Safe systems of work, 105
Handover – construction to commissioning,
147–148
Handover – commissioning to operations,
240–241
Hazard study, 30–32
I
Instrumentation checks, 42
Insulation check sheet, 61, 221, 227
Intent and use of the handbook, xxi
Interlock check sheet/procedure, 223
Introduction, xi–xii
Introduction of hazardous chemicals, 230–234
Introduction of safe chemicals, 149–152
L
Leak test rig, 159
Leak testing, 60, 155–166, 219
Service test, 155–156
Safe chemical leak test, 156–158
Toxic test, 159–161
Vacuum test, 159
Lubrication check sheet, 61, 229
M
Mechanical (documentation preparation),
80, 235
Construction checks, 83
Isometric drawing to P&ID check, 80
Lubrication, 85
Mechanical documents, 84
Pipeline cleanliness checks, 80–83
Vendor equipment checks, 83–84, 84–85
Vessel checks, 83–84
Modular construction, 112–114
Motor check sheet, 222
N
“Norms”, 24
O
Office setup and organization, 48–49
P
Post punchlist check sheet, 143, 145, 209–210
Pre-commissioning, xiii, 129–136, 152
Pre start up safety review, 61, 230
Prioritization, 6, 24
Procure commissioning chemicals, 51–52
Punch listing, 108, 141–147
R
Relief system check sheet, 213
Reviews
3-D model, 34
Action upon alarm, 35
Control system, 34
Isometric drawing, 34
Layout, 32
P&ID, 32–34
Risk assessment and HAZCON, 34
Roles
Commissioning control/instrument/
electrical engineer, 42–43
Commissioning engineer, 41–42
Commissioning manager, 40–41
Commissioning mechanical engineer, 43
Operating procedure coordinator, 43–44
Training coordinator, 44
S
Safe chemical introduction check sheet, 216
Safety, xvii
Scope of commissioning, 9–22
INDEX 285
Standard operating procedures, 43, 62,
93–100, 239
Contents of operating procedure manual,
95–96
Start up, xiii, 24
Steam blow target plate diagram, 279
System file, 26, 56–63, 155–241
System file index, 56
System status, 119–121
Systemization, 24–29
Systemized drawings, 28
T
Table of commissioning systems, 37
Tagging system, 107–108, 271
Target Values – Worked example, 56, 269
Tracking Progress, 119–121
Training materials – development of,
86–93
Training packs – worked example,
253–267
V
Vessel checks, 136–137
Vessel inspection report – worked example,
213
W
Wet commissioning, xiii–xv