Background I have been fascinated by the process of commissioning chemical and processing plants ever since my introduction to the

discipline. At that time I had worked at ICI (Imperial Chemical Industry) for four years and then as a process plant operator. While operating and assisting in the commissioning of a new plant, I was intrigued by the activities that had to be compiled and organized the checking out, the testing, and the rechecking of many plant items to allow the asset to be started up in an efficient and effective way. As I became engrossed by the experience and moved from the first commissioning project to the second, I was amazed that the whole process had to be rethought, almost reinvented, and that there was so much scrambling by the commissioning engineers on the new project to piece together the paperwork, procedural format, and general documentation from past commissioning campaigns to allow the new plant to begin to be organized so that its delivery could be completed. By that time I had subconsciously chosen commissioning as my future career and made a personal commitment to document the whole process in the best way I could. The result was my book Chemical and Process Plant Commissioning Handbook. Process plant commissioning in the chemical industry and related industries has an interesting dynamic, as there are few or no formal qualifications for commissioning a new plant. Process engineering has elements that address the subject, but the lack of published works on the topic has created the potential for commissioning to be a discipline that can be susceptible to serious problems during the key stage in a projects delivery. There is a three-step methodology that works well and has formed the basis of my career in process plant commissioning, which has now spanned more than 30 years. The Three-Phase Methodology The commissioning of a process plant should be considered and implemented in three distinct phases. Prepare

This phase covers activities undertaken to set up the commissioning, gather information, select the commissioning team, develop the schedule, and create documentation. These all are typically home office tasks. Implement This phase, which traditionally has been perceived as commissioning, involves examining the facets that address the installation, checking out, precommissioning, wet and dry commissioning, and start-up of the new equipment at the job site. Closeout This is the final stage of the commissioning process and the one most often neglected. It entails ensuring that all paperwork systems and trials are complete and updated to as commissioned status and that the plant and equipment have met the performance and acceptance criteria, allowing the plant to be handed to the ongoing operations group. For optimum success in a commissioning exercise, the members of a project team responsible for the commissioning phase should be involved at an early stage of the project to ensure that all considerations related to the start-up of the plant are considered.

Much emphasis is placed on the design and construction phases of a project, yet what is arguably the most important phase the start-up and delivery of the asset is an activity that may be neglected. Commissioning teams can turn up toward the end of construction and hurriedly compose the documents normally created during the

preparation phase, but I believe that what you get out of an endeavor is directly proportional to the effort you put in; if your preparation for the commissioning of a new asset is sloppy, late, without research, ill prepared, and unplanned, the start-up will be pretty much the same. Projects that are driven with a successful start-up as the aim and that have duly considered and implemented the commissioning tend to be the most successful. The main activities associated with and conducted in each of the three commissioning phases are shown in Table 1. Table 1 Main Activities and Phases

Phase

Activities

Appoint the commissioning manager.

Define the commissioning scope.

Systemize the plant into commissioning systems by using the project piping and instrument diagrams (P&IDs) and other relevant documents, Prepare including layout drawings, mechanical flow diagrams, and equipment lists.

Integrate commissioning systems into the engineering documents, line tables, instrument index, P&IDs, equipment lists, and procurement plans.

Input to Design: Attendance at the following reviews is required to ensure that commissioning activities are considered and relevant operational

experience is brought to the table: P&IDs, plant layout, constructability, 3D model, project schedule, safety integrity level (SIL), layers of protection analysis (LOPA), and control philosophy.

Compile the commissioning philosophy.

Compile the commissioning estimate and/or budget.

Agree on the interface/handover procedure with project, client, and construction groups.

Obtain pertinent and relevant engineering documents and establish the electronic commissioning team library.

Attend various hazard studies.

Compile the initial commissioning schedule (level 2).

Set up the site commissioning base and compile the commissioning consumables list.

Determine the initial fill chemicals and simulants and procure them.

Create the commissioning manual.

Compile the standard operating procedures (SOP).

Compile the training packages.

Agree on safe systems of work with all interested parties.

Compile the commissioning procedures.

Give input as required to the user requirement specification (URS) for a distributed control system (DCS) or supervisory control and data acquisition (SCADA).

Compile the initial commissioning schedule (level 3).

Compile the decontamination procedures.

Attendance at the factory equipment acceptance and predelivery tests.

Attendance at the computer hardware factory acceptance tests (HFATs), Implement software factory acceptance tests (SFAT), and review functional design specification (FDS) for the DCS.

Attendance at the site acceptance tests (SATs) for a DCS control system.

Be involved with the management and decommissioning and/or decontamination of existing plant if required.

Check construction progress and quality.

Start the commissioning log.

Test and clean pipe work and equipment.

Generate the punch list as required for each commissioning system.

Commence training of plant and maintenance personnel.

Manage handover construction to commissioning and/or operations.

Attend to and/or manage pre-start-up safety checks.

Complete all leak testing.

Precommission the systems.

Manage post-start-up modifications.

Manage the introduction of safe process chemicals.

Move the team to a shift management role if required.

Issue first draft of the standard operating procedures.

Start up the plant.

Validate plant performance with the quality team.

Update to all commissioning documents and standard operating procedures to as commissioned status.

Manage post-start-up modifications Closeout Update to training documents to as commissioned status.

Run and manage the plant to predetermined design production rates and initial output for the required duration.

Commissioning Logic The logical steps required to complete the three-phase commissioning process can be shown to flow in accordance with a simple logic, although it is accepted that some activities may run in parallel when actually delivered (see Figure 1).

Figure 1 Logic of the Three-Phase Commissioning Project

Prepare The major preparatory activities before the work actually commences in the field can include the following main elements. Some of the tasks more relevant to milestone events are not explained here. Appoint the Commissioning Manager The commissioning manager is an important part of the project team, and by its nature, the role requires a close working relationship with both the construction manager and the operations manager to ensure that the delivery of the new asset as a fully functional operation plant is completed in the most cost-effective and schedule-efficient manner. A good commissioning manager must have the ability to understand chemical processes; have knowledge of instrument, electrical, and control systems; be familiar with structured work methodologies; and be experienced in commissioning plant and equipment. Define the Commissioning Scope The area that can cause the most confusion if it is poorly prepared and drafted in a contract for commissioning services is scope definition. The exact role of the commissioning organization, the full scope of its activities, and definitions of when those activities are deemed complete should be documented clearly. It is important to specify clearly who will draft operating procedures and prepare and deliver training packages. In any scope document mention should be made of the practical factors such as who will operate valves, how control of energy introduction will be managed, and who has management control of all the various commissioning stages. Prioritized Asset Systemization Once the commissioning scope of the project has been defined and the initial key project documents (P&IDs, layout drawings, plot plans, and mechanical handling drawings) have been drafted and issued, 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 provides the structure for all the other organizational tasks the team will perform, sets the priority for document and checkout progress management, and assists in the efficient initial plant commissioning and start-up in the most effective and timely way. Input to Design As was indicated above, commissioning engineers are typically experienced individuals in their initial disciplines and invariably have commissioning-specific and operational experience. This type of expertise is invaluable at engineering design reviews, and the engineers attendance should be encouraged. Their experience adds value to the appreciation of P&IDs, 3-D models, and control philosophy reviews. Create the Commissioning Philosophy The aim of this document is to identify the key commissioning project aims, objectives, activities, and general philosophy; this should be compiled at an early stage in the commissioning teams life, after the team scope definition. The initial commissioning plan most often is utilized when a contracting commissioning organization is appointed to a project, and it may be the first indication to the client project management and operations and engineering teams of how the commissioning will be planned and the activities managed. Compile the Commissioning Estimate and/or Budget Many factors should be considered for inclusion in the commissioning team budget, including labor power costs, initial chemical fill costs, travel, and accommodation at the job site. Typically calculated on a simple spreadsheet, each cost should be accompanied with adequate descriptions of the expense in question. Many projects have a percentage commissioning cost scheme in place; in general, these costs range from 2 to 3% of the overall capital spent on simple projects up to 25% of the capital cost

for complicated nuclear facility commissioning, where much simulant testing must be developed and performed. Devise Handover Procedure It is absolutely crucial to clarify, agree on, and document the various handover steps among the range of engineering disciplines in a project. The focus here is on handovers between the construction group and the commissioning team and then between the commissioning team and the operations team. It is important to clarify what will be handed over and how and what the acceptance criteria are. Compile Initial Commissioning Schedules (Levels 2 and 3) The level 2 commissioning schedule, which is compiled at an early stage in the commissioning teams formation, entails drafting acurate estimates of all the teams activities. These activities include tasks in all three phases of a project. However, other than showing the duration of an activity (e.g., compilation of commissioning documents), the actual commissioning system in question is not specified. The level 3 schedule will provide a very acurate timeline for all the in-depth commissioning activities, typically from the mechanical completion phase. The schedule is compiled on a task-by-task basis and written on a system-by-system basis and is very detailed. Create Commissioning Documents and the System File In the commissioning of a processing plant, the creation of the specific documents and the accompanying filing system is of some significance. The suite of commissioning documents produced provides a demonstration and shows that everything necessary has been done by the commissioning team to check and countercheck the constructed plant. This allows the delivery of the project to design specifications in the most safe, effective, and timely manner, to the highest possible standard, backed up by correct, prudent, and accurately composed documentation that is completed and signed off on

in full. Anything undertaken in a commissioning campaign must be documented and stored in the system file to which it belongs; hence, the complete picture of all that has been done to commission the plant safely and efficiently can be demonstrated. Implement The field execution activities will change the plant from a build project to an operating asset. Attendance at Factory Acceptance Tests Much of the work to start the checkout of equipment can be completed at the factory before delivery to the site, and the completion of this work should be encoraged as it has the potential to save costs and time if vendor equipment does not perform initially. Activities performed at the factory acceptance test can include leak tests, intial operational runs, control system checkout, cleanliness checks, and test fitting of internals. Check Construction and Quality of Build The commissioning team plays a key role in the checkout of the systems in conjunction with the main plant construction. Schedule time and costs can be reduced by means of prompt identification and correction of faults; these faults can range from equipment installed incorrectly to valve handles protruding into walkways, causing safety hazards. Cleaning Procedures and Drying Before pipes and equipment are put in 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 that have been left inside pipe work and then find their way to pumps and other equipment, causing significant damage and schedule delay as a result of rectification work. The following methods of cleaning are common to fulfill this task:

cleaning by blowing (air or nitrogen), steam blowing, cleaning via flushing (water), chemical cleaning, use of a pig, and mechanical cleaning and visual inspection. Vessel Check Sheets Conducting the checkout of the plant and equipment being installed requires documentary evidence that each item has been installed in accordance with the design and is fit for ongoing commissioning and operations. No plant item should be closed until an internal inspection has taken place. This documents that an inspection with authority to close equipment has been made. Commissioning Punch Listing This is one of the major activities the commissioning team will conduct. The setting of high standards, principles, and methodology for effective punch listing, snagging, or checkout of the system that has been constructed is vitally important to the smooth ongoing commissioning of the asset and is the standard and key indicator by which a commissioning team will be measured. Precommissioning Hazard and Operability Studies or Pre-Start-Up Before the introduction of hazardous chemicals into a commissioning system or systems, a detailed check must be made to ensure that the plant is ready and fit for ongoing operation. Commissioning Leak Testing During the construction phase, hydrostatic tests will have been conducted to prove pipe integrity; however, many potential leak path points will still exist in an untested state. The object of a full system leak test is to test all leak potential suitably and practically before the introduction of process and hazardous chemicals. Commissioning and initial Start-Up-Plus Procedures

This activity could be described as the flagship activity among the many the team will undertake during a project. Here, where possible, safe chemicals are introduced water, steam, and air to simulate closely the unit in actual operation and to provide an indication of how the plant will perform when the process chemicals are introduced and the main commissioning and start-up event takes place. During commissioning execution, all safety-related systems are checked rigorously, including confirmation of alarm activation points by means of manipulation of the actual process variables; confirmation of the operation of all control system software trip logic by various means, including variability of the process conditions both manually and via the control system; confirmation of all hardwired emergency shutdown systems by various documented operational means; and confirmation of the operation and control of all DCS sequences, including full testing of all failure monitoring. All aspects of future operation are tested, including starting up, scheduled and emergency shutdowns, and the actions required after a loss of site services, including power and instrument air. Closeout The activities in the final phase are all associated with the successful and efficient closeout of the commissioning teams actions. Conclusion Monitoring and helping to mold the transformation of a plant from initial design intent, through the building and construction site phase, to successful commissioning and operation is an occupation that requires much organization and disciplined delivery. However, when it is based on and assisted by a methodology such as the one described here, it can lead to commissioning being a career that provides job satisfaction and pride. Enjoy safe and happy commissioning.

So what is commissioning?

In my experience commissioning is often viewed in different terms. My belief is that commissioning is best described when broken into three categories; all three composing the greater item, commissioning; 1. Pre-commissioning, activities carried out, starting during the construction phase of a project that prepare and enable the unit to move to the main commissioning phase, the range of pre-commissioning 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.

With my view of commissioning having now been explained, I want to stress one vitally important and critical factor to the success of a project...

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 projects life, not just after construction is complete. Follow this methodology and the steps explained within the handbook on all manner of projects, irrespective of size and the journey within commissioning should be made that much simpler...

"I strongly believe a logical, structured approach to correct commissioning practices will help transform any plant system, on any duty, into a production unit operating safety, effectively and fully delivering to its design intent within all time and cost constraints."

The three phases of commissioning

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. The Chemical and Process Plant Commissioning Handbook 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 startup. Having described above what commissioning is, my methodology and therefore the handbook approaches the topic of delivering of the actual commissioning process in three distinct stages.

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. The basic composition of these phases is: Prepare - Activities to be undertaken to set commissioning up, gather information, select the team, develop the schedule and create documentation. Implement - This phase traditionally perceived as "commissioning", examines the facets that address the installation, checking out 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, the plant or equipment has met its acceptance criteria enabling the plant to be handed to the ongoing operations group

Each stage within my commissioning approach and indeed the handbook 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 where-ever 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.

Please refer to the Commissioning Logic section of this site for further information on the overall commissioning process.

"what you get out of something, is directly proportional to the effort 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.

Commissioning Logic

Overview of Commissioning Stages

Check, Check and Check again, the foundation of successful commissioning

Key Commissioning Elements

As identified within the commissioning logic diagram, there are many phases to a successful commissioning effort; here I further describe perhaps the most important, key elements of the process

PREPARE
Preparatory activities prior to the work actually commencing in the field.

Appointing the Commissioning Manager The commissioning manager is a fundementally important position within the project team and by it's nature, the role demands a close working relationship with both the construction manager and the operations manager to ensure the delivery of the new asset to a fully functional operation plant is completed in the most cost effective and schedule efficient manner. A good commissioning manager must possess the ability to understand chemical processes, have knowledge of instrument, electrical and control systems, structured work methodologies and experience of commissioning plant and equipment. Prioritized asset Systemization Once the commissioning scope of the project has been defined and initial key project documents (P&ID's, 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, set the priority for document and checkout progress management and help assist in the efficient initial plant commissioning and startup in the most effective and timely way. Create commissioning documents and the System File Within the entity that is the commissioning of processing plants the creation of the specific documents and filing system thereof is of some significance. The suite of commissioning documents produced provide 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 highest possible standard, backed up by correct, prudent and accurately composed documentation, completed and signed off in full. Devise Handover Procedure It is absolutely crucial requirement to clarify, agree and document the various handover steps between the range of engineering disciplines within a project, handbook appraises the key features of this phase with regard to the commissioning organization. The Handovers focus on those between the Construction Group to the Commissioning Team, then the Commissioning Team to the Operations Team.

IMPLEMENT
The field execution activities that will change the plant from a build project to that of an operating asset.

Check Construction and Quality of Build The commissioning team play a key role in the check-out of the systems in conjunction with the main plant construction Cleaning procedures and drying 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 un-common for an initial plant commissioning period to be marred by foreign materials having been left inside pipe work, which then find there way to pumps and other equipment causing significant damage and schedule delay due to rectification procedures. The importance of robust cleaning procedures is the basis of this book chapter and the following methods of cleaning are reviewed in detail; Cleaning by blowing (air or nitrogen), Steam blowing, cleaning via flushing (water), chemical cleaning, use of a "pig" and mechanical cleaning and visual inspection. Vessel Check Sheets Conducting the check-out of the plant and equipment being installed will require documentory evidence that each item has been installed as per the design and is fit for ongoing commissioning and operations. Commissioning Punch listing This is a significant and one of the major activities the commissioning team will conduct; the setting of high standards, principles and methodology for effective punch listing, snagging or check-out of the system having been constructed is vitally important to the smooth ongoing commissioning of the asset and is the standard and key indicator that a good commissioning team will measured by. Pre-commissioning HAZOP Studies or Pre Start-Up Prior to the introduction of hazardous chemicals into a commissioning system, or systems, a detailed check must be made to ensure the plant is ready and fit for on going operation. Commissioning Leak Testing During the construction phase hydrostatic tests will have been conducted to proved pipe integrity, however many potential leak path points will still exist, untested. The object of the full system leak test is to suitably and practically test all leak potential prior to the introduction of process and hazardous chemicals. Commissioning and initial Start-up plus procedures This activity could be described as the "flagship" activity in the many the team will undertake during a project. 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 then process chemicals are introduced and the main commissioning and start-up event takes place. During commissioning execution all safety related systems are rigorously checked including; confirmation of alarm activation points via manipulation of the actual process variables, 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, confirmation of all hard wired emergency shut down systems by various documented operational means and the confirmation of the operation and control of all DCS sequences including full testing of all failure monitoring. All aspects of future operation are tested

including starting up, scheduled and emergency shut-downs and the actions required upon a loss of site services including power and instrument air.

CLOSEOUT
The final phase of activities are all associated with the successful and efficient close out the commissioning teams actions.

Complete Training and operating proceudres to "as commissioned" The importance to review all training packages and operating procedures and to update them with known operational experience.

Good projects have a successful start-up as the main aim, sound commissioning practices are a key element in the delivery of that goal.

The Commissioning System File

Many documents will be compiled within the prepare phase of commissioning preparation, a system is required to manage the documents produced. My methodology incorporates the use of a file, per commissioning system to house these documenst, a typical file table of contents is provided below.

System P&ID's Decontamination procedure & isolation register System cleaning procedures Hazard Study and actions Equipment Check Sheets, off and on site checks System Punch lists Action upon Alarm Sheet Handover Certificate Construction/Maintenance to Commissioning Project documentation check sheet prior to introduction of safe chemicals Safe Chemical Commissioning authorization and Pre-commissioning Procedures Leak Test Checklist and Procedures Instrument Check Sheet Motor Check Sheet Interlock check procedures Emergency Shut Down System check procedures DCS sequence test procedures Relief Stream Check Sheets Critical Insulation Checks Critical Gasket Installation Checks Lubrication Check Sheet PSSR, Plant Check-out prior to introduction of Hazardous Chemicals Documentation Requirements for Ongoing Maintenance Group Authority to Introduce Process Chemicals, check sheet & Certificate Commissioning Procedures Standard Operating Procedures Commissioning to Plant Handover Certificate

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.