Chapter l • Commissioning Phase One- Prepare 5

The tasks on the follmving bulleted lisl 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 activiries during this initial phase.

Appointing the commissioning manager

Commissioning scope and contracts
Budget estimation
Prioritized asset s·ystemization
Support design
Develop an in ilia! commissioning plan or philosophy
l\ppointment and composition of the commissioning team, roles, responsibilities and
organization chart
Documentation and sign-off requirements, the library and electronic filing
Dc\'ise assignment details, site and ofhcc requirements. consumables and pro curl'
commissioning chemicals
Create commissioning documents and the system tile
Conlrol, instrument, electrical commissioning document preparation
Mechanical commissioning document preparation
Develop training materials
Develop Standard Operating Procedures
Develop Commissioning Schedule
, TOO
Devise handover procedure
1 ~,,-
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 \'vith 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 \'\'ill high-
light the general attributes required oft he pusan a project manager or head of operations
may wish to consider in the ll.ppointment ol' 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 prac-
tices necessary for commissioning of a giYen process plant, to enable the equipment and
systems vvithin 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
"US product specification.
I :B The commissioning manager is ob\·iously a main project role, the incumbent
• J.E becoming responsible for selecting and appointing the actual commissioning team. The
'1].8 systems of work the individual musr then lead. develop and implement arc best executed
6 CHEMICAL AND PROCESS PL~i\T CClMM!SS!ClN!NG Ho:\:c: ~ ;;

based on the practices and methods explained in this hanG-:::_ ~ :~c commbsioning
manager will also become the main pivotal role and princ:p"'-- ::·.c<2~ace bet\·veen the
various discipline's comprising the project team, \'vith particular e-:-:-.9:-.c.sis generally being
focused on the construction to commissioning and commissio:--.::--.s :o operations group
interfaces and handovers.
It is vital the commissioning manager is able to fully understc..:1C. and comprehend how
each facility, system or process unit within the asset, including 3recific main plant items
and their ancillary processes, is designed to operate, can be cunL::-olled and also main-
tained. Once this understanding is gained, the commissioning manager then needs to
correctly sequence the systemization and as importantly prioritization of the variom
systems that make up the plant; this will then al\mv the procedures, check sheets and
other commissioning documents to be \Vritten, \vhich \\-ill address the following main
process activities and major process operations:

Pre-commissioning
Commissioning
Start-up
Normal shut~dmvn
Emergency shut-down
Decontamination.
lt cannot be stressed highly enough the need to allmv sufficient time for the commis-
sioning manager to become totally familiar with the intended process design and tJ1e
opera lion 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 re~ponsibilities due for consideration in
the selection of a commissioning manager. !Vlost of the skill set, qualities and level of
qualification desired in a suitable commissioning manager will Jay the foundation for the
recruitment of members and thereafter within the commissioning team to be formed.

Attributes
Adaptable ami flexible approach lo \Vork
Sound knowledge of safety, health and t:twironmental. especially \Vith regard to risk,
safe systems of work, statutory and regulatory requirements
Kcadily able to become familiar with process design
Experience and knmvledge of commissioning process plant
Knmvledge of a "systemized" approach to commissioning
• Experience of commissioning new· equipment within an existing operational asset
including:
Experience of project commissioning \Vitbin the management of a major overhaul or
turnaround
Proven record of working to strict budget and schedule limitations
 ClwpU!r I • Commissioning Phase One- Prepare 7

Experience of technical problem solving in an operational environment

\1\Torking within the constraints of a highly active and fluid operational environment
Ability to successfully manage \Vithin 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 preparator:/ vvnrk such as existing equipment decontami--
nation is considered and documentation suitably prepared
Management of the check-out of new equipment and systems to ensure installation is
as per design. proven methodolog:.-r 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 arc carried out w confirm equipment and systems work safely ;:md
correctl'J
Ensuring equipment is not brought into service until registration and documentation
have been completed
Ensuring suitable isolation standards are incorporated in design for both commis-
sioning and ongoing operations
Ensuring that all commissioning documentation b handed over to the operating plant
manager post completion of commissioning activities
If required lead and/or complete the requirements of Hazard studies, ?vfanagement
of Change CviOC) p8perwork. Authorization to Introduce Safe and Process Chem-
icals and Pre Start-up Safety 1\evievv :PSSR) documentation. in addition ensure all
relevant Hazard study. MOC and PSSH actions are completed and closed out prior
to st<Jrt-up
Management of the development and incorporation into the main project of an
1; ...., n~K
acceptable commissioning estimate and budget
Management of the development of off-site vendor in~pection~ and factory accep-
tance checks
Establishing and management of the training program for a competent commis-
sioning, operating and maintenance team
Clarify the operations/project/commissioning hand over and responsibility
philosophy
Manage the production of specific \\Tit ten commissioning procedures for each
system and/or each item of equipmem, covering all aspects of the commissioning
process
8 CHEMICAL A'-:IJ PROCeSS PLAI\T CO!vl~l\SSIOI\i!'IG \IANllllOClK

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 speciflc methods of commissioning to
be used on the project
Attend design and project revie\VS as agreed with the project manager supporting the
design process as required. Ensure that rele\·ant standards pertinent to the operation
arc upheld throughout the design phase, particularly when the pruject or mollification
is substantial
Participate in all coordination, scheduling, safety and progress review meetings
\:'~nsuring all instrument and electrical tests and check-out are completed per
commissioning system. including checkout of new computer control systems, inter-
locks and shut-down systems
Update all assigned commissioning documentation post start-up
~-lanagement a11d organization for the potpntial of shift work patterns and working of
long unsocial hours.

Qualifications
Bachelors Chemical Engineering Degree Education-+ 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 sklll 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 vvithin
product specification.

Key Points
The commissioning manager is to specify. schedule anD ci:rec:iy o\·ersee the
implementation of the procedures and practices nece"s<::-y for ccnnmissioning of
a given process plant. to enable the equipment and .... ·~ ~..::-::.:; ,,,::!::~n the asset
to be safely and reliably brought into operation and !-'.a:---.22-i ~-.-e~ w the plant
production organization for ongoing production at co::-:-.:.:: ..:-:~:~:::. :.-<.nes and
product specification