search for books and compare prices
Tables of Contents for Start-Up
Chapter/Section Title
Page #
Page Count
The Role of the CST in a Start-Up
1
14
Job Descriptions
2
6
Training
3
1
Safety Inspection
4
1
Liaison
4
1
Technician Duties
5
1
Quality Control
5
2
Design and Engineering
7
1
Leadership
7
1
Baseline, Daily, and Future Tasks
8
2
Baseline Duties
8
1
Wet and Dry Runs
9
1
Planning for the Future: Maintenance
9
1
Calibrations and Loop Checks
10
1
Initial Equipment Start-up Activities
10
5
Burner Management Systems
11
1
Regenerative Systems
11
1
Control Loops
12
1
Summary
13
1
Quiz
13
2
Applicable Safety Practices and Standards
15
32
The Fourteen Points of Process Safety Management (PSM)
16
9
Employee Involvement
17
1
Process Safety Information
17
2
Process Hazard Analysis (PHA)
19
1
Operating Procedures and Practices
19
1
Employee Training
19
1
Contractors
20
1
Pre-start-up Safety
20
1
Mechanical Integrity
21
1
Nonroutine Work Authorizations
21
1
Managing Change
22
2
Investigation of Incidents
24
1
Emergency Preparedness
24
1
Compliance Audits
24
1
Trade Secrets
25
1
Summary: The CST and the Fourteen Points
25
1
The Common Types of Safety Meetings
25
4
The Common Types of Safety Training
29
5
OSHA Regulatory Training
29
3
Industry- or Plant-specific Training
32
2
Lockout/Tagout at Plant Start-Up
34
2
Compliant Documentation
36
4
Material Safety Data Sheets (MSDS)
37
3
Frequently Encountered Safety Equipment
40
7
Practical Examples
41
2
Summary
43
1
Quiz
44
3
Documenting the Start-up Process
47
32
Types of Documents
47
2
Document Formats
49
2
Original Drawings
49
1
Computer-aided Design (CAD) Drawings
49
1
Layered Drawings
50
1
Changes and Annotations
51
1
Document Location
51
1
The Different Diagrams
52
19
Gantt Charts
52
1
Process Flow Diagram (PFD)
53
1
Mass (or Material) Balance
54
2
Piping and Instrumentation Drawing (P&ID)
56
4
General Arrangement (GA) Drawing
60
1
Loop Diagrams (Loop Sheets)
60
1
Loop-check Log Sheet
60
3
Calibration Data Sheet
63
1
Installation Detail
64
1
Other Documents and Drawings
65
6
Documentation Needed during Start-Up
71
1
Maintenance, Upkeep, and Control of Start-up Documents
72
7
Summary
75
1
Quiz
76
3
Working with Others
79
14
Basic Start-up Duties of Other Disciplines
81
7
Operations Department
82
1
Project Engineering Department
83
1
Process Engineering (Technical Department)
83
1
Management
84
1
Maintenance Department
84
1
Environmental Department
85
1
Purchasing Department
85
1
Personnel Department
86
1
Contractors
86
1
Vendors
87
1
CST Interaction with Other Disciplines
88
1
Contractor Liaison
88
1
Personnel from Other Plants
88
1
Working with Manufacturing Representatives
89
1
``Chain of Command''
89
4
Summary
91
1
Quiz
91
2
Verifying and Managing Changes
93
20
Documentation: Development, Location, and Use
94
4
Access to Paperwork
95
1
Verifying Calibration
95
1
Off-Site Calibration
96
1
Factory Acceptance Test
96
1
In-Shop Calibrations
96
1
Site Acceptance Test and Validation
97
1
Completion Order of Loops
98
1
Calibration and Loop Checking: Verification of Completion
99
10
Calibration Data Sheets
99
2
Verifying Calibration
101
4
Performance Check
105
4
Management of Change (MOC)
109
4
Summary
110
1
Quiz
111
2
Start-up Plan for the CST
113
3
Required Number of Personnel
113
3
Division of Responsibility
113
1
Early Start-up
114
1
Environmental Problems
115
1
Processing Problems
115
1
Equipment Problems
115
1
Staffing and Overtime
116
1
``Cross-training''
117
8
Installation Training
118
1
Maintenance Training
118
1
Other Training
119
1
Task Assignments and Responsibilities
119
1
Proper Sequencing of the Start-up Plan
120
2
MOC and Redlining
122
1
Emergency Contacts
122
3
Summary
122
2
Quiz
124
1
Assisting Operations and Site Personnel
125
16
Identify and Correct Problems
126
4
Change Calibrations
130
2
Recalibration
130
2
Faulty Loops--A Typical Scenario
132
3
Troubleshooting
135
1
Required Tools and Test Equipment
136
2
Working with Specialists and Manufacturing Reps
138
3
Summary
139
1
Quiz
139
2
Tuning Control Loops
141
26
Types of Loops
142
3
Types of Signals
145
2
Types of Control
147
3
Closed-Loop or Feedback Control
147
3
Open-Loop Control
150
1
Discrete Control
150
1
Continuous Control
150
1
Parameters Used during Loop Checking
150
3
PID Algorithm
152
1
Control Action
153
3
On-Off Action
153
1
Proportional-Only Control
154
2
Proportional-Integral Control
156
1
Proportional-Derivative Control
156
1
Ziegler-Nichols Methods
156
3
Open-Loop Technique
157
1
Closed-Loop Technique
157
2
How to Tune
159
2
Trial and Error
159
1
Software Solutions
159
1
Calculating Control Parameters
160
1
Who Is Responsible for Changes
161
1
How Changes Affect Process and Other Loops
161
2
Whom to Notify of Changes
163
1
Documenting Changes
163
1
Backing Up or Saving Changes
163
4
Summary
164
1
Quiz
164
2
References/Bibliography
166
1
Appendix A Sample Job Description
167
4
Appendix B Sample Material Safety Data Sheet (MSDS)
171
8
Appendix C Vendor Document: Factory Acceptance Test (FAT)
179
12
Appendix D Answers to Exercises and Quizzes
191
20
Appendix E Relevant Standards
211
2
Index
213