Chemical and Process Plant Commissioning Handbook

A Practical Guide to Plant System and Equipment Installation and Commissioning


  • Martin Killcross, Commissioning manager for Sasol, Louisiana, USA

The Chemical and Process Plant Commissioning Handbook, winner of the 2012 Basil Brennan Medal from the Institution of Chemical Engineers, is a guide to converting a newly constructed plant or equipment into a fully integrated and operational process unit. Good commissioning is based on a disciplined, systematic and proven methodology and approach that achieve results in the safest, most efficient, cost effective and timely manner.

The book is supported by detailed, proven and effective commission templates, plus extensive commissioning scenarios that enable the reader to learn the context of good commissioning practice from an experienced commissioning manager. It focuses on the critical safety assessment and inspection regimes necessary to ensure that new plants are compliant with OSHA and environmental requirements. Martin Killcross has brought together the theory of textbooks and technical information obtained from sales literature, in order to provide engineers with what they need to know before initiating talks with vendors regarding equipment selection.

Commissioning files can be found here;

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Chemical and process engineers. Industrial and plant engineers


Book information

  • Published: September 2011
  • ISBN: 978-0-08-097174-2


"This handbook for new and experienced commissioning engineers, project managers, and operations managers offers a methodology for commissioning chemical and process plants, which can be used when commissioning a new plant, or for modified equipment in an existing facility, or in a turnaround or overhaul scenario. The handbook takes the approach that commissioning is a series of checks and counter-checks to confirm that the newly constructed chemical plant is fit for purpose and suitable for ongoing operation. The book is divided into sections on preparation, implementation, and close-out, with much information in bullet list format. For each step of the process, the handbook offers worked examples, checklists, and guidance on paperwork. The book also includes about 70 pages of sample blank documents, which can be used to creation commissioning manuals, plus 40 pages of schematics and engineering drawings especially designed to illustrate info in the handbook. Killcross is a commissioning consultant."--Reference and Research Book News, October 2012

Table of Contents

Introduction 6

What is commissioning? 9

Safety and Environmental Considerations 12

A simplified commissioning logic 14

The commissioning approach 15

Commissioning Phase One – PREPARE 18

Appointing the Commissioning Manager 20

Commissioning Scope and Contracts 24

Budget Estimation 35

Prioritized asset Systemization 38

Support Design 45

Develop Initial Commissioning Plan or Philosophy 52

Appointment and composition of the Commissioning Team, roles, responsibilities and organisation chart 54

Documentation and sign off requirements, the library and
electronic filing 63

Devise assignment details, site and office requirements, consumables and procure commissioning chemicals 66

Create commissioning documents and the System File 70

Control, Instrument, Electrical commissioning document
preparation 82

Mechanical commissioning document preparation 100

Develop Training Materials 107

Develop Standard Operating Procedures 113

Develop Commissioning Schedule 120

Devise Handover Procedure 124

Devise commissioning tagging system 127

Commissioning Phase Two – IMPLEMENT 129

Factory Acceptance Testing & Modular Construction 131

Check Construction and Quality of Build 138

Tracking Progress & System Status 140

Cleaning procedures and drying 143

Pre-commissioning procedures 152

Vessel Check Sheets 160

Instrument Loop, Electrical and Control system testing 164

Commissioning Punch listing 166

Handover from construction to commissioning 173

Introduction of Safe Chemicals 174

Pre-commissioning HAZOP Studies or Pre Start-Up 178

Commissioning Leak Testing 181

Commissioning and initial Start-up plus procedures 195

Handover to operations 207

Commissioning Phase Three – CLOSEOUT 211

Close out reservations 213

Complete Commissioning Documentation 213

Complete Training and update documents to "as commissioned" 213

Update Operating Procedures to "as commissioned" 214

Assist continued operation, troubleshooting and or
debottlenecking projects 214

Close Down Commissioning Team 215

Complete close out Hazard Study 215

The Commissioning System File, a full catalogue of blank commissioning documents 216

Index 283

Glossary of Terms 287

Appendices 288

About the author 323