Chemical and Process Plant Commissioning Handbook book cover

Chemical and Process Plant Commissioning Handbook

A Practical Guide to Plant System and Equipment Installation and Commissioning

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;


Chemical and process engineers. Industrial and plant engineers

Hardbound, 312 Pages

Published: September 2011

Imprint: Butterworth Heinemann

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


  • 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


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