Chemical and Process Plant Commissioning Handbook

Chemical and Process Plant Commissioning Handbook

A Practical Guide to Plant System and Equipment Installation and Commissioning

1st Edition - September 27, 2011

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  • Author: Martin Killcross
  • Hardcover ISBN: 9780080971742
  • eBook ISBN: 9780080971759

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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.

Key Features

  • Unique information from a respected, global commissioning manager: delivers the know-how to succeed for anyone commissioning new plant or equipment
  • Comes with online commissioning process templates that make this title a working tool kit as well as a key reference
  • Extensive examples of successful commissioning processes with step-by-step guidance enable readers to understand the function and performance of the wide range of tasks required in the commissioning process


Chemical and process engineers. Industrial and plant engineers

Table of Contents

  • Acknowledgment


    What is Commissioning

    Safety and Environmental Considerations

    A Simplified Commissioning

    Intent and Use of the Handbook

    The Commissioning Approach

    Chapter 1. Commissioning Phase One – Prepare

    Appointing the Commissioning Manager

    Commissioning Scope and Contracts


    Budget Estimation

    Prioritized Asset Systemization

    Support Design

    Develop an Initial Commissioning Plan or Philosophy

    Appointment, Composition of the Commissioning Team, Roles, Responsibilities and Organization Chart

    Documentation and Sign-Off Requirements, the Library and Electronic Filing

    Devise Assignment Details, Site and Office Requirements, Consumables and Procure Commissioning Chemicals

    Create Commissioning Documents and the System File

    Control, Instrument, Electrical Commissioning Document Preparation

    Mechanical Commissioning Document Preparation

    Develop Training Materials

    Develop Standard Operating Procedures (SOPs)

    Develop Commissioning Schedule

    Devise Handover Procedure

    Devise Commissioning Tagging System

    2. Commissioning Phase Two – Implement

    Factory Acceptance Testing

    Check Construction and Quality of Build

    Tracking Progress and System Status

    Cleaning Procedures and Drying

    Pre-Commissioning Procedures

    Vessel Check Sheets

    Instrument Loop, Electrical and Control System Testing

    Commissioning Punchlisting

    Handover from Construction to Commissioning

    Introduction of Safe Chemicals

    Pre-Commissioning HAZOP Studies or Pre-Start-Up Safety

    Commissioning Leak Testing

    Commissioning and Initial Start-Up Plus Procedures

    Handover to Operations

    3. Commissioning Phase Three – Close-Out

    Close Out Reservations

    Complete Commissioning Documentation

    Complete Training and Update Documents to “As Commissioned”

    Update Operating Procedures to “As Commissioned”

    Assist Continued Operation, Troubleshooting and/or De-bottlenecking Projects

    Close Down the Commissioning Team

    Complete Close-Out Hazard Study

    Chapter 4. The Commissioning System File, a Full Catalogue of Blank Commissioning Documents

    Commissioning System File

    Commissioning System File System

    1. System P&IDs

    2. Decontamination Procedure and Isolation Register

    3. System Cleaning Checklist and Procedures

    4. Hazard Study Actions

    5. Equipment Check Sheets, Off- and On-Site Checks

    6. System Punchlists

    7. Action Upon Alarm Sheet

    8. Handover Certificate Construction to Commissioning

    9. Project Documentation Check Sheet Prior to Introduction of Safe Chemicals

    10. Safe Chemical Commissioning Authorization and Pre-Commissioning Procedures

    11. Leak Test Check List and Procedure

    12. Instrument Check Sheet

    13. Motor Check Sheet

    14. Interlock Check Sheet

    15. Emergency Shut-Down Check Sheet

    16. DCS Sequence Test Procedure

    17. Relief Stream Check Sheets

    18. Critical Insulation Checks

    19. Critical Gasket Checks

    20. Lubrication Check Sheet

    21. PSSR and Plant Check-Out Prior to Introduction of Hazardous Chemicals

    22. Documentation Requirements for Ongoing Maintenance Group

    23. Authority to Introduce Process Chemicals, Check Sheet and Certificate

    24. Commissioning Procedures

    25. Standard Operating Procedures (SOPs)

    26. Commissioning to Operations Handover Certificate

    Glossary of Terms

    Appendix 1. Commissioning Team Meeting Agenda

    Appendix 2. Commissioning System Documentation Validation Matrix

    Appendix 3. Control System Fault Log

    Appendix 4. Loop Test Sheet

    Appendix 5. Worked Example of a Knowledge-Based Training Package

    Appendix 6. Appendix

    Appendix 7. Example Labels and Tags

    Appendix 8. Worked Example of a Vendor Shop Inspection Report

    Appendix 9. Commissioning System Status Chart

    Appendix 10. Steam Blow Target Plate Configuration

    About the Author


Product details

  • No. of pages: 312
  • Language: English
  • Copyright: © Butterworth-Heinemann 2011
  • Published: September 27, 2011
  • Imprint: Butterworth-Heinemann
  • Hardcover ISBN: 9780080971742
  • eBook ISBN: 9780080971759

About the Author

Martin Killcross

Martin Killcross
Current Manager of Commissioning in the UK energy sector, a world scale Nuclear Deconversion Project (circ £1B) which is in the final commissioning stages. With over 41 years in the Chemical, Nuclear and related business sectors, 38 of those years specifically commissioning, de-commissioning and operating assets world-wide, including 25 years with ICI, subsequently working in both the client and contracting commissioning leadership capacities. The author has commissioned most unit operations and handled many hazardous chemicals. Since the publication of the 1st edition of this book, the author has presented at conferences and training events worldwide

Affiliations and Expertise

Commissioning Manager, URENCO ChemPlants, UK

Ratings and Reviews

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  • Moises R. Mon May 16 2022

    Chemical and Process Plant Comissioning Handbook

    As simple and to the point as a handbook should be, has a lot of helpful formats and checklists you can adapt and use as starting point to implement in your process when you are not that knowledgeable, explanation of each point on them is simple and gives real examples on how to apply them.

  • Geneviève G. Mon May 14 2018

    Very useful

    As we are still in the preparation phase of our plant construction and start-up, I found this book to be very useful, presenting a comprehensive approach to commissioning with real life experience and examples.

  • Paul W. Thu Dec 28 2017

    Chemical and Process Plant Commissioning Handbook

    An excellent guidance manual for best practice commissioning