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Chemical and Process Plant Commissioning Handbook - 1st Edition - ISBN: 9780080971742, 9780080971759

Chemical and Process Plant Commissioning Handbook

1st Edition

A Practical Guide to Plant System and Equipment Installation and Commissioning

Author: Martin Killcross
Hardcover ISBN: 9780080971742
eBook ISBN: 9780080971759
Imprint: Butterworth-Heinemann
Published Date: 27th September 2011
Page Count: 312
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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



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



No. of pages:
© Butterworth-Heinemann 2012
27th September 2011
Hardcover ISBN:
eBook ISBN:

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


The Basil Brennan Medal 2012, Institution of Chemical Engineers


"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

Ratings and Reviews