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Chemical and Process Plant Commissioning Handbook - 2nd Edition - ISBN: 9780128240496

Chemical and Process Plant Commissioning Handbook

2nd Edition

A Practical Guide to Plant System and Equipment Installation and Commissioning

Author: Martin Killcross
Hardcover ISBN: 9780128240496
Imprint: Butterworth-Heinemann
Published Date: 22nd March 2021
Page Count: 534
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Chemical and Process Plant Commissioning Handbook: A Practical Guide to Plant System and Equipment Installation and Commissioning, Second Edition, 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. The book is supported by detailed, proven and effective commission templates and includes extensive commissioning scenarios that enable the reader to good commissioning practices. Sections focus on the critical safety assessment and inspection regimes necessary to ensure that new plants are compliant with OSHA and environmental requirements.

Martin Killcross has comprehensively brought together the theory of textbooks and technical information obtained from sales literature to provide engineers with what they need to know before initiating talks with vendors regarding equipment selection.

Key Features

  • Outlines how to organize and commission a process plant
  • Includes extensive examples of successful commissioning processes with step-by-step guidance that enables readers to understand the function and performance of the wide range of tasks required in the commissioning process
  • Offers an understanding of supplementary factors of commissioning such as risk and hazard management
  • Reviews commonly asked commissioning questions
  • Includes the basis of the commissioning paperwork system


Process Engineers, Project Managers, Operations personal, Commissioning Engineers and Managers. Possible textbook for university courses/supplementary text

Table of Contents

1. Appointing the Commissioning manager
2. Commissioning Scope
3. Contracts
4. Commissioning in highly regulated industries
5. Budget Estimation
6. Prioritized asset Systemization
7. Support design
8. Develop Initial Commissioning Plan, Philosophy and Strategy
9. Commissioning Risk Management
10. Appointment and composition of the Commissioning Team, Roles, responsibilities, organisation chart and interview considerations
11. Suitable, Qualified and Experienced Personnel (SQEP), for commissioning
12. Documentation and sign off requirements, required for commissioning preparation
13. Devise assignment details, site and office requirements, consumables and procure commissioning chemicals
14. Create commissioning documents and the System File
15. Control, Instrument, Electrical commissioning document preparation
16. Mechanical commissioning document preparation
17. Develop Training Materials
18. Develop Standard Operating Procedures
19. Developing Commissioning Schedules and Contingency plans
20. Determination of Commissioning Readiness and Commissioning Team Audits
21. Devise Handover Procedure
22. Devise commissioning tagging system
23. Commissioning Terminology
24. Capturing Lessons Learnt
25. Factory Acceptance Testing
26. Check Construction and Quality of Build
27. Tracking Progress and System Status
28. Fault Management
29. Temporary Commissioning Defeat systems
30. Simultaneous Construction and Commissioning considerations
31. Cleaning procedures and drying
32. Pre-commissioning procedures
33. Logs, Reports and Dashboards
34. Vessel Check Sheets
35. Instrument Loop, Electrical and Control system testing
36. Commissioning Punch listing
37. Handover from construction to commissioning
38. Project Documentation Check Sheet Prior to Introduction of Safe Chemicals
39. Introduction of Safe Chemicals and Simulant Testing
40. Pre-commissioning HAZOP Studies or Pre-Start-Up Safety
41. Commissioning Leak Testing
42. Commissioning and initial Start-up plus Procedures
43. Re-commissioning of plant after an event or delay in commissioning activities
44. Laboratory analysis
45. Handover to operations and transition of ownership
46. Close out reservations
47. Complete Commissioning Documentation
48. Complete Training and update documents to “as commissioned”
49. Update Operating Procedures to “as commissioned”
50. Assist continued operation, troubleshooting and or debottlenecking projects
51. Close down all commissioning temporary defeats commissioning faults and modification paperwork systems
52. Close Down Commissioning Team
53. Complete close out Hazard Study


No. of pages:
© Butterworth-Heinemann 2021
22nd March 2021
Hardcover 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

Ratings and Reviews