Chemical and Process Plant Commissioning Handbook

1st Edition

A Practical Guide to Plant System and Equipment Installation and Commissioning

Authors: Martin Killcross
Hardcover ISBN: 9780080971742
eBook ISBN: 9780080971759
Imprint: Butterworth-Heinemann
Published Date: 27th September 2011
Page Count: 312
130.00 + applicable tax
79.00 + applicable tax
98.95 + applicable tax
Compatible Not compatible
VitalSource PC, Mac, iPhone & iPad Amazon Kindle eReader
ePub & PDF Apple & PC desktop. Mobile devices (Apple & Android) Amazon Kindle eReader
Mobi Amazon Kindle eReader Anything else

Institutional Access


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;

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



No. of pages:
© Butterworth-Heinemann 2012
eBook ISBN:
Hardcover ISBN:
Paperback ISBN:

About the Author

Martin Killcross

Commissioning manager for URENCO ChemPlants, UK

Affiliations and Expertise

Commissioning manager for 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