The three stages of equipment installation and commissioning

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(1) On-site installation ① The on-site installation of the equipment must be carried out in accordance with the installation instructions provided by the manufacturer, or under the guidance of the manufacturer’s professionals, by the manufacturer’s staff or our own personnel. The main tasks and precautions include: a. Positioning the equipment, adjusting its level, and securing the base. b. Assembly of the equipment’s separation components. c. Connections for electricity, gas, water, and air conditioning required for the operation of the equipment. d. Cleaning, lubrication, tightening, adjustment, and corrosion protection of equipment components. ②Equipment installation must comply with the requirements of the contract. Equipment engineers should keep daily records, and in particular, any discrepancies from the contract requirements should be reported to the manufacturer promptly so that they can be corrected as soon as possible. ③After the equipment installation is completed and before testing begins, the responsible engineer must prepare a progress summary report to provide a comprehensive description of the work carried out. The report will ultimately be attached as an appendix to the acceptance report. (2) No-load test run ① After installation is complete, a no-load test run can be carried out. The main contents and precautions include: a. First, confirm that the power supply, gas supply, water supply, and air conditioning are functioning properly. b. In accordance with the no-load operation instructions, verify whether the equipment can be turned on and off properly, whether the starting, display, and operating functions of its various components are normal, and whether it can perform the actions specified in the design. c. Focus on testing whether the key indicators specified in the contract (such as travel distance, speed, temperature, operating cycle, etc.) meet the required standards. d. Make corresponding organizational adjustments when necessary. ②If a defect is detected when the equipment is not under load, the equipment engineer should promptly communicate with the manufacturer to determine the corrective action plan and the deadline for completion. ③After the no-load test run is completed, the responsible engineer must prepare a interim summary report to provide a comprehensive description of this work. The report will ultimately be attached as an appendix to the acceptance report. (3) Load testing ① After the no-load testing is completed, load testing can begin once the processing materials are ready. Its main tasks and considerations include: a. First, the equipment engineer is responsible for organizing and preparing the raw materials, tools, and auxiliary materials required for the commissioning tests specified in the contract, as well as the plan for conducting load testing. b. If it is new production equipment, the equipment engineer must issue an Engineering Change Request (ECR) to inform the process engineer to adjust the process parameters. c. In accordance with the trial production plan specified in the contract, carry out trial production for different products and specifications one by one, and retain a sufficient quantity of products to be inspected ； The key quality characteristics of the finished products and the key performance parameters of the equipment (such as processing accuracy, qualification rate, production capacity, etc.) are measured, recorded, analyzed, and evaluated using the testing methods specified in the contract or industry testing standards. d. During the trial run with actual materials, the focus is on assessing the equipment’s ability to handle the incoming materials and its capability to produce products that meet specified standards, such as processing accuracy, quality rate, and production capacity. e. During the trial run, the reliability, serviceability, and operational economy of the equipment are also evaluated. ②Equipment engineers must conduct equipment evaluations in a planned and systematic manner, strictly in accordance with the technical requirements specified in the contract, and keep records as well as collect and process data throughout the load testing process. ③In the event of any abnormalities during the load testing, communicate openly and amicably with the manufacturer to clarify in writing the subsequent corrective actions and resolution plans. ④After the load test is completed, the responsible engineer must prepare a interim summary report to provide a comprehensive description of the work carried out. The report will ultimately be attached as an appendix to the acceptance report. (4) If the installation and commissioning period or deadline exceeds what is specified in the contract, it must be recorded in the inspection and confirmation form and signed by both parties, to serve as a basis for contract payment settlement. (5) During installation and commissioning, equipment engineers should organize specialized equipment operators and maintenance personnel for synchronized training. (6) During installation and commissioning, the equipment engineer should indicate the status of the equipment with a sign reading “Installation and Commissioning”. (7) If the equipment includes devices or components that require measurement (such as thermometers, pressure gauges, etc.), it is necessary to request measurement verification from a measurement engineer during the no-load or load testing phase, depending on the specific circumstances. The measurement report submitted by the metrology engineer serves as an attachment to the equipment load testing inspection. The requirements related to measurement confirmation are specified in the \"Monitoring and Measurement Equipment Management Procedure\" (SP-044). (8) After the equipment has been installed and tested, and successful no-load trials have been completed, the responsible engineer fills out the \"Preliminary Equipment Acceptance Report\", which serves as the basis for financial payment.