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Conditions for single-unit trial run

2009-02-14View Original

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Single-unit testing: After installation, the drive apparatus, machinery, and complete units must undergo single-unit testing. In cases where testing cannot be carried out due to constraints imposed by the medium used, it is necessary to obtain approval from the on-site technical supervisor, as well as from the owner and supervising party; otherwise, the testing can be done together during the trial operation with material fed into the system. 1. The following conditions must be met prior to the machine’s trial run: The work within the scope of the trial run must have been completed in full in accordance with the contents of the design documents and the quality standards set out in relevant regulations, and the following documents must be provided to the owner: a. Certificates of conformity for various products ; b. Construction records and inspection approval documents ; c. Records of concealed works d. Documentation of piping systems: a) Certificates of conformity or re-inspection reports for various products ; b) Test pass records for various valves in the production facility ; c) Installation documents for the piping system, accompanied by a single-line diagram, including the specifications and materials of pipes, fittings, piping accessories, gaskets, supports, etc., the locations of welded joints, welder codes, and records of non-destructive testing and heat treatment (if any). e. Documentation confirming that steam pipes, process pipes, circulating water pipes, soft water pipes, etc. have been purged or cleaned properly ; f. All power steam pipes (inlet pipes for turbines and turbine pumps) must undergo chemical cleaning and shot blasting tests to pass, with corresponding records kept ; g. Documentation confirming the successful cleaning of the machine’s lubricating oil, sealing oil, and control oil systems, along with reports showing satisfactory oil quality analysis results ; h. Documentation confirming the successful pressure test of the piping system ; i. Documentation confirming the inspection and approval of machines that require opening for inspection ; j. Documentation confirming the leakage rate and integrity test results of the heat exchanger ; k. Documentation confirming the successful calibration of the safety valve for a single unit ; l. Documentation confirming the successful calibration of electrical and instrumentation systems related to single-unit testing. The commissioning plan has been approved internally and submitted to the supervision unit and the owner for approval. The commissioning organization has been established; the commissioning operators have completed training, passed examinations, are familiar with the commissioning plan and operating procedures, and are capable of performing the operations correctly. The fuel, power, steam, instrument air, cooling water, desalinated water, etc., required for testing are indeed guaranteed to be available. Testing instruments, tools, and record forms are all available, and the warranty technicians are on site. 2. Single-unit testing shall comply with the following requirements: a. A testing area shall be designated, and unauthorized personnel are not allowed to enter it ; b. Install blind flanges to isolate the testing system from other systems ; c. Single-unit testing must include automatic control devices such as protective interlocks and alarms ; d. Commands and operations must be carried out in accordance with the mechanical instructions or operation manuals, commissioning plans, and operating procedures. Multiple leaders or levels of command are strictly prohibited, as well as any illegal operations, to prevent accidents ; e. Assign a specific person to conduct the testing and keep thorough records. 3. Once the single-unit trial run is successful, the units involved in the trial run shall jointly sign and confirm on the form specified in the \"Code for Construction and Acceptance of Chemical Machinery Installation Projects\" (General Provisions).

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