Several questions about original driving

Chapter 18 Single Testing Plan for High-Pressure Pump Section 1 Preparation Fill the steam condensate tank to 80%, start the condensate pump, and connect temporary pipes to the buffer tank. When the buffer tank is full, do the following preparations: 1. Before commissioning, the relevant electrical and instrument engineering installation and adjustment must be completed to meet the usage requirements, and the electrician shall be contacted. 2. Add lubricating oil: Before refueling the crankcase, flush the crankcase first (use kerosene or thin oil) to ensure that no dirt is brought into the oil. Add oil to 3/4 of the oil level. After the unit is running, some lubricating oil enters the oil pipe, oil cooler, and filter, causing the oil level in the crankcase to drop. At this time, the crankcase should be replenished with lubricating oil to bring the oil level to the normal height. Refuel the reduction gearbox according to the manufacturer's instructions, use the specified type of lubricating oil, and refuel the lubricator to 2/3 of the liquid level. 3. Check the main motor (1) Since the rotation direction of the reciprocating pump is fixed and cannot be reversed, the rotation direction of the main motor must be correct. Before the initial trial operation, remove the coupling on the main motor side for steering inspection. If the motor rotates reversely, you need to adjust the wiring and then reconnect the coupling. 4. Pour cooling water into the oil cooler and stuffing box (1) Pour in cooling water into the oil cooler before starting the oil pump to ensure that the cooling water inlet and outlet are smooth. (2) When the sealing water is introduced into the stuffing box, open the inlet and outlet to ensure smooth flow of cooling water. 5. Test the oil pump (1) Turn the oil pump 3-4 times to check the flexibility of the pump and whether there is any abnormal sound. (2) Check the oil pump device filter, instrument control device, valves, etc. (3) Before the trial operation of the NH3 pump, start the oil pump to allow the lubricating oil to circulate in the circulation loop to check whether the lubrication device is working normally. Open the inspection cover on the crankcase, check the oil circuit circulation in the crankcase, and observe the pressure difference between the front and rear of the fine filter. When the pressure difference exceeds 0.05MPa, manually switch the filter and check the filter. The oil pressure interlock in the lubricating oil device also needs to be checked to see if it is easy to use, that is, whether it will alarm when the oil pressure drops to 0.18MPa, whether it will cut off the main engine when it drops to 0.14MPa, and whether the current is in the parking state. Usually, the oil pump is qualified after 4 hours of trial operation. Section 2: Test run of high-pressure NH3 pump. Use clean water. A filter should be installed in the inlet pipe of the pump. The test run of high-pressure NH3 pump should be carried out in the following order.: (1) Start the oil pump to check the oil supply and the oil pressure reaches 0.4MPa. (2) Before starting the high-pressure NH3 pump, the gland of the stuffing box should be loosened by 1/3 turn to prevent excessive frictional heat from damaging the stuffing ring and plunger. (3) Start the oil injector, open the oil injector in the stuffing box and adjust it. (4) Open the inlet valve and the outlet valve (discharge valve) to determine the root valve of the pump outlet pressure. (5) Whether the rotation of the 2-3 rotation pump is flexible and whether there is any abnormal sound. (6) Before starting the high-pressure NH3 pump for the first time, the motor should be started briefly to see if the pump is sensitive. Under normal circumstances, the pump should stop gently after rotating. If it is found that it has stopped suddenly, the cause must be found and eliminated. (7) Start the pump again, let the pump run for 2 to 3 minutes and then stop. Check during operation.: Check whether the packing is moving. If so, tighten the packing gland. If the packing is found to be overheated, loosen the stuffing box gland and check the heating conditions of all bearings and crossheads. If a temperature difference is found, find out the cause and eliminate it. (8) Start the pump again and stop after running for 10 minutes. During this operation, the pump speed should be checked to ensure that the speed is within the normal range. At the same time, all parts of the pump should be comprehensively inspected. (9) Start the pump again, raise the speed to 50% of the maximum speed, and then run it at this speed for 1 hour. You should also check the speed and conduct a comprehensive inspection of the pump. If there is no problem in the final inspection, you can conduct a 4-hour trial run with load. During the operation of the vehicle, pressurize and add 2.0MPa every 15 minutes, and add it to the normal process indicators. During the trial run, check whether the operation of the entire pump is in good condition. like: Lubricating oil pressure, oil temperature, cooling water temperature of the oil cooler, packing seal water condition, temperature of the motor, crankshaft, connecting rod, crosshead plunger, working conditions of the three cylinders, and whether there are any abnormal sounds. It can be qualified only after running continuously for 4 hours under the following conditions without any problems. Section 3. Single test run plan for the ammonium methane pump. Fill the steam condensate tank (F511) to 80%. Start the steam condensate pump (J510) to fill the ammonia tank (F508) to 80%. Start the desorption pump (J513) to fill the low-pressure methane ammonium condenser (C504). After the liquid level of the low-pressure methane ammonium condenser liquid level tank (F505) reaches the normal indicator, make the following preparations.: The preparation work of the methane-ammonium pump and the test run of the methane-ammonium pump are the same as the test run plan of the high-pressure NH3 pump. Section 4 Centrifugal pump test run plan 1. Fill the steam condensate tank (F511), urine tank (F506), and ammonia tank (F508) to 80% liquid level. 2. Contact an electrician to supply power to each centrifugal pump. 3. Check the motor and unloading coupling, start the motor and check whether the motor's direction is reversed. If it is reversed, you need to adjust the wiring, and then reconnect the coupling. 4. Fill the centrifugal pump to 1/2 liquid level. 5. Turn the pump 3-4 times to check whether there is any abnormal sound and whether the rotation is sensitive. 6. Open the pump inlet and introduce the liquid into the pump. Use the outlet drain to discharge the gas in the pump body. After the gas is exhausted, close the outlet drain. Section 5 Test Pump Operation 1. Press the start pump switch button to start the pump and check whether the outlet pressure of the pump is within the normal process index range. 2. Check whether the outlet pressure gauge of the pump swings and measure the situation. 3. Check the vibration of the pump and whether the bolts between the foundation and the pump body are loose. 4. Check whether the packing is leaking, whether the shaft seal is leaking oil, the motor temperature, etc. 5. After there are no problems, stop the pump, close the inlet valve, and drain the liquid in the pump body before it is qualified.

Pump unit commissioning Before starting the installation, the performance of each new pump should be tested and checked for defects. A temporary filter should be installed on the pump inlet line during commissioning. The commissioning of the pump is also the cleaning of relevant pipelines and equipment. The closed circulation loop should make the normal flow path as long as possible. The entire process system can be divided into several sections for circulation, or all pumps can be started at the same time. Operators should be familiar with the information provided by the pump and motor manufacturers and should comply with some of their special regulations. 1. Single motor test run 1.1 Preparation work ⑴ All installation work is completed and accepted, and the site is cleaned up. ⑵ Check whether the motor and its ancillary electrical equipment meet the relevant technical requirements according to the construction drawings. Only after confirming that there are no problems can the test run be carried out. ⑶ Clean the motor bearing box and replace the lubricating grease. ⑷ Turn the car manually to check whether the motor rotates flexibly and whether there is any jamming. ⑸ Disassemble the backrest wheel connecting the pump and motor. ⑹ Prepare a thermometer to test the bearing temperature. ⑺ Have notebooks and reports ready. 1.2 Test run of the motor unit ⑴ Check the insulation of the motor. After passing the test, turn on the power supply. ⑵ According to the requirements of starting the motor, start the motor and stop it immediately (that is, test the motor). Check whether the motor's rotation direction is consistent with the direction marked on the motor, and whether there are any abnormal sounds or abnormal phenomena. ⑶ Restart the motor and after reaching the rated speed, check whether there is vibration in the motor, whether the electrical equipment and motor are operating normally, and whether the bearing temperature rises. If there is a problem, you should stop processing immediately and try again. ⑷ If it runs continuously for 4 hours without vibration, and the temperature rise of the motor and electrical equipment meet the specified technical requirements, the test run can be considered qualified and the motor can be stopped. ⑸ Regularly record the test run conditions, such as current, temperature rise, and problems that occur during the test run. 3. Flushing 1. Repeatedly flush the pipeline entering the boundary area and connect it after passing the test. 2. Repeatedly flush the disassembly opening in section "3" of the preparation work in sections. After the qualified section is connected, the size of the flushing water in the next section is controlled by the cut-off valve in the boundary area. 3. Establish the liquid level above 50%, disassemble the bottom drain valve and flush it. 4. When the liquid level of the glass liquid level gauge is above 90%, disassemble the outlet end of the gas-liquid phase cut-off valve and flush it. five. The pump inlet pipeline flushing 1 and its water inlet pipeline have been flushed to a qualified standard, all instruments and glass liquid levels of F0210 have been restored, and the main control can display and adjust normally. 2. Remove the flow orifice plate on the pipeline and close all transmission switches. 3． Remove the pump inlet filter, use the inlet valve control to flush the inlet pipeline repeatedly, and install a temporary filter after passing the test. 4. Disassemble the pump outlet check valve, open the pump inlet valve, flush the pump, and install it after it is qualified. Disassemble FV-1215, 1216, 1217, 1218. Open the pump inlet valve. 2. Single unit test run of J0205A/B and J0206A/B pumps ⑴ Single unit test run of the pump shall be carried out after the equipment and pipelines have been purged and flushed. ⑵ The cooling water or circulating water for test run is put into use. Temporary water sources must be used for pump commissioning, and multiple temporary water sources can be considered so that they can be flexibly selected according to the prevailing conditions during commissioning. ⑶ The preparations, methods and requirements for commissioning of all pumps are the same, except for the location where water enters the pump and the discharge point. Except for the specific requirements that need to be described and explained separately, the rest are explained in a unified manner and will not be repeated. ⑷ This protocol should be read in conjunction with the flow chart. ⑸ Since the design of the project has not yet been finalized when this plan is prepared, the selection of pipeline/equipment cleaning, water inlets, discharge outlets, etc. should be appropriately adjusted according to the site conditions. 2.1 Check and compare with the construction drawings to check whether the inlet and outlet pipes, pipe fittings, instructions and measuring instruments of each pump are consistent with the drawings. Check the tightening of the pump's anchor bolts and confirm whether the pump installation meets the specifications. 2.2 Preparations for commissioning of the pump unit ⑴ A temporary filter should be installed on the inlet pipeline of the pump. ⑵ Connect the pump and motor backrest wheels. Clean the bearing box of the pump and replace the lubricating grease. ⑶ Clean the motor bearing box and replace the lubricating grease. ⑷ Open the sealing water and cooling water valves of the pump. ⑸ Have a thermometer ready to test the pump bearing temperature. ⑹ First turn the car manually to check whether the rotation is flexible and whether there is any jamming. ⑺ Remove the flow orifice plate and turbine flow meter on the pump outlet pipe. ⑻ Open the pump inlet valve, introduce water into the pump, open the pump outlet pressure gauge cock valve and the pour valve, and drain the gas in the pump. ⑼ The motor is powered on. ⑽ Open the relevant valves and related pipelines of the mechanical seal pump. 2.3 Pump unit test run ⑴ Close the pump outlet valve, open the return pipe flow regulating valve, exhaust the pump body and turn the pump to confirm that there are no problems. Start the pump according to the operating procedures and stop immediately. Check whether the pump running direction is consistent with the direction marked on the pump. Start the pump and run the pump continuously for 8 hours. ⑵ Start the pump again. After reaching the normal speed, gradually open the pump outlet valve to control the pump outlet flow to prevent motor overload. ⑶ Check the operation conditions, such as vibration, bearing temperature rise, whether there are any abnormalities, whether the pump inlet and outlet pressure and flow are stable, whether the motor exceeds the rated current, etc. If there are any abnormalities, stop immediately and deal with it. ⑷ If the inlet pressure drops during operation, the pump should be stopped to clean the filter and then try again. ⑸ Each pump can run continuously for at least 4 to 6 hours without any abnormality. Only when the test is deemed to be qualified can the pump be stopped. ⑹ ． After 8 hours of continuous operation, stop the pump, remove the temporary filter, and install the formal filter. ⑺ During the test run, pay attention to maintaining the pump inlet and outlet pressure and replenish the water volume in a timely manner to prevent damage to the pump due to evacuation. ⑻ Record test run data and problems every half hour. six. Pump outlet pipe flushing 1. Notify the chemical water station to send qualified desalted water to establish the F0210 liquid level, and use LIC-1208 to control the liquid level by 80%. Jog the pump to run and check whether the pump is running in the correct direction. 2. Restart the pump operation intermittently, and flush the opening of the return pipeline flow regulating valve (FV-1215, 1216, 1217, 1218) until the flushing is qualified. (During the flushing process, closely monitor the F0201 liquid level to prevent evacuation from damaging the pump and monitor the motor current. If there is overcurrent, the outlet valve should be closed), install the return pipeline flow regulating valve, and disassemble the check valve after the regulating valve. 3． Start the pump operation intermittently, disassemble the check valve after returning to the flow regulating valve, and flush repeatedly until it is qualified. Install the check valve. After opening the check valve, cut the rolling valve, disassemble F0210 and return it to the main pipe nozzle, start the pump to flush until it is qualified, and then install the disassembly opening. Open up the import and export process of J0205 and J0206

Both canned pumps and magnetic pumps must be tested in water. The magnetic pump can be tested according to the normal centrifugal pump. First disassemble the coupling and test the motor. After running without problems, perform a joint test run. plan: To prepare before the test run, add a filter screen of about 100 mesh in front of the suction inlet. During the test run, pay attention to the operation of the pump, listen to the sound and look at the ammeter. Once any abnormality is found, stop the pump for inspection, and pay attention to cleaning the filter screen frequently. The main reason is that it is afraid of clogging and causing idling without liquid. Before driving, open the inlet valve, outlet valve, and open the exhaust pipe on the outlet pipe to allow water to enter the pump body. Once fully entered, close the outlet valve. Turn the car manually and press the start button after there are no abnormalities. After starting, check the pressure gauge reading, open and adjust the outlet valve until the outlet pressure is normal. When stopping, first close the outlet valve and then press the stop button.

10KV high-voltage switch cabinet single commissioning plan (1) 1. Preparation work 1.1 Equipment department inspection personnel and maintenance personnel are in place； The general lowering operation personnel of the power workshop are in place ； Equipment manufacturers have technical personnel in place. 1.2 The tools are fully prepared and the operators wear labor protection supplies. The information is fully prepared. 2. Inspection of the 10KV power distribution room 2.1 Check that the 3# main transformer incoming cabinet switch is in the test position and in the open state, the secondary plug has been plugged in, the energy storage power supply has been supplied, the energy storage is good, there are no abnormal alarms, and the heating power supply and lighting are supplied. 2.2 Check that the 1# main transformer inlet cabinet switch is in the test position and in the open state, the secondary plug has been plugged in, the energy storage power supply has been supplied, the energy storage is good, there are no abnormal alarms, and the heating power supply and lighting have been supplied. 2.3 Check that the switch of the 2# transformer incoming cabinet is in the test position and in the open state, the secondary plug has been plugged in, the energy storage power supply has been supplied, the energy storage is good, there are no abnormal alarms, and the heating power supply and lighting have been supplied. 2.4 Check that the 1# bus coupler switch is in the test position and in the open state, the secondary plug has been plugged in, the energy storage power supply has been supplied, the energy storage is good, the 1# bus coupler switch - the isolation switch has been pushed to the working position, there is no abnormal alarm, and the heating power supply and lighting are supplied. 2.5 Check that the 2# bus coupler switch is in the test position and in the open state, the secondary plug has been plugged in, the energy storage power supply has been supplied, the energy storage is good, the 2# bus coupler switch - the isolation switch has been pushed to the working position, there is no abnormal alarm, and the heating power supply and lighting are supplied. 2.6 Check that the 3# bus coupler switch is in the test position and in the open state, the secondary plug has been plugged in, the energy storage power supply has been supplied, the energy storage is good, the 3# bus coupler switch - the isolation switch has been pushed to the working position, there is no abnormal alarm, and the heating power supply and lighting are supplied. 2.7 Check that the 4# bus coupler switch is in the test position and in the open state, the secondary plug has been plugged in, the energy storage power supply has been supplied, the energy storage is good, the 3# bus coupler switch - the isolation switch has been pushed to the working position, there is no abnormal alarm, and the heating power supply and lighting are supplied. 2.8 Check that the primary fuse of the I-section busbar PT is in good conduction, plug in the secondary plug, and push the handcart to the working position. There is no short circuit in the secondary measurement and only one point is grounded. Provide heating lighting switch and PT secondary switch. 2.9 Check that the primary fuse of the II section busbar PT is in good conduction, plug in the secondary plug, and push the handcart to the working position. There is no short circuit in the secondary measurement and only one point is grounded. Provide heating lighting switch and PT secondary switch. 2.10 Check that the primary fuse of section III busbar PT is in good conduction, plug in the secondary plug, and push the handcart to the working position. There is no short circuit in the secondary measurement and only one point is grounded. Provide heating lighting switch and PT secondary switch. 2.11 Check that the primary fuse of the IV section busbar PT is in good conduction, plug in the secondary plug, and push the handcart to the working position. There is no short circuit in the secondary measurement and only one point is grounded. Send the heating lighting switch, PT secondary switch 3, section I bus charging a. Input the low-voltage side switch control power supply of the 1# main transformer, put in the protection pressure plate, and push the low-voltage side switch of the 1# main transformer to the working position. b. Exit the mother joint investment protection c. Close the low-voltage side switch of the 1# main transformer to charge the section I bus. d. Check that the I section PT wiring is correct and the phase sequence measured in the PT cabinet is correct. ； Measure phase-to-ground and phase sequence on the protective screen. The metering screen measures phase to ground and phase sequence.

10KV high-voltage switch cabinet single test run plan (2) 2007-02-22 18:034, II section busbar charging a. Insert the 2# main transformer low-voltage side switch control power supply, put in the protection pressure plate, and push the 2# main transformer low-voltage side switch to the working position. b. Exit the mother joint investment protection c. Close the low-voltage side switch of the 2# main transformer to charge the II section bus. d. Check that the PT wiring in section II is correct and the phase sequence measured in the PT cabinet is correct. ； Measure phase-to-ground and phase sequence on the protective screen. The metering screen measures phase to ground and phase sequence. f. Check the PT phase twice in Section I and Section II, make sure the wiring is correct and the phase sequence is correct. 5. Section III bus charging a. Insert the 3# main transformer low-voltage side switch control power supply, put in the protection pressure plate, and push the 3# main transformer low-voltage side switch to the working position. b. Exit the mother joint investment protection c. Close the low-voltage side switch of the main transformer #3 to charge the section III bus. d. Check that the PT wiring in section III is correct and the phase sequence measured in the PT cabinet is correct. ； Measure the phase-to-ground and phase sequence of A620, B620, and C620 on the protective screen. The metering screen measures A620, B620, C620 phase to ground and phase sequence. f. In the second phase verification of the PT in sections II and III, the wiring is correct and the phase sequence is correct. 6. IV section bus charging a. Push the 3# bus coupler switch isolation knife to the working position b. Push the 3# bus coupler switch to the working position, turn on the control power supply, and put in the protection pressure plate. c. Close the 3# bus coupler switch to charge the IV section bus. d. Check that the IV section PT wiring is correct and the phase sequence measured in the PT cabinet is correct. ； Measure the phase-to-ground and phase sequence of A620, B620, and C620 on the protective screen. The metering screen measures A620, B620, C620 phase to ground and phase sequence. f. Check the PT phase for the second time in sections III and IV, make sure the wiring is correct and the phase sequence is correct. 7. 10KV bus tie ready operation test 7.1 1# bus tie ready operation test a. Push the isolation knife switch of the 1# bus coupler switch to the working position, turn on the protection and control power of the 1# bus coupler switch, and put in the protection pressure plate. b. Disconnect the low-voltage side switch of the 2# main transformer and check the reliable operation of the 1# bus coupler. c. Close the low-voltage side switch of the 2# main transformer and disconnect the 1# bus coupler. 7.2 2# bus link preparation test a. Push the isolation knife switch of the 2# bus coupler switch to the working position, turn on the protection and control power of the 2# bus coupler switch, and put in the protection pressure plate. b. Disconnect the low-voltage side switch of the 3# main transformer and check the reliable operation of the 2# bus coupler. c. Close the low-voltage side switch of the 3# main transformer and disconnect the 2# bus coupler. 7.3 3# bus link preparation test a. Push the isolation knife switch of the 3# bus tie switch to the working position, turn on the protection and control power of the 3# bus tie switch, and turn on the protection pressure plate. b. Disconnect the low-voltage side switch of the 1# main transformer and check the reliable operation of the 1# bus coupler. c. Close the low-voltage side switch of the 1# main transformer and disconnect the 3# bus coupler.

P-2201A/B test run plan 1. Basis for preparation 1.1. PID diagram of the oxidation section of the 200,000 tons/year phenol propylene device of XXXXXXXX Company 1.2. Pump information provided by equipment supplier Check and assess the mechanical performance and installation quality of pump P-2201A/B. 2.4. Check whether the process flow meets the process design requirements. 3. Test run scope 3.1. P-2201A/B 3.2. P-2201A inlet pipeline P-2002-6〞 3.3. P-2201B inlet pipeline P-2002-6〞 3.4. P-2201A/B outlet goes to V2201 return line P-2004-6〞 and P-2071-10〞P-2003-1〞. 4. Prerequisites for commissioning 4.1. The on-site electrical operation switch is well connected ； 4.2. P-2201A/B pressure gauge PG-2038 and PG-2039 can be used after passing the calibration ； 4.3. Confirm that the rotation of the motor should match the rotation of the pump ； 4.4. Confirm that there should be no looseness in each fixed connection part. ； 4.5. Remove the pump inlet filter and replace the temporary filter. ； 4.6. P-2004-6〞, P-2002-6〞, P-2071-10〞, P-2144-1.5〞, P-2128-1.5〞P-2259-1.5〞, P-2138-1.5〞, P-2135-1.5〞 P-2003-1〞The pressure test has been completed and the flushing has passed ； 4.7. Remove the corresponding components and install the blind plate according to the circuit diagram ； 4.11 Close the inlet and outlet valves of the pump and pipelines P-2107, P-2094, P-2095, P-2108, P-2073, P-2000, P-2144, P-2202 Gate valves on P-2803, P-2128, P-2259, P-2135, P-2138, and butterfly valves closing the ends of P-2042 and P-2047 ； Remove the flow-restricting orifice plate RO-2013 and close the valve on the sampler SN-107 pipeline. 5. Main process control indicators 5.1 Operating medium: Salt/water 5.2 relative density: 1.02 5.3 Normal operating flow: 42550 Kg/h 5.4 Operating temperature: 43℃ 5.5 pump parameters 5.5.1 model: GSA 4×3×8H EA15 5.5.2 lift: 35.2m 5.5.3 Normal flow: 135m3/h minimum flow allowed: 42.9m3/h 5.5.5 rated power: 24.7KW 5.5.6 speed: 2945rpm 5.5.7 Pump normal outlet pressure: 3.11barG maximum inlet pressure: 116.7KPa 5.5.7 Pump efficiency: 52.23% 5.6 motor 5.6.1 model: YB2-200L1-2W 5.6.2 rated power: 30KW 5.6.3 Voltage: 380V/660V 6. Commissioning steps 6.1 Connect the temporary pipe from the SO port of V-2201 to lead the desalted water to the liquid level LG2007 of 20%. 6.2 Manually turn the car 3 to 4 times to confirm that there is no jamming. Apply for a power supply ticket, contact the electrical personnel to send power, start on-site for a spot test, and confirm whether the rotation direction of the motor and pump is correct. Otherwise, inspection is required. ； 6.3 Open the pump inlet valve, slightly open the pump outlet valve, fill with water and exhaust ； 6.4 Start P-2201A, observe whether there are any abnormalities, and if so, stop the pump for inspection. 6.5 After confirming that the outlet pressure is normal, slowly open the pump outlet valve and adjust the pump outlet pressure. Control the pump delivery volume to 48.7m3/h and the head to run at 53m. ； 6.6 Check the cleanliness of V-2201 water in time. If the water quality deteriorates or the color turns red or the turbidity increases, stop the pump and drain the water in V-2201 into the ditch. When the discharged water becomes clean, start P-2201A ； 6.7 When the V-2201 liquid level is lower than 5%, replenish desalted water in time. 6.8 Check the operating status of the pump. If there is no abnormality after running for at least 4 hours, the test run of P-2201A is completed. 6.9 Repeat the above operations for P-2201B for test run. 6.11 After the test run of P-2201A/B is completed, close the outlet valve of the pump, stop the pump and apply for a power outage ticket, close the inlet valve, drain the pump body cleanly, remove the temporary filter and replace it with the official filter, and change the oil in the bearing box at the same time. 6.12 Remove each blind plate and reset the corresponding components. 7 Acceptance criteria 7.1 Each fixed connection part should not be loose ； 7.2 The rotor and moving parts should operate normally and there should be no abnormal sounds. ； 7.3 The pump circulation loop should operate normally ； Pipe connections should be firm and leak-free ； 7.4 The temperature of the bearing should not be greater than 75℃ ； 7.5 Pumps that need to measure the vibration value of the bearing body should be measured under conditions without cavitation. ； 7.6 The continuous trial operation time of the pump at rated flow should not be less than 2h ； 7.7 The safety protection and electronic control devices of the pump and all instruments should be sensitive, correct and reliable. ； 8 Material preparation 8.1 Record book and record sheet used for pump test ； 8.2 A thermometer, a speedometer, a listening stick, and a vibration meter ； 8.3 Two size F wrenches each ； 9 Personnel preparation 9.1 One person in charge of pump testing, responsible for command and coordination during the pump testing process ； 9.2 1 technical instructor from the manufacturer, responsible for technical guidance during the pump test process ； 9.3 One operator, responsible for the specific work during the pump test process ； 9.4 There will be one mechanical, electrical and instrument personnel each responsible for the specific professional work during the pump test process. 10 Test run safety precautions 10.1 During the pump test process, attention should be paid to the outlet pressure of the pump. If the outlet pressure fluctuates violently and the pump body makes abnormal sounds, it is necessary to stop the pump, clean the filter and then start it again. 10.2 Pay attention to the liquid level of V-2201 to prevent emptying. When the liquid level is lower than 5%, add desalted water in time. 10.3 If an abnormality occurs during the pump test, stop the pump immediately to find out the cause, and restart it after troubleshooting. 10.4 Strictly operate the pump in accordance with the operating procedures provided by the manufacturer. 10.5 Record relevant parameters every 20 minutes. appendix: Appendix 1: Test run circuit diagram appendix 2: Appendix 3 of the pump performance test report provided by the manufacturer: Appendix 4 of test run record sheet: Blind List Appendix 3: P-2201A/B test run record time: 2007 month, day, data, time, motor, pump operating temperature, current indication, operating sound, vibration, bearing temperature, presence or absence of abnormal sound, outlet pressure, shaft vibration recorder: person in charge:

Testing plan for single unit of moving equipment in chemical preparation workshop http://down.zhulong.com/tech/detailprof53183NT.htm

Interim Provisions on Production Preparation and Commissioning of Large and Medium-sized Chemical Mines Interim Provisions on Production Preparation and Commissioning of Large and Medium-sized Chemical Mines Source: Author of Hua Ji Zi No. 780: Ministry of Chemical Industry - Chapter 1 General Provisions Chapter 2 Production Preparation Section 1 Organizational Preparation Section 2 Technical Preparation Section 3 All-staff Training Section 4 Safety Preparation Section 5 Material Preparation Chapter 3 Test Run Work Section 1 Test Run Preparation Section 2 Single Test Run and Linked Test Run Section 3 Load Linked Test Run Chapter 4 Trial Production and Assessment Chapter 5 Supplementary Provisions Chapter 1 General Provisions Article 1 Production preparation and test run work are important components of capital construction. In order to ensure that the mine mining and load selection test run is successful at the first time, and that safe, continuous and stable production can be achieved, the design capacity can be reached as soon as possible, and investment benefits can be maximized, these interim regulations are specially formulated. 　　Article 2 Large and medium-sized chemical mines must meet four basic conditions in order to successfully put into trial operation and put into normal production.: (1) The engineering design is complete and complete, the selected mining method is feasible, and the mineral processing technology is reasonable, which is conducive to the comprehensive utilization of resources. ； (2) The productive and auxiliary projects have been completed according to the design and the quality is qualified. ； (3) Mine resources are basically stable, and the second (third) grade ore volume meets the design requirements. ； (4) Have a high-quality workforce. 　　Article 3 Production preparation is an extremely important basic work in mine construction and should run through the entire process of capital construction. It must be grasped, arranged and implemented early, and the production preparation and project construction should be kept in sync to lay a solid foundation for ensuring stable production after production is put into operation. 　　Chapter 2 Production Preparations Section 1 Organizational Preparations Article 4 When a construction project is approved to start construction, the construction unit shall establish a construction and production leadership team that can firmly implement the party's line, have production and construction experience, and understand technical business. There must be at least one key member of the team who is responsible for production preparations from the beginning of construction to ensure the continuity of project construction and production. 　　Article 5 According to the design requirements and the spirit of reform, the construction unit must establish a management system suitable for modern mines from the beginning of basic construction, and set up management institutions in accordance with the principles of simplicity, unity, and efficiency. According to the actual needs of production, production preparation institutions such as planning and finance, production technology, mechanical power, material supply and marketing, labor education, safety and environmental protection, geological survey, monitoring tests and life management, as well as workshops and work areas are gradually established, and are enriched and improved according to the work process to meet the needs of each stage of work. 　　Article 6 Newly built and expanded mines must effectively establish the production team. According to the design capacity and job technical standards, select or hire some cadres with experience in organizational management and professional counterparts and workers with practical operating experience from similar enterprises as the backbone. Cadres should be gradually deployed according to the needs of work progress. The main production technical backbone must enter the mine during project preparation and participate in technical negotiations, design review, construction supervision and production preparation. Operators and maintenance workers of key equipment should mainly be recruited from technical technical graduates and high school graduates, and they should be selected on the basis of examination. 　　Article 7 The production preparation organization must formulate clear scope of responsibilities and establish and improve various rules and regulations. Mainly include: 　　1. Implement the mine manager responsibility system and be responsible for the entire process of production preparation. 　　2. It is necessary to clarify the job responsibilities of leaders at all levels and the scope of responsibilities of each functional agency, so that project construction and production preparations can be carried out in a synchronized and coordinated manner. 　　3. Establish various management systems centered on production. For example, systems such as planning, finance, labor wages, material supply and marketing, production scheduling, safety and environmental protection, equipment management, measurement and monitoring, quality control, and living welfare. 　　4. Establish various rules and systems centered on the job responsibility system. 　　5. Establish various original vouchers and various accounting and statistical report systems according to the requirements of superiors and the company's internal production and economic activities. 　　Section 2 Technical Preparation Article 8 The main task of technical preparation is to enable production personnel and technical managers to master production technology. They should mainly work on mining methods, mineral processing processes, equipment maintenance and use, safety, etc., to achieve the ability to correctly guide and handle various technical problems. From the beginning of production preparation, a technical management system with the chief engineer as the main body must be established. 　　Article 9 Main work contents of technical preparation: 1. Equip technical backbone and establish technical responsibility system. New mines must be equipped with professional and technical backbones in geological surveying, mining, mineral processing, instrumentation, electrical, machinery, analysis, safety, environmental protection and other aspects as early as possible, and letters of appointment and responsibilities must be signed to establish a job responsibility system for technical personnel. The personnel should remain relatively stable, and the technical person in charge should not be easily changed, and the scope of technical responsibilities should not be easily changed. All work in this major starts from histology * , preparation of procedures, formulation of commissioning plan and the whole process of commissioning should be participated. It is necessary to create conditions so that technical backbones can easily master technology, collect information, engage in special investigations on key technologies, and participate in various professional conferences.

2. Improve process and engineering design. While production personnel are familiar with and master the production process, they must also be familiar with the engineering design content and interrelationships, familiar with relevant standards and specifications, timely discover problems in design and construction installation, and cooperate with the design and construction departments to improve design and construction. 　　3. Research and prepare trial production plans, formulate technical standards and main technical and economic indicators of products. 　　4. Learn repeatedly the key technical parts of the project such as mining methods, mineral processing processes, etc. * , research, participate in experiments, and truly master. The technical department should organize efforts to understand the geological conditions of the mine, stope roof management, slope management, mineral processing process, equipment performance, automatic control methods, etc., and have preventive measures for various technical problems that may arise during the test run. 　　5. Collect and compile production and safety technical data. 　　(1) Collect water collection and drainage capabilities of surface water source systems, rivers, and ditches in and around the mining area, as well as flood data with the highest rainfall over the years. 　　(2) In mining areas with complex hydrogeological conditions, it is necessary to understand the hydrogeological conditions of the mining areas and tunnels, and prepare water prevention and control plans and annual waterproofing plans. 　　(3) In collapsible loess areas, settlement observations should be set up and system maps should be drawn. 　　(4) Develop an emergency incident handling plan. 　　(5) Prepare technical manuals for each major and handouts on technical issues for each equipment. 　　(6) Collect the following system information: 　　A. Original and comprehensive data on up and down measurement and control results, up and down comparison diagrams, open-pit mine infrastructure completion drawings, geology, engineering geology, and hydrogeology ； 　　B. Production capacity measurement data, including second (third) level ore volume calculation, mining test and mineral processing test results, etc. ； 　　C. Diagram of transportation, lifting, ventilation, water supply and drainage, air pressure, piping system and communication system up and down the shaft ； 　　D. Surface and underground power distribution system diagram and underground electrical equipment layout schematic diagram. 　　(7) Based on the geological exploration report and preliminary design, compile basic technical information on safety and health. For example, data on hazardous geological features such as large faults, fracture zones, landslides, debris flows, etc. where the mining area is located ； The composition, content and changing patterns of minerals harmful to the human body are compiled from mining sites, * * Information on typical accident cases in warehouses, mineral processing plants and other workshops. 　　(8) Collect the production status and various production technical data of similar mining areas at home and abroad. 　　(9) Compile information on the distribution and use of safety, fire protection, and flood control facilities in mining areas. 　　(10) Establish engineering technical files. Collect, compile, organize and archive project construction documents and technical information. 　　6. Establish and improve regulations and systems. 　　(1) Establish equipment operation, maintenance, and inspection procedures. Including the maintenance, overhaul, use system of mechanical and electrical equipment such as mining, lifting, transportation, ventilation, air pressure, power supply, heating, water supply and drainage, communications, and the processing and management system of spare parts. 　　(2) Various process operating procedures for mining, mineral processing and auxiliary workshops. 　　(3) Prepare safety technical regulations for mining, mining and stripping working surfaces, mineral processing and auxiliary workshops, and safety operating procedures for each position. 　　(4) Underground mining mines must establish roof management and goaf area treatment systems, and have monitoring and accident prevention measures for collapse areas and stopes with unstable roofs. 　　(5) For open-pit mining mines with developed joints and gaps in the surrounding rocks and mineral seams, a slope management system should be established to maintain the stability of the slope and prevent landslides. 　　(6) For mines with complex engineering geology and dangers of ground pressure activities and rolling stones, the rules of ground pressure activities and rolling stone movements should be understood, the scope of influence should be predicted, and preventive measures should be formulated. 　　(7) Develop safety, environmental protection, fire protection, and flood control facilities use, maintenance and management procedures. 　　7. Prepare a load test plan. 　　Section 3 All-staff training Article 10 All-staff training is the main work and central link of production preparation. The whole mine, from leading cadres, professional managers, technicians to every employee, especially the backbone of production, major technical jobs and skilled workers in key positions, must undergo professional training, pass the examination and obtain a certificate before they can hold office or be employed. 　　Article 11 The goal of all-staff training is to cultivate a team of workers capable of mastering production operations and equipment maintenance and a team of administrative management and technical cadres at all levels who are familiar with the business. During the training, we must adhere to high standards and strict requirements, practice skills and work style, master the performance of processes and equipment, and ensure correct operation to ensure safe production and smooth processes in all production links. 　　Article 12 Steps and Requirements for Training 1. Do a good job of training throughout the entire process. In the personnel training work, the training of a large number of production workers is the most important, which can generally be divided into four stages.:

The first stage is to organize the newly recruited production workers and learn* For basic mining knowledge, process theory, and production technology knowledge, professional technicians and experienced workers or personnel from design institutes and construction companies are invited to give on-site lectures and guidance. 　　The second stage is to send new workers to domestic production mines with similar production processes and technical equipment for practical training. * , focusing on being familiar with and mastering the process flow, process operations, process control and equipment performance of the corresponding position. 　　For some projects that use new advanced technology and technical equipment, if there is a lack of similar companies in the country, they can be organized by themselves, ask relevant experts or entrust relevant colleges and universities to conduct some short-term technical training courses, or send them to similar foreign companies for short-term training. 　　Reality * Training work must implement "six fixes, two guarantees and one training", that is, fixing team leaders, fixing training points, and fixing training personnel ； Set time, set tasks, and conduct regular assessments ； The training unit guarantees the teaching and the trainee guarantees the meeting ； Operate on the job under the supervision of the master. Operators and maintenance personnel at major production positions must be trained according to the technical requirements of the positions. The length of training and on-the-job time are determined according to the syllabus and the technical complexity of the production positions. It should be adapted to the time of commissioning and production, so that production workers can enter their positions in time as required. 　　The third stage is to organize production workers to participate in construction supervision and inspection work, participate in equipment installation, debugging, and commissioning, and conduct actual operations. From equipment disassembly and cleaning, installation, electrical and instrument debugging, to completion of commissioning, every step should be attended. For key equipment, operators should be given the opportunity to operate independently. For difficult rotating equipment, more training should be provided. * Driving and parking in various situations. Before commissioning, operators must be trained to familiarize themselves with the signal and instrument locking devices to avoid incorrect operations. This stage is an important stage of training and should be closely integrated with on-site training. 　　The fourth stage is to conduct actual training one by one according to the requirements of technological process, start-up plan and so on. Through on-site training, the command ability, operational level and ability to respond to accidents are improved, and the personnel are familiar with the site, the process, the control, the equipment, the rules and regulations, and the relationship between the front and rear positions. Through on-site training, production personnel must achieve "four understandings and three skills" about the equipment, that is, understanding the structure, understanding the principles, understanding the performance, and understanding the uses. ； Know how to use, maintain and troubleshoot. The training time is about 3 to 6 months. 　　2. Prepare leadership teams at all levels at the grassroots level and provide key training for key driving personnel. It is necessary to have a leadership team that is united, complementary, and capable of fighting, and a considerable number of technical cadres must be included in the teams at all levels. Key training should be focused on workshop directors, section leaders, production dispatchers, full-time engineers, shift leaders, team leaders and other key personnel. The production technical backbone personnel must participate in various preparations before the load test run. They will take the lead in every step of the work before the test run. They must be familiar with the site, the operation and the personnel situation, cultivate and exercise to improve organizational leadership capabilities, and give full play to the role of the technical backbone. 　　3. Strictly enforce the examination system and promote training. Before taking up their posts, workshop directors and dispatchers shall be examined by the production and mine director (chief engineer), full-time engineers shall be examined by the mine technology department, and shift leaders and post operators and maintenance workers may be examined by full-time engineers together with the safety department. Those who fail the examination must pass the make-up examination before they can be employed. 　　4. Consolidate results and improve team quality. The four-stage whole-process training cannot fully reach the depth it should have. We must make up for what is missing based on the assessment results, and pay close attention to the weak links in the training. If you practice the basic skills of the job, you can gradually improve your proficiency through further operation and practice of load-linked commissioning and trial production, consolidate the training results, adhere to the theory and practice, and adopt various forms, such as lectures, special discussions, on-site simulations, etc., to learn repeatedly. * , continue to deepen and improve the quality of the team. 　　Section 4 Safety Preparation Article 13 Safety work is the top priority for normal production in chemical mines. It is also a complex technical and management issue. Good preparation in this area is of decisive significance for safe commissioning and safe production. Leaders at all levels must adhere to the policy of "safety first" and "prevention first" and conscientiously implement the "Mining Safety Regulations" and "Chemical Mine Safety Regulations". The main leaders must personally make safety preparations. When there is a conflict between production and safety, they must obey safety. 　　Article 14 Safety preparations must focus on the actual situation of the mine and study the occurrence, characteristics, prevention and treatment methods of unsafe factors. In safety preparation work, we must first conscientiously implement the following three principles:: 　　1. Actively implement preventive management for all employees and take effective preventive measures ； 　　2. Implement early detection of hidden dangers to achieve early detection and early treatment without leaving any hidden dangers. ； 　　3. Give full play to people's subjective initiative, improve the reliability of equipment, and improve personal safety.

Article 15 Requirements for safety preparations 1. Careful histology* Implement the safety conditions that must be met before load testing. 　　(1) Mining and stripping working surfaces, tunnels, tunnels, ground buildings, working platforms, etc. must undergo strict quality inspection and comply with safety production conditions. 　　(2) All equipment, pipelines, electrical appliances, and instruments have been quality inspected and debugged to meet the standards of good condition and meet the load test requirements. 　　(3) The main fan in the mine has undergone trial operation, and the air volume and wind speed meet the requirements of safety regulations. ； The underground ventilation structures (dampers, wind bridges, dampers, windshields, air ducts, etc.) are tight and intact, and a complete and reasonable ventilation system is formed according to the design requirements. 　　(4) Mines with reverse wind devices can change the wind flow direction within the time required by regulations (within 10 minutes) after passing the reverse wind test. 　　(5) Underground and above ground (such as stopes, ore warehouses, dressing plants, machine repairs, * * (Processing, etc.) workplaces that generate dust have complete dust removal facilities, sufficient water supply, and complete safety testing instruments such as ventilation and dust measurement. 　　(6) The safety protection device of the lifting system has been tested and complies with the safety regulations. Devices for lifting personnel cages in vertical shafts, transporting personnel in inclined shafts and horizontal tunnels, anti-falling devices for people and vehicles, and decoupling protection devices have passed the test and are flexible and reliable in action. 　　(7) The power supply, voltage, circuits, protection and operation of safe electricity in mines are reliable. 　　(8) Ground lightning protection and anti-static facilities, and the grounding wires of all equipment pipe racks are fully installed and qualified. 　　(9) The grounding system of all equipment cables and metal structures in the mine is complete, and the formed grounding network meets the requirements of security regulations. 　　(10) On the high and low voltage feeders of underground power substations and distribution stations, the leakage detection and protection devices are sensitive and reliable. 　　(11) Safety communication systems such as telephones, signal lights, walkie-talkies, whistles, and horns all meet the design requirements and are easy to use. 　　(12) The production, transportation, storage, custody, testing, destruction and use systems of explosive equipment are sound and comply with relevant regulations issued by the State Council and the public security department. Employees and managers engaged in blasting operations and blasting material production must undergo review and technical training, and can only engage in work after passing the assessment. 　　(13) The safety exits of the mine and each middle section must meet the requirements of safety regulations. There must be road signs at the branch entrances of underground tunnels to indicate the direction to the surface exit. All underground workers must be familiar with safety exits. 　　(14) The laying of pipes, cables and air ducts in wells and lanes must be standardized and must not obstruct pedestrians or accumulate debris. Tunnels that have been excavated or abandoned during construction must be closed. 　　(15) Covers for ditches, pits and manholes in ground industrial sites are complete and complete, floor perforations must have covers, and ground roads must be unobstructed. 　　(16) Mine safety signs and safety protection facilities, ladders, handrails, guardrails, lighting, and safety covers must be strong and complete. 　　(17) The tools and labor protection supplies necessary for driving meet explosion-proof, fire-proof and other safety requirements. 　　(18) Mining enterprises must, in accordance with the requirements of the "Fire Protection Supervision Conditions", establish a ground fire prevention system and fire protection organization, set up fire protection facilities, and formulate underground and wellhead fire prevention measures. 　　(19) The ground drainage, flood control, and drainage systems in the mining area are complete, and the management system is sound, which can prevent floods from leaking into open pits or underground mines, prevent flash floods from destroying production and transportation systems, buildings, and structures, prevent slopes from sliding, or cause mudslides in dump sites, waste rock dumps, and tailings dams, so as to avoid major accidents. 　　(20) All electrical equipment and lighting fixtures designed to be explosion-proof must comply with explosion-proof standards. Temporary wires and fixtures may not be used without approval. 　　2. Establish a safety production responsibility system. 　　(1) Mining enterprises should implement safe production * * Responsibility system, establish and improve safety institutions, directly led by main administrative leaders at all levels. 　　(2) While managing production, leading cadres at all levels must be responsible for managing safety work, incorporating safety requirements into various technical management procedures, and making safety work institutional, regular and scientific. 　　(3) Implement the safety production responsibility system for organizations and personnel at all levels from the mine director to the safety officer. Personnel from various functional agencies of mining enterprises and workers of all types of work must be responsible for achieving safety production requirements within their respective business scopes. 　　3. A full-time safety agency must be established and equipped with the necessary number of competent safety technicians, managers and safety officers at all levels to comprehensively do a good job in safety work, conduct regular supervision and inspections, and assist in analyzing and handling accidents. 　　4. Carry out safety education seriously. The safety department should organize employees to learn safety procedures and safety technology in a planned way. * and training. Leading cadres and production command personnel at all levels must take the lead in complying with safety regulations. New workers must undergo three-level safety education in the mine, work area (workshop), and team before taking up their posts, and pass the examination.

Section 5 Material Preparation Article 16 Load-linked commissioning and normal production must have certain material reserves and sufficient external conditions. Since the chemical mining project consumes a large amount of materials, has many varieties and specifications, and has high requirements, in addition to the efforts of the enterprise itself, it also requires close cooperation and cooperation from a wide range of aspects. 　　Article 17 During the production preparation process, a certain amount of various materials must be reserved according to the trial run and trial production plans and various consumption quotas, and according to the designed variety and quality requirements to meet the needs of trial run and initial production, and a material plan must be prepared at the same time. It is necessary to designate full-time personnel, implement supply channels, sign supply contracts, and solve transportation problems. For valve materials with special requirements, special applications must be made to organize trial production. 　　Article 18 Material preparation includes raw materials (such as ore), fuel (such as raw coal, heavy oil, etc.), auxiliary materials (such as * * , chemicals, steel balls, lubricating grease, etc.), large tools, spare parts, small hardware, etc. 　　Article 19 Before the load-linked test run of the mineral processing plant, the mining preparation plan and the mineral processing load test run plan must be connected with each other. Mining production personnel must enter the mining site or mining area in advance to prepare the first batch of ore. 　　Article 20 It is necessary to ensure the supply of living materials (including living, teaching, office equipment, medical and sanitary equipment and transportation needed for offices, canteens, dormitories, residences, medical clinics, nurseries, schools and other facilities). This is the material basis for gathering teams and preparing for production, and must be properly arranged and resolved. 　　Chapter 3 Test Run Work Section 1 Test Run Preparation Article 21 Test run work includes single machine test run, linkage test run and load linkage test run. The main task of the preparation work before the mine load linkage test run is to open up the public works, complete the single unit test run, the linkage test run and all other preparations. This is of decisive significance to successfully achieve the first-time success of the load test. 　　Article 22 A scientific and reasonable overall commissioning plan must be prepared. It is jointly studied by production, construction, design and other units and formulated by the construction unit. It is a guiding document for project completion and load commissioning. It must be revised, enriched and improved in a timely manner as the work continues to deepen. The overall commissioning plan should meet the following requirements: 　　1. Adhere to the principles of early single unit test, complete linkage test, and stable load test. 　　2. Adhere to scientific commissioning procedures, with public works first and then the main works. Ensure the connection between project completion and commissioning, the connection between public engineering commissioning and production equipment commissioning, and the connection between single unit commissioning, linkage commissioning and load commissioning. 　　3. It is necessary to compare and optimize multiple plans from the aspects of technology, economy, safety, etc., and select the most economical, safe and feasible best trial run plan. 　　4. It is necessary to achieve "eight clear explanations", that is, to clearly explain the test run procedures, the key points of each procedure, and the indicators to be achieved. ； The progress and connection between the steps before and during the test run should be clearly explained. ； The four major balances of materials, fuel, power, storage and transportation must be clearly understood ； Explain clearly the key technical and operational issues during commissioning ； Be clear about safety and emergency handling ； The main line of conflict in the test run should be clearly stated ； Be clear about the external conditions such as public works that must be guaranteed ； The measures to ensure a successful test run should be clearly stated. 　　Article 23 In order to make the overall commissioning overall plan feasible, commissioning implementation plans for each stage must be prepared. The construction unit is responsible for preparing the single-unit and no-load linkage test run plan, and the design and construction units discuss and approve it. ； The production unit is responsible for preparing the load-linked test run plan, and the construction design and construction units work closely together. The load-linked test run plan (including test run costs) can only be implemented after being approved by the competent department. 　　Article 24 According to the requirements of the commissioning plan, infrastructure and production must cooperate closely to ensure that the completion and commissioning work are completed on time. 　　1. Strengthen the leadership of the completion and finishing work, implement weekly plans and daily arrangements according to the commissioning schedule requirements, and ensure the progress of the infrastructure finishing work to meet the requirements of the overall commissioning overall plan. 　　2. Before joint commissioning, "three checks and four determinations" must be carefully carried out, that is, checking for design omissions, checking project quality and hidden dangers, and checking unfinished work. For the identified problems, tasks, personnel, measures, and completion time must be determined. “"Three checks and four determinations" should be carried out comprehensively and signed for confirmation according to the design by section and item. 　　3. Pay close attention to the data review and intermediate acceptance work. The intermediate handover data should ensure the quality, be complete and accurate, and meet the specification requirements to promote the completion and commissioning of the project. 　　Section 2 Single Test Run and Linked Test Run Article 25 Single test run and no-load linkage test run are the most important components of the construction project and should be included in the scope of the project contract.

Article 26 The purpose of single unit test run is to: 　　1. Inspect equipment manufacturing and installation quality ； 　　2. Understand equipment performance and master operations ； 　　3. Whether various indicators meet the design requirements. 　　Article 27 Single unit test run must be strictly inspected according to the equipment instructions and equipment installation technical specifications, and can only be carried out after confirming that the conditions are met. Detailed records of inspection, processing and driving conditions must be kept and organized for filing. 　　Construction quality or equipment problems discovered during single-unit commissioning must be resolved by the construction unit before joint commissioning. 　　Article 28 The construction unit is responsible for the command, operation, and security of the single unit test run, and the construction unit sends personnel to participate. 　　Article 29 After the single unit passes the test run, the joint test run can be carried out according to the design requirements and test run procedures. The conditions that should be met for linkage test run are:: 　　1. The "three checks and four fixes" work has been completed, and the identified problems that will affect the commissioning work have been eliminated. ； 　　2. The main project, auxiliary projects and public projects have already met the conditions for joint commissioning. ； 　　3. The joint test run plan, relevant operating procedures and safety technical measures have been reviewed, approved and announced ； 　　4. The commissioning command personnel, full-time technical personnel, operators and maintenance personnel have been determined. 　　Article 30: Purpose of joint test run: The first is to check whether the cooperation and process flow of each production line or linkage equipment and industrial buildings meet the design requirements when the equipment is jointly operated. The second is to check whether the interlocking device is sensitive and reliable, and whether the signaling device is accurate. Necessary process equipment must also be tested with water. 　　Article 31 The construction unit is responsible for the command, operation and security of the joint test run. Construction and design should actively cooperate and send personnel to participate. After the preparations are completed, the start-up can be officially started only with the approval of the commissioning leading organization composed of production, construction, and design units. 　　Article 32: Design, construction, equipment and other problems discovered during the joint commissioning must be studied and eliminated one by one. The required expenses shall be budgeted by the construction unit and shall be paid within the infrastructure investment commissioning fee after review and approval by the construction unit. After passing the general linkage test run, the construction unit and the construction unit should immediately handle the handover procedures of engineering and technical data. 　　Section 3 Load Linkage Test Run Article 33 Load Linkage Test Run means that after the no-load linkage test run, joint operation will continue and materials will be gradually fed to the linkage unit. Its purpose is to test the performance of main equipment, production capacity, process parameters and product quality indicators under the condition of feeding materials, assess the quality of the project, open up the process flow, expose problems in design, construction, equipment and other aspects and rectify them. 　　Article 34 Load-linked test runs must adhere to high standards and strict requirements. The entire process from inputting materials to producing qualified products requires smooth processes, uninterrupted test runs, and no major accidents. We strive to produce qualified products in one go and achieve the best plan for test runs. 　　The assessment standard for mining ore dressing load-linked testing is based on the production of qualified products at the process terminal for 72 consecutive hours. 　　Article 35 The load-linked test run shall be organized by the construction unit, the production unit shall be responsible for command, operation, and the design unit shall participate, and the construction unit shall send bodyguards. After passing the general load linkage test run, under the auspices of the test run leadership agency, the construction unit, production unit and construction unit will issue individual project acceptance certificates and handle the handover of fixed assets. 　　Article 36 In order to ensure a successful load-linked test run, it should be done: 　　1. Carefully command and form a strong command system under the auspices of the trial leadership agency. During the test run, the mine production general dispatcher is responsible for the command of the entire system. Within the work area (workshop), a full-time engineer directs the test run, combining technical responsibility and command. 　　2. Careful management is centered on the job responsibility system and strictly implements various rules and regulations. All staff, from commanders to operators and maintenance workers, must study carefully. * All relevant systems are followed and work is carried out according to the system. 　　3. Carefully prepare and carefully check and implement the necessary conditions for load-linked test run. 　　(1) The main project has been completed as designed, the quality of the project is qualified, and the construction records are complete and accurate. 　　(2) All equipment has been carefully inspected according to regulations, the single test run and the joint test run meet the requirements, and the pipelines and lines are smooth. 　　(3) All electrical appliances, instruments and other devices meet the conditions for normal operation. 　　(4) All safety, fire-fighting and rescue facilities shall pass inspection and testing. 　　(5) Storage (ore bins, fuel and chemical storage tanks, * * Warehouses, etc.), transportation (belt corridors, pipelines, highways, railways) facilities, there are no problems after inspection, and the relevant measuring devices have been calibrated and are ready for use.

(6) Guaranteed supply of water, electricity, wind, steam, etc. 　　(7) Raw materials, fuel, spare parts, production tools and repair tools are prepared as required and have been transported to the specified location. 　　(8) The production command system and the signaling and communication facilities within the work area (workshop) can be used normally. 　　(9) Maintenance and bodyguard teams have been formed. 　　(10) Test run organizations at all levels have been established, operators have been deployed, and all have been trained, mastered operating skills, and passed the examination. 　　(11) Process regulations, safety regulations, operating procedures, equipment maintenance systems and commissioning plans have been completed and approved. 　　(12) Original record forms, assessment record forms, various wall charts, and wall charts have been prepared. 　　(13) There are already facilities for the treatment of the discharged “three wastes”. 　　For these conditions, the commissioning leading agency must carefully inspect and final confirm. The inspections are mainly professional inspections, and at the same time, the mines, workshops, and teams of the production units must conduct three-level inspections. 　　4. Carry out load-linked test runs carefully and strictly according to the procedures. During the commissioning period, the work must be steady, the organization must be tight, the requirements must be strict, the measures must be reliable, and the command must be correct. We must insist on not driving if the procedures are unclear, not driving if the conditions are not met, not driving if the commander is not present, not driving if the commander violates the rules, not driving until a problem is investigated, and not driving if a problem is solved. For key positions, it is necessary to strengthen patrol inspections and implement a two-person operation supervision system with one person operating and one person supervising to ensure safety. 　　Article 37 Problems in design, construction, equipment and other aspects exposed by the load-linked test run shall be carefully analyzed by the test run leading agency, responsibilities shall be clarified, rectification contents and measures shall be implemented and rectification shall be completed within a time limit. 　　Thirty-eighth, commissioning of special railways, power generation, power supply, heating projects, etc. shall be carried out in accordance with the regulations of the relevant professional departments, and representatives of the relevant professional departments shall be invited for guidance, confirmation and visa application. 　　Chapter 4 Trial Production and Assessment Article 39 After the load-linked trial run is successful, trial production and assessment can begin after the exposed problems have been eliminated. The purpose of trial production is to inspect the design, equipment, engineering quality and production preparations, assess the actual production capacity, process indicators and product quality of the completed project, determine labor productivity, product costs and economic benefits, lay a good foundation for formal production and provide a basis for completion acceptance. The production unit is responsible for the trial production assessment, and the construction and design units cooperate. 　　Article 40 The purpose and main content of trial production are: Further examine and identify the production capacity, mining capacity, mineral processing capacity, mineral processing process and parameters of the main equipment ； Determine various production-related procedures, systems, quotas, process parameters and product costs. In particular, trial production is used to improve the technical level, business management level, and production organization and command capabilities of production workers and technical managers, including leading cadres. And comprehensively collect and systematically organize various records and materials of the trial production process to provide a basis for formal production. 　　Article 41 The time for trial production may be determined based on the size of the mine. Large mines can be longer, medium ones can be shorter, generally 20 to 30 days for mining-only enterprises, 2 to 3 months for mining and dressing combined enterprises, and 3 to 5 days for full-load continuous production assessment. 　　Except for projects with new processes and new technologies that must be approved before trial production can be arranged by capital construction investment, under normal circumstances, the cost of trial production should be included in the production cost expenditure. 　　The trial production and assessment time of the imported part shall be carried out according to the contract. 　　Article 42 After the trial production task is completed, the production unit shall submit a trial production assessment report to the superior authority to explain whether the product quantity and unit consumption, product cost, main process indicators, labor productivity, mechanical and electrical equipment integrity rate, "three wastes" treatment effects, etc. meet the design requirements. To verify the economic benefits of the project and clarify the time and steps to achieve design capabilities after it is officially put into production. 　　Chapter 5 Supplementary Provisions Article 43 These regulations apply to newly built or expanded large and medium-sized chemical mine infrastructure projects, and small chemical mine infrastructure projects may be implemented accordingly. 　　Article 44 This provision and * * If there is any conflict with the relevant provisions, the * * Provisions are enforced. 　　Article 45 These regulations will be implemented on a trial basis from the date of promulgation. 　　Article 46 The right to interpret these regulations belongs to the Ministry of Chemical Industry.

Catalog of the original start-up water-linked test run plan of the urea workshop 1. Basis and principles of preparation ---------2 4. Preparation work before test run————————————————————————————4 5. Water linkage process————————————————————————————5 6. Safety precautions for water linkage test run——6 7. Cold water linkage————————————————————7 8. Hot water linkage-------9 1. Basis and principles of compilation (1) Basis of compilation: 1. "Commissioning Specifications for Large and Medium-sized Equipment in the Chemical Industry" HGJ231-91 2. "Operation Guide for Urea Unit in Aqueous Solution Full Cycle Process" published by the National Fertilizer Industry Information Center 3. "Practical Operation Technical Guide for Chemical Plant" published by Chemical Industry Press (2). Compilation Principles 1. The urea system must be tested according to the requirements before the water-linked test run. It is required to complete the system purging and cleaning, the test run of the machine and pump unit, the trays or packings in the process equipment have been installed and the strength test has been carried out, the evaporation system airtightness test and vacuum test, and the instrument system testing and inspection, all conditions of the public works must meet the requirements of water linkage test run. 2. Water linkage is divided into two processes: cold water linkage and hot water linkage. Cold water linkage requires operators at each position to be familiar with each piece of equipment, valves, and control instruments in their position, master the performance of the equipment, and be familiar with the operation of the position. When the hot water is linked, the heating work of the synthesis tower is carried out at the same time. The operator must be proficient in the gas-water cycle operation of water volume balance, and cannot start and stop the operating equipment at will, or add a large amount of cold water during operation. 3. During the water-linked test run, avoid over-temperature, over-pressure and liquid shock to ensure the continuity of the test run and the safety of personnel and equipment. 2. Purpose of water-linked commissioning 1. To conduct a comprehensive inspection of the production process and equipment, pipelines, valves, instruments, automatic control systems, steam insulation pipelines, and synthesis tower leak detection systems. It is also a comprehensive inspection of the design and installation quality of the urea unit. 2. Conduct a comprehensive training and familiarity operation for the operators, improve the technical level of the operators, and create conditions for trial production of materials. 3. Adjusting instruments and automatic control systems to ensure normal operation is an important task for water linkage. Each detection point and each adjustment system must be inspected and accepted by the operator one by one. The water-linked test run can only be completed after complete adjustment. 4. Thoroughly clean out the dirt and debris from the system through water-linked test run. Prevent debris from clogging equipment, pipes, valves, instrument components or damaging pumps during trial production. 5. Check the supply and operation of circulating water, desalted water, primary water, steam, electrical and electrical equipment, instrument air, medium and low pressure air, medium and low pressure nitrogen, etc. 6. Eliminate defects and problems found during test runs and create conditions for chemical test runs. 3. Conditions for water linkage commissioning 1. The public engineering system has been running stably, and circulating water, desalted water, primary water, steam, instrument air, medium and low pressure air, medium and low pressure nitrogen, power supply, etc. can meet the requirements for linkage commissioning of the entire system. 2. The water-linked test run plan has been approved by the production management department, the workshop command structure has been established, and the operators at each position are fully familiar with the test run plan. 3. Establish a position responsibility system, and determine the position team leader between the water-linked test run and the trial production. He is responsible for assisting the squad leader in organizing all personnel in this position to complete the test run tasks and requirements issued by the workshop during the test run of this position. 4. The process pipelines and equipment of the entire device have been purged to qualified standards (including steam pipelines in the device, steam insulation and condensate drainage system pipelines, leak detection systems, etc.). The removed regulating valves, flow meters and other pipe fittings have been restored. 5. The evaporation system air tightness test and vacuum test pass. 6. All electrical equipment and instrumentation equipment have been inspected and calibrated to be qualified and delivered for use. 7. If there are any parts of the pipeline that have been changed, the welding slag removal must be completed before water linkage. 8. The machine and pump unit has passed the test run and has the conditions for start-up operation. 9. The safety valve is properly adjusted and has working conditions. 10. Safety and fire-fighting equipment are in place, tools and records and reports are complete, the site has been cleaned up, and communication between all positions is smooth. 4. Preparations before test run 1. During water-linked test run, the system water volume should be balanced and the circulation should be stable. Calculate whether the original process pipeline is sufficient based on the liquid injection volume of each plunger pump. If it is not enough, add temporary pipelines and remove them after the test run. 1.1 Close the inlet valves of each ammonia pump, that is, disconnect one section from the ammonia pump inlet during test run. The inlet water of the ammonia pump is sent by the steam condensate pump. 1.2 Configure a hose or temporary pipeline to connect the urine tank and the ammonium bicarbonate liquid tank to balance the water in the two tanks. 1.3 Configure a DN50 temporary pipeline at the outlet of the urine pump to the condensate tank. The purpose is to pump the water in the urine tank to the condensate tank. The condensate pump will send the water to the ammonia pump, dimethyl pump and ammonia water pump inlet to maintain the circulation of system water. 2. Add a filter to the inlet of centrifugal pumps such as condensate pumps, urine pumps, desorption pumps, and secondary meter pumps to filter out debris and dirt from the water belt in the tank. They will no longer be pumped into the system during circulation to achieve the purpose of thoroughly cleaning the device. If the filter screen is clogged and the pump outlet pressure drops, the pump can be reversed. 3. Check whether the temporary blind plates on the system and pipelines entering the workshop for liquid ammonia, water, steam, desalted water, etc. and for system purging have been removed. 4. Fill the cleaned urine tank, ammonium bicarbonate liquid tank, steam condensate tank, second surface tank, and hydraulic jet circulating water tank with desalted water. 5. Remove the short pipe behind the inlet valve of the CO2 compressor, and add a fine wire mesh to the side of the compressor to vent it to the atmosphere. Use air during water linkage test. 6. The urea device needs to be cleaned and pressure tested before the water-linked test run. 6.1 The entire circulation system must be cleaned with water before the water-linked test run. If there is difficulty in supplying desalted water, clean primary water can be used to fill the system. When filling the system with water, it is necessary to open the vent valves on the gas phase outlet pipelines of ammonia cooler A and pre-separator to remove system air. When the water is filled to the highest point of the system, open the drainage guide at the lowest part of the device to drain the water from the system. Determine whether a second system cleaning is required depending on the cleanliness of the discharge water. Notice: The highest point vent valve must be opened when the system is drained. 6.2 Before gas-water linkage, the urea synthesis tower needs to use desalted water for a hydraulic pressure test to 25.0Mpa. After the pressure test is completed, the water in the synthesis tower does not need to be discharged, and cold water linkage can be continued. When water enters a section of the system, test the pressure to 2.0Mpa and eliminate any leaks in a timely manner. The water pressure of the second-stage system is tested to 0.4Mpa. After the pressure test, the system water is discharged to the equipment that needs water during water linkage. Then there is no need to refill the system with water during water linkage. 7. Prepare a certain number of wrenches, pliers, F-wrenches, hoses and other tools on site. 8. Before commissioning, a comprehensive inspection of each position should be carried out, and the shut-off valves between each system must be closed. The latest reply author: chfr (2008-12-22 08:52:10) 5. Water linkage process Carry out gas-water linkage test run according to the normal production process, but the water volume and gas volume must be controlled for operation. Otherwise, the main pressure regulating valve and the first and second liquid level regulating valves will not be able to discharge excess gas or water due to flow problems, and overpressure accidents will occur in each section. That is, the air supply volume of the compressor, the liquid infusion volume of each liquid injection pump, and the circulation volume of the system are determined according to the flow area of ​​the main regulating valve of the system. The flow volume (air and water) of each section cannot be adjusted arbitrarily, otherwise the water linkage cannot be carried out in an orderly manner. The air volume of the CO2 compressor is based on practice. One valve is fully opened at one time, and the outlet pressure of one section is controlled at 0.08~0.1Mpa. When the outlet of the five stages is maintained at 14.0~15.0Mpa, the temperature of each section does not exceed 140°C. However, in some sections, the oil and water valve must be opened to release some air to maintain the compression ratio when the section is not overheated. The pressure in one section of the cycle needs to be maintained by the auxiliary line (not exceeding 1.7Mpa). If the evaporation system is not connected in series, the water can be drained to the ammonium bicarbonate liquid tank through the discharge pipeline behind the two-part tower. ； It can also be discharged to the urine tank through a vacuum preconcentrator. When the evaporation system enters the linkage, the first and second sections are evacuated, the melt pump is turned on, and the evaporation is discharged from the outlet circulation line to the urine tank. 6. Safety precautions for water linkage test run 1. Before starting the operating equipment, the equipment must be cranked and the oil level and valve switches must be checked. 2. The compressor, ammonia pump, and A-A pump must be started with the consent of the dispatcher, and each pump must be started without problems before being officially started to ensure the safety of the equipment. 3. The amount of water sent by the A-A pump and ammonia pump to the synthesis tower and the amount of air sent by the compressor to the synthesis tower should be adjusted in time according to the pressure of the synthesis tower and the opening of the PV204 regulating valve to prevent the synthesis tower from overpressure. The pressure of PV204 is controlled at 14~15Mpa (gauge pressure). 4. The first-stage circulation pressure PV301 and the second-stage circulation pressure PV302 can be controlled by the line valve. The PV301 pressure is controlled at 1.7Mpa (gauge pressure), and the PV302 pressure is controlled at 0.15Mpa (gauge pressure). The evaporation pressure of the first stage is controlled at 0.033Mpa (absolute pressure), and the evaporation pressure of the second stage is controlled at 0.0066Mpa (absolute pressure). 5. Water linkage test run When the cold water linkage is changed to hot water linkage, each heater should be slowly raised to prevent liquid shock. 6. Keep records of commissioning process parameters such as pressure, temperature, flow rate, liquid level, etc. 7. Strictly control the liquid level of each equipment to prevent overpressure caused by air in the system not being discharged. 8. After the test run, the accumulated water in the equipment and pipelines must be drained in time to prevent freezing damage. During drainage, the high-point venting of the system is open to prevent the equipment from being pumped down. 9. The inspection of the leak detection hole of the synthesis tower shall be carried out by a dedicated person. 10. Equipment defects detected during test run must be recorded and contacted to relevant units for processing. 11. All positions should be in close contact and work together to complete the water linkage test run. 7. Cold water linkage 1. On the basis that the pressure test of the urea synthesis tower and the first and second stages of the cycle has passed, the synthesis tower will not be drained, and the first and second stages will be drained until the ammonium bicarbonate liquid tank reaches the liquid level in each equipment. 2. Start the second-class pump at the lowest speed of the pump, and first inject water into the heat utilization section of the first steam heater. ； Ammonia water pump fills water into inert scrubber ； The primary and secondary cooling liquid levels are kept stable by water injection from the evaporative condensate pump. Start the first pump again and adjust the speed of the first suction tower while keeping the liquid level in the first suction tower fixed. ； Start the ammonia pump, and the speed is determined by the water balance of the pump itself. Adjust the opening of the large auxiliary line to keep the liquid level of the liquid ammonia buffer tank stable. This level is adjusted together with the amount of reflux ammonia entering the first suction tower. 3. The minimum speed of the dimethyl pump and ammonia water pump should be stable. Add water to the primary and secondary coolers to stabilize the liquid levels of the primary and secondary coolers. The amount of water added to the first and second coolers should be consistent with the amount of liquid injected at the lowest speed of the second-A pump and the ammonia water pump. Therefore, you can check whether there is any deviation in the indicated value of the first and second cooler water flow meters. 4. The speed of the first-A pump is fixed when the liquid level in the first-suction tower remains stable. From this speed, the liquid pumping volume of the first-A pump can be known. The stability of the liquid level in the first suction tower also depends on the balance of the amount of water entering the liquid ammonia tank from the large auxiliary line of the ammonia pump and then entering the first suction tower through the reflux ammonia pipe. 5. Manually operate the liquid level regulating valve for the first and second liquid levels to control the liquid level required by the process. The water after the two-part tower can be discharged into the ammonium bicarbonate liquid tank or into the urine tank through the flash tank. The ammonium bicarbonate liquid tank and the urine tank are connected by a temporary pipe to keep the water levels of the two tanks balanced. A part of the water is sent to the steam condensate tank through the temporary pipeline at the urine pump outlet, and is sent to the ammonia pump inlet by the steam condensate pump. ； The other part of water is sent to the buffer tank in front of the pump and the ammonia pump inlet through the temporary pipeline at the outlet of the desorption pump. While adjusting the liquid levels of the entire system's process equipment to be stable, the liquid levels of the ammonium bicarbonate liquid tank, urine tank, and steam condensate tank are also stabilized. 6. The water linkage at the evaporation station will be carried out after the system is inflated and pressurized. 7. Start a CO2 compressor, use one cycle to control the outlet pressure of one stage to keep it at 0.08~0.1Mpa, and vent the outlet of the fifth stage first to maintain it at 15.0Mpa. When it is necessary to supply air to the synthesis tower, open the outlet valve of the fifth stage to supply air to the synthesis tower ( Compressors should pay attention to the outlet pressure of the fifth stage). At this time, the main pipe pressure will drop, the pressure in the synthesis tower will gradually rise, and the outlet pressure of the high-pressure liquid ammonia pump and the first-A pump will also gradually rise. Pay attention to the liquid injection volume of each pump, and increase the speed if necessary to maintain the liquid level of each process equipment. 8. When the pressure in the synthesis tower reaches 5.0MPa, you can slightly open the PV204 valve, supply air to the first stage, and gradually build up the first stage pressure and the second stage pressure. When the pressure of the synthesis tower reaches 15.0MPa, the P4 valve controls the pressure of each section of the entire system. After the pressure of the high, medium and low pressure sections stabilizes, each pressure regulating valve is put into automatic control. If the pressure in one section is overpressure, it can be released a little by the overpressure discharge valve in one section to maintain the pressure in one section at 1.7MPa. 9. Evacuate the evaporation station, maintain a certain degree of vacuum in the first and second sections, and keep the vacuum difference between the first and second sections at 0.03MPa, so that the water after the second separation can enter the first evaporation system from the vacuum feed through the flash tank. Maintain the water level in the first and second stage evaporator separators, start the urea melting pump, and return it to the urine tank through the auxiliary line. 10. During cold water linkage, when the system water volume and air volume are balanced, adjust the secondary meter or the indicated value displayed in the microcomputer control screen according to the on-site pressure gauge, liquid level gauge, and flow meter. 11. If overpressure occurs in each section of the system during water linkage, on-site line valves can be used to adjust it, and the amount of air entering the system can be adjusted. If overpressure occurs due to excessive equipment liquid level, equipment discharge valves can be used to discharge part of the liquid. 12. During the cold water linkage, each class will perform more operations such as driving, short-term parking, and various accident anticipation operations. After changing each operation, the balance adjustment of the system's circulating water volume will be re-adjusted. ； The operating equipment often performs the operation of inverting the pump and stopping the pump (machine), which can establish perceptual experience for the adjustment of the amount of chemical feed and the opening of the valve in the future. 8. Hot water linkage Hot water linkage is accompanied by the heating work of the synthesis tower, so the temperature of the two streams of water entering the synthesis tower does not increase by more than 6 to 8°C per hour. At this time, the temperature rise starts from the bottom of the tower, and the tower temperature gradually moves up to the top of the tower. Finally, the temperature at the top and bottom of the tower reaches 100 to 120°C. The time of the hot water linkage circulation is determined by the entire heating process of the synthesis tower, which is 36 to 48 hours in winter. The heating rate should not be too fast. The temperature rise should be based on the temperature rise at the bottom of the tower. At the same time, observe the temperature rise at the bottom and wall of the tower. The temperature difference should not be greater than 40°C. The stable temperature rise and balance of the synthesis tower mainly depends on the stability of the circulating water volume. It must be carried out on the basis of maintaining a good balance of water volume and gas volume during cold water linkage. If the water volume is unbalanced, the hot water will flow out from the ammonium bicarbonate tank when it is full, while the cold water will be continuously replenished from the steam condensate tank. In this way, even the full amount of steam in the heater part of the system cannot raise the water temperature to 100°C. The water temperature entering the synthesis tower is not allowed to be too high or too low, and the temperature rise or cooling cannot be greater than 6~8℃/h. The hot water linkage should be carried out on the basis of the balance of cold water volume. If the pump needs to be reversed, it must be operated in the official driving state, and the water volume cannot fluctuate. The heating operation process is as follows: 1. When hot water is linked, close the circulating water return valves of the soft water cooler and primary and secondary cooling, and close the circulating water return valves of the vacuum preconcentration condenser, first-stage evaporation surface condenser, and second-stage evaporation surface condenser. 2. The water injected into the synthesis tower by the liquid ammonia pump is added with steam from the liquid ammonia preheater. The temperature rise rate is controlled by the thermocouple temperature TR202-3a/b at the outlet of the liquid ammonia preheater, and is recorded. It is necessary to control the water output of the steam condensate of the ammonia preheater to prevent water accumulation in the jacket and cause fluctuations in the synthesis tower. 3. The water injected into the synthesis tower by the first-A pump comes from the second-A pump, the ammonia water pump and the top reflux ammonia pipeline. Only the water from the second-A pump can be heated by adding steam through the first-suction external cooler. The heating temperature here is higher, and the liquid temperature of the first-suction tower is controlled to rise by 6 to 8°C/h. The steam condensate generated by the first suction external cooler can be controlled by TV302 to be discharged into the condensate tank. 4. After the liquid ammonia preheater and the first-suction external cooler steam are all put into use, when the temperature rise rate at the bottom of the synthesis tower is less than 6 to 8°C, the steam regulating valves of the first-stage heater TV301 and the second-stage heater TV303 can be gradually opened. Initially, the outlet water temperature should be controlled not to exceed 80°C. If the temperature is raised too fast, liquid shock will occur in the first-absorption tower or the second-circulation and one-cooler. Then gradually increase the water temperature of the first heater and the second heater to 100°C. 5. After the water passes through the evaporation system, because it operates under vacuum, the hot water cools down. At this time, the evaporation heater must add steam to raise the temperature. The heating should not be too high at the beginning, based on the water temperature rate of the synthesis tower. In the subsequent process, the temperature increase of the two evaporation heaters should be within the process specifications based on the vacuum degree of the first and second stages. The temperature of the evaporation heater is too high and the vacuum degree drops. 6. When the synthesis tower is linked with hot water, nitrogen leakage can be passed through to check whether each leak detection point is unobstructed. 7. When hot water is linked, pass steam through the material pipe with steam accompanying pipe or jacket to check the steam inlet or liquid outlet. 8. After each heater is activated, check the water trap status of each heater. 9. It is necessary to check in detail whether there is internal leakage in the valves at each discharge point, water inlet point, steam inlet point, and analysis sampling point, and check whether the process flow, equipment internal parts, and piping are suitable. Any discomfort will be eliminated after the linkage is completed. 10. Check whether the on-site thermometer indication is correct. When the system water temperature reaches 100°C, adjust each thermocouple and thermal resistance thermometer. 11. After the hot water linkage is completed, the synthesis tower is drained, and then steam is passed to preheat the synthesis tower. When the temperature in the tower is above 100°C, the synthesis tower is passivated according to the passivation plan. Drain the condensate from the equipment and pipelines cleanly, and the system can be filled with nitrogen to avoid leaving dead ends. 12. Drain the water in each storage tank, clean it and then add desalted water for feeding. 9. Equipment rectification after the water linkage test run 1. After the hot water linkage test run, the bolts of each flange of the equipment and pipelines must be tightened once. No items or bolts can be missed, including the last instrument installation point of the equipment and the bolts on the equipment sight glass. 2. Tighten the large cover bolts of the urea synthesis tower and the flange bolts on the discharge pipe of the synthesis tower and the three material pipelines entering the tower after the synthesis tower is preheated to 150°C. 3. Tighten the valve stem gland bolts of high, medium and low pressure valves on the process material pipeline once. If the valve packing is insufficient, add packing and tighten again. 4. Check whether there are impurities blocking the valve heads of PV204, LV302, LV303 and other regulating valves. 5. Check the defoaming net at the gas phase outlet of the first absorption tower and the second tower to see if it is complete or contains impurities. 6. Disassemble and clean the special filters and filters in the pipeline and then reinstall them. 7. Remove the filter screen added to the rear flange of the condensate pump, desorption pump, urine pump, and second meter pump inlet. Clean the filter on the rear flange of the urine pump inlet and then reinstall it. Remove temporary pipes. 8. Restore the short pipe behind the inlet valve of the carbon dioxide machine. 9. For the first-A pump, ammonia pump, second-A pump, and ammonia water pump, the one-way valve or combination valve must be disassembled and inspected, and the wear of the plunger, packing, and cylinder should be inspected. 10. For desorption pumps, secondary surface pumps, condensate pumps, melting pumps, urea feed pumps, and urine pumps, disassemble and inspect whether there is wear between the impeller and the casing. 11. Disassemble and inspect the evaporative injector to see if there are any impurities in the pipe. 12. Tighten the bracket of the pipe. 13. Eliminate equipment defects in carbon dioxide compressors. 14. After the system is processed, check for leaks again according to the system pressure test plan. If there are no problems, the system will be ready to start. Author: chfr (2008-12-22 08:52:27) 10. Water-linked test run time arrangement and organizational structure 1. Water-linked test run is arranged according to the overall test run schedule of the urea project. Water linkage test run time: 3 to 4 days 2. Water linkage test organization structure: Team leader: deputy team leader: Team members: Full command of 1 person ； 6 technicians ； 1 safety manager ； Several chemical engineering personnel ； Several maintenance personnel. 11. Water-linked test operation control index pressure (Mpa) Urea synthesis tower 14.0~15.0 (table) First-stage cycle 1.70~1.75 (table) Second-stage cycle 0.15~0.20 (table) First-stage evaporation 0.033 (absolute) Second-stage evaporation 0.0066 (absolute) Temperature (℃) The outlet temperature of each section of the compressor is <150℃ Initial <80°C, increases with water temperature, up to 120°C. First-stage decomposition temperature ~ 150 Second-stage decomposition temperature ~ 120 First-suction cooler temperature 100 ~ 110 Liquid ammonia preheater temperature 100 ~ 120 Urea synthesis tower bottom temperature 100 ~ 110 Flow rate (m3/h) Liquid ammonia pump to synthesis tower water volume 10 ~ 24 Use the frequency converter to control the water volume from the first pump to the synthesis tower 10 to 12. Use the frequency converter to control the compressor to the synthesis tower. The gas volume is 3600 to 4500. This amount can be appropriately adjusted according to the first and second stage circulation pressure and the pressure of the synthesis tower using the P4 valve.

Regulations on Production Preparation and Commissioning of Large-Scale Equipment in the Chemical Industry (issued as (88) Chemical Industry Document No. 381 on May 3, 1988) Chapter 1 General Provisions Article 1 Production preparation and commissioning are important components of capital construction. In order to ensure a successful chemical industry commissioning, safe, continuous and stable production, achieve design capabilities as soon as possible, and maximize investment benefits, these regulations are formulated. 　　Article 2 The main content of production preparation is to make preparations in six aspects: personnel organization, technology, all-staff training, safety, materials and external conditions, and management. Production preparation work runs through the entire process of capital construction and is an extremely important basic work for factory construction. This work must be put on the important agenda from the beginning of capital construction, grasp it early and implement it early, so as to create conditions for ensuring the success of the chemical test run and lay a solid foundation for long-term normal production after the start of production. 　　Article 3 The commissioning work is a comprehensive assessment of the design, equipment manufacturing, construction quality and production preparation of the construction project. High standards and strict requirements must be adhered to to ensure that the project quality is excellent and no hidden dangers are left. ； The main project and supporting projects are completed at the same time, leaving no tail. ； In order for the test operation to be accurate and accident-free, the single machine test should be carried out early, the whole system should be fully linked and the chemical feed should be stable. During the commissioning, we must adhere to the principle that the procedures that should be followed must not be reduced by one step, the standards that should be achieved must not be lowered at all, and the time that should be striven for cannot be let go for a minute. The leadership of the commissioning work must be strengthened, and the design, construction, and production units must work closely together to ensure the realization of the best plan for the chemical commissioning and the success of the commissioning, and achieve better economic benefits. Chapter 2 Production Preparations Section 1 Personnel Organization and Preparation Article 4 Before approving the start of construction projects, leaders with production and construction experience and technical knowledge should be selected to form a production leadership team that can firmly implement the party's principles and policies and meet the requirements of revolution, youth, knowledge and specialization to adapt to the needs of modern factory production and construction. 　　At least one key member of the production leadership team must participate in the leadership of the plant from the beginning of construction (in charge of production preparation) to ensure the continuity of project construction and production preparation. 　　The construction unit should set up a production preparation organization from the beginning of capital construction to be responsible for various production preparation work. 　　Article 5: Establish a factory management system that adapts to the characteristics of production equipment based on the design requirements and the spirit of reform, and set up management institutions in accordance with the principles of simplicity, unity, and efficiency. The management organization and production command system must be gradually enriched and improved to meet the needs of each stage of work. For imported equipment, its foreign affairs office must be equipped with professionals with strong business capabilities to facilitate taking the initiative in foreign affairs. 　　Article 6: Do a good job in establishing the production team. According to the design capacity and job technical standards, select or hire some cadres with organizational management experience and professional counterpart technicians and workers with practical operation experience from old factories of the same type as the backbone. The backbone of production technology must enter the factory when it is being built and participate in technical negotiations, design review, construction supervision and production preparation. Operators and maintenance workers should mainly be recruited from technical technical graduates and high school graduates, and they should be selected on the basis of examination. Operation and maintenance personnel in major positions must enter the factory one and a half to two years before the completion of the factory installation according to the staffing plan. 　　Article 7: The factory director’s target responsibility system is implemented. The factory director is responsible for the entire process from the preparation of the factory to the handover and acceptance of the entire project. Section 2 Technical Preparation Eighth The task of technical preparation is to enable production personnel to master the technology of all production devices. They should mainly work on four aspects: process operation, process control (instrument interlocking and analysis), equipment maintenance and use, and safety, so as to achieve the requirement of being able to independently guide and handle various technical problems. From the beginning of production preparation, the technical system must be established. 　　Article 9: Four work contents of technical preparation. 　　1． Equip technical backbones and establish a technical responsibility system. 　　The factory must be equipped with professional and technical backbones in the fields of technology, instrumentation, electrical, machinery, analysis, etc. as early as possible, sign a letter of responsibility, adhere to a consistent system, and be responsible for the technical preparation work of this profession to the end. 　　2. Participate in design review, improve process and engineering design. 　　While production personnel are familiar with the production process, they must also pay attention to engineering technology, be familiar with relevant standards and specifications, promptly discover problems in design and installation, and cooperate with the design and construction departments to improve design and construction. 　　3. Prepare various technical regulations, start-up plans and materials. 　　According to the design documents, combined with the actual situation on site, and with reference to relevant domestic and foreign technical data, the factory should prepare the following important procedures and plans. 　　(1) Public engineering operating procedures, including boilers, water supply and drainage, circulating water, desalted water, electricity, instruments, gas, etc. 　　(2) Process regulations and post operation methods of the production device (written from the perspective of automatic control instruments, and the logic diagram of the instrument control loop and interlocking signal system should be attached). 　　(3) Operation procedures for large units, including large compressors, large pumps and matching turbines, oil systems, vacuum systems, etc. 　　(4) Factory safety technical regulations and key points for safe operation of each device and position. 　　(5) Analysis procedures, including chemical analysis and device analysis. 　　(6) Maintenance and overhaul procedures for mechanical equipment, including machine backup management. 　　(7) Maintenance and inspection procedures for electrical equipment, including signaling, interlocking operation and maintenance. 　　(8) Maintenance and inspection procedures for automatic control instruments and interlocking. 　　(9) Various start-up plans, including equipment cleaning, pipeline cleaning, purging, stand-alone test run, linkage test run, air tightness test, replacement, coal contact loading, oven, chemical feed test run, etc. 　　(10) Emergency handling plan. 　　4. Technical regulations and start-up plans should be discussed by relevant experts and must be reviewed by the chief engineer and approved by the factory director. Section 3 Full-Staff Training Article 10 Full-Staff Training requires all factory leaders, professional managers, technical staff and even every employee (especially analysis, laboratory and mechanical, electrical, and instrument repair professionals) to undergo professional training and pass the exam before they can take up a position or take up a post. This is a central link in production preparations. 　　Article 11 The goal of all-staff training is to focus on ideological construction and team quality to cultivate a strong team that can meet the needs of a successful test run. In training, we must adhere to high standards and strict requirements, focus on team training, practice thinking, practice skills, and practice style. If we practice the ability to drive successfully once, we must master process operations, master process control, master equipment maintenance and use, and master safety. You must have "four understandings and three skills" for equipment, that is, understand the structure, understand the original quantity, understand the performance, understand the purpose, know how to use it, know how to maintain it, and know how to troubleshoot. 　　Article 12 While training all employees, there should be focused training on production commanders and production technical backbones. Main technical backbones such as production dispatchers, workshop directors, full-time engineers, and central control shift leaders should undergo “full-process training” to establish system concepts and strengthen system management. The training period for special types of work such as mechanical, electrical, instrument repair, analysis, and testing is long and difficult. These personnel should enter the factory early and receive early training. They should also participate in equipment inspection, installation and debugging, and master maintenance and analysis and testing techniques. 　　Article 13 Strengthen training and ensure training quality. During the construction phase, the factory must focus on personnel training and formulate training plans based on the construction period to ensure training time and training quality. 　　Article 14: We must do a good job in training throughout the entire process. Full process training consists of four stages. 　　The first stage is basic knowledge of chemical engineering and process theory * The stage lasts about 3 to 6 months. 　　The second stage is the actual * stage, about 6 to 18 months. The focus is on being familiar with and mastering the process flow, process operations, process control and equipment performance of the corresponding position. Reality * The training work implements "six fixes, two guarantees and one guarantee", that is, fixing the team leader, fixing the training point, fixing the training personnel, fixing the time, fixing the responsibility, and regular assessment ； The training unit provides teaching, and the training staff provides training ； Work on duty under the supervision of the master. 　　The third stage is the on-site training stage, which lasts about 3 to 6 months. On-site training must be carried out one by one in accordance with the requirements of technological processes, driving plans, etc. One person trains and multiple people find faults, practice according to imaginary accidents, focus on key points and weak links, and practice repeatedly. Through on-site training, the command ability is improved, and the soldiers are familiar with the site, the process, the control, the equipment, the rules and regulations, and the relationship between the front and rear positions. 　　The fourth stage is to participate in various test runs before chemical input and conduct practical operation training. Participating in pipeline verification, purging, air tightness testing, installation, commissioning and commissioning of electrical instruments is an important stage of training. On the basis of external training, production operators are combined with construction site learning * Training, familiar with the pipeline directions of various media, valve positions, control room instrument layout, control methods, control loops and interlocking systems, etc. 　　After the above four stages of full-process training, operators can master the whole process of starting and stopping, normal operation, accident handling, etc. ； Mechanical, electrical, and instrument maintenance personnel can master the entire process of equipment maintenance, installation and scheduling. 　　Article 15: Strictly enforce the assessment system and promote training. Before taking up their posts, workshop directors and dispatchers will be appointed by the factory director. ； Full-time engineers are appointed by the factory's technical department. ； The shift leader, position operator, maintenance, and analytical laboratory workers will be examined by the workshop director in conjunction with the safety department. Only after passing the examination will they be issued a safe operation certificate before they can take up their posts. 　　Article 16 Comprehensive training and improvement of team quality. While providing technical training to the workforce, we must also strengthen the construction of spiritual civilization. Strengthen ideological and political work and carry out ideal education, moral education, discipline education, law and system education. During the entire training process, we must adhere to strict requirements, conscientiously implement the job responsibility system, strictly implement various rules and regulations, comprehensively improve the quality of the team, and build a workforce with ideals, ethics, discipline, excellent work style, technical skills, and high management levels that can adapt to modernization. Section 4 Safety Preparation Article 17 The safety work of large chemical installations is a complex technical and management work. We must always adhere to the policy of "safety first, prevention first" for safe commissioning and production safety, and the main leaders must personally make safety preparations. 　　Safety preparation should focus on the actual situation of factory production equipment and study the sources and characteristics of its dangers. In safety preparation work, we must conscientiously implement the following three principles:: 　　1． Actively implement preventive management for all employees and take effective preventive measures ； 　　2. Implement early detection of hidden dangers to achieve early detection and early treatment ； 　　3. Ensure personal safety, give full play to people's subjective initiative, and improve equipment reliability. 　　Article 18 On the basis of fully collecting safety-related information and cases at home and abroad, the following safety technical regulations and information should be prepared: 　　(1) Compilation of accident cases of similar chemical equipment at home and abroad ； 　　(2) Factory fire prevention guidelines, that is, detailed preventive measures for each substance, such as precautions for transportation, storage, production and use, handling methods in case of leakage, fire extinguishing, first aid, etc. ； 　　(3) Technical regulations for safe operation of the entire factory and each workshop ； 　　(4) Safety and fire-fighting facility use, maintenance and management regulations and the distribution and use information of fire-fighting facilities throughout the plant. 　　Article 19 The following safety conditions must be met before feeding chemicals (referred to as Safety Article 20). 　　(1) All equipment, pipes, valves, electrical appliances, instruments, etc. must undergo strict quality inspections to ensure that the quality of equipment, pipe fittings, materials, manufacturing and installation meets design requirements, and that the design meets process requirements. 　　(2) Equipment and pipelines pass the hydraulic strength test. 　　(3) The system air tightness test and leakage amount meet the specification standards. 　　(4) The safety valve should be debugged more than three times to ensure sensitive take-off, and the pressure of the corresponding process device should be checked. There should be a safety department seal after the test. Explosion-proof panels, flame arresters, breathing valves, water seals, molecular seals, vacuum breakers, etc. must meet process requirements and have excellent installation quality. 　　(5) The debugging of each alarm interlocking system in the process meets the requirements, and should be statically debugged more than three times to ensure that the operation is correct and usable. 　　(6) The automatic control instruments (temperature, pressure, flow level, analysis) are sensitive and easy to use after debugging ； Meters installed locally should have maximum and minimum limit signs. 　　(7) High-pressure fire pump rooms, fire pools, foam devices, water curtains, automatic fire protection, fire communication alarms, combustible gas detectors, etc. should all be tested jointly by the safety and fire protection department and the production unit to prove their usefulness. Be equipped with enough firearms to extinguish the initial fire. 　　(8) Lightning protection, anti-static facilities and grounding wires of all equipment and pipe racks must be installed and tested to be qualified. 　　(9) Safety communication systems such as telephones, signal lights, walkie-talkies, whistles, and loudspeakers should all meet the design requirements and be easy to use. 　　(10) The ventilation equipment is good and the designed number of air changes is achieved. 　　(11) All electrical equipment and lighting fixtures designed to be explosion-proof shall comply with explosion-proof standards. Temporary wires and fixtures shall not be used without approval. 　　(12) Safety protection facilities, ladders, guardrails, and safety covers must be strong and complete, and on-site eyewash and showers must be smooth and usable in all seasons. 　　(13) Covers for ditches, pits and manholes are complete and complete, and there must be covers for perforations in floor slabs. The ground is smooth and unobstructed, and roads are clearly numbered and unobstructed. 　　(14) After the installation area has been cleaned, no debris, especially flammable items, are allowed to be piled. Daily oils and chemicals must be piled in the location designated by the safety department. 　　(15) Production commanders and operators must pass the technical assessment and safety assessment before being allowed to take up their posts. 　　(16) Various rules and regulations are in place and everyone has rules to follow. 　　(17) Equipment signs and pipeline flow direction signs are complete, and fire hydrants, underground cable trenches, traffic prohibitions, safety wells and other signs in the factory area are complete and eye-catching. 　　(18) The necessary tools and labor protection supplies for driving are complete and comply with explosion-proof and fire-proof requirements. 　　(19) Establish and improve mass safety, firefighting, and rescue organizations, and be able to master fire-fighting and rescue skills through training. They have a clear division of responsibilities, so that they are responsible for their duties in normal times, can be used in emergencies, and remain calm in times of crisis. 　　(20) Emergency first aid equipment is complete, including gas masks, oxygen respirators, seat belts, stretchers, first aid kits, etc., and everyone can use them. 　　Article 20 Establish a sound and effective safety management system. 　　Establish a two-level safety organization at the factory and workshop level, and provide competent safety technicians, managers and safety officers at all levels. The main functions of the safety management system are as follows. 　　(1) Incorporate safety work into various technical management procedures to make safety work institutionalized, regular and scientific. 　　(2) Implement the safety responsibility system for personnel at all levels from the factory to the safety officer and the responsibility system for safety fire-fighting facilities. Study regularly * Training, continuous improvement of management level, and improvement of own level construction. 　　(3) Continuously and repeatedly provide employees with safety technical training and education on compliance with regulations and disciplines to ensure safety. 　　(4) Supervise and inspect the implementation of various safety regulations and responsibility systems, prevent various accidents that may occur, and closely integrate education, supervision, and prevention. 　　(5) It is necessary to ensure the safety and reliability of mechanical, electrical, instrument and other equipment and eliminate some potential unsafe factors. 　　Strictly follow the pressure vessel regulations and various relevant regulations to ensure the quality of every step of installation and commissioning and ensure that the equipment is in good condition. 　　Article 21 It is necessary to analyze and study each set of equipment, clarify the possible dangerous factors and the level of dangerous areas in each part, prepare accident handling plans at the factory and workshop levels, fully consider various possibilities on the basis of accident predictions, and formulate various corresponding measures. 　　Anti-leakage, anti-open flame, anti-static, anti-lightning strike, anti-electrical sparks, anti-freeze cracking, anti-residual oxygen, anti-suffocation, anti-vibration, anti-violation, and anti-misoperation should be regarded as the main content of the implementation of safety prevention policies. Operators, maintenance workers, electrical instrumentation personnel and safety personnel must conduct regular inspections in order to achieve early detection and early treatment of hidden dangers. 　　Article 22 Establish and improve the fire protection system, strictly train full-time and voluntary fire fighters, formulate fire-fighting plans, and conduct training accordingly. We should engage in fake fire shows from time to time * , to cultivate and check the sense of responsibility and professional level of fire fighters. 　　Article 23: Conduct safety inspections regularly. Before the test run, repeated safety inspections must be carried out in accordance with the "Twenty Safety Rules" to ensure that you cannot drive until the hidden dangers are eliminated, you cannot drive until the accident handling plan is implemented, and you cannot drive until the safety department confirms it. Section 5 Materials and External Conditions Preparation Article 24 It is necessary to designate full-time personnel to master the varieties, specifications, quantities, technical standards, packaging forms, storage and transportation conditions of raw materials, fuels, chemicals, and lubricants required for trial operation according to the design requirements, implement supply channels, and sign supply contracts. Propose analysis and development requirements as needed. Chemical raw materials and other materials entering the factory must be properly stored and preserved according to their characteristics to avoid damage, loss and deterioration. 　　Article 25: Implement supply channels for spare parts and do a good job in surveying, mapping and manufacturing of spare parts. After receiving the construction drawing design, the factory should organize manpower to prepare an inventory of spare parts for the equipment. For equipment parts that are not supplied by the equipment manufacturer, it should organize efforts to conduct surveying, mapping and trial production to ensure the need for test runs. 　　Spare parts, materials (including welding rods) and special tools entering the factory should be kept by designated personnel and shall not be misappropriated, damaged or lost at will. 　　Article 26 The mechanical, electrical, and instrument repair workshops will be built before the whole system is linked to the test run, and will be equipped with supporting equipment to form production capabilities to serve the test run. Self-manufactured spare parts should be studied and trial-produced as early as possible. Section 6 Management Preparation 27. Based on the characteristics of the device, formulate various scientific management systems centered on the job responsibility system. Before the entire plant starts single-machine testing, it will be issued to relevant personnel after approval by the factory leaders. * Be familiar with it and strictly implement it during the test run. Each functional department must define its own scope of responsibilities for serving production and serving the grassroots. ； Department, office and workshop heads, as well as functional personnel at all levels, must develop a responsibility system. Auxiliary workshops must formulate corresponding responsibility systems for process services, and operations, mechanical, electrical, instrument repair, and analytical workers must formulate job responsibility systems. 　　Article 28 In order to improve management and ensure a successful test run, the following basic regulations should be formulated: 　　(1) Provisions on strengthening the management of public works ； 　　(2) Regulations on the division of various pipeline management scopes ； 　　(3) Regulations on equipment maintenance, repair and equipment management ； 　　(4) Provisions on instrumentation and interlocking management ； 　　(5) Regulations on circulating water management ； 　　(6) Provisions on safe and civilized production workshop standards ； 　　(7) Regulations on the strict implementation of various job responsibility systems ； 　　(8) Provisions on test run command issues ； 　　(9) Regulations on the strict implementation of safety rules during chemical commissioning and commissioning ； 　　(10) Regulations on blind plate management during test run ； 　　(11) Provisions on maintenance and inspection during commissioning ； 　　(12) Several regulations regarding pipeline operation and management during commissioning. Chapter 3 Preparation and Commissioning before Chemical Industry Feeding Section 1 Project Closing Article 29 During the project closing and commissioning phase, the work is trivial, detailed, complex, demanding, and difficult. The construction headquarters or the project general contracting unit must strictly organize the design, construction, and production units and make overall arrangements to ensure the quality and progress of the project closing and put an end to simple commissioning and production regardless of conditions. 　　The construction unit must strictly perform the contract (the contract should have a clear commissioning responsibility system and reward and punishment methods), clarify the economic responsibilities of the final commissioning stage, establish a "century-long plan, quality first", be responsible for the project to the end, actively serve production, and complete the project completion and commissioning tasks according to the requirements of the overall commissioning control plan. 　　The design unit should provide relevant technical documents, start-up guidance and technical services according to different contracting methods, conduct core inspections of construction and installation projects according to design requirements, and conduct a comprehensive review of the design. 　　The production unit must organize production personnel to work early in the morning, and actively cooperate with the construction unit to complete the project and "three checks and four determinations" (the three checks include checking for missing items in the design, checking the quality and hidden dangers of the project, and checking the quantity of unfinished work) ； The four determinations are to determine tasks, personnel, measures, and time to complete the problems detected), stand-alone test run and linkage test run, and identify problems as early as possible to raise issues. 　　Article 30 The transition from engineering installation to final commissioning has work characteristics of different natures. The construction headquarters or general contracting unit shall promptly adjust and strengthen the leadership of the final commissioning work according to the division of commissioning stages. Organize the leadership team for the final commissioning, arrange the final commissioning work according to the unified overall commissioning control plan, implement the commissioning plan, check the progress of the commissioning, and be responsible for solving problems during the commissioning. 　　Article 31 The completion of the project is a very important sign that the project is about to be completed. It is a key link to shorten the construction cycle and put it into production as soon as possible. It must be of high standards and strict requirements, and it must be done early, quickly and hard. According to the unified overall commissioning control plan, arrange the completion progress of the project to meet the commissioning requirements and complete the project on time with quality and quantity guaranteed. 　　Before the project is about to be completed, it is necessary to conduct a major inspection of design and construction quality, organize construction, design, and production units, fully mobilize the masses, and carry out "three inspections and four determinations" according to majors and divisions of work. “The "three checks and four determinations" inspection can be divided into three stages, namely before the single machine test run, before the whole system linkage test run, and before the chemical input test run. The inspection method is mainly based on self-inspection. On the basis of self-inspection, the construction headquarters or the general contracting unit shall organize a joint inspection by the design, construction, and production units, and jointly confirm the signatures. A designated person shall be designated to complete the identified problems within a time limit. 　　Article 32: Promptly carry out document review and intermediate acceptance work. 　　Intermediate handover data should ensure quality, be complete and accurate, and meet regulatory requirements. After reviewing the materials and passing the final test run, the intermediate acceptance and handover procedures should be carried out to clarify the responsibilities of both parties, or handle it in accordance with the provisions of the contract. The review of project data and intermediate acceptance (handover) are important procedures for comprehensively inspecting project quality, promoting final commissioning, and strengthening capital construction management, and must be taken seriously. Section 2 Mechanical Commissioning Article 33 The mechanical commissioning of production equipment is generally divided into two stages. The first stage is stand-alone test run (that is, partial linkage or unit linkage test run of a single transmission equipment and auxiliary equipment) ； The second stage is the joint test run of the whole system (i.e. fake material test run). 　　Article 34 The following principles should be adhered to in the mechanical commissioning of large chemical plants. 　　1． The public engineering system must adhere to the commissioning principles of early completion, early commissioning, and early stability to create conditions for early stand-alone commissioning of the main equipment and provide a reliable guarantee for the first-time success of chemical commissioning commissioning. 　　2. A single machine must be tested early. If it fails to meet the standards, it must be tested and processed repeatedly. It is not allowed to bring the problem to the whole system linkage test stage. 　　3. The system-wide linkage test run (i.e. fake material test run) must be "complete" and the time must be fully guaranteed. It is necessary to comprehensively expose problems, eliminate hidden dangers, and be fully prepared for the first-time success of chemical feeding. 　　The division of responsibilities between the two stages of mechanical commissioning should be clarified in the contract according to different contracting methods. 　　Article 35: Prepare a feasible overall commissioning plan. The core of the overall commissioning plan is to prepare a commissioning overall control plan (network diagram) to connect various tasks and guide the project completion and commissioning work. The construction headquarters or the general contracting unit of the project must do a good job in organization and coordination. The design, construction, and production units should organize the project completion and commissioning work according to the commissioning procedures to ensure that the commissioning is coordinated and controlled and the plan is completed on time. 　　The overall commissioning plan shall be organized and designed by the construction headquarters or the general contracting unit. Construction and production units shall refer to the "Method for Preparing the Overall Commissioning Plan for the Later Stage of Large and Medium-sized Construction Projects". 　　 * * The overall commissioning plan for key construction projects should be reported to the competent authority for approval three months before the factory receives water and electricity. 　　For imported equipment, in addition to approval by leaders, the commissioning plans at each stage must also be confirmed in writing by foreign on-site technical personnel before they can be implemented. 　　Contents that the commissioning plan should include: 　　1． Test run purpose ； 　　2. Test run organization, test run person in charge and persons participating in the test run ； 　　3. Necessary conditions for test run ； 　　4. Catalog of preparations and inspection contents required for test run ； 　　5. Plans for external collaboration conditions and temporary facilities required for commissioning ； 　　6． List of raw materials, fuels, chemicals, water, electricity, steam, gas, spare parts and other materials required for test run ； 　　7. Trial process conditions and control indicators ； 　　8． Commissioning procedures and schedule ； 　　9. Procedures and requirements for starting, stopping and emergency handling ； 　　10． Commissioning cost budget. 　　Article 36 Single machine test run shall meet the following conditions: 　　1． The single-machine transmission equipment (including auxiliary equipment) has been carefully inspected, the lubrication and sealing oil systems have been completed, and the oil circulation has met the requirements. ； Technical data such as construction records meet the requirements and have been confirmed through the "three checks and four determinations" inspection, and existing problems have been eliminated (the imported equipment must be confirmed by on-site foreign experts) ； 　　2. All piping related to stand-alone test run has been completed ； 　　3. Pipe purging, cleaning and pressure testing related to commissioning are qualified ； 　　4. The power supply conditions for the test equipment have been met, and the electrical insulation test has been completed. ； 　　5. The site around the test equipment must be clean of materials upon completion of work. ； 　　6． The commissioning plan and relevant operating procedures have been approved and published ； 　　7. A commissioning team has been established, and full-time commissioning technicians and operators have been identified ； 　　8． The test run record form is ready. 　　Article 37 The completed installation of the device must meet the following standards: 　　1． All piping works are completed (including thermal insulation and accompanying pipes) ； 　　2. All instrument debugging is completed in one go ； 　　3. The insulation test of electrical equipment is completed and the power supply conditions are met ； 　　4. All rotating equipment that is eligible for stand-alone trial operation has passed the trial operation. ； 　　5. Pipe purging and chemical cleaning work is completed ； 　　6． The equipment and pipelines have passed the hydraulic pressure test and system air tightness test. ； 　　7. Filling is qualified ； 　　8． The analytical laboratory has been delivered for production use ； 　　9. Insulation and painting work mostly completed ； 　　10． Water supply and sewerage, road vertical leveling, lighting and communication projects within the boundary have been completed ； 　　11． The site has been cleared of materials after work has been completed ； 　　12. Construction records are complete and accurate ； 　　13. The quality of the project meets the requirements, and the unqualified projects have been repaired and passed. 　　Article 38 A comprehensive inspection of engineering quality and production preparations must be carried out before the whole-system linkage test run. The superior leadership department organizes experienced experts from all aspects to conduct inspections on project quality, design quality, equipment manufacturing quality and mutual adaptability. ； Conduct a comprehensive inspection of the production leadership team, management system and production preparations. Propose solutions to all problems found to be unsuitable for commissioning and complete them within a time limit to fully prepare for a successful chemical commissioning trial. 　　Article 39 The whole system linkage test run shall meet the following conditions: 　　1． Established job responsibility system ； 　　2. Full-time technical personnel and operators have been identified and passed the examination ； 　　3. The public engineering system has been operating stably and can meet the conditions for joint commissioning of the entire system. ； 　　4. The commissioning plan and relevant operating procedures have been announced ； 　　5. All process indicators have been approved and published by the production management department, and each operator has a copy ； 　　6． The production record report has been prepared and distributed to the post. ； 　　7. The setting values ​​of instrument interlocks and alarms have been approved and published, and each operator has a copy. Chapter 4 Chemical Engineering Commissioning and Commissioning Article 40 Chemical Engineering Commissioning and Commissioning refers to the commissioning of a chemical production device or an auxiliary production device, the completion of stand-alone and linkage commissioning, and the completion of the entire project, starting from the input of materials. The basic policy of chemical industry input and commissioning must be stable:: Work steadily and steadily, take clear steps, take one step at a time and look at the next step, constantly sum up experience, and move forward steadily. The criteria for a successful chemical feed test run are: From the input of production raw materials into the device to the output of qualified final products, the test run will not be interrupted, no major accidents will occur, qualified products will be produced at one time, and the best plan for the test run will be realized. After a certain period of operation adjustment, various design (contract) indicators will be achieved. 　　Article 41: Chemical input shall meet the following conditions (referred to as Article 30: Article 30). 　　(1) All devices and supporting projects have been completed according to the design (including design changes). After checking the materials, wall thicknesses, flanges, gaskets, bolts, various valves, pipe fittings, valve directions and positions, detection point sampling points, accompanying pipes, diversions, operating platforms, etc., each piece of equipment and each pipeline by serial number, the quality of the project meets the requirements, and the unqualified ones have been reworked to pass the standards. 　　(2) Construction records must be complete and accurate. 　　(3) All process pipelines and equipment have passed the strength test, and the purging and cleaning of the equipment and pipelines have been completed. 　　(4) The equipment and pipelines have been airtightly tested and confirmed to be qualified. 　　(5) The rotating equipment of the institute has been carefully inspected according to regulations, and the single test run and linkage test run are in compliance with the requirements and can be used for normal operation. 　　(6) The filling work of all equipment that needs to be filled with catalysts, fillers, desiccants, and additives has been completed. 　　(7) The oven industry of various industrial furnaces has ended. 　　(8) All kinds of pickling, passivation, degreasing, boiling, pre-drying, pre-activation, pre-sulfurization and other work that need to be carried out before feeding have been completed. 　　(9) The conditional water test run, fake material test run, and physical test run have been successfully passed, and the exposed problems have been resolved. 　　(10) The pre-filming work of the circulating water system has been completed and is in cold film-preserving operation. All indicators meet the requirements. 　　(11) The debugging of the automatic control instruments has been completed, the alarm and interlock setting values ​​have been accurately and easily used through static debugging, and the sample gas of the automatic analysis instrument has been prepared for use. 　　(12) The relay adjustment and insulation test of all electrical equipment have been completed and are in condition for normal operation. 　　(13) The supply of water, electricity, steam, instrument air, factory air, accident nitrogen, etc. for public works can be guaranteed according to the design value. 　　(14) All laboratory analysis facilities, standard solution preparation, etc. are ready for use. 　　(15) All safety and fire-fighting facilities in the factory, including safety nets, safety covers, blind panels, explosion-proof panels, lightning protection and electrostatic facilities, anti-virus, dust-proof, accident first aid facilities, fire hydrants, combustible gas monitors, fire alarm systems, etc., have been installed, passed inspection and testing, and have a dedicated person in charge. 　　(16) The storage and transportation system (shipping and loading dock) has been inspected and there are no problems. The fuel and raw material storage tanks and intermediate tank areas have been cleaned and have storage capabilities. The relevant measuring instruments have been calibrated and are ready for use. 　　(17) Chemical raw materials, fuel and auxiliary chemical raw materials, lubricating grease, etc. have been prepared, the quality meets the design requirements, and have been transported to the designated location. 　　(18) The medium temperature and anti-corrosion work of equipment and pipelines has been completed, and the equipment, pipelines, valves, electrical appliances, instruments, etc. must be marked with Chinese characters or codes with the site number, name, medium, and flow direction. 　　(19) For communication of the production command system, the communication facilities inside the device can be used normally. 　　(20) The mechanical, electrical and instrument maintenance facilities have all been completed and put into use, and relevant departments have formed a strong maintenance bodyguard team. 　　(21) The living and sanitary facilities in each workshop have been put into use. 　　(22) Technical data such as process procedures, safety procedures, analysis procedures, equipment maintenance procedures, job operation methods and commissioning plans have been completed and approved for issuance. 　　(23) Test run command organizations at all levels have been established, operators have been assigned, and their responsibilities are clearly defined. They have all been trained, mastered the operating skills, have reached the "four understandings and three skills", and have passed the examination. 　　(24) Various systems centered on the job responsibility system have been established, and various wall charts and charts are complete. 　　(25) The original records, special forms for commissioning, and assessment records have been prepared. 　　(26) Easily damaged spare parts and special tools are fully prepared. 　　(27) There are treatment methods or reasonable solutions for the three wastes discharged. 　　(28) All types of personnel have carefully studied * Safety regulations issued by the factory, safety education, and passing the examination. 　　(29) After a professional and comprehensive inspection before feeding, it was confirmed that the connection conditions between various production devices have been met, and various production preparations have been completed. 　　(30) Vertical leveling of roads and sites within the factory area has been completed. 　　Article 42 In order to achieve a successful start-up of the chemical industry, careful command, careful management, careful organization, and careful operation should be achieved. 　　1． Carefully command and form a powerful test command system. A start-up command organization must be established at both the factory and workshop levels. The command organization must clarify its responsibilities and grant authority. The command must be accurate, timely, and foreseeable. Establish and improve a highly centralized and unified production command system. The general production dispatching room of the factory is the center for daily command of the whole plant. Water dispatch, electric dispatch, transportation dispatch, and each workshop control room should form a daily production direct dispatching network under the unified command of the general production dispatcher. During the commissioning period, the factory's production chief will be responsible for directing and ensuring public works and external conditions. The workshop will be responsible for all internal commands, with full-time engineers conducting the test runs to unify technology and command. Mechanical, electrical, instrumentation, and analysis are subject to the unified arrangements of the production workshop and must actively cooperate. Specific command principles and key points must be prepared based on the actual situation of the factory and announced for implementation. 　　2. Carefully manage and strictly implement various rules and regulations. 　　3. Carefully organized, repeated inspection and final confirmation before chemical input. 　　Inspections are divided into professional inspections, three-level inspections and comprehensive inspections. 　　Professional inspection: Inspections organized by departments according to professional systems ； 　　Level 3 inspection: Inspection of factories, workshops and operating positions ； 　　Comprehensive inspection: A comprehensive team composed of relevant comrades from production, design, construction and other units will conduct inspections. 　　The inspection is mainly based on professional inspection, mainly on post and workshop self-inspection, and finally confirmed by comprehensive inspection. Eliminate problems discovered through repeated inspections before feeding. Supervisors must participate in the inspection so that they can be well aware of the situation and make decisions on existing problems. 　　During the inspection, the "Thirty Rules for Feeding Materials" and the "Twenty Rules for Safety" must be strictly followed. No feeding is allowed if the conditions are not met. 　　4. Operate carefully and strictly follow the steps for commissioning. 　　During the test run, procedures must be followed for all work ； Work must be secure ； Organization must be tight ； The requirements must be strict ； Measures must be reliable ； The command must be correct. At the same time, we must ensure that we do not drive unless the conditions are met. ； Don’t drive if the procedure is unclear ； Don’t drive if the conductor is not present ； Commanded to not drive in violation of traffic regulations ； If something goes wrong, don't drive until you find out. ； Don't drive if you don't solve the problem. 　　During the test run, everything should be done carefully and strictly ； Implementation of job responsibility system must be strict ； The implementation of various process indicators must be strict ； Be strict in obtaining complete and accurate primary information ； Instrument control and analysis results must be strict ； Water quality management must be strict ； Oil system management must be strict ； Be strict about the quality of materials, fuels and chemicals ； Implement safety technical regulations strictly ； Strict requirements for antifreeze measures ； The materials and specifications of spare parts should be strict ； Equipment use, maintenance and repair requirements must be strict ； The requirements for following procedures must be strict. 　　During the entire test run, key parts must be strictly controlled, patrol inspections strengthened, and problems discovered early. A two-person operation supervision system with one person operating and one person monitoring should be implemented to ensure safety. 　　Interlocking and safety devices must not be dismantled or cut off at will, and the setting values ​​must not be modified at will. Accident generators and uninterruptible power supplies must be tested regularly and kept in good standby condition. 　　Article 43 The construction unit (or general contracting unit) must organize a capable bodyguard team before the chemical industry is put into commissioning. The bodyguard team must have complete types of work and complete tools. There must be a person in charge on duty at the scene, establish a 24-hour bodyguard team duty system, be responsible for patrol inspections, do a good job in equipment maintenance, detect problems in advance and deal with them in a timely manner, and track the bodyguards. Chapter 5 Production Assessment Article 44 Production assessment is a comprehensive assessment of whether the production capacity, process indicators, consumption indicators, product quality, equipment performance, self-control level, economic benefits, etc. of the device after chemical input and commissioning meet the design requirements. Production assessment should include a comprehensive assessment of the capabilities of supporting utilities and auxiliary devices. 　　Article 45 The production assessment of imported equipment shall be conducted in accordance with the provisions of the contract. The production assessment is not only a final comprehensive inspection of the technical and economic indicators and production capacity of the equipment designed and provided by foreign companies, but also a comprehensive inspection of the project quality, production operation level, team ideological style, etc. Domestic devices are also subject to production assessment. Devices that have not undergone production assessment are not allowed to submit to * * Delivery and acceptance. 　　Article 46 Make preparations before the assessment. 　　1． Establish assessment organizations at both factory and workshop levels. 　　2. Carefully study and familiarize yourself with the production assessment materials provided by the design department or foreign companies ； 　　3. Mobilize employees to look for hidden dangers and problems that may affect the normal conduct of assessments ； 　　4. All measuring instruments required for assessment must be debugged correctly and confirmed together with the design department or foreign investors. 　　5. Prepare assessment plans and record reports. 　　Article 47 The assessment shall meet the following conditions: 　　1． The problems exposed under full-load production conditions have been eliminated, and the production of chemical equipment has been stabilized. ； 　　2. All automatic control instruments and interlocks are put into use ； 　　3. Spare equipment is in good condition ； 　　4. The analysis method is correct and the data is complete ； 　　5. The quality of raw materials and fuel supply meets the design requirements ； 　　6． There are a certain amount of reserves of chemical raw materials, lubricants, and wearing parts. ； 　　7. Product packaging is qualified and transportation is smooth ； 　　8． Develop assessment methods with the design department or foreign investors. 　　Article 48 The appraisal and assessment time after the assessment is generally stipulated as 3 to 5 days of continuous production at full load. The imported equipment may be stipulated in the contract. 　　The assessment results should ensure that product quality, quantity, unit consumption, product cost, main process indicators, automatic control commissioning rate, mechanical and electrical equipment integrity rate, and three waste treatment effects meet the design requirements. Chapter 6 Supplementary Provisions Article 49 These regulations apply to newly built or expanded large-scale chemical industry installations, and small and medium-sized projects must also be implemented accordingly. All contents must be carefully implemented according to the scope of responsibilities defined in the project contract. 　　Article 50 These regulations will come into effect from the date of promulgation, and the "Working System for Production Preparation and Commissioning of Large-scale Equipment in the Chemical Industry (Trial)" issued by the former Ministry of Chemical Industry in [80] Hua Ji Zi No. 508 will be abolished at the same time. The Bureau of Infrastructure of the Ministry of Chemical Industry is responsible for the explanation. Publishing department: Ministry of Chemical Industry (Changed) Release date: Implementation date: May 3, 1988: May 3, 1988 (Central Regulations)

Linked commissioning of chemical equipment 1. The purpose and main content of linked commissioning Linked commissioning is a trial operation stage of a new chemical plant from stand-alone trial operation (some are completed mechanically) to chemical commissioning. It starts with the test preparations being qualified and finally meeting the conditions for chemical commissioning. Its content includes all the preparations for on-site commissioning and commissioning. The purpose is to comprehensively inspect the performance and quality of the installation's machinery and equipment, pipelines, valves, automatic control instruments, interlocks and power supply and other public engineering supporting facilities, comprehensively inspect whether the construction and installation conforms to the design and standard specifications and meet the requirements for chemical input, and conduct practical drills for production operators. Therefore, orderly completion of the various provisions of the linkage test run is an important guarantee to prevent delays and accidents during chemical feeding, which may cause significant economic losses. The content of linkage commissioning varies with the process of chemical equipment. The commissioning work generally includes: System airtightness, drying, replacement and three-agent filling (chemicals, catalysts, desiccants, etc.), refractory lining baking, oven, inert gas replacement, instrument system debugging, single machine or large unit system trial operation with fake materials (usually air, water, oil, etc.) and system water trial operation, oil combined transportation and "reverse start-up" with physical or substitute materials, etc. 2. Preparation of the linkage commissioning plan The linkage commissioning plan is a programmatic document that guides the linkage commissioning. It is prepared by the production unit and organizes implementation, construction and design and other relevant units. It usually consists of the following aspects. (1) The purpose and preparation basis of the test run. (2) Organization and command system for commissioning. (3) Conditions that should be met for test run. (4) Network diagram of test run content, procedures and progress. (5) Main process indicators, analysis and control indicators, instrument interlocking values, alarm values, etc. (6) Starting, stopping, normal operation control methods, and accident handling measures. (7) Quantity and quality requirements for materials used for commissioning (including public engineering parts). (8) Guarantee and transportation system during commissioning. 3. Conditions that must be met before linkage commissioning (1) The intermediate handover of the project is completed. (2) The required public works can be supplied in a balanced manner. (3) The equipment tag number, channel media name and flow direction mark are completed. (4) Mechanical and electrical instrument repairs, analytical tests, etc. are put into use, and communication and dispatching connections are smooth. (5) Fire protection and gas protection equipment, combustible gas alarm systems, and radioactive material protection facilities have been constructed in accordance with design requirements and are in good condition. (6) Post dust and noise detection points have been determined. (7) The equipment technician, operation squad leader, and position operators have been determined. (8) The job responsibility system has been formulated and improved. (9) The test run plan, operating procedures, and operating methods have been issued to the production test run personnel, and the main process indicators, instrument interlocking, and alarm setting values ​​have been approved and announced. (10) Production operators have been trained and passed the assessment, and hold employment certificates. (11) The chemical raw materials and lubricating oil (grease) used for linkage test run are fully prepared. (12) Production records and other auxiliary supplies are complete. 4. The organization and command system of the linked test run. The linked test run of chemical equipment is a stage where conflicts and difficulties are concentrated in the engineering construction process. The content and nature of the test run and the intersection with the construction completion, the various contradictions and handling exposed during the test run, the coordination of internal and external relations and the supply of various materials for the test run, etc. These determine that during the linkage test run, a test run organization structure must be established with the participation of the production (user) department organization, command, construction (engineering party), design and other departments. This organization should be able to embody the high concentration of commissioning command and fully utilize the synergy of construction and other participating construction units. The organization should embody matrix management in order to quickly and correctly solve various problems that arise during the commissioning process, such as installation and construction, design, equipment and materials, patented technology and commissioning operations, and create favorable conditions for subsequent chemical input and commissioning. The figure below is a model established in accordance with the above requirements for reference. Support user trial operation headquarters (full-time: Production director) Public relations group planning statistics material supply test run acceptance safety security test run scheduling production scheduling engineering side driving manager driving engineer patent company representative safety engineer equipment manufacturing factory representative test run maintenance execution test run unit design representative 5. Linked test run methods There are many contents and methods for linkage test run of chemical equipment, including purging, cleaning, pre-filming, chemical cleaning of boilers and steam pipe networks inside equipment and pipeline systems. Washing, refractory lining baking, catalyst and other three agent filling, system air tightness test and drying, large unit trial operation, etc. have been specifically described in other chapters of this book. This section will introduce the methods and key points of nitrogen replacement, fuel, raw oil and gas reception, steam introduction in the steam pipe network, system water intermodal transportation, oil intermodal transportation, etc. in the linked trial run. The "reverse driving" method, which is one of the linked trial runs, will be introduced in 6. (1) Nitrogen replacement in the system Most chemical plants, especially petrochemical plants, have raw materials, fuels, and semi-finished products and finished products in the production process. Most of them are flammable and explosive. Therefore, before such flammable and explosive substances are introduced into the system, the air in the system must be replaced with nitrogen and the oxygen content must be reduced to less than 0.5% (volume) to avoid the mixing of materials and air to form explosive mixtures. In some cases, nitrogen replacement is also an important measure to prevent the surface of equipment in the system from being oxidized and corroded by humid air. ①Conditions that should be met for nitrogen replacement and preparations before replacement a. The system has passed the air tightness test, and the system that needs to be dried has passed the drying test. b. When using nitrogen for replacement, the oxygen content is required to be less than 0.1% (volume). The boundary pressure should usually be 0.6-0.7MPa. The dew point of nitrogen used in low-temperature systems should reach -60~-70℃. c. Public engineering related systems are running normally. d. The formulation and preparation of the system nitrogen replacement process, which includes the introduction of nitrogen, the determination of flow direction, discharge ports, analysis sampling points, etc., and the allocation of materials. e. All instruments, regulating systems, and safety devices (including interlocks) have been debugged and are in good standby condition. f. Nitrogen is an asphyxiating gas, so safety work is very important. Good ventilation conditions and necessary anti-asphyxiation and other safety equipment must be provided on site. ②replacement method. The nitrogen replacement method generally adopts an intermittent method, that is, first fill the system with nitrogen to ~0.5MPA, close the nitrogen filling valve, open the nitrogen discharge port, etc. to depressurize the system to ≈0.01MPA, then close the discharge valve and fill with nitrogen. Repeat several times until the O2 in the analyzed gas at each sampling point is <0.5% (volume) to prevent catalyst oxidation. When O2 is <0.2 (volume), the system replacement is qualified. However, the replacement of the low-temperature system must also measure the dew point of the system at each sampling point and meet the requirements. ③Post-replacement processing and precautions a. After the replacement is completed, the system that has been replaced should be noted on the flow chart, and the pressure and times of pressure filling and pressure relief, analysis results and qualifying time should be recorded. b. After the replacement is qualified, close all discharge valves and sampling valves, and fill the system with nitrogen again to 0.5MPA for air tightness test. After passing the replacement, reduce the pressure of the system to ≈0.05MPA (G) and maintain the pressure for use. (2) Receipt of fuel, raw oil, and gas. Fuel, raw oil, and gas are all flammable and explosive substances. Therefore, before installing them or systems, the device or system equipment must be comprehensively inspected and confirmed to comply with relevant statutory safety regulations. At the same time, various fire prevention and control measures should be taken when oil, gas, etc. are introduced. ①Receiving of combustible gases and raw materials a. After nitrogen replacement, system equipment and pipelines are already in a nitrogen-sealed state under a pressure of ≈0.05MPA (G). b. Before introducing external fuel and raw gas, the valve between the fuel gas and the device system should be cut off, and a blind plate should be added to the main valve to prevent combustible gas from jumping into each system. But it is necessary to open the upstream and downstream valves of the regulating valve to the torch. c. The reception of fuel and raw gas should usually be carried out after the second gas source ignites the continuous light of the torch. d. After the fuel raw gas enters the system, gradually open the discharge valve to the flare and put it into automatic control. The system pressure is controlled according to the design regulations and is ready for use. ②Receipt of fuel raw material oil products a. Reception of heavy fuel oil raw material oil ● The system should be qualified through water transport and the accumulated water should be drained, and the nitrogen replacement should be qualified. ● Open the system accompanying pipe to insulate steam, introduce raw fuel oil into the system storage tank, and open the tank bottom pipe to heat the steam to maintain the oil temperature in the tank at ≈80°C. When the liquid level reaches 80%, start the fuel oil pump and perform its own small cycle. After heavy oil enters the system, attention should be paid to cutting water and controlling the oil temperature to prevent sudden boiling. After the oil level of the storage tank is switched to automatic control, it is in a standby state. b. Receiving of light raw oil ● The system should be passed through water transport and drained of accumulated water. After passing nitrogen replacement, the system should be maintained at a slight positive pressure. ● Introduce light raw oil into the system. When the liquid level in the storage tank reaches 70-80%, stop receiving materials and conduct sampling analysis. At the same time, pay attention to removing the accumulated water from the bottom of the tank. ● Start the light raw oil pump small cycle and set it aside. ● When introducing light oil with a high freezing point, attention should be paid to heating the pipe (opening the accompanying pipe for insulation) and insulating the storage tank before introducing it to prevent condensation. (3) Steam introduction into the system ① Conditions a. The installation of valves, instruments and insulation appliances of the steam pipe network is completed. b. The steam pipe network pressure test, chemical cleaning, and steam purging are qualified. c. Other utility systems are operating normally. d. All instruments, adjustment control systems, and safety devices have been debugged and are in standby mode. e. The external steam supply or the boiler of this device is running normally and the steam supply conditions are met. Some or all of the process equipment of this device is in standby steam state. ②Warm pipe a. Open each diversion and discharge valve of the pipe network, and close the steam inlet valve of each user (equipment). b. Manually and slowly open the steam pressure control valves at all levels (≈5% each time during the pipe warming process). c. Manually open the steam vent valves of pressure pipes at all levels to ≈50%. d. Open the boiler or external steam inlet system valve slightly, and warm the steam pipe network at all levels. When heating the pipes, the speed should be slow to prevent water hammer. e. When all on-site discharge diversions in the steam pipe network are dry gas, close the diversions, open the front and rear valves of each trap, close their bypass valves, and connect the steam condensate to the grid. ③Network construction a. Slowly open the inlet valve of the large boiler or external steam supply. During the pressure increase process, gradually build up the pressure of the pipe network at all levels. During the pressure increase process, pay attention to prevent overpressure of the pipe network and prevent the temperature from being lower than the saturation temperature of the steam. b. Automatically activate the vent valves in each pressure section of the pipe network. c. Put the desuperheater in each pressure section into automatic control according to the set temperature to prevent over-temperature. d. After the pressure in each section of the pipeline network reaches the target, put the pressure control valve in each section into automatic operation, and the pipeline network is established and ready for use. (4) Water intermodal transportation Water intermodal transportation is also called water interlinked test run. It uses water or inert gases such as water and air as the medium to simulate the operation of a system where chemical equipment is operated with liquid or liquid and gas. Its purpose is to test all the performance and safety quality of its equipment or system except those affected by the medium in real chemical feeds, especially the effect of instrument linkage control. Conducting a comprehensive training and familiarization operation for the operators, conducting an assessment of the water, electricity, steam and air (instrument air, inert gas) supply conditions of the public works, eliminating the defects discovered during the trial operation, and at the same time continuing to bring out a small amount of rust spots, small welding slag and debris that may still remain in the system after purging through a high-speed liquid circulation. ①Conditions that should be met for water combined transport commissioning: a. The device or system equipment, pipelines, etc. must pass the air tightness test after purging and flushing ； The vacuum system vacuum test passed. b. All instruments and control systems are qualified and ready for use. c. The transmission equipment alone passes the test run and is delivered for use ； Sufficient spare parts are used for operating equipment. d. All equipment and pipelines have been insulated as designed. ； Each safety valve has passed the inspection according to the designed set pressure. e. Complete safety and fire-fighting facilities ； Complete tools and records and reports ； Site cleanup completed ； The roads are smooth and dispatch and communication are smooth. f. The public engineering system has been running stably, and the cooling water, desalted water, steam, instrument air and service air and electricity can meet the commissioning requirements of the whole system. g. The commissioning plan and operating procedures have been prepared and published (including the water circulation diagram of water combined transportation). h. All process indicators have been approved and published by the production department, and each operator has a copy. i. Position responsibility system has been established. j. Full-time technical personnel and operators have been identified, and have passed the examination and obtained certificates. k. The temporary pipelines and related measures that should be added before commissioning have been completed. ②Water combined transport test run steps and operating points a. Preparation ● Check that all equipment, pipes, valves, instruments, and safety valves are in good condition. ● According to water combined transport requirements, check whether the blind plates and temporary pipelines that need to be disassembled and installed in the system are in place. ● Check whether the valves that should be opened and closed are in the correct state. ● Lead utility water, electricity, steam, wind and desalted water to the boundary. b. Test run steps ● System pressurization In chemical equipment, the flow of many substances is realized by pressure difference. Therefore, before establishing water transport, the system must be pressurized with air. The pressurization pressure should generally be close to the system operating pressure. ● According to the requirements of the water circulation system, temporary pipes or pumps are used to deliver desalted water to each tower tank of the system to establish their respective normal liquid levels. The pumps are turned on to establish circulation and adjust to the corresponding flow rate. ● Introduce related public works, such as cooling water steam, etc. to the system equipment, and gradually adjust to the indicators required by the water cycle. ● The vacuum system uses system water to pump vacuum. ● Check the indicators of each measurement and control point in the entire system, and put all the automatic control devices into automatic control as much as possible to check the self-adjusting performance of the automatic control instruments. ● Generally, the water cycle running stably for 48 hours is considered qualified. ③Things to note in water combined transport a. Water combined transport is carried out according to the water cycle, and water should be prevented from jumping into other systems that do not participate in water combined transport. b. When the water passes through the cooler heat exchanger and control valve, if there is a secondary line, it should go through the secondary line first, and then go through the heat exchanger and control valve after it is clean. c. If it is found that the filter screen or pipeline is clogged during water transport, the filter screen should be removed and cleaned in time, or the blockage should be found and cleaned. d. In water combined transportation, the pump outlet flow must be controlled not to be too large to prevent the motor from overcurrent (limited to the rated current of the motor). e. The standby pump should be switched for use during intermodal transportation. f. After the tower container heat exchanger and other equipment are filled with water, sewage must be discharged at each low point before starting water combined transportation. g. After the circulating water is dirty, it may be partially discharged, fresh water added or all discharged, depending on the situation, to re-establish the cycle. h. After the water cycle is completed, the entire system must be evacuated in a timely manner. At this time, attention should be paid to the same atmosphere in each container to prevent a vacuum from being created in the container during drainage and damaging the equipment. i. After the water combined transport is completed, a water combined transport simulation test report should be filled out. j. When carrying out water transport in winter, anti-freezing measures must be fully considered. (5) Oil intermodal transportation Oil intermodal transportation is also called oil trial operation. It is a full cycle trial operation of the equipment and pipelines of the oil system using oil products close to the operation as the medium. For example, the oil trial operation of the ethylene unit usually uses the heavy fraction of the raw material light diesel oil for the raw material light diesel system, the conditioned oil system, and the quenching oil system. Heavy fuel oil system and light fuel oil system are put into trial operation. The activation of automatic control instruments during the oil intermodal transportation process is beneficial to the operation of the oil intermodal transportation, and it is also an inspection of the automatic control system. The combined oil transportation also achieves the purpose of further cleaning the equipment pipeline dirt. Therefore, the combined oil transportation is a necessary step to ensure the good operation of the device after it is officially put into operation. ①Conditions that should be met for oil combined transportation: a. The system equipment and pipelines must pass the purge, flushing, leak test and air tightness test. b. The transmission equipment unit has passed the test run. c. All instruments and control systems must be debugged and ready for use. d. The equipment and pipelines must be insulated according to the design requirements, and those equipped with heat tracing pipelines can be put into use. e. Safety and fire-fighting and fire-fighting facilities are in place, the site has been cleared, and roads and command communications are open. f. Temporary measures required by oil combined transportation (such as the installation and disassembly of temporary piping valve blind plates, etc.) have been completed. g. The public engineering system has been operating stably, and fire water, system protective nitrogen, etc. have been introduced into the boundary area. ②Oil intermodal transportation operation and key points a. Oil intermodal transportation adopts a single system small cycle according to the intermodal transportation plan and then forms a large cycle through temporary piping in series, leaving no dead ends. b. When using oil containing light components such as light diesel oil as circulating oil, the nitrogen seal or nitrogen filling pressure of storage tanks, towers and other equipment in the system should be maintained to prevent low-volatile components from forming baozha with air. * things. c. During operation, the oil circulation volume should be close to the normal value, and attention should be paid to maintaining the liquid level in the tower and storage tank to prevent full tank, tower and evacuation accidents. d. In the circulation project, a certain oil temperature should be maintained according to the freezing point of the oil to prevent dead ends and blockages. e. During oil combined transportation, the oil pump must be switched regularly and the inlet filter in front of the pump must be cleaned. f. The oil combined transport effect, in addition to the normal operation of each small cycle for more than 72 hours, and when the inlet filter of each oil pump is almost no longer blocked by impurities, the oil combined transport is considered qualified. g. When emptying the oil after the trial operation, attention should be paid to the low points and dead ends of each equipment and pipelines. Mobile pumps and other means must be used to extract the residual unclean oil and send it to the fuel oil storage tank for later use. h. When the circulating oil is completely emptied from the system, it should be purged with nitrogen. After purging, relieve pressure, remove blind plates, temporary pipelines, etc. and reset them. After reset, nitrogen gas is still supplied to keep the oil system in a nitrogen sealing or pressurized (≈0.04MPA) state for protection. i. After the oil combined transportation is completed, an oil trial transportation report should be filled out.

Chemical test run standard production organization The production unit must organize production personnel to work early in the morning, and actively cooperate with the construction unit to complete the project completion and "three checks and four determinations" (the three checks are to check for missing items in the design, check the project quality and hidden dangers, and check the unfinished project quantity)； The four determinations are to determine tasks, personnel, measures, and time to complete the problems detected), stand-alone test run and linkage test run, and identify problems as early as possible to raise issues. Article 30 The transition from engineering installation to final commissioning has work characteristics of different natures. The construction headquarters or general contracting unit shall promptly adjust and strengthen the leadership of the final commissioning work according to the division of commissioning stages. Organize the leadership team for the final commissioning, arrange the final commissioning work according to the unified overall commissioning control plan, implement the commissioning plan, check the progress of the commissioning, and be responsible for solving problems during the commissioning. Article 31 The completion of the project is a very important sign that the project is about to be completed. It is a key link to shorten the construction cycle and put it into production as soon as possible. It must be of high standards and strict requirements, and it must be done early, quickly and hard. According to the unified overall commissioning control plan, arrange the completion progress of the project to meet the commissioning requirements and complete the project on time with quality and quantity guaranteed. Before the project is about to be completed, it is necessary to conduct a major inspection of design and construction quality, organize construction, design, and production units, fully mobilize the masses, and carry out "three inspections and four determinations" according to majors and divisions of work. “The "three checks and four determinations" inspection can be divided into three stages, namely before the single machine test run, before the whole system linkage test run, and before the chemical input test run. The inspection method is mainly based on self-inspection. On the basis of self-inspection, the construction headquarters or the general contracting unit shall organize a joint inspection by the design, construction, and production units, and jointly confirm the signatures. A designated person shall be designated to complete the identified problems within a time limit. Article 32: Promptly carry out document review and intermediate acceptance work. Intermediate handover data should ensure quality, be complete and accurate, and meet regulatory requirements. After reviewing the materials and passing the final test run, the intermediate acceptance and handover procedures should be carried out to clarify the responsibilities of both parties, or handle it in accordance with the provisions of the contract. The review of project data and intermediate acceptance (handover) are important procedures for comprehensively inspecting project quality, promoting final commissioning, and strengthening capital construction management, and must be taken seriously. Section 2 Mechanical Commissioning Article 33 The mechanical commissioning of production equipment is generally divided into two stages. The first stage is stand-alone test run (that is, partial linkage or unit linkage test run of a single transmission equipment and auxiliary equipment) ； The second stage is the joint test run of the whole system (i.e. fake material test run). Article 34 The following principles should be adhered to in the mechanical commissioning of large chemical plants. 1． The public engineering system must adhere to the commissioning principles of early completion, early commissioning, and early stability to create conditions for early stand-alone commissioning of the main equipment and provide a reliable guarantee for the first-time success of chemical commissioning commissioning. 2. A single machine must be tested early. If it fails to meet the standards, it must be tested and processed repeatedly. It is not allowed to bring the problem to the whole system linkage test stage. 3． The system-wide linkage test run (i.e. fake material test run) must be "complete" and the time must be fully guaranteed. It is necessary to comprehensively expose problems, eliminate hidden dangers, and be fully prepared for the first-time success of chemical feeding. The division of responsibilities between the two stages of mechanical commissioning should be clarified in the contract according to different contracting methods. Article 35: Prepare a feasible overall commissioning plan. The core of the overall commissioning plan is to prepare a commissioning overall control plan (network diagram) to connect various tasks and guide the project completion and commissioning work. The construction headquarters or the general contracting unit of the project must do a good job in organization and coordination. The design, construction, and production units should organize the project completion and commissioning work according to the commissioning procedures to ensure that the commissioning is coordinated and controlled and the plan is completed on time. The overall commissioning plan shall be organized and designed by the construction headquarters or the general contracting unit. Construction and production units shall refer to the "Method for Preparing the Overall Commissioning Plan for the Later Stage of Large and Medium-sized Construction Projects". * * The overall commissioning plan for key construction projects should be reported to the competent authority for approval three months before the factory receives water and electricity and then be implemented. For imported equipment, in addition to approval by leaders, the commissioning plans at each stage must also be confirmed in writing by foreign on-site technical personnel before they can be implemented. Contents that the commissioning plan should include: 1． Test run purpose ； 2. Test run organization, test run person in charge and persons participating in the test run ； 3． Necessary conditions for test run ； 4. Catalog of preparations and inspection contents required for test run ； 5. Plans for external collaboration conditions and temporary facilities required for commissioning ； 6. List of raw materials, fuels, chemicals, water, electricity, steam, gas, spare parts and other materials required for test run ； 7. Trial process conditions and control indicators ； 8. Commissioning procedures and schedule ； 9. Procedures and requirements for starting, stopping and emergency handling ； 10. Commissioning cost budget. Article 36 Single machine test run shall meet the following conditions: 1． The single-machine transmission equipment (including auxiliary equipment) has been carefully inspected, the lubrication and sealing oil systems have been completed, and the oil circulation has met the requirements. ； Technical data such as construction records meet the requirements and have been confirmed through the "three checks and four determinations" inspection, and existing problems have been eliminated (the imported equipment must be confirmed by on-site foreign experts) ； 2. All piping related to stand-alone test run has been completed ； 3． Pipe purging, cleaning and pressure testing related to commissioning are qualified ； 4. The power supply conditions for the test equipment have been met, and the electrical insulation test has been completed. ； 5. The site around the test equipment must be clean of materials upon completion of work. ； 6. The commissioning plan and relevant operating procedures have been approved and published ； 7. A commissioning team has been established, and full-time commissioning technicians and operators have been identified ； 8. The test run record form is ready. Article 37 The completed installation of the device must meet the following standards: 1． All piping works are completed (including thermal insulation and accompanying pipes) ； 2. All instrument debugging is completed in one go ； 3． The insulation test of electrical equipment is completed and the power supply conditions are met ； 4. All rotating equipment that is eligible for stand-alone trial operation has passed the trial operation. ； 5. Pipe purging and chemical cleaning work is completed ； 6. The equipment and pipelines have passed the hydraulic pressure test and system air tightness test. ； 7. Filling is qualified ； 8. The analytical laboratory has been delivered for production use ； 9. Insulation and painting work mostly completed ； 10. Water supply and sewerage, road vertical leveling, lighting and communication projects within the boundary have been completed ； 11. The site has been cleared of materials after work has been completed ； 12. Construction records are complete and accurate ； 13. The quality of the project meets the requirements, and the unqualified projects have been repaired and passed. Article 38 A comprehensive inspection of engineering quality and production preparations must be carried out before the whole-system linkage test run. The superior leadership department organizes experienced experts from all aspects to conduct inspections on project quality, design quality, equipment manufacturing quality and mutual adaptability. ； Conduct a comprehensive inspection of the production leadership team, management system and production preparations. Propose solutions to all problems found to be unsuitable for commissioning and complete them within a time limit to fully prepare for a successful chemical commissioning trial. Article 39 The whole system linkage test run shall meet the following conditions: 1． Established job responsibility system ； 2. Full-time technical personnel and operators have been identified and passed the examination ； 3． The public engineering system has been operating stably and can meet the conditions for joint commissioning of the entire system. ； 4. The commissioning plan and relevant operating procedures have been announced ； 5. All process indicators have been approved and published by the production management department, and each operator has a copy ； 6. The production record report has been prepared and distributed to the post. ； 7. The setting values ​​of instrument interlocks and alarms have been approved and published, and each operator has a copy.