What needs to be done after a new chemical plant is built?

Chapter 1 General Provisions Article 1 Production preparation and commissioning are important components of capital construction. These provisions are formulated to ensure the successful completion of chemical plant commissioning on the first attempt, to enable safe, continuous, and stable production, to reach the designed capacity as soon as possible, and to maximize the return on investment. Article 2: The main aspects of production preparation include making preparations in six areas: personnel organization, technology, comprehensive training for all staff, safety, materials and external conditions, and management. Production preparation work runs through the entire process of capital construction and is an extremely important foundational task in factory building. It is essential to place this work high on the agenda from the very beginning of the capital construction process, to address it early and implement it promptly, so as to create the conditions for a successful first trial run of the chemical plant and lay a solid foundation for long-term normal operation after it goes into production. Article 3: Testing work represents a comprehensive assessment of the design, equipment manufacturing, construction quality, and production preparation aspects of a construction project. It is essential to adhere to high standards and strict requirements to ensure that the quality of every aspect of the project is excellent, with no potential problems remaining ； The main project and the supporting projects are completed simultaneously, without any unfinished tasks ； The commissioning operations must be carried out accurately without any accidents; single-unit testing should be conducted as early as possible, full-system joint testing should be thorough, and the addition of chemical materials should be done steadily. During the commissioning process, it is essential to adhere strictly to the prescribed procedures without skipping any step, not to lower the standards that must be met, and not to waste even a single minute. Leadership over the commissioning work needs to be strengthened, and the design, construction, and production teams must work closely together to ensure the implementation of the best plan for chemical feeding during commissioning and to achieve success on the first attempt, thereby securing good economic benefits. 　　Chapter 2: Preparation for Production Section 1: Preparation in Terms of Personnel Organization Article 4: Before a construction project is approved to begin, it is necessary to select leadership personnel with experience in production and construction as well as technical expertise. Such a leadership team should be able to firmly implement the Party’s policies and principles, and meet the requirements of being revolutionary, young, knowledgeable, and professional, in order to meet the needs of modern factory production and construction. At least one key member of the production leadership team should have been involved in leading the plant’s construction from the outset (in charge of production preparation), to ensure continuity in both the construction work and production preparation. The construction unit should establish a production preparation organization from the very beginning of the capital construction project, responsible for ensuring that all production preparation tasks are carried out properly. Article 5: A factory management system suited to the characteristics of the production facilities shall be established in accordance with design requirements and the spirit of reform, with management organizations set up on the principles of streamlining, standardization, and efficiency. The management agencies and production command systems need to be gradually strengthened and improved to meet the requirements of work at various stages. For imported equipment, the foreign affairs department should be staffed with professionals with strong operational capabilities to maintain control over foreign affairs matters. Article 6: Make thorough efforts to establish the production team. In accordance with the designed staffing quota and job technical standards, some cadres with organizational management experience, as well as professional technicians and workers with practical operational experience in relevant fields, are selected or hired from similar existing factories to serve as the core team. Key production technology personnel should arrive at the factory during its setup phase to participate in technical negotiations, design reviews, construction supervision, and production preparation work. Operators and maintenance workers should primarily be recruited from secondary technical school graduates and high school graduates, with those selected based on their performance in examinations. The operators and maintenance personnel for the key positions should arrive at the factory according to the staffing plan, 1.5 to 2 years before the completion of its installation. Article 7: A target responsibility system for the factory director shall be implemented; the factory director is responsible for the entire process of the factory, from its establishment to the completion and acceptance of the construction work. Section 2: Technical Preparation Article 8: The task of technical preparation is to enable production staff to master the technology related to all production facilities. Efforts should be focused on four areas: process operation, process control (instrument interlocks and analysis), equipment maintenance and use, and safety, so as to ensure that they are capable of independently addressing and resolving various technical issues. From the very beginning of production preparation, the technical system must be established. Article 9: The four tasks of technical preparation. 1. Assign key technical personnel and establish a technical responsibility system. The factory should as early as possible recruit skilled professionals in areas such as process engineering, instrumentation, electrical systems, mechanics, and analysis, and sign responsibility agreements to ensure consistent oversight and take full responsibility for the technical preparation work in these fields. 2. Participate in design reviews to improve processes and engineering designs. While mastering the production processes, production staff should also pay attention to engineering techniques, be familiar with relevant standards and specifications, identify problems in design and installation in a timely manner, and work together with the design and construction teams to improve the design and construction process. 3. Prepare various technical specifications, startup plans, and documents. Based on the design documents, taking into account the actual conditions on site and referring to relevant domestic and international technical materials, the factory should prepare the following important regulations and plans. (1) Operating procedures for utility systems, including boilers, water supply and drainage, circulating water, desalinated water, electricity, instrumentation, gas, etc. (2) Process procedures for the production equipment, and operational procedures for specific positions (to be written from the perspective of automatic control instruments; circuit diagrams of the instrument control systems and logic diagrams of the interlock signal systems should be attached). (3) Operating procedures for large-scale units, including large compressors, large pumps, as well as the associated turbines, oil systems, vacuum systems, etc. (4) Factory safety technical regulations and key safety operation points for various devices and positions. (5) Analysis procedures, including chemical analysis and instrumental analysis. (6) Procedures for the maintenance and repair of mechanical equipment, including the management of spare machines. (7) Procedures for the maintenance and repair of electrical equipment, including signal and interlock operation and maintenance. (8) Procedures for the maintenance and repair of automatic control instruments and interlocks. (9) Various commissioning procedures, including equipment cleaning, pipeline cleaning, purging, individual unit testing, integrated system testing, airtightness testing, replacement, coal charging, furnace drying, and chemical feeding tests. (10) Emergency accident response plan. 4. Technical specifications and startup plans shall be discussed by relevant experts, reviewed by the chief engineer, and approved by the plant manager. Section 3: Training for All Employees Article 10: Requirements for Training All leaders, professional managers, technical personnel in the factory, as well as every employee (especially those specializing in analysis, testing, and mechanical, electrical, and instrumentation maintenance) must receive specialized training and pass relevant examinations before they can take up their positions or start working. This is a key aspect of the production preparation process. Article 11: The goal of comprehensive training is to focus on ideological development and the quality of the team, in order to build a capable team that can ensure the success of each test run. In training, high standards and strict requirements must be upheld; focus should be placed on the training of the team, working on their mindset, skills, and work ethic. It is necessary to develop the ability to drive successfully, as well as mastery of process operations, process control, equipment maintenance and use, and safety protocols. One should have a thorough understanding of the equipment in terms of the ’four understandings and three skills’: understanding its structure, original specifications, performance, and purpose; as well as being able to use it, maintain it, and troubleshoot any issues that arise. Article 12: In addition to training all employees, special emphasis should be placed on training production supervisors and key production technical personnel. Key technical personnel such as production schedulers, workshop supervisors, full-time engineers, and central control shift leaders should receive \"comprehensive training\" to develop a systematic mindset and enhance system management. Special job types such as mechanical, electrical, and instrumentation maintenance, as well as analysis and testing, require long training periods and present significant challenges. Such personnel should enter the factory early and receive training at an early stage; they should also participate in equipment inspection and installation and commissioning, in order to master maintenance and analysis/testing techniques. Article 13: Strengthen training to ensure its quality. During the construction phase, the factory must focus on staff training; a training plan should be developed based on the construction timeline to ensure sufficient time for training and maintain its quality. Article 14: Full-process training must be ensured. The comprehensive training process consists of four stages. The first phase is the study of basic chemical engineering knowledge and process theory*, lasting approximately 3 to 6 months. The second phase is the implementation phase, lasting about 6 to 18 months. The focus is on becoming familiar with and mastering the process flows, operational procedures, process control, and equipment performance related to the specific position. The practical training program follows the principle of \"six determinations and two responsibilities plus one assessment\", that is, determining the team leader, the training location, the trainers, the schedule, the required competencies, and conducting regular assessments ； The training provider ensures instruction, while the trainers guarantee proficiency ； Operate under the supervision of a mentor. The third phase is the on-site training phase, lasting about 3 to 6 months. On-site training should be carried out step by step in accordance with requirements such as the process flow and startup plan; multiple people should identify flaws as one person conducts the training. Training should be conducted using hypothetical accidents, with repeated practice focused on key areas and weak points. Through on-site training, command capabilities can be improved, as well as familiarity with the site, the processes, control systems, equipment, rules and regulations, and the coordination between different positions around the area. The fourth phase is to participate in various trial runs prior to chemical feeding, which is the stage for practical operation training. Participating in tasks such as pipeline verification, purging, airtightness testing, installation and commissioning of electrical instruments, as well as trial operation, is an important phase of the training process. Based on external training, production operators combine on-site learning and practice to become familiar with the layout of pipelines for various media and the locations of valves, as well as with the arrangement of instruments in the control room, control methods, control circuits, and interlock systems. After completing the training in these four stages, operators will be able to handle startup and shutdown procedures, normal operation, as well as accident response throughout the entire process ； Mechanical, electrical, and instrumentation maintenance personnel are able to handle the entire process of equipment maintenance and installation scheduling. Fifteenth: A strict assessment system to promote training efforts. Before taking up their posts, workshop supervisors and dispatchers are assessed and appointed by the factory manager ； Full-time engineers are appointed after passing the assessment conducted by the factory’s technical department ； Shift supervisors, operators, maintenance staff, and analysis and testing personnel must pass an examination conducted by the workshop supervisor in conjunction with the safety department; only after passing this exam can they be issued a safety operation certificate and allowed to take up their posts. Article 16: Provide comprehensive training to improve the quality of the team. While providing technical training for employees, it is also necessary to strengthen the construction of spiritual civilization. Strengthen ideological work, carry out education on ideals, morality, discipline, and rules. Throughout the entire training process, strict requirements must be upheld, job responsibility systems must be implemented earnestly, various rules and regulations must be strictly enforced, and the quality of the workforce must be improved comprehensively, in order to build a team of employees who possess ideals, moral integrity, discipline, a strong work ethic, excellent technical skills, high management capabilities, and are capable of meeting the demands of modernization efforts. Section 4 Safety Preparedness Article 17 The safety management of large-scale chemical plants is a complex task involving both technical and managerial aspects. For safety tests and safe production, it is essential to always adhere to the principle of \"safety first, prevention foremost,\" with top leaders personally overseeing safety preparations. Safety preparations should focus on the actual conditions of factory production equipment, analyzing the sources and characteristics of their hazards. In safety preparation work, the following three principles must be strictly followed: 1. Actively implement preventive management for all employees, and take effective preventive measures ； 2. Implement early detection of potential hazards to ensure early identification and prompt handling ； 3. Ensure personal safety, leverage people’s initiative, and improve the reliability of equipment. Article 18: On the basis of fully collecting relevant domestic and international data and cases related to safety, the following safety technical regulations and materials shall be prepared: (1) A compilation of accident examples from similar chemical plants both domestically and internationally ； (2) Factory fire prevention measures, that is, detailed preventive actions for each substance, such as precautions for transportation, storage, and production use, procedures for dealing with leaks, fire extinguishing, first aid, etc ； (3) Safety operation technical procedures for the entire plant and various workshops ； (4) Procedures for the use, maintenance, and management of safety and fire protection facilities, as well as information on the distribution and usage of fire protection facilities throughout the plant. Article 19: The following safety conditions must be met prior to the feeding of chemicals (referred to as the Twenty Safety Rules). (1) All equipment, pipelines, valves, electrical systems, instruments, etc. must undergo strict quality inspections to ensure that the quality of the equipment, fittings, materials, as well as the manufacturing and installation processes meets the design requirements, and that the design itself satisfies the process requirements. (2) The hydraulic strength tests of the equipment and pipelines have passed. (3) The system’s airtightness test and leakage rate meet the specified standards. (4) The safety valve should be tested and activated at least 3 times to ensure sensitive operation; the pressure in the relevant process equipment must also be checked, and after testing, the device should be sealed by the safety department. Explosion-proof panels, flame arresters, breather valves, water seals, molecular seals, vacuum breakers, etc. must meet the process requirements and be of high quality in terms of installation. (5) The alarm and interlock systems for various processes must be tested to meet the required standards; static testing should be carried out at least three times to ensure that they function correctly. (6) The automatic control instruments (temperature, pressure, flow, level, analysis) are well tuned and functional ； Meters installed on-site should have highest and lowest limit markers. (7) High-pressure fire pump rooms, fire water tanks, foam systems, water curtains, automatic fire suppression systems, fire communication and alarm systems, combustible gas detectors, and so on, must all undergo practical tests conducted jointly by the safety and fire protection authorities and the manufacturing units to prove their effectiveness. Sufficient numbers of fire extinguishing devices must be available to put out incipient fires. (8) Lightning and static protection facilities, as well as the grounding wires for all equipment and pipe racks, must be properly installed and pass testing. (9) Safety communication systems such as telephones, signal lights, intercoms, horns, and speakers shall all meet the design requirements and be functional. (10) The ventilation equipment is in good condition, achieving the designed number of air changes per hour. (11) All electrical equipment and lighting fixtures designed to be explosion-proof must comply with explosion-proof standards; temporary wires and fixtures shall not be used without approval. (12) Safety protection facilities, walkways, guardrails, and safety covers must be sturdy and in good condition; on-site eye wash stations and showers must be available and functional throughout all seasons. (13) Ditches and manhole covers are complete and in good condition; there are covers over any holes in the floor slabs. The ground is level with no obstacles, and road markings are clear and unobstructed. (14) Once cleaning is completed within the plant area, it is not allowed to store any miscellaneous items there, especially flammable substances. Oil products and chemicals used on a daily basis must be stored in locations designated by the safety department. (15) Production supervisors and operators may take up their posts only after passing technical and safety assessments. (16) Various rules and regulations are in place, ensuring that everyone has guidelines to follow. (17) The equipment markings and pipeline direction indicators are complete; the signs for fire hydrants in the plant area, underground cable trenches, traffic restrictions, safety wells, etc., are all present and clearly visible. (18) The vehicle must be equipped with all necessary tools and protective equipment, and meet the requirements for explosion and fire prevention. (19) Establish and improve mass-based safety, fire protection, and rescue organizations; these organizations should be trained so that their members can master firefighting and rescue skills. There should also be clear divisions of responsibilities, ensuring that people are accountable in normal times and can step in when needed, remaining calm in emergencies. (20) Emergency rescue equipment is fully available, including gas masks, oxygen respirators, safety belts, stretchers, first-aid kits, etc., and everyone knows how to use them. Article 20: Establish a sound and effective safety management system. Establish safety organizations at the plant and workshop levels, and assign 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 institutionalize, regularize, and scientify it. (2) Implement a safety responsibility system for personnel at all levels, from the factory to the safety officers, as well as a responsibility system for safety and fire protection facilities. Carry out regular training to continuously improve management skills and enhance one’s own capabilities. (3) Continuously and repeatedly provide employees with training in safety techniques as well as education on adhering to rules and regulations to ensure safety. (4) Supervise and inspect the implementation of various safety regulations and responsibility systems, prevent potential accidents, and closely integrate education, supervision, and prevention. (5) It is necessary to ensure the safety and reliability of mechanical, electrical, and instrumentation equipment, and to eliminate any potential sources of insecurity. Strictly follow the regulations for pressure vessels and various related standards to ensure the quality of every stage of installation and commissioning, so that all equipment is in good condition. Article 21: Each set of equipment must be analyzed and studied to identify the factors that could pose risks in various parts as well as the risk levels of those areas. Accident response plans at both the plant and workshop levels should be developed, taking into full account all possible scenarios based on accident predictions, and corresponding measures should be established. Leak prevention, protection against open flames, static electricity prevention, lightning protection, protection against electrical sparks, prevention of freezing and cracking, control of residual oxygen, prevention of suffocation, vibration resistance, avoidance of violations, and prevention of misoperations should be regarded as the main elements in implementing safety prevention policies. Inspectors such as operators, maintenance workers, electrical and instrumentation personnel, and safety officers should conduct regular inspections at set times, in order to detect potential problems early and address them promptly. Article 22: Establish and improve fire protection systems, provide rigorous training for professional and volunteer firefighters, formulate fire extinguishing plans, and conduct training in accordance with these plans. Fake fire drills should be conducted from time to time in order to foster and assess the sense of responsibility and professional competence of firefighters. Article 23 Conduct thorough safety inspections. Before conducting a test drive, repeated safety checks must be carried out in accordance with the \"20 Safety Rules\"; driving is not permitted until potential hazards have been eliminated, accident response plans have been implemented, and approval has been given by the safety department. Section 5: Preparation of Materials and External Conditions Article 24: Designated personnel shall be assigned to determine, in accordance with the design requirements, the types, specifications, quantities, technical standards, packaging forms, and storage and transportation conditions of the raw materials, fuels, chemicals, and lubricants required for testing. Supply channels shall be established, and supply contracts shall be signed. Propose analysis and development requirements as needed. Chemical raw materials and other supplies entering the factory must be stored properly, in accordance with their specific properties, to prevent damage, loss, and deterioration. Article 25: Establish supply channels for spare parts, and carry out the surveying, mapping, and manufacturing of such spare parts. Upon receiving the construction drawings, the factory should promptly assign personnel to prepare a list of spare parts for the equipment. For those components that are not supplied by the equipment manufacturer, efforts should be made to design and produce them on-site, in order to meet the requirements of testing. Spares, components, materials (including welding rods) as well as special tools that enter the factory should be kept under the supervision of designated personnel, and must not be misused, damaged, or lost. Article 26: The machinery, electrical, and instrumentation repair workshops shall be completed prior to the system-wide joint commissioning, with all necessary facilities in place to enable production capabilities, thereby serving the commissioning process. Self-manufactured spare parts should be researched and prototyped as early as possible. Section 6: Management Preparation Article 27: Based on the characteristics of the equipment, various scientific management systems centered around post responsibility systems shall be established. Before starting single-unit tests throughout the plant, these systems shall be approved by the plant’s management and distributed to the relevant personnel for study and familiarity, to be strictly followed during the testing process. Each functional department must define its own scope of responsibilities in serving production and the grassroots level ； Person in charge of departments, sections, and workshops, as well as staff at all levels, must establish responsibility systems. Auxiliary workshops should establish corresponding responsibility systems to serve the manufacturing process; operators, machine technicians, electrical technicians, instrumentation maintenance staff, and analysts must all have defined job responsibility systems. Article 28: To ensure effective management and the successful completion of tests in just one attempt, the following basic regulations shall be established: (1) Regulations on strengthening the management of utility services ； (2) Provisions regarding the division of management areas for various pipelines ； (3) Provisions regarding equipment maintenance, repair, and spare unit management ； (4) Provisions regarding instrument and interlock management ； (5) Provisions regarding circulating water management ； (6) Provisions regarding the standards for safe and civilized production workshops ； (7) Provisions regarding the strict implementation of various post responsibility systems ； (8) Provisions regarding the supervision of test runs ； (9) Provisions on the strict enforcement of safety rules during the chemical feeding commissioning phase ； (10) Provisions regarding the management of blind flanges during testing ； (11) Provisions regarding maintenance and repair during the trial operation period ； (12) Several regulations regarding the operation and management of pipelines during the commissioning period. 　　Chapter 3: Preparations Before Chemical Feed-in and Commissioning Section 1: Project Completion Article 29: During the project completion and commissioning phase, the tasks are numerous, intricate, demanding, and challenging. The construction command center or the general contractor must organize design, construction, and production units carefully and make comprehensive arrangements to ensure the quality and schedule of this final commissioning process, thereby preventing hasty commissioning or operation without taking the relevant conditions into account. The construction unit must strictly abide by the contract (which should specify clear responsibilities regarding commissioning, as well as reward and punishment mechanisms), define the economic responsibilities associated with the final commissioning phase, uphold the principle that \"quality comes first in any long-term project,\" take full responsibility for the work, and have a proactive attitude toward serving production needs. It must complete the tasks related to the final stages of the project and its commissioning in accordance with the requirements outlined in the commissioning control plan. The design unit shall, depending on the different contracting methods, provide relevant technical documents, offer commissioning guidance and technical services, and conduct core inspections of the construction and installation works in accordance with the design requirements, as well as carry out a comprehensive review of the design. The production unit must organize its workers to start working in the morning, and actively cooperate with the construction unit to complete the remaining tasks of the project, as well as to carry out the \"three inspections and four determinations\" (the three inspections refer to checking for any omissions in the design, assessing the quality of the work and any potential hazards, and examining the amount of work that remains unfinished) ； The \"four fixings\" refer to assigning tasks, designating personnel, determining measures, and setting deadlines for addressing the identified issues); single-unit testing and integrated testing are carried out to identify and raise issues as early as possible. Article 30: The transition from project installation to final commissioning involves work with different characteristics. The construction command headquarters or the general contractor shall, in accordance with the division of the commissioning phases, promptly adjust and strengthen leadership over the final commissioning work. Organize the leadership team for the final testing phase, arrange the work related to this phase in accordance with a unified testing control plan, implement the testing schedule, monitor the progress of the tests, and handle any issues that arise during the testing process. Article 31: The final stages of a project represent an important indicator that it is nearing completion. They are a crucial step in shortening the construction period and enabling the project to become operational as soon as possible. It is necessary to apply high standards and strict requirements, and to take action early, promptly, and with determination. In accordance with the unified commissioning control plan, the final stages of the project are scheduled to meet the commissioning requirements, ensuring completion on time and to the required quality and quantity standards. Before the project is nearly completed, a thorough inspection of the design and construction quality must be carried out. Construction, design, and production units should be organized, and the workforce should be fully mobilized to carry out the \"three inspections and four determinations\" in a systematic manner based on their respective specialties and responsibilities. “ The “three inspections and four determinations” can be further divided into three stages: before individual unit testing, before full-system joint testing, and before testing with chemical feed. The inspection method relies primarily on self-inspection; on the basis of this, the construction command team or the general contractor organizes joint inspections by the design, construction, and production units, with all parties signing to confirm the results. For any issues identified, a specific person is assigned to address them within a set time limit. Article 32: Expedite the work on document review and intermediate acceptance. The intermediate handover documents must ensure quality, be complete and accurate, and meet the specified requirements. After the review of documents and successful completion of the final testing, intermediate acceptance and handover procedures should be carried out to clarify the responsibilities of both parties, or in accordance with the provisions of the contract. The review of engineering documents and intermediate acceptance (handover) are important procedures for comprehensively inspecting the quality of construction projects, facilitating final testing, and strengthening infrastructure management; they must be taken seriously. Section 2: Mechanical Commissioning Article 33: The mechanical commissioning of production units is generally divided into two phases. The first phase is single-unit testing (that is, partial or unit-level testing of individual drive equipment and auxiliary equipment) ； The second phase is a system-wide joint trial run (i.e., trial run with fake materials). Article 34 The mechanical commissioning of large-scale chemical plants shall adhere to the following principles. 1. The utility system should adhere to the principle of completing construction, conducting trials, and achieving stability as early as possible, thereby creating conditions for early individual unit tests of the main equipment and providing a reliable guarantee for a successful first trial run with chemical feedstock. 2. Single-unit testing should be carried out early; if the standards are not met, repeated testing and adjustments are necessary. It is not allowed to bring issues into the stage of system-wide joint testing. 3. The full-system joint commissioning (i.e., commissioning with fake materials) must be comprehensive, with sufficient time allocated for it. It is necessary to fully expose the problems and eliminate potential risks, so as to ensure a successful first attempt at chemical feeding. The division of responsibilities for the two phases of mechanical commissioning should be specified in the contract according to different contracting methods. Article 35: Develop a practical and feasible overall commissioning plan. The core of the overall commissioning plan is to develop a comprehensive control plan for commissioning (a network diagram) to ensure proper coordination among various tasks, thereby guiding the final stages of the project and the commissioning process. The construction command office or the general contractor shall carry out proper organization and coordination; the design, construction, and production units should organize the final stages of the project and the commissioning process in accordance with the specified procedures, to ensure that commissioning is carried out under unified control and completed on schedule. The overall commissioning plan is designed by the construction command headquarters or the general contractor. Construction and production units shall formulate them with reference to the \"Methods for Compiling Overall Commissioning Plans for Large and Medium-Sized Construction Projects.\" **The overall commissioning plan for key construction projects shall be submitted to the competent authority for approval 3 months prior to the plant receiving water and electricity, and then implemented. For the introduced equipment, the commissioning plans for each stage must be approved by management and also require written confirmation from the foreign supplier’s on-site technical personnel before they can be implemented. Contents that the commissioning plan should include: 1. Purpose of commissioning ； 2. Test run organization, person in charge of the test run, and personnel participating in the test run ； 3. Conditions necessary for testing ； 4. List of preparatory work and inspection items required for testing ； 5. Requirements for external cooperation and plans for temporary facilities needed for testing ； 6. List of materials required for testing, including raw materials, fuel, chemicals, as well as water, electricity, steam, gas, and spare parts ； 7. Commissioning process conditions and control parameters ； 8. Commissioning procedures and schedule ； 9. Procedures and requirements for starting, stopping, and handling emergency incidents ； 10. Budget for testing costs. Article 36 The following conditions must be met for single-unit testing: 1. The single-unit transmission equipment (including auxiliary equipment) has been thoroughly inspected, the lubrication and sealing oil systems have been completed, and the oil circulation meets the required standards ； Technical documents such as construction records meet the requirements; they have been verified through the \"three inspections and four confirmations\" process, and any existing issues have been resolved (the introduced equipment must be approved by foreign experts on site) ； 2. All piping related to the single-unit trial run has been completed ； 3. Pipeline purging, cleaning, and pressure testing related to commissioning are successful ； 4. The power supply conditions for the testing equipment are in place, and the electrical insulation tests have been completed ； 5. The area around the testing equipment shall be kept clean with all materials removed once the work is completed ； 6. The commissioning plan and relevant operating procedures have been approved and published ； 7. The commissioning team has been established, and the dedicated technical personnel and operators for commissioning have been identified ； 8. The test run record forms are all prepared. Article 37: The completion of device installation must meet the following standards: 1. All piping work must be completed (including insulated piping) ； 2. All initial instrument adjustments have been completed ； 3. The insulation testing of electrical equipment has been completed, and the conditions for power supply are met ； 4. All rotating equipment that meets the conditions for single-unit trial operation has passed the trial run ； 5. The purging and chemical cleaning of the pipelines are complete ； 6. The equipment and pipelines have passed the hydrostatic test and system airtightness test successfully ； 7. The filler has been filled properly ； 8. The analysis laboratory has been delivered and put into use in production ； 9. Most of the insulation and painting work is completed ； 10. The water supply and drainage systems, road grading, lighting, and communication facilities within the site have been completed ； 11. The site is left clean and free of all materials once the work is completed ； 12. The construction record documents are complete and accurate ； 13. The project quality meets the requirements; any projects that did not meet the standards have been repaired and brought up to standard. Article 38: A comprehensive inspection of the engineering quality and production preparation work must be carried out prior to the system-wide joint commissioning test. Experienced experts from various fields are organized by the higher-level supervisory authorities to assess the quality of the project, the quality of the design, the quality of equipment manufacturing, and their mutual compatibility ； A comprehensive inspection is conducted on four aspects: the production leadership team, the management system, and related production preparations. For all issues identified as being incompatible with the commissioning process, solutions are proposed to be implemented within a set deadline, in order to ensure a successful first attempt at commissioning the chemical plant. Article 39: The system-wide joint commissioning shall meet the following conditions: 1. A post responsibility system has been established ； 2. The full-time technical personnel and operators have been identified and passed the examinations ； 3. The utility systems are operating stably and can meet the requirements for joint system commissioning ； 4. The commissioning plan and relevant operating procedures have been published ； 5. All process parameters have been approved and published by the production management department, with one copy provided to each operator ； 6. The production record forms have been prepared and distributed to the respective positions ； 7. The set values for instrument interlocks and alarms have been approved and published, with one copy available for each operator. 　　Chapter 4: Chemical Plant Commissioning with Material Input Article 40: Chemical plant commissioning with material input refers to the testing process of a chemical production facility or an auxiliary production unit, following the completion of individual unit tests and integrated tests, as well as the overall completion of the project; it begins once materials are introduced into the facility. Chemical plant commissioning must be carried out steadily; the basic principle is to proceed methodically, with clear steps, to look ahead after each step taken, to continuously draw lessons from experience, and to move forward steadily. The standard for a successful first trial run of a chemical plant is that, from the introduction of raw materials into the facility to the production of qualified final products, the trial run proceeds without interruption or major accidents; qualified products are produced from the very first attempt, the optimal plan for the trial run is implemented, and after some time of operation and adjustment, all design (contract) specifications are met. Article 41: Chemical feedstock shall meet the following conditions (referred to as the 30 conditions for feedstock). (1) All equipment and associated works have been fully constructed in accordance with the design specifications (including design changes). Each piece of equipment and each pipeline has been inspected one by one to verify the material, wall thickness, flanges, gaskets, bolts, various valves, pipe fittings, the direction and position of valves, sampling points for testing, accompanying pipes, drain pipes, operation platforms, etc. The quality of the work meets the required standards; any items that did not meet the standards have been reworked until they are satisfactory. (2) The construction record documents are complete and accurate. (3) All process pipelines and equipment have passed strength tests, and the purging and cleaning of the equipment and pipelines have been completed. (4) The equipment and pipelines have undergone airtightness tests and been found to be qualified. (5) The rotating equipment in the plant has been thoroughly inspected as required; the individual tests and combined tests have met the specifications, allowing for normal operation. (6) The filling of catalysts, fillers, desiccants, and additives in all equipment that requires such filling has been completed. (7) The heating-up process for various industrial furnaces has been completed. (8) All various tasks that need to be carried out prior to material feeding, such as acid washing, passivation, degreasing, furnace cooking, pre-drying, pre-activation, and pre-vulcanization, have been completed. (9) The conditionally conducted water testing, test runs with dummy materials, and actual test runs have been successfully completed, and the issues identified have been resolved. (10) The pre-coating process for the circulating water system has been completed; it is now in cold-state coating maintenance mode, with all parameters meeting the required standards. (11) The calibration of all automatic control instruments has been completed; the set values for alarms and interlocks have been verified to be accurate and functional through static testing, and the sample gas for the automatic analysis instruments has been prepared and is ready for use. (12) The relay adjustment and insulation testing of all electrical equipment have been completed, and they are ready for normal operation. (13) Water, electricity, steam, instrument air, plant air, emergency nitrogen, and other utility services can be supplied at the values specified in the design. (14) All laboratory analysis facilities and standard solution preparation are ready for use. (15) All safety and fire protection facilities throughout the plant, including safety nets, guards, blind plates, explosion-proof panels, lightning and static electricity protection systems, gas and dust prevention measures, emergency rescue equipment, fire hydrants, combustible gas detectors, and fire alarm systems, have been installed. They have passed inspection and testing, and there are dedicated personnel in charge of them. (16) The storage and transportation system (loading docks for ships and vehicles) has been inspected and found to be in good condition; the fuel and raw material storage tanks as well as the intermediate tank areas have been cleaned and are ready for storage; the relevant measuring instruments have been calibrated and are available for use. (17) Chemical raw materials, fuels, auxiliary chemical materials, lubricants, etc., have been supplied in full; their quality meets the design requirements, and they have been delivered to the designated locations. (18) The medium-temperature treatment and anti-corrosion work on the equipment and pipelines have been completed, and the tag numbers, names, media types, and flow directions of the equipment, pipelines, valves, electrical systems, instruments, etc. must all be marked using Chinese characters or codes. (19) For communication in the production control system, the internal communication facilities are now operational. (20) The maintenance facilities for mechanical, electrical, and instrumentation systems have all been completed and put into use, and the relevant departments have formed a strong maintenance team. (21) The living and sanitary facilities in each workshop are now ready for use. (22) Technical documents such as process procedures, safety regulations, analysis procedures, equipment maintenance procedures, operating procedures for specific positions, and commissioning plans are available and have been approved for issuance. (23) Test operation command organizations at all levels have been established; operators have been assigned, with clear responsibilities, and they have all received training to acquire the necessary operational skills, meeting the requirements of \"four understandings and three abilities,\" and have passed the relevant examinations. (24) Various systems centered on the post responsibility system have been established, and all kinds of wall charts and schedules are available. (25) The original records, special forms for testing, and records for assessment are all fully prepared. (26) Sensitive and consumable spare parts and specialized tools are fully prepared. (27) There are solutions or reasonable arrangements in place for all three types of waste generated. (28) All types of personnel have carefully studied the safety regulations issued by the factory, received safety training, and passed the examinations. (29) Following professional and comprehensive pre-production inspections, it has been confirmed that the conditions for connection between various production units are met, and all preparatory work for production has been completed. (30) The vertical grading of roads and areas within the plant site has been completed. Article 42: To ensure the successful completion of a chemical plant’s commissioning trial in just one attempt, it is necessary to provide careful supervision, meticulous management, thorough organization, and precise operation. 1. Provide careful oversight to establish a strong testing command system. Command organizations for startup operations must be established at both the plant and workshop levels. These organizations should have clear responsibilities and be granted appropriate authority; their commands must be accurate, timely, and proactive. Establish a highly centralized and unified production command system. The plant’s main production control room serves as the center for daily command across the entire plant. The water control, power control, and transportation control systems, along with the control rooms of various workshops, should work under the unified command of the main production control room to form a network for daily production management. During the test run, the plant’s production supervisor is responsible for giving instructions to ensure the proper functioning of utility systems and external conditions. All command within the workshop is handled by the workshop itself; a dedicated engineer is responsible for overseeing the testing, ensuring unity between technical operations and command. Mechanical, electrical, instrumentation, and analytical tasks must follow the unified arrangements of the production workshop and provide active cooperation. Specific guidelines for command should be formulated based on the actual conditions of the factory, and these guidelines should be made public and put into practice. 2. Manage meticulously and strictly enforce all rules and regulations. 3. Organize meticulously, and conduct repeated checks and final confirmations prior to adding chemicals. Inspections are divided into professional inspections, level-3 inspections, and comprehensive inspections. Professional examination: Conducted by the department in accordance with professional protocols ； Level 3 inspection: Inspection at the factory, workshop, and operational posts ； Comprehensive inspection: A comprehensive team composed of relevant personnel from production, design, construction, and other units conducts the inspection. During inspection, professional inspections are carried out as the main method, along with self-inspections by the respective positions and workshops, with the final confirmation being obtained through a comprehensive inspection. Eliminate the problems identified through repeated inspections before material feeding. The supervising manager must be present during the inspection to have a clear understanding and make decisions regarding any issues that arise. During inspections, strict adherence to the ’30 Rules for Material Input’ and the ’20 Safety Rules’ is required; material input is not permitted if the conditions are not met. 4. Operate with care and strictly follow the steps for feeding materials and conducting trials. During the testing period, it is necessary to adhere to the established procedures for all tasks ； Work must be done carefully ； The organization must be tight-knit ； Strict requirements are necessary ； The measures must be reliable ； The command must be correct. At the same time, one should not drive when the conditions are not met ； Do not drive if the procedure is unclear ； The commander is not present, so driving is not allowed ； Order not to drive in violation of regulations ； If there’s a problem, don’t drive until it’s investigated properly ； I won’t drive until the problem is solved. During testing, everything must be handled with great care and in a strict manner ； Strict enforcement of post responsibility systems is required ； Strict adherence is required when implementing various process parameters ； It is essential to be thorough and accurate when obtaining primary data ； Strict control is required for instrument operations and analysis results ； Water quality management must be strict ； Oil system management must be strict ； Strict standards must be applied to the quality of materials, fuels, and chemicals ； Strict adherence is required when implementing various safety technical regulations ； Strict requirements are imposed on anti-freezing measures ； The material and specifications of spare parts must be strict ； Strict requirements must be applied to the use, maintenance, and repair of the equipment ； The requirement to follow procedures strictly must be upheld. Throughout the testing process, strict control must be exercised over key areas, and regular inspections should be carried out to identify problems early. A two-person operation and supervision system, with one person operating and another monitoring, should be implemented to ensure safety. Interlocks and safety devices must not be removed or disconnected arbitrarily, nor must their setting values be altered without permission. Emergency generators and uninterruptible power supplies should be tested regularly to ensure they are in good standby condition. Article 43: Before starting up the chemical plant with material feeding, the construction unit (or general contractor) shall organize a capable security team. A bodyguard team needs a complete range of roles and appropriate equipment. There must be a person in charge on site, and a 24-hour bodyguard duty system should be established to carry out regular inspections, ensure proper maintenance of the equipment, address any issues that arise in advance, and provide continuous supervision by the bodyguards. 　　Chapter 5 Production Assessment Article 44 Production assessment involves a comprehensive evaluation of whether the production capacity, process parameters, consumption levels, product quality, equipment performance, level of automatic control, and economic efficiency of the plant, after undergoing chemical feeding and commissioning tests, meet the design requirements. Production assessment should include a comprehensive evaluation of the capacity of the supporting utility systems and auxiliary equipment. Article 45: The production assessment of the introduced equipment shall be carried out in accordance with the provisions of the contract. Production assessment is not only a final comprehensive inspection of the equipment designed and provided by foreign parties in terms of technical and economic indicators as well as production capacity, but it is also a comprehensive evaluation of the quality of the project, the level of production operations, and the mental attitude and work style of the team. Domestic installations also need to undergo production assessments; installations that have not passed such assessments shall not be submitted for **handover and acceptance. Article 46: Make proper preparations before the assessment. 1. Establish assessment organizations at the plant and workshop levels. 2. Thoroughly study and become familiar with the production assessment materials provided by the design department or foreign clients ； 3. Mobilize employees to identify potential hazards and issues that could affect the proper conduct of assessments ； 4. All measuring instruments required for the assessment must be calibrated correctly in conjunction with the design department or the foreign party, and this should be confirmed jointly. 5. Develop assessment plans and record reports. Article 47: The assessment shall meet the following conditions: 1. The problems that arose under full-load production conditions have been resolved, and the operation of the chemical plant is now stable ； 2. All automatic control instruments and interlocks are put into use ； 3. The backup equipment is in good condition ； 4. The analysis method is correct, and all data have been collected ； 5. The quality of raw material and fuel supply meets the design requirements ； 6. There is a certain stock of chemical raw materials, lubricants, and wear-prone components ； 7. The product packaging is qualified, and transportation is unobstructed ； 8. Establish assessment methods with the design department or foreign partners. Article 48: Evaluation after testing. The testing period is generally set at 3 to 5 days of continuous full-load production; for newly introduced equipment, it may be determined in accordance with the contract provisions. The assessment results should ensure that the product’s quality, quantity, unit consumption, production cost, key process parameters, automation utilization rate, integrity rate of mechanical and electrical equipment, and the effectiveness of waste treatment all meet the design requirements.