Commissioning of large-scale units
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To ensure the successful first start-up of large-scale units, let’s discuss what preparatory work should be done before starting up in order to guarantee a successful first attempt.
I believe that regardless of the scale of a project, there aren’t many technical aspects involved in getting the equipment up and running; what matters most is the quality of the management. Organizing things in an orderly manner helps to improve efficiency and quality. Manufacturers also play a key role – their support can accelerate progress and ensure success on the first attempt. Having workers do repetitive work is what’s most demoralizing
One must be confident and clear-headed to remain calm in the face of challenges
More practically, from the stage of project construction, the personnel assigned to that unit begin to monitor its installation and commissioning, and continue to do so until it is put into operation. Their goal is to gain a thorough understanding of both the equipment of the unit and the manufacturing process associated with it; this involves integrating seamlessly the information provided by the equipment manufacturers with that provided by the process design firms. The relevant operations are carried out under the guidance of the manufacturer’s staff. Domestic manufacturers do not perform as well in terms of guiding installation and commissioning, whereas foreign manufacturers are much better at this.
It involves the calibration of the instruments, as well as single-turbine tests and individual unit tests; any issues identified during this process help to prepare for the actual operation. Mainly, if the preliminary preparations are done thoroughly, driving is very simple.
Individual tests of equipment must be conducted rigorously; there should be no shortcuts, no uncertainties, and no violations of safety rules in an attempt to speed things up.
Careful installation, thorough inspection, strict adherence to the operation manual, and compliance with unified instructions
Prepare a startup plan based on the process flow and the unit’s operation manual; if necessary, the manufacturer will provide approval. Check the oil level and fluid levels. Ensure proper staff training, and carry out instrument calibration as well as water and air tests in advance
First, our department prepares an OK form for driving, assigning each specific responsibility to an individual, with managers at all levels signing off to confirm it. The specific items depend on the design of your unit; generally, there are isolation gas, sealing gas, oil system, unit pressure, process conditions, etc. Additionally, plans for dealing with safety incidents and similar situations should be in place when driving at the beginning. Plan ahead!