Original commissioning of chemical plants ~ Technical discussion thread for one-on-one issues

To carry out commissioning work properly, there are three key points: 1. Understand the commissioning procedures, such as mechanical completion, installation completion, pre-commissioning, cold testing, joint testing, hot testing, commissioning with feedstock, startup, trial operation, operational testing, functional testing, circuit testing, and so on. Failing to understand the basic definitions and differences can lead to confusion in the work and even affect the costs associated with contract execution. 2. Basic test driving skills. Commissioning work is a complex task; commissioning engineers not only need to understand operations and testing procedures, but also possess expertise in areas such as processes, piping, equipment, instruments, electricity, and safety. They must be versatile individuals with multiple skills in order to become excellent commissioning engineers. 3. Assemble a good test drive team. By relying on technology, taking procedures as the core, adhering to safety principles, controlling quality, aiming for timely completion, and ensuring effective management through coordinated planning, successful and smooth testing can be achieved.

Impressive; I’ll seek your advice more often if I get the chance.

I’ve seen the posts about the OP’s driving experiences; they’re great! It mentions steam purge sign language – what exactly are those? What are the key things to pay attention to during steam purging?

There are some precautions for steam purging mentioned in the text; they are also basic. Since the steam temperature is high, the first purge must be done slowly – not too quickly. Monitor the process while introducing the steam to ensure proper warming of the pipes. We usually don’t pay much attention to sign language. In the projects I’m in charge of, I provide specialized training for them, involving the establishment of some simple signs such as ‘on’, ‘off’, the speed of turning on/off, and the degree of opening. In noisy environments, having agreed upon such signs is extremely convenient for operating the equipment.

It’s obvious from the start that it’s a legitimate central state-owned enterprise; small companies simply can’t achieve such standards

I’ve switched between state-owned enterprises and foreign companies several times.

　　Cement is an essential material in house construction; it is used to strengthen the connection between the bricks, making it an indispensable substance. Since the reform and opening up, the pace of housing construction in China has accelerated alongside economic development. The rapidly built houses come with certain risks, and one such risk is foam; fortunately, cement mortar defoamers are available to eliminate this problem. 　　Cement is divided into three types: general-purpose cement, special-purpose cement, and specialty cement. Manufacturers of cement mortar defoamers explain that each type of cement has its own unique uses and properties, enabling it to be applied to various construction tasks. The production process of silicate cement is representative in cement manufacturing. It uses limestone and clay as the main raw materials, which are crushed, mixed, and ground to form clinker; this clinker is then fed into a cement kiln to be calcined into mature cement, which is subsequently ground together with an appropriate amount of gypsum (and sometimes mixed materials or admixtures). 　　The reasons for foaming when cement is used are as follows: (1) Unappropriate gradation, with too much coarse aggregate and too little fine aggregate ； 　　(2) Improper aggregate size, excessive content of flaky and needle-shaped particles ； 　　(3) Concrete with high water consumption and a high water-cement ratio ； 　　(4) It is related to certain admixtures as well as the chemical composition of the cement itself. Defoamers. Biochemical treatment involves using microorganisms such as bacteria, fungi, algae, and protozoa to oxidize and decompose harmful substances in water into harmless ones. These microorganisms can survive in water containing toxins, use these toxins as nutrients for reproduction, and thus convert the toxins into new substances that are harmless to humans. 　　For defoamers, the greatest advantage is their ability to eliminate foam rapidly, as well as their foaming-inhibiting properties. In various manufacturing processes, numerous bubbles can form due to factors related to the silice-free defoaming agents themselves or to external environmental conditions. Small bubbles can dissipate on their own, but as the number of bubbles increases, if they are not removed in a timely manner, it is likely to affect the progress of production as well as the quality of the products manufactured. 　　For a company, every minute and second of operation is extremely valuable; therefore, if the smooth progress of production processes is not ensured, it often leads to unnecessary losses. For large amounts of foam, this leads to unnecessary losses for businesses; it not only delays production but also results in waste of funds, time, labor, and so on. Therefore, in various industrial processes, it is particularly important to ensure the elimination of foam; only by eliminating such foam can businesses operate smoothly, which in turn brings more positive effects to their development.

May I ask the original poster if there are any Russian testing specifications? Please share them! Thank you

May I ask the original poster what the definitions are for material feeding and commissioning, startup, trial operation, operability testing, functionality testing, and circuit testing? What is the difference between commissioning with feed and actual operation?