Guide to Preparations for Starting Up Petrochemical Enterprises

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The commissioning of petrochemical plants is a complex and multifaceted systematic project that requires careful preparation by coordinating various resources related to processes, equipment, environmental protection, safety, quality, and more. At present, many petrochemical plants in China are undergoing maintenance, renovation, and expansion work; therefore, we have compiled relevant materials for reference by the production and technical management personnel in these plants. Article 1: Preparation for Commencement of Operations I. Organizational Preparation: Management agencies for trial operation and production preparation should be established in a manner appropriate to local conditions. II. Personnel preparation: 1. Develop a comprehensive labor allocation plan and an annual plan based on the approved staffing levels. Personnel categories, sources, and qualification requirements ； The time it takes for managers, technicians, and workers to be assigned to their posts. 2. Personnel training: Formulate the overall network plan and phase plans for personnel training ； The methods and steps for personnel training generally follow stages such as learning basic knowledge, learning specialized knowledge, working with relevant equipment and conducting practical exercises, participating in single-unit tests and joint tests, on-site training, and computer simulation training ； Selection and arrangement of training providers ； Training for leaders, managers, technical personnel, and operators at all levels ； 3. Exams and assessments for various training stages and for different types of personnel. III. Technical preparation: 1. Translation and printing of technical documents, drawings, and operation manuals ； 2. Develop various technical specifications and job operation procedures ； 3. Compile various types of comprehensive technical materials ； 4. Formulate various rules and regulations for enterprise management ； 5. Prepare plans for the commissioning of large-scale units, as well as for system drying, purging, and the filling of various chemicals; simultaneously work with the construction team to develop plans for system purging, airtightness testing, and chemical cleaning ； 6. Prepare commissioning plans for storage and transportation, utility systems, on-site generator sets, thermal power plants, boilers, fire protection, etc ； 7. Prepare plans for overall trial operation, unit interlock trial operation, material feed trial operation, and production assessment ； 8. Computer simulation training technical equipment ； 9. Plans for compiling and publishing domestic and international technical materials ； 10. Planning for the development of various test run plans ； 11. Overall network plan for technical preparation. IV. Material Preparation: 1. Main raw materials, fuel, and commissioning materials ； 2. Auxiliary materials, three types of reagents, chemicals ； 3. Lubricating oil ； 4. Domestic and international ordering plans for spare parts, as well as arrangements for the surveying, mapping, and trial production of imported spare parts ； 5. Domestic supply situation for the three types of reagents used in the installation, chemical substances, standard gas samples, and lubricants ； 6. Production-specific tools, equipment, pipes, pipe fittings, valves, etc ； 7. Safety and hygiene, fire protection, gas prevention, first aid equipment, labor protection, etc ； 8. Transport vehicles, railways, docks ； 9. Production records, office and daily-use items ； 10. Communication equipment, packaging materials ； 11. Other supplies. V. Fund preparation: 1. Prepare an annual plan for production preparation funds, and include it in the project construction plan ； 2. Prepare cost plans for stages such as large-unit commissioning and joint commissioning, as well as cost plans for the commissioning phase with materials supplied; develop a cost control plan from the start of material supply up to the year-end commissioning ； 3. Prepare working capital plans for each phase. VI. Marketing Preparation: 1. Investigate the demand and usage of the company’s products in the market, gather market information, and study sales strategies. 2. Marketing system and responsibility system. 3. Hold user seminars to promote and introduce the product quality, performance, and usage methods of the enterprise. 4. Implement the product distribution routes, via road, rail, and water transport. 5. Compile product manuals to describe the product quality and performance. 6. Organize the design of corporate product trademarks and carry out trademark registration. VII. Preparation of external conditions: 1. Ensure the connection to external sources of power such as electricity, water, and steam, as well as determine the timing of their supply ； 2. Connection of off-site roads, rainwater drainage, industrial wastewater, and other related systems ； 3. Time of activation for external and internal telecommunications networking ； 4. Coordination of projects such as railways, ports, transfer stations, and pipelines for material exchange ； 5. Applications, approvals, and certification for labor safety, fire protection, industrial hygiene, environmental protection, boilers, pressure vessels, etc ； 6. Implement social-based mechanical, electrical, and instrumentation maintenance capabilities as well as public service facilities. VIII. Production preparation: Comprehensive network planning: The seven aspects of production preparation, as well as major unit commissioning, system purging, leak testing, drying, gas replacement, filling of catalysts/adsorbents/solvents, integrated test runs, “reverse startup”, and trial operation with feedstock, should have their key control points plotted on an annual, quarterly, and monthly basis. These points must then be incorporated into the overall coordinated control plan for chemical construction projects. Article 2: Preparation of the Overall Commissioning Plan I. Project Overview: 1. Scale and construction status of production units and utility systems 2. Supply of raw materials, fuel, and power, as well as product flow II. Bases and principles for preparing the overall commissioning plan III. Guiding principles for commissioning and the standards to be achieved IV. Conditions required for commissioning V. Commissioning organization and command system: Commissioning organization structure and command ； Technical advisory team and driving crew ； VI. Commissioning Schedule: 1. Principles for arranging the commissioning schedule, the actual schedule, as well as the timing for feeding materials and producing qualified products. 2. Commissioning procedures, key control points, device evaluation, and scheduling for trial production. 3. Diagram showing the overall relationship between various elements in the commissioning process.

VII. Material Balance: 1. The load associated with material feeding during commissioning. 2. Comparison between planned consumption levels of key raw materials and their design values. 3. Material balance sheets (summary table of main product outputs, table of key raw material consumption levels, table showing the status of material feeding during commissioning, economic and technical indicators, and charts showing input and output of key materials).

VIII. Fuel and Power Balance: 1. Balance of fuel, water, electricity, steam, air, and nitrogen. 2. Supplementary tables (fuel balance sheet, electricity usage plan, heat load table, steam consumption balance sheet, water usage balance sheet, nitrogen balance sheet, and others).

IX. Environmental Protection: 1. Environmental monitoring and treatment of “three wastes”. 2. Measures, methods, and standards for treating “three wastes”. 3. Table summarizing the emission and treatment of “three wastes”.

X. Labor Safety, Health, and Fire Protection: Prepared in accordance with the requirements of the Ministry of Safety and Environmental Protection.

XI. Challenges in Commissioning and Corresponding Solutions: Analysis of challenges related to commissioning procedures, “reverse operation”, device load, material balance, etc., along with appropriate solutions.

XII. Economic Benefits: 1. Calculation of economic benefits (calculation conditions, results, and analysis). 2. Measures to improve the efficiency of commissioning.

XIII. Other Issues That Need to Be Addressed: Conditions required for material feeding during commissioning. Material feeding during commissioning must be carried out to high standards and with strict requirements, following the approved commissioning plan and procedures. None of the required steps should be omitted, none of the standards should be lowered, and no time should be wasted. It is necessary to thoroughly check and confirm that all conditions are met before starting the commissioning process. Part 3: Conditions Required for Commissioning
I. Completion of interim handover of the project:
1. The preliminary evaluation of project quality is satisfactory ； 2. The rectification of issues under the “three inspections and four determinations” has been completed, and all remaining items have been addressed ； 3. The design change projects that affected the material feeding have been completed ； 4. The project has completed the intermediate handover procedures ； 5. All temporary facilities used for construction in the plant area have been removed ； The site is clean, free of clutter, and unobstructed ； 6. The device tag numbers, pipeline medium names, and flow direction indicators are all complete ； 7. The system has been purged, cleaned, and made airtight. II. The joint commissioning has been completed: 1. Drying, purging, loading of the three types of reagents, and calibration of the computer-based instruments have all been carried out and verified ； 2. The equipment is in good condition and ready for use ； 3. Online analytical instruments have been calibrated and are ready for use; industrial air conditioning systems are in operation ； 4. The instrumentation, computers, monitoring, control, interlock, and alarm systems have been calibrated and are accurate and reliable ； 5. The tools and equipment for the positions have been fully provided. III. Personnel training has been completed: 1. Training on similar domestic and international installations, as well as practical training, has been finished ； 2. Training for specific positions, simulated training, and accident-prevention training have been carried out ； 3. Personnel in all trades have passed the examinations and obtained work permits ； 4. Accident cases of similar devices at home and abroad have been compiled, and studies have been conducted. In accordance with the principle of \"not letting any accident go unaddressed,\" accidents and potential accident signs that have occurred since the commissioning of this device have been analyzed to draw lessons from them. IV. All production management systems have been implemented: 1. Clear division of responsibilities among positions, and team production operation systems have been established ； 2. Test operation command systems at all levels have been established, personnel are on duty, and a regular meeting system has been put in place ； 3. Production scheduling systems at all levels have been established ； 4. Systems such as job responsibilities, routine inspections, and shift handover procedures have been established ； 5. All instructions and information transmissions have been put in written form, and the original record data has been formatted into tables. V. The feed-in commissioning plan, approved by the higher authorities, has been communicated to the production staff: 1. Process technical specifications, safety technical regulations, operating procedures, etc. are available to each employee, and a copy of the feed-in commissioning plan is provided to all personnel holding supervisory positions or above ； 2. There is a written plan for each testing step, and both the supervisors and operators are familiar with it ； 3. “Kanban” or “wall-mounted” management has been implemented ； 4. Accident plan briefing, training, and discussion have been conducted ； 5. The anticipated plan for handling the accident has been formulated and implemented. VI. The logistics support measures have been implemented: 1. The scope and responsibilities for logistics support have been defined ； 2. The logistics team has been formed ； 3. The shipping staff are on duty and wearing identification badges ； 4. The transportation equipment and tools have been secured ； 5. The location designated for freight handling duties has been identified and marked, with 24-hour coverage ensured ； 6. Backup personnel for freight transportation have been arranged ； 7. Material supply services are provided on-site, with 24-hour duty coverage ； 8. Mechanical, electrical, and instrumentation maintenance personnel are on duty ； 9. Contracts have been signed with the mechanical, electrical, and instrumentation maintenance services available in the community. VII. The water supply and drainage system is operating normally: 1. The pressure, flow rate, and water quality of the water network meet the process requirements, with stable water supply ； 2. The pre-film treatment of the circulating water system has been completed successfully, and its operation is stable ； 3. The chemical water, fire-fighting water, condensate water, and drainage systems are all in operation and function reliably. VIII. The power supply system is operating stably: 1. Dual power sources and dual circuits for power supply have been implemented ； 2. The instrument power supply is operating stably ； 3. The emergency power supply has been secured, and the backup generator is in good condition for use ； 4. Power dispatchers are on duty ； 5. The maintenance of the power supply lines has been arranged, and personnel have started to conduct round-robin inspections. IX. The steam system is supplying steam steadily: 1. The steam system is operating normally according to the specified pressure levels, with stable parameters ； 2. No leaks, and good heat retention. X. The nitrogen and air supply systems are operating normally: 1. The industrial air, instrument air, and nitrogen systems are functioning properly ； 2. Parameters such as pressure, flow rate, and dew point are within acceptable ranges. XI. Chemical raw materials and lubricants are fully available: 1. All chemical raw materials and lubricants have arrived and passed quality inspection ； 2. The “three-dose” loading is complete ； 3. The three-stage lubricating oil filtration system has been implemented, and the lubrication points for the equipment have been identified. XII. Complete spare parts and accessories: 1. The spare parts and accessories are sufficient to meet the needs of testing; they are already on hand, and the inventory matches the records ； 2. The warehouse has implemented a day-and-night duty system; the staff are familiar with the specifications, quantities, and storage locations of the goods, ensuring timely and accurate dispatching of items. 13. The communication system operates reliably: 1. The telephone lines of the command system are unobstructed ； 2. The positions and direct phone lines are available and in use ； 3. The dispatch, fire alarm, and emergency service phones are reliable and easy to use ； 4. Wireless phones and telephones provide clear calls. 14. The material storage system is in good condition and ready for use: 1. The storage tanks for raw materials, fuel, intermediate products, and finished products have all been purged, pressure-tested, made airtight, calibrated, dried, and sealed with nitrogen ； 2. After the combined testing of the pumps and pipelines is completed, they are in good condition and ready for use ； 3. The anti-static and lightning protection facilities of the storage tank are in good condition ； 4. The breather valve and safety valve of the storage tank have been properly calibrated ； 5. The tank location numbers, the names of the media in the pipelines, and the flow directions have been indicated; there are clear signs for fire prevention in the tank area. 15. The distribution system is in good condition and ready for use: 1. Railway, road, port, and pipeline transportation systems have been built and put into operation ； 2. Systems regarding the quality, quantity, and method of transfer for raw materials, fuels, intermediate products, and finished products have been established ； 3. Measures for handling non-conforming products have been implemented ； 4. The product packaging equipment has been tested using actual materials, and all packaging materials are available ； 5. The methods for product sales and transportation have been arranged ； 6. The factory inspection, loading, and transportation of the products have been arranged. 16. The safety, fire protection, and first-aid systems are well-established: 1. There are complete systems, regulations, and records for safe production; a safety management system has been put in place, and personnel work after receiving safety training and obtaining the necessary certifications ； 2. The firework use regulations, smoking ban regulations, and vehicle management regulations have been established and made public ； 3. Road traffic signs and radiation protection signs are complete ； 4. The fire inspection system and the management system for fire trucks on site have been established; fire fighting plans have been put in place, fire roads are unobstructed, and fire drills have been conducted* ； 5. Fire-fighting equipment and protective gear are available at the post, and everyone knows how to use them ； 6. Gas protection and emergency response measures have been implemented; a gas protection plan has been formulated and drills conducted* ； 7. The on-site personnel are wearing appropriate personal protective equipment, and basic first-aid knowledge among the workers has been widely disseminated ； 8. The fire foam stations, steam curtains, water curtains, sprinklers, as well as smoke and fire detectors, combustible gas and toxic gas monitors in the production facilities and tank areas are in operation, with a 100% availability rate. 9. Pressure testing, calibration, setting of pressure value, and sealing of the safety valve completed ； 10. Boilers, pressure vessels, cranes, and elevators have been approved and certified by the labor department ； 11. There is a dedicated person in charge of blind plate management, which is carried out on a dynamic basis; records are kept, and signs are posted at the site ； 12. An on-site first aid station has been established, equipped with ambulances and other facilities, and operates on a 24-hour basis. 17. The production scheduling system is now operating normally: 1. A scheduling framework has been established, and all necessary scheduling personnel for various tasks have been assigned and qualified for their positions ； 2. A normal order has been established for commissioning scheduling work, and a regular scheduling meeting system has been put in place ； 3. The dispatchers are familiar with various material transportation plans; the relationships regarding material supply between different plants and units are clear, and the pipelines are already in use ； 4. During the trial operation period, raw materials, fuel, products, by-products, and power balance are all incorporated into the normal management of the scheduling system. 18. Environmental protection efforts meet the “three simultaneities” requirement: 1. The pretreatment design for the “three wastes” generated by production facilities has been completed and put into use ； 2. The treatment facilities for the three types of waste have been built and put into operation ； 3. The instruments and chemicals required for environmental monitoring are all available, and the analysis procedures and reports have been prepared ； 4. Analog sampling and analog analysis have been completed. 19. Preparatory work for laboratory analysis is complete: 1. Normal analysis and testing procedures have been established in the chemistry laboratory and the analysis laboratory ； 2. The laboratory analysis items, frequency, and methods have been determined; the instruments have been calibrated, the reagents are available, and the analysts are qualified to carry out the work ； 3. The sampling points have been determined, and the sampling equipment as well as the persons responsible for sampling have been assigned ； 4. Analog sampling and analog analysis have been completed. 20. On-site security has been arranged: 1. The organization, personnel, and transportation for on-site security have been secured ； 2. The entry system and security protocols for key areas such as the control room have been established ； 3. Measures for joint local defense have been implemented and a notice has been issued. 21. Logistics services for daily life have been arranged: 1. Employee shuttle buses meet the needs of shift testing and overtime work on holidays, ensuring safety and punctuality ； 2. The cafeteria operates on a 24-hour duty schedule, with meals delivered to the site ； 3. Shift-based dormitory management has returned to normal ； 4. Implementation of the cleaning and hygiene responsibility system. 22. The crew members and experts for driving have arrived at the site: 1. The crew members and experts have arrived as planned ； 2. The office locations, transportation, accommodation, and other needs of the convoy staff and experts have all been arranged ； 3. On-site translation is ready ； 4. The feed-in commissioning plan has been approved by experts, and the suggestions from the startup team have been fully presented.