Specifications for Safe Commissioning of Chemical Processing Units in Shandong Province

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1 Scope This specification specifies the safety management requirements for the production preparation and commissioning phases of newly built, renovated, or expanded chemical processing units. To ensure the smooth commissioning of chemical plants, as well as their safe, stable, and continuous operation, to meet the scheduled timeline, and to achieve all the technical and economic objectives specified in the design. Regarding the project quality, safety, environmental protection, fire protection, earthquake resistance and disaster mitigation, occupational health, metrology, special equipment, etc., as covered by these specifications, the relevant existing laws, regulations, standards and specifications of ** and Shandong Province shall be complied with. The trial production (use) of large and medium-sized hazardous chemical production facilities that are newly constructed, renovated, or expanded within the administrative territory of Shandong Province shall comply with these specifications ； When small hazardous chemical production units and other general chemical plants implement these specifications, the commissioning procedures and requirement details can be appropriately simplified, provided that safety is ensured. The startup of operational chemical plants that require long-term shutdowns or have changed safety conditions shall be carried out in accordance with the relevant provisions of these specifications ； For the commissioning of facilities involved in the production, storage, and use of hazardous chemicals in enterprises such as those in the pharmaceutical, light industry, metallurgy, and building materials sectors, the relevant provisions of these specifications may be referred to. The commissioning of imported chemical processing units may be carried out in accordance with the commissioning standards specified in the relevant contract for those units, provided that such standards are not lower than the requirements of these specifications. 2 Normative reference documents The following documents are essential for the application of this document. For reference documents dated, only the version dated shall apply to this document. For reference documents without a date, the latest version (including all amendment sheets) applies to this document. GB 15603 General Rules for the Storage of Commonly Used Chemical Hazards GB 18218 Identification of Major Hazard Sources AQ 3013 General Specifications for Safety Standardization in Units Engaged in Chemical Hazardous Materials Operations HG 20231 Specifications for Commissioning of Chemical Industry Construction Projects 3 Terms and Definitions The following terms and definitions apply to this document. 3.1 Construction (Production) Unit: A construction (production) unit is a corporate entity responsible for the construction of chemical engineering projects or the management of the production of chemical plants. It is tasked with raising funds for such projects, organizing the construction of production facilities, carrying out preparatory work for production, conducting commissioning tests, and evaluating production performance. 3.2 Integrated Plan on Construction: This is the overall plan for the construction of chemical engineering projects, providing comprehensive arrangements for various stages such as preliminary preparation for the project, commencement of construction, building work, preparation for production, commissioning, performance evaluation during production, and final acceptance. 3.3 Reasonable duration: The reasonable duration refers to the period, determined using systems engineering principles and based on the characteristics of the construction project as well as the construction conditions, in accordance with the principles of appropriate safety measures, technical feasibility, economic rationality, and compliance with construction and commissioning procedures; it spans from the official start of construction of the facility until the completion of production assessment. 3.4 Production Preparation: Production preparation refers to the preparations carried out during the construction of chemical engineering projects for commissioning and initial production. It mainly includes organizational, personnel, technical, safety, material and external condition-related arrangements, as well as preparations in terms of marketing and product storage and transportation, logistical support, and other aspects. These efforts aim to create the necessary conditions for commissioning and lay the foundation for safe and stable production. 3.5 Pre-commissioning refers to the series of preparatory activities such as system tuning, cleaning, and mechanical and electrical performance tests carried out prior to testing, after the installation of equipment and piping systems is completed. This includes the flushing and purging of piping systems, chemical cleaning of static equipment and piping systems, furnace drying, commissioning of electrical and instrumentation systems, as well as individual testing of dynamic equipment. 3.6 Single-unit testing: Mechanical test of rotating equipment. Specified operational tests are carried out on individually installed rotating equipment or units, either under no-load conditions or with a safe medium, in order to evaluate their mechanical properties as well as the quality of their manufacturing and installation, aside from the effects of the process medium. 3.7 Combined Commissioning (Cold Commissioning): This refers to the simulated operation using water, air, or other safe media, along with tests and adjustments of equipment, pipelines, electrical and automatic control systems within a specified range, after preliminary testing has been completed. The purpose is to evaluate all aspects of their performance, as well as their manufacturing and installation quality, independent of the influence of the process media. It also involves organizing training for the personnel involved in the commissioning process. Upon completion of the joint commissioning, the facility is ready to carry out chemical feeding trials. 3.8 Chemical Commissioning Test (Hot Commissioning): This refers to the process of establishing the production flow in the entire plant using the actual process media specified in the design documents, and carrying out trial operations to ensure proper connection between various units. The aim is to evaluate all aspects of the plant’s performance aside from economic indicators, to prevent any safety incidents, and to produce qualified products. 3.9 Intermediate Handover of Project: Refers to the handover process between the construction party and the project owner, which takes place after all work related to a specific project or certain equipment has been completed in accordance with the specifications outlined in the design documents. This handover occurs once the pipeline systems and equipment have been properly prepared, the electrical and instrumentation systems have been tested, and individual units have been successfully tested. 3.10 Project Handover: Project handover refers to the transfer of all chemical processing units, carried out by the construction party and the construction (production) party in accordance with the provisions and time limits specified in the contract, after the commissioning tests are completed. 3.11 Production assessment – A performance test refers to a period of full-load operation and measurement carried out within a specified time frame, after the chemical plant has been commissioned, to evaluate whether the production facility is operating safely and stably, in accordance with the requirements outlined in the design documents and contracts. 3.12 Equipment: refers to fixed assets other than land and buildings that can be used repeatedly over a long period during the operation of a facility, while maintaining their original physical form and functions to a large extent. The equipment referred to in these specifications includes, but is not limited to, moving equipment and stationary equipment. 3.13 Rotating equipment: Mechanical devices equipped with driving mechanisms and characterized by moving components. The moving equipment mentioned in these specifications includes, but is not limited to, pumps, fans, compressors, conveyors, crushers, filters, dryers, and mixers. 3.14 Static equipment: Mechanical equipment that primarily consists of components that remain stationary. The static equipment mentioned in these specifications includes, but is not limited to, towers, heat exchangers, separators, reactors, tanks, and filters. 3.15 Machine unit: A combination of two or more different types of equipment, as well as automatic monitoring and control systems, that work together to carry out a specific task. 3.16 Chemical plant installations refer to all the process units and auxiliary facilities that make up the production process for chemical products. 3.17 Trial operation refers to the series of operational adjustments carried out on the various units of a project after the chemical feeding trial run is completed, with the aim of enabling them to operate in a stable and normal manner over time, as well as to conduct assessments of production performance. 4 General Provisions 4.1 Before starting the trial operation of a chemical plant, it is necessary to submit in writing to the local authorities relevant documents such as the trial production plan, the signed approvals from the design, construction, and supervision units as well as external experts regarding the trial production plan and the conditions for trial production, as well as the safety assessment report on those production conditions issued by a qualified organization, in accordance with the requirements of relevant regulations. 4.2 The commissioning of chemical plants is divided into four stages, namely the production preparation stage prior to commissioning, the pre-commissioning and joint test run stage, the chemical feeding commissioning stage, and the production evaluation stage. Starting from the pre-commissioning phase, each stage must meet the specified conditions, procedures, and standard requirements before moving on to the next stage. 4.3 The commissioning of chemical plants and all preparatory work for production must adhere to the principle of \"safety first, prevention first, and comprehensive management\"; safety considerations must be integrated throughout the entire commissioning process. 4.4 The commissioning of chemical processing units should follow the principles of \"conducting individual unit tests early, ensuring strict airtightness during purging, carrying out comprehensive integrated tests, proceeding with feed-in testing in a steady manner, and having an optimized commissioning plan\" to ensure safety and reliability. 4.5 The construction (production) unit shall be responsible for tasks such as fund raising during the construction of chemical engineering projects, organizing construction or maintenance work, carrying out production preparations, conducting commissioning tests, and evaluating production performance. Unless otherwise stipulated in the contract, the organization and supervision of the chemical feed-in commissioning, as well as the organization of production assessment tasks, must be the responsibility of the construction (production) unit. 4.6 After the construction of the safety facilities for chemical plants is completed, the construction (production) unit shall, in accordance with relevant laws, regulations, rules, standards and other provisions, organize engineering and technical personnel or entrust equipment manufacturing, testing and inspection units to carry out commissioning, inspection and testing of these safety facilities, so as to ensure that they meet the safety requirements for the production, storage and use of hazardous chemicals and remain in proper working condition. 5 Production Preparation 5.1 General Provisions 5.1.1 The main task of production preparation is to make arrangements in terms of organization, personnel, technology, safety, materials and external conditions, marketing and product storage and transportation, as well as other related aspects, in order to lay the foundation for trial operation and safe and stable production. 5.1.2 Production preparation work should begin after the approval (approval, registration) of the chemical construction project. The construction (production) unit should incorporate production preparation work into the overall planning for project construction. It should promptly organize the production preparation department and hire experts in design, construction, supervision, and production to assist in formulating the comprehensive plan for chemical plant construction. These experts should also be involved in the design review of the project, handling design changes, overseeing the manufacture of custom equipment, monitoring project quality, and coordinating project progress. Additionally, they are responsible for carrying out procedures such as technical briefings, intermediate handovers, and final project handovers. (The details of the production preparation work are provided in Appendix A, \"Key Points for Preparations for Commissioning and Production\"). 5.1.3 During production preparation, the following conditions must be strictly checked and confirmed; however, these are not the only conditions that need to be considered: a) The production processes and technologies used in the chemical plant must be mature, safe, and reliable ； b) The design, construction, and supervision of chemical plants must be carried out by entities with the appropriate qualifications ； c) The equipment, materials, and all other supplies used in chemical processing facilities must comply with ** and relevant industry standards to ensure satisfactory quality ； d) During the construction and installation of chemical plants, it is necessary to strengthen construction quality control and carry out quality supervision for chemical engineering projects ； e) The safety facilities of chemical plants must be designed, constructed, and put into operation simultaneously with the main plant itself, in compliance with relevant standard requirements and to meet the needs of commissioning ； Fire protection facilities must pass inspection by the relevant authorities ； f) All special equipment and their safety accessories must pass mandatory inspection and testing in accordance with the law; otherwise, they shall not be put into use under any circumstances ； g) Chemical processing units must be inspected in accordance with the items specified in the construction and acceptance specifications; equipment manufactured on-site shall meet the requirements of relevant manufacturing and acceptance specifications and standards, and there must be proper records to prove this. 5.1.4 Before starting up the chemical plant after feeding in materials, the construction (production) unit must complete all production preparation work in accordance with the requirements of the design documents and the project construction plan. 5.2 Organizational Preparation 5.2.1 After the approval (authorization, registration) of a chemical engineering construction project, the construction (production) unit should establish leadership and working bodies for production preparation and commissioning as early as possible. Based on the progress of the project construction, and in accordance with the principles of \"streamlining, unity, and efficiency\", these bodies shall organize and coordinate the activities related to production preparation and commissioning of the chemical plant. 5.2.2 The leading body is responsible for organizing, directing, coordinating, and supervising the production preparation and commissioning of chemical processing units; its head should be the principal person in charge of the construction (production) unit, with members including those in charge of production, technology, safety, environmental protection, project construction, equipment and power supply, among other areas ； If necessary, relevant personnel from units such as design, construction, supervision, and equipment manufacturing, as well as experts from similar enterprises, should also be involved. 5.2.3 The operating organization shall, based on the production principles, process flow, and structure of the chemical plant, establish several working groups in areas such as engineering technology, safety management, on-site management, and service support, organized by specialty or unit system; the specific setup and division of responsibilities can be determined according to actual conditions. The heads of each working group should be the responsible persons from the construction (production) unit, with members consisting of key personnel from relevant specialties. 5.2.4 Before the commissioning of chemical processing units, the construction (production) unit shall establish and improve relevant safety management system documents: in accordance with the provisions of AQ 3013, it shall organize the formulation of various safety production responsibility systems, safety production management systems, commissioning command systems, production scheduling systems, and other corresponding management systems. 5.3 Personnel Preparation 5.3.1 The construction (production) unit shall, in accordance with the production staffing quota specified in the design documents, formulate specific staffing plans and personnel allocation schemes. Adhering to the principles of \"determining qualifications based on job requirements, recruiting personnel according to those qualifications, providing training tailored to each position, and conducting strict assessments,\" it shall allocate and train personnel in a planned manner. 5.3.2 The staffing shall meet the following requirements: a) Key production and technical personnel should have extensive experience in production practice and project construction ； The key technical personnel should be in place at the outset of project preparation, participating in technical negotiations, design reviews, construction supervision, and production preparations ； b) Operators for key positions, including those involved in operation, analysis, and maintenance, must hold the corresponding qualification certificates and be on site during the pre-commissioning phase ； c) In terms of staffing, attention should be paid to the age structure, educational level, and technical and skill levels; those who have worked in similar positions should account for more than one-quarter of the total staff quota for the project ； d) The principal persons in charge of construction (production) units, safety production management personnel, and personnel engaged in special operations must, in accordance with the law, receive safety production training and safety operation training organized by the relevant competent authorities. Only after passing the assessments and obtaining the corresponding safety certification or qualification certificate for special operations can they take up their positions or start working. 5.3.3 Personnel training shall meet the following requirements: a) The construction (production) unit shall, in accordance with the relevant regulations and provincial requirements regarding safety training for production and business operations, provide safety training for all employees. At the same time, the construction (production) units, taking into account the production characteristics of chemical plants as well as the knowledge and skill levels of the workforce, organize training activities in a hierarchical, phased, specialized manner, with an emphasis on skill training and safety education ； b) Production supervisors, key process engineers, production team leaders, and operators in critical positions must undergo training across at least four stages, so as to become familiar with the entire process including startup and shutdown, normal operation, handling of abnormal situations, and accident response, as well as to understand the interrelationships between different positions, sequential processes, and elements both within and outside the facility ； Mechanical, electrical, and instrumentation maintenance personnel possess skills in equipment repair and maintenance, and are familiar with the entire process of installation and commissioning: 1) First stage: Professional training. The training covers basic knowledge of the chemical engineering field and the hazardous chemicals involved, knowledge related to machinery, equipment, electricity, instrumentation, and analysis, process principles and production processes as well as operating procedures, information on hazardous factors, and knowledge related to emergency rescue ； 2) Phase 2: Practical training. Learn practical operational knowledge such as production operations and control, equipment performance, startup and shutdown procedures, and accident handling from companies of the same type. The practical training follows the principle of “six fixations and two responsibilities”: fixing the leader in charge, the training location, the trainers, the schedule, the tasks, and the assessment period; while the training organization is responsible for providing instruction, and the trainers are responsible for ensuring that the trainees master the skills ； 3) Phase 3: On-site drill. In accordance with the requirements of the trial operation plan, training is carried out item by item to familiarize oneself with the site, manufacturing processes, control systems, equipment, rules and regulations, as well as the interactions between different positions. Through these drills, capabilities in production management, operational control, and emergency response are improved ； 4) Phase 4: Practical operation training. Participate in various commissioning tasks prior to chemical feeding, receive training in practical operation skills, take part in on-site pre-commissioning and joint commissioning activities, become familiar with command and operation procedures, and conduct emergency drills. c) For overseas training for complete sets of imported equipment, key personnel for such training should be carefully selected, and the relevant conditions for technical training and on-the-job training should be specified in the contract. 5.3.4 Training is subject to periodic assessments; only after passing the assessment of a previous phase can one proceed to the next stage of training ； The assessment scores for each stage should be included in the individual’s technical training records as a basis for obtaining certification to work. 5.3.5 The construction (production) unit must provide strict safety training to the construction workers, project supervisors, and externally hired logistics personnel involved in the trial operation. 5.4 Technical Preparation
5.4.1 The main tasks of technical preparation involve formulating various commissioning plans, production-related technical documentation, and management regulations, so that production personnel can master the techniques related to the operation of each unit, equipment maintenance, and handling of abnormal situations. 5.4.2 The construction (production) unit should establish a production technology management system as early as possible, and bring together, in phases, technical experts from fields such as process engineering, machinery, equipment, electrical systems, instrumentation, and analysis. By participating in technical negotiations, design discussions, and design reviews, these experts can gain thorough knowledge of technologies related to processes, equipment, instrumentation, computers, safety, and environmental protection, thereby acquiring the ability to handle various technical issues independently. The personnel involved in the technical preparation work should remain stable and take full responsibility for the professional tasks assigned to them. 5.4.3 Technical preparation work should focus on the following aspects: a) Organizing the preparation, or participating in the preparation and review, of plans for preliminary testing and joint testing ； b) Organize the preparation of the overall commissioning plan and the chemical feeding commissioning plan ； c) Organize the translation, reproduction, review, and editing of materials such as flowchart manuals for the introduced equipment, mechanical schematic handbooks, *** instructions, and operation manuals ； d) Organize the preparation of technical training materials, and place various test run plans (summaries) at the test site in an appropriate manner ； e) Organize the preparation of various operating procedures and process cards ； f) Collect information on design modification projects, changes in operating methods, and major issues that arise during installation and commissioning ； g) Prepare the test run operation record form and book. 5.4.4 The construction (production) unit shall, prior to the commissioning of the chemical plant, organize the production preparation department or engage relevant technical personnel from design and construction firms to prepare a commissioning plan and scheme for the chemical plant ； Two months prior to the chemical feed-in commissioning, an \"Overall Commissioning Plan\" shall be prepared based on the design documents and the \"Key Points for Preparations for Commissioning Production.\" The Overall Commissioning Plan must comply with the provisions of these specifications (see Appendix B: Outline for Preparing the Overall Commissioning Plan for details). 5.4.5 The construction (production) unit shall, based on the design documents and drawing on relevant information from similar installations both domestically and internationally, complete the preparation of various training materials, technical documents, commissioning plans, and assessment plans in a timely manner: a) Training materials mainly include: operating procedures and process cards, basic and specialized knowledge in areas such as processes, equipment, electrical systems, and instrument control, structural diagrams of major equipment, process flow diagrams, production preparation manuals, accident cases, conditions that must be met prior to commissioning, as well as materials on safety, environmental protection, occupational health, fire prevention, and gas protection ； b) Production technical documents mainly include: process flow diagrams, Safety Data Sheets for chemicals, process cards, operating procedures, analytical procedures, maintenance procedures, emergency response plans for accidents, Hazard and Operability Study (HAZOP) reports, safety instrumented function assessment reports (for installations classified as “two key areas and one major hazard”), control and interlock logic programs, design modification items, and major issues arising during the installation and commissioning phases; various reports, registers, technical archives, etc ； c) Comprehensive technical documents mainly include: information on enterprises and chemical plants, raw material manuals, material balance manuals, automatic control system manuals, product quality manuals, lubricants (greases) manuals, manuals on the discharge of waste gases, wastewater, and solid waste, equipment manuals, spare parts manuals, lists of safety facilities, lists of valves and gaskets, lists of bearings, etc., as well as the timely collection and organization of supplementary materials ； d) Various commissioning plans should cover all commissioning tasks, mainly including: 1) Power supply: from the external power grid to the main substation (main step-down station), from the main substation to the substations of various devices, connection of the on-site power plant to the external power grid, emergency power supplies, uninterruptible power supplies (UPS), DC power supply, and other power transmission and reception schemes ； 2) Water supply and drainage system: from the water source to the chemical plant area, raw water pretreatment, desalinated water, flushing of the circulating cooling water system, chemical cleaning, pre-coating, and commissioning plan for the wastewater treatment plant ； 3) Process air and instrument air: Air compressor commissioning, equipment and pipeline purging plan ； 4) Boilers and steam supply systems: Schemes for fuel systems, boiler flushing, chemical cleaning, boiler steaming, boiler drying, safety valve pressure setting, purging of steam pipelines at various pressures, temperature and pressure reducers calibration, and grid connection of multiple boilers (two or more) ； 5) Other industrial furnace solutions such as chemical cleaning, furnace boiling, and furnace drying ； 6) Air separation unit: air compressors, purging, pressure testing, airtightness testing, natural cooling, installation of insulation materials for air separation pipelines and equipment; operational plans for systems such as nitrogen compressors, oxygen compressors, liquid nitrogen, liquid oxygen, and liquid argon ； 7) Storage and transportation system: Plans for storing raw materials, fuels, acids and bases, the three types of agents (catalysts, solvents, additives), lubricants (greases), intermediate materials, and products (by-products), as well as for their transfer in and out of the facility (via railways, roads, ports, transfer stations, etc.) ； 8) Fire protection system: Testing plans for fire-fighting water, foam, dry powder, steam, nitrogen and carbon dioxide, detection of flammable and toxic gases, fire alarm systems, as well as other fire prevention and extinguishing facilities ； 9) Dispatch communication systems: call systems, intercom systems, dispatch telephones, fire alarm telephones, and other solutions ； 10) Plans for system cleaning, purging, pressure testing, airtightness testing, drying, and purging of chemical processing units ； 11) Loading, drying, activation, temperature-raising reduction, and regeneration procedures for the three types of agents (catalyst, solvent, additive) in chemical processing units ； 12) Commissioning plans for self-provided generator sets, emergency generators, self-provided thermal power plants, etc ； 13) Commissioning plans for key equipment such as large-scale units in chemical plants, as well as commissioning plans for equipment operating under ultra-high pressure, with a high length-to-diameter ratio, and equipment that involves flammable and explosive materials ； 14) Commissioning plan with interlocking, chemical feeding commissioning plan ； 15) Disposal plan for hazardous waste generated during the commissioning process. 5.4.6 The incoming equipment requires the translation and reproduction of technical documents such as detailed process descriptions, electrical diagrams, interlock logic diagrams, automatic control circuit diagrams, equipment schematic diagrams, patent-pending equipment structure diagrams, and operation manuals. A comparison table of domestic and international specifications for valves, flanges, gaskets, lubricants, steel materials, welding electrodes, bearings, etc., shall also be prepared. 5.4.7 The overall commissioning plan for chemical processing units and the commissioning plan involving the introduction of chemical materials shall be approved by the person in charge of the construction (production) unit or the commissioning management body ； All other types of commissioning plans, training materials, technical documents, etc., shall be approved by the technical director of the construction (production) unit or the commissioning oversight body. 5.5 Safety Preparedness 5.5.1 The construction (production) unit shall ensure adequate funding for safe production during the construction, production preparation, and commissioning phases of chemical plant projects. 5.5.2 Before the commissioning of a chemical plant, the construction (production) unit shall, in accordance with relevant laws and regulations, establish a safety production management organization and assign full-time safety production managers. During the test run, additional safety personnel should also be added as needed to meet the requirements for safe testing. 5.5.3 The construction (production) unit shall thoroughly collect, organize, and compile relevant domestic and international safety technical materials and accident cases, as well as the enterprise’s regulations for the use, maintenance, and management of safety and fire protection facilities in chemical plants, along with information on the location and usage of such facilities. It is necessary to identify the safety conditions that must be met prior to the commissioning of chemical plants, and to use this information to develop training materials for targeted education. 5.5.4 The construction (production) unit must, in accordance with the design documents and the provisions of **relevant standards, provide employees with personal protective equipment that meets **the standards or industry standards, and supervise and educate them on how to wear and use such equipment correctly. Equipment for safety, occupational health, fire protection, gas prevention, first aid, communication, etc., should be provided at the work sites as required by the design and testing processes. 5.5.5 The construction (production) unit shall, in accordance with the risk assessment management procedures, use methods such as Job Hazard Analysis (JHA), Safety Checklist Analysis (SCL), Preliminary Hazard Analysis (PHA), and Hazard and Operability Study (HAZOP) to analyze various units, auxiliary facilities, and operational activities. It shall identify potential hazard factors and the levels of risk in different areas, formulate corresponding measures, prepare emergency response plans, establish emergency rescue organizations and teams, organize training and drills, and file relevant reports with the local authorities. 5.5.6 The construction (production) unit shall employ Hazard and Operability Study (HAZOP) techniques to systematically and thoroughly examine the process and operations, analyze the established operating procedures, identify the causes and consequences of deviations, determine the safety devices that should be used to address such deviations and consequences, and propose corresponding improvement measures. For installations involving the \"two key areas and one major concern\" (highly regulated hazardous chemical processes, highly regulated hazardous chemicals, and major hazard sources of hazardous chemicals), safety instrument functions and the requirements for risk reduction are determined through risk analysis, based on process hazard analyses such as Hazard and Operability Studies. This analysis is used to assess whether the existing safety instrument functions meet the requirements for risk reduction. 5.5.7 The emergency exits at the chemical plant commissioning site should be kept unobstructed ； The safety exit doors of buildings should open outward, and their number must meet the required standards ； The safety evacuation routes for the framework or platform of the equipment should be properly arranged ； The evacuation routes are equipped with emergency lighting and evacuation signs ； Wind vane should be installed at locations where toxic and harmful gases may leak or be released. 5.5.8 The construction (production) unit shall, prior to the trial run with raw materials, complete the identification, safety assessment, classification, registration, and documentation of major hazard sources, and submit materials such as the files on major hazard sources to the local competent authorities for the record as required. 5.5.9 The construction (production) unit shall organize investigations into the safety conditions of the environment surrounding the chemical plant, and take appropriate measures in advance to ensure safety in the area around the plant during commissioning: a) The location of the chemical plant shall comply with relevant national and local laws, regulations, rules, and standards regarding urban and rural planning, safety, environmental protection, fire protection, and occupational health. Villages, residential areas, buildings, and industrial facilities that are planned to be relocated in the vicinity must be moved away, and any other issues that could affect safe production must be completely resolved ； b) Before commissioning chemical plants involving major hazard sources and hazards such as flammability, explosiveness, toxicity, and severe noise pollution, the construction (production) unit shall, in accordance with relevant regulations, inform neighboring enterprises and residential areas of these hazards in an appropriate manner ； c) In cases where various surrounding production and daily activities may have a serious impact on the safety of chemical plant commissioning, the construction (production) unit shall report such activities and harmful factors to the local ** and relevant authorities, to assist them in organizing corrective actions to eliminate these risks. 5.5.10 Before commissioning, it is necessary to designate restricted areas and implement measures to limit personnel access to the chemical processing unit areas. Except for those who must be present for on-site command, liaison, and production operations, those not included in the commissioning process must evacuate to a safe area ； All personnel entering or exiting restricted areas must be registered, with their contact information and work areas clearly recorded: a) For all individuals entering restricted areas, zone-based management and positioning measures shall be implemented; during test runs, they must not arbitrarily exceed the designated areas ； b) Before testing, the area within the installation site must have clear markings indicating the area restrictions; management procedures should be established, and targeted training should be provided. 5.6 Preparation of Materials and External Conditions 5.6.1 Material Preparation 5.6.1.1 The construction (production) unit must conduct thorough investigations into the suppliers of major raw materials and fuels, to ensure that the types and specifications of the supplied materials meet the requirements specified in the design documents, thereby guaranteeing a stable supply on time, in terms of quality and quantity. 5.6.1.2 The construction (production) unit shall, in accordance with the requirements of the commissioning plan, prepare a supply plan for the raw materials, fuels, three types of agents (catalysts, solvents, additives), chemical substances, standard sample gases, spare parts, lubricants, emergency supplies, packaging materials, and packaging containers required for commissioning. It shall also determine the types and quantities needed (including the amount for initial loading, the amount used during commissioning, and the reserve amount) based on the schedule of usage, and enter into supply agreements or contracts with the suppliers. 5.6.1.3 All kinds of chemical raw materials, lubricants (greases), spare parts, tools, etc. should undergo strict quality inspection, and be stored and kept properly to prevent damage, loss, or deterioration. Additionally, classification, record-keeping, card management, and shelving should be carried out to ensure that the records match the actual items. 5.6.2 Preparation of external conditions 5.6.2.1 The construction (production) unit shall, in accordance with the agreements regarding water supply, steam supply, power supply, communications, etc., signed with external parties, and in line with the requirements of the overall commissioning plan, determine the timing of activation, the amount to be used, and the technical parameters. 5.6.2.2 The construction (production) unit shall, in accordance with the progress of projects such as roads, railways, docks, transfer stations outside the plant, flood control and drainage systems, industrial wastewater treatment, and waste disposal, promptly coordinate with the relevant management departments to ensure their operation. 5.6.2.3 The construction (production) unit shall implement various measures related to safety, fire protection, environmental protection, occupational health, earthquake resistance, lightning protection, and the inspection of special equipment. It shall apply to the relevant authorities for the necessary approval procedures in accordance with laws and regulations, so as to carry out tests in a lawful manner. 5.6.2.4 If a construction (production) unit needs to rely on social emergency rescue forces such as fire protection and medical assistance, as well as public service facilities, it shall promptly enter into agreements or contracts with such relying entities. 5.6.3 The construction (production) unit shall prepare an annual production preparation fund plan based on the design estimate to ensure the availability of funds for production preparation. When preparing the overall commissioning plan, a plan for commissioning costs and working capital should be formulated to ensure they are secured as early as possible. 5.7 Marketing and Product Storage and Transportation Preparation 5.7.1 Marketing Preparation Before starting up chemical production, the manufacturing (production) unit should determine the distribution route for the products and enter into sales agreements or contracts with customers. In addition, a product instruction manual should be prepared; for products that are hazardous chemicals, safety data sheets and safety labels must also be prepared in accordance with **relevant standard requirements, and the necessary permits must be obtained. 5.7.2 Product storage preparation: Before starting up the plant with chemical feedstocks, the storage facilities must be properly connected to the production units to ensure safe and smooth transfer and storage of products. Chemical feeding trials shall not be carried out when product marketing and storage capabilities cannot meet the requirements of the trial run. 5.7.3 Logistics Preparation: Before starting up the chemical production process, the construction (production) unit must determine the methods and channels for transporting the products, establish a comprehensive system for verifying transportation qualifications, licenses, and safety facilities, and handle all necessary procedures related to the transport of raw materials and products in accordance with **relevant regulations. Those transporting highly toxic chemicals by road must apply to *** authorities for a road transport permit ； For those relying on external transportation services, a transportation agreement and a safety agreement should be signed with the transportation company to ensure smooth product logistics. 5.8 Other Preparations 5.8.1 Preparation for Logistics Support The construction (production) unit shall, based on factors such as the time, location, personnel involved, and environment of the trial run, implement support measures related to logistics aspects such as food and accommodation, transportation, communication, medical emergency services, heat prevention and cooling, cold and frost protection, as well as weather information, to ensure that the necessary personnel, measures, facilities, and standards are in place. 5.8.2 Preparations related to technology provision, patent ownership, or the cooperation of contractors 5.8.2.1 Conduct on-site technical verification of the equipment and propose as well as implement corrective actions. 5.8.2.2 The control systems of the equipment, such as DCS and SIS, have been successfully commissioned. 5.8.2.3 Provide relevant technical training to the personnel of the construction (production) units. 5.8.2.4 Formulate test plan, objectives, and requirements based on the characteristics of the proprietary technology. 5.8.2.5 Participate in the development of production assessment methods and procedures, and assist in carrying out production assessments for projects. 5.8.3 Relevant preparations for cooperation with the design unit
5.8.3.1 Verify the building installation works in accordance with the design requirements, and conduct a comprehensive review of the design (including any design changes). 5.8.3.2 Provide operation manuals, analysis manuals, and safety guidelines in construction drawing format. 5.8.3.3 Participate in the review of the owner’s operating procedures, safety technical regulations, analysis procedures, etc., to confirm various operational indicators. 5.8.3.4 Participate in tasks such as project handover. 5.8.3.5 Participate in the development of production assessment methods and procedures, and assist in carrying out the production assessment work for the project. 5.8.4 Relevant preparations by the construction and supervision units 5.8.4.1 Complete the final stages of the project and related commissioning tasks in accordance with the requirements of the overall commissioning control plan. 5.8.4.2 Participate in the preparation of the overall commissioning plan and ensure proper coordination among various tasks. 5.8.4.3 Before the chemical plant is put into operation following material feeding, a commissioning service team should be organized to carry out regular inspections, ensure proper maintenance of the relevant equipment, and address any issues that arise promptly. 5.8.4.4 Issue a conclusion on the supervision of project quality. 5.8.4.5 Complete the relevant procedures for special equipment. 5.8.5 Relevant preparations by equipment manufacturing and supply units 5.8.5.1 Providing a list of spare parts within their shelf life, along with those spare parts themselves. 5.8.5.2 Guide the installation of equipment, verify the conditions for individual unit tests, review and confirm the plans for such tests, resolve any issues related to the equipment during individual unit tests, and participate in joint tests as well as tests involving the introduction of chemical materials. 5.8.5.3 Provide equipment operation, maintenance, and repair manuals. 5.8.5.4 Provide training for personnel from the construction (production) units on equipment principles, accident handling, startup and shutdown, operation, and maintenance. 5.8.5.5 Provide the product certificate of conformity, product quality certificate, as-built drawings, and the product manufacturing safety and quality supervision inspection certificate issued by the quality and technical supervision department, etc. 6 Preliminary Testing and Combined Testing 6.1 General Provisions 6.1.1 The main purposes of preliminary testing and combined testing are to carry out internal work on the piping systems and equipment, as well as electrical and instrumentation adjustments, and to conduct individual unit tests and combined tests on the chemical processing plant after the installation is completed but before starting up the plant with actual chemicals, thereby preparing it for operation. 6.1.2 General requirements for pre-commissioning and joint commissioning: a) Pre-commissioning and joint commissioning must be carried out in accordance with the overall commissioning plan and the provisions of the commissioning scheme; commissioning shall not proceed if the necessary conditions are not met ； b) Pre-commissioning and joint commissioning shall be carried out after the necessary production preparation work is completed and fire protection and utility systems are in proper operating condition ； c) Before the preliminary test run and the combined test run, the construction (production) unit, the design unit, the construction contractor, the technology provider, and the equipment manufacturer or supplier shall explain the potential hazards during the test run process as well as the relevant technical measures, and provide written records thereof; the construction contractor shall prepare a report on the construction of safety facilities for the project and submit it to the construction (production) unit ； d) Before the preliminary test run and the joint test run, it is necessary to confirm that the testing unit is isolated from other equipment or pipelines that are in use or awaiting testing, and that appropriate safety measures have been taken; a dedicated person should be assigned to supervise the testing process ； e) Pre-commissioning and integrated commissioning must be carried out step by step. Safety must be given top priority; safety facilities must be commissioned simultaneously with the production equipment. Commissioning of the next step shall not proceed until the causes of any accidents in the preceding step have been identified and all defects have been eliminated ； f) For equipment that cannot be tested due to limitations imposed by utility services or media, it may be postponed to the stage of chemical feeding and testing, upon mutual agreement among the construction (production) unit, the design unit, and the equipment manufacturing or supply unit ； g) After all preliminary testing and joint commissioning activities are completed, the construction (production) unit shall organize relevant departments and experts to conduct an inspection to confirm whether the conditions for chemical feeding and commissioning are met. 6.1.3 During the pre-commissioning and joint commissioning phases, depending on factors such as process technology, equipment and facilities, utility and auxiliary systems, as well as the scale and complexity of the installation, the following aspects should be primarily controlled: pressure testing of the piping system ； Pipeline system leak test ； Water flushing ； Steam purging ； Chemical cleaning ； Air purge ； Pre-film formation in the circulating water system ； System replacement ； Commissioning of general motor-driven equipment ； Testing of steam turbines and pumps ； Reciprocating compressor commissioning ； Oven drying ； Boiling furnace ； Filling of towers and vessel internals ； Filling of catalysts, adsorbents, molecular sieves, etc ； Re-inspection of heat exchangers ； Commissioning of the instrument system ； Commissioning of electrical systems ； Interim project handover ； Joint commissioning. 6.1.4 The system cleaning, purging, and boiler boiling shall be planned by the construction (production) unit, and carried out by the same unit. Stringent quality control must be applied to system cleaning and purging; parameters such as the medium used, flow rate, velocity, and pressure, as well as the inspection methods, must meet the requirements of the design specifications. The equipment introduced must comply with the standards provided by the foreign suppliers. During system purging, it is strictly prohibited for unqualified media to enter equipment such as pumps, heat exchangers, cryogenic tanks, towers, and reactors. Orifice plates, flow meters, control valves, temperature sensors, etc., installed on pipelines should be removed during chemical cleaning or purging, and for welded valves, the valve cores should be removed or the valves should be fully opened. The purging and cleaning of oxygen pipelines, high-pressure boilers (high-pressure steam pipelines), and other pipelines and equipment with special requirements shall be carried out in accordance with relevant specifications. After purging and cleaning are completed, it should be handed over to the production unit for protection with nitrogen or another medium. Air should be used as much as possible for system purging ； When nitrogen must be used, measures to prevent nitrogen asphyxiation should be established ； If steam or fuel gas is used, corresponding safety measures must also be in place. 6.1.5 Records for the pre-commissioning and joint commissioning phases: a) The pre-commissioning and joint commissioning reports shall be prepared by the commissioning oversight body, and signed off by authorized representatives from all units involved in the commissioning process ； b) The pre-commissioning and joint commissioning reports shall include the commissioning items, dates, participants, brief process, commissioning conclusions, as well as existing safety hazards and corrective measures ； c) The format, content, and number of copies for the pre-commissioning and joint commissioning records shall be proposed by the commissioning organization, and shall be used after approval by the principal responsible person of the commissioning leadership body ； d) A test run record must be filled out for each test run project, and it must be signed and confirmed by an authorized person from the unit participating in the test run. 6.2 Single-unit commissioning
6.2.1 Prior to single-unit commissioning, engineering installation and finishing work should be essentially completed, so that the conditions for single-unit commissioning are met. 6.2.2 The construction (production) unit should focus on commissioning tests and ensure the completion of final tasks, coordinating and synchronizing the progress of these final tasks with the commissioning process. It should organize production staff to arrive at the site as early as possible, and carry out \"three inspections and four determinations\" on a specialized basis: checking for design omissions, assessing the quality of the work and any potential hazards, and identifying unfinished tasks. For the issues identified, tasks, responsible persons, measures, and deadlines for rectification should be determined, so that problems can be detected and resolved promptly. 6.2.3 Before single-unit commissioning, the commissioning plan has been formulated and approved ； The commissioning organization has been established; the commissioning operators have received training and passed the assessments, are familiar with the commissioning plan and operating procedures, and are able to carry out the operations correctly ； There is a definite guarantee for the fuel, power, instrument air, cooling water, demineralized water, etc. required for testing ； Testing instruments, tools, and record forms are all available, and the warranty technician is on site. 6.2.4 The individual testing of rotating equipment, excluding key equipment such as large-scale units, shall be organized by the construction (production) unit, which shall establish a testing team ； The construction unit prepares and implements the commissioning plan, with the cooperation of the construction (production) unit, and participation from relevant personnel from design, supply, and other units. 6.2.5 The commissioning must include automatic control devices such as protective interlocks and alarms ； Command and operation must be carried out in accordance with the mechanical equipment manual, commissioning plan, and operating procedures ； Multiple leaders giving orders, as well as illegal commands and operations, are strictly prohibited to prevent accidents. 6.2.6 For the individual testing of key equipment such as large-scale units, the construction (production) unit shall organize a testing team; the construction unit shall prepare a testing plan, which must be jointly approved by the construction (production) unit along with the design, construction, and supply vendors. The commissioning operations shall be carried out by operating personnel selected by the construction (production) unit, who have received proper training and hold valid work permits. The commissioning of large-scale units should be carried out under the guidance or supervision of the supplier, and the supplier’s responsibilities for technical guidance or supervision should be clearly specified in the supply contract. 6.2.7 The temporary facilities to be added during the single-unit commissioning (such as pipelines, valves, blind flanges, strainers, etc.) shall be planned by the construction unit, reviewed by the construction (production) unit, and then constructed by the construction unit. 6.2.8 The electricity, steam, process water, circulating water, deionized water, instrument air, process air, nitrogen, fuel gas, lubricating oil (grease), and materials required for single-unit commissioning shall be supplied by the construction (production) unit, or in accordance with the relevant contract terms. 6.2.9 During the single-unit commissioning process, commissioning records must be filled out in a timely manner. Once the single-unit commissioning is successful, the construction (production) unit shall organize personnel from the construction (production), construction, design, supervision, quality inspection, and other relevant units to conduct verification and sign off. The introduction of installations or equipment is carried out in accordance with the contract. 6.3 Interim Handover of the Project 6.3.1 When a single project or part of the installation is completed, and after the internal processing of the piping systems and equipment, as well as the electrical and instrumentation debugging, have been finished and the individual unit tests have been successful, the construction (production) unit and the contracting party may proceed with the interim handover of the project, thereby moving from individual unit testing to combined system testing. Interim handovers in engineering projects are generally carried out on a per-project or per-system basis; for technical renovation projects that overlap with production, interim handovers for sub-projects can also be conducted. After the interim handover of the project, the construction contractor shall remain responsible for the project until its final acceptance. 6.3.2 Conditions required for intermediate handover of the project: a) The project has been completed in accordance with the design specifications ； b) The preliminary assessment of the project quality is satisfactory ； c) The pipeline pressure test is complete; the system has been cleaned, purged, and made airtight, with insulation work largely finished ； d) The strength tests, non-destructive inspections, vacuum tests, airtightness tests, etc., of the static equipment have been completed; cleaning is finished, and the safety accessories (safety valves, explosion-proof doors, etc.) have been properly calibrated ； e) The individual testing of the moving equipment has been successful (except for those that could not be tested due to limitations imposed by utility systems or media) ； f) The load testing using air, nitrogen, or other media for large-scale units has been completed, and the automatic control systems such as unit protection interlocks and alarms have been successfully calibrated and tested ； g) The electrical, instrumentation and control systems of the device, as well as systems for preventing poison, fire and explosion, have passed commissioning and calibration tests ； h) The temporary facilities used during construction in the equipment area have been removed; the work is completed, all materials have been cleared away, and the site is clean; the vertical structure construction has been finished ； i) The “three inspections and four determinations” items and design changes that affect the joint commissioning have been resolved; the responsibilities and completion timelines for all other outstanding construction tasks unrelated to the joint commissioning have also been clearly defined. 6.3.3 Contents of interim project handover 6.3.3.1 Verification and handover of the physical quantities of the project in accordance with the design specifications. 6.3.3.2 Review, verification, and handover of preliminary evaluation materials for project quality and relevant commissioning records. 6.3.3.3 Handover of specialized installation tools and remaining spare parts and materials. 6.3.3.4 Implementation plan for the settlement of project residual items and confirmation of completion time. 6.3.3.5 Handover of random technical documents. 6.3.4 For intermediate handover of the project, the construction (production) unit shall first organize the general contractor, production team, construction team, supervision team, design team, and other relevant parties to conduct intermediate inspections on a unit-by-unit and specialty-by-specialty basis. Finally, an intermediate handover meeting shall be held with the participation of the general contractor, design team, construction team, supervision team, and project management team, all of whom shall sign the certificate of intermediate project handover along with its attachments. The intermediate handover of projects involving the introduction of installations or equipment is carried out in accordance with the contract. 6.4 Combined Testing 6.4.1 The focus of combined testing is to master the starting and stopping processes as well as the simulation of various process conditions, and to identify any defects. It is generally advisable to begin with a single system, and then progress to the combined operation of several systems or the entire installation. 6.4.2 The joint commissioning must meet the following conditions, and may only commence after a thorough inspection confirms that all requirements are satisfied: a) All individual tests of the machines and equipment within the commissioning scope have been successful, and the construction of individual projects or units as well as the intermediate handovers have been completed ； b) A production management organization has been established, and post responsibility systems have been formulated, implemented, and enforced ； c) The technical personnel, team leaders, and operators have been identified, passed the examinations, and obtained their work permits ； d) The equipment tag numbers, the names of the pipeline media, their flow direction, and safety colors have been marked in accordance with the specifications ； e) The public utilities are operating smoothly ； f) The commissioning plan and relevant operating procedures have been approved and distributed to the respective positions and individuals, and are displayed in an appropriate form on site ； g) The commissioning process parameters, interlock values, and alarm values shall be approved and published by the production technology department ； h) The production record forms are complete and have been distributed to the relevant positions ； i) The mechanical, electrical, instrumentation repair areas and the laboratory have been put into use ； j) The communication system is now operational ； k) Safety facilities (facilities for preventing accidents, controlling accidents, and mitigating/eliminating the effects of accidents) are in good condition ； l) The occupational health monitoring sites have been identified, and the signboards and warning signs that should be installed in accordance with regulations and standards are in place ； m) The logistics team has been assembled and is in place ； n) All hazards such as equipment, debris in areas and passages that pose a safety risk at the commissioning site have been removed. 6.4.3 The joint commissioning plan shall be prepared and implemented by the construction (production) unit, with the participation of the construction and design units. It mainly includes the following: a) the purpose of testing, the organization and command of testing, and the conditions required for testing. b) Commissioning procedures, progress network diagram. c) Main process parameters, analysis parameters, interlock values, and alarm values. d) Key points for startup, shutdown, and normal operation. e) Appropriate safety measures and emergency response plans for accidents. f) Quantity and quality requirements for commissioning materials. g) Commissioning and operation maintenance system. 6.4.4 Display instruments and alarm devices that are not affected by process conditions shall all participate in the joint commissioning. Automatic control and interlock devices may be put into service gradually during the commissioning process. Prior to the activation of the interlock devices, measures must be taken to ensure safety. During the commissioning, it is necessary to check and verify that the valve positions of all automatic control valves correspond to those displayed in the control room. 6.4.5 The joint commissioning should ensure that the system operates smoothly and in a connected manner within the specified time frame ； Personnel participating in the trial run must, according to their levels and categories, master the operational skills related to startup, shutdown, accident handling, and adjustment of process conditions ； Through joint commissioning, any defects and potential hazards in the chemical plant can be promptly identified and eliminated, thereby improving the conditions for the actual feedstock commissioning. Upon the completion of the joint commissioning, the construction (production) unit may carry out the project handover procedures with the construction contractor or general contractor, in accordance with the contract provisions. 7 Chemical Industry Commissioning 7.1 Commissioning Conditions Prior to the commissioning of chemical processes, the construction (production) unit must conduct a strict and thorough inspection of the commissioning conditions. Test runs must adhere to high standards and strict requirements. They should be carefully organized, with strict observance of the “four no-start rules”: do not start if conditions are not met; do not start if procedures are unclear; do not start if supervisors are absent; and do not start if problems remain unresolved. Without proper preparatory work, the chemical feed trial run shall not be carried out. For details, please refer to Appendix D: “Conditions Required for Chemical Plant Commissioning”. 7.2 Commissioning plan and standards 7.2.1 The commissioning plan for chemical plant start-up shall be prepared and implemented by the construction (production) unit, with the participation of design and construction units; for imported equipment, the provisions of the contract shall be followed. It mainly includes the following basic contents: a) Overview of the equipment and commissioning objectives; organization and command system for commissioning ； b) Conditions required for trial operation ； c) Commissioning procedures, schedule, and control points ； d) Test run load and balance of raw materials and fuel ； e) Balance of water, electricity, steam, gas, etc. during trial operation ； f) Process technical indicators, interlock values, alarm values ； g) Key points for startup, shutdown, and normal operation, as well as emergency measures for accidents; safety measures and precautions against fire, explosion, poisoning, asphyxiation, etc ； h) Environmental protection measures, commissioning and operation assurance system, difficulties in commissioning and countermeasures ； i) Possible problems during trial runs and their solutions ； j) Budget for commissioning costs. 7.2.2 The following regulations shall be observed for the commissioning of chemical plants: a) The commissioning must be under unified command; multiple chains of command and commands given beyond the designated level are strictly prohibited ； b) Strictly control the number of personnel at the test run site. Personnel participating in the test run must wear test run badges in a visible location; those without such badges are not allowed to enter the test run area ； c) Conduct the testing strictly in accordance with the testing plan and operating procedures ； d) The primary objectives of testing are safe operation, establishing a functional production process, and producing qualified products; there is no requirement to achieve optimal process conditions or production volumes ； e) Testing must be carried out step by step; the next testing stage shall not proceed if the previous stage is not stable or the conditions for the next stage are not met ； f) Instrumentation, electrical, and mechanical personnel must work closely with operators; when repairing machinery or adjusting instruments and electrical systems, a safety work permit must be obtained in advance ； g) During the test run, in addition to conducting analyses according to the items and frequencies specified in the design documents and analysis procedures, additional analysis items and frequencies should be added as needed during the test run, with proper records kept ； h) In the event of an accident, it must be handled resolutely in accordance with the relevant regulations on emergency response ； i) Chemical feeding commissioning should be carried out as far as possible away from the severe winter season; otherwise, a winter commissioning plan must be developed and anti-freezing measures implemented ； j) After the chemical plant’s commissioning tests are successful, any defects and potential hazards identified during the tests should be promptly addressed, gradually progressing to full-load testing so as to create conditions for production evaluation. 7.2.3 The chemical feeding commissioning shall meet the following standards: a) The key control points of the commissioning shall be reached on schedule, and qualified products shall be produced through continuous operation ； b) No accidents occur related to equipment, operations, fire, explosion, personal injury, environmental protection, etc ； c) Ensure that safety, environmental protection, fire protection, and occupational health measures are implemented simultaneously, with monitoring parameters meeting relevant standards ； d) After producing qualified products, operate continuously for more than 72 hours ； e) Ensure proper material balance and keep trial operation costs under control. 7.3 Commissioning team
7.3.1 For the commissioning involving chemical feedstock introduction, a commissioning team should be formed based on the actual circumstances of the chemical plant and the construction (production) unit. This team should primarily consist of personnel from the construction (production) unit, along with representatives from the general contractor, design firm, construction contractors, technical or start-up assistance providers, as well as domestic and foreign experts. 7.3.2 During the commissioning period, the construction (production) unit may, depending on the technical complexity of the installation, hire experts to form a commissioning technical advisory team to analyze the technical challenges associated with commissioning and propose corresponding countermeasures. 7.3.3 The design unit shall arrange key design personnel to go to the site to address design issues identified during testing. 7.3.4 The construction (production) unit may, in accordance with the requirements of commissioning, arrange in advance the personnel and schedule of units providing assistance for startup or relevant technical experts to be on site, so as to fully leverage their role in providing technical oversight and guidance (see Appendix E: Guidelines for Hiring Technical Advisors and Startup Personnel). 7.3.5 The construction (production) unit shall, in conjunction with the general contractor, construction team, design unit and other parties, establish a maintenance organization to uniformly coordinate the maintenance work during the commissioning period. In line with the principle of \"whoever installs it is responsible for its maintenance,\" a maintenance contract shall be signed with the construction unit. The construction unit shall implement a system of full responsibility for installation, commissioning, and operation maintenance; the operation maintenance staff shall be on duty at the site 24 hours a day to ensure continuous operation maintenance throughout the process. 8 Parking 8.1 Normal Parking 8.1.1 Normal parking refers to a planned and deliberate shutdown that takes place after a chemical plant has been in operation for some time, due to maintenance work on the plant, anticipated abnormalities in the supply of utility services, or failures in upstream or downstream processes. 8.1.2 For routine shutdowns of chemical processing units, the following preparatory measures shall be taken: a) Prepare a shutdown plan, and all personnel involved in the shutdown must be trained and familiar with this plan ； b) Various tickets such as parking operation tickets and process operation coordination tickets are complete and distributed to the relevant positions ； c) Parking tools and equipment, as well as personal protective equipment, are fully available, such as specialized parking tools, communication devices, emergency lights, protective clothing, etc ； d) Replacement cleaning plan after parking, parking valve layout, etc ； e) Various forms and registers for parking. 8.1.3 The conventional shutdown plan for chemical plants mainly includes the following: a) Organization of the shutdown, as well as assignment of tasks and responsibilities to personnel ； b) Shutdown time, steps, range of process variations, process control parameters, shutdown sequence table, and corresponding operation tickets ； c) Tools required for parking, as well as instruments for measurement, analysis, etc ； d) Operating procedures for isolation, purging, blanketing, cleaning, etc. of chemical plants ； e) Safety measures for chemical plants and personnel, as well as emergency response plans for accidents ； f) Methods for handling residual materials in chemical plants ； g) Maintenance and care measures after parking. 8.1.4 The following points should be noted for routine shutdown of chemical processing units: a) All personnel responsible for command, operation, etc. must be present ； b) The relevant contact form must be filled out and approved by the production scheduling department and relevant supervisors ； c) It must be carried out according to the steps specified in the parking plan ； d) Maintain close communication with upstream and downstream processes as well as related sections (such as boilers, power distribution rooms, etc.), and stop the operation of equipment in strict accordance with established procedures; when stopping large-scale transmission equipment, it is necessary to first shut down the main units and then the auxiliary units ； e) The pressure relief operation of the equipment should be carried out slowly; the equipment must not be disassembled until the pressure has been fully released ； Pay attention to the emission and release of hazardous chemicals that are flammable, explosive, toxic, etc., to prevent accidents ； f) Flammable, explosive, toxic, and corrosive materials should be discharged into designated safe locations or storage tanks, with warning signs and labels installed ； Combustible and toxic gases emitted that cannot be collected and utilized should be sent to a flare for combustion or subjected to other non-toxic and harmless treatment methods ； g) The system’s pressure and temperature must be reduced in accordance with the specified rates, following a sequence of reducing pressure first before reducing temperature. In cases where it is necessary to maintain constant pressure or temperature, the changes in pressure and temperature must be recorded at regular intervals after the system is shut down ； h) The valve should not be opened too quickly; pay attention to pipeline preheating, condensate removal, and protection against water hammer ； i) When shutting down high-temperature vacuum equipment, it is necessary to first eliminate the vacuum condition; only after the temperature of the medium inside the equipment drops below its auto-ignition point can it be connected to the atmosphere, in order to prevent air from entering and causing a fire or explosion ； j) The shutdown procedure must be carried out strictly in accordance with the cooling curve specified in the regulations, taking into account the impact of the extinguishment of burners in various areas on the uniformity of furnace cooling ； Draining and low-point condensate removal must not be carried out when the burners have not been completely extinguished or when the furnace temperature is high, to prevent combustible gases from entering the furnace and causing accidents ； k) It is strictly prohibited to let high voltage leak into low voltage while parking ； l) When parking, proper safety measures must be taken to protect relevant personnel from being injured by materials ； m) After parking in winter, take anti-freezing and insulation measures; pay attention to low-lying areas, dead corners, as well as water, steam, pipelines, valves, traps, and insulation bypass pipes to prevent damage due to freezing ； n) The automatic stop interlock device used for emergency handling should not be used for normal stops. 8.2 Emergency Shutdown 8.2.1 An emergency shutdown refers to an unplanned and passive shutdown that occurs during the operation of a chemical plant, as a result of unexpected equipment failures, human operational errors, or deteriorating process conditions, which make it impossible to maintain the normal operation of the plant. Emergency shutdowns are divided into partial emergency shutdowns and full emergency shutdowns. A local emergency shutdown refers to the emergency shutdown of a specific piece of equipment or a particular part of the production system during the manufacturing process, while a full-scale emergency shutdown refers to the emergency shutdown of the entire production facility system during that process. 8.2.2 In view of the unpredictability of emergency shutdowns in chemical plants, the construction (production) unit shall, based on the design documents and relevant information regarding the process equipment, conduct a thorough analysis of all possible conditions that could lead to an emergency shutdown, and prepare targeted shutdown response plans in advance. The emergency shutdown response plan should mainly include the following contents: a) Identification and analysis of risk factors that could lead to an emergency shutdown of the chemical plant ； b) Key control points leading to emergency shutdown and preventive measures ； c) Personnel dispatch procedures, role assignments, emergency shutdown operation sequences, and process control parameters for the emergency shutdown of chemical plants under various operating conditions ； d) Device maintenance measures after emergency shutdown ； e) Safety measures for personnel after an emergency stop. 8.2.3 Precautions during emergency shutdown of chemical plants: In addition to following the procedures for normal shutdown, the following points should also be taken into account: a) Upon detecting or experiencing an emergency, it is necessary to report it immediately to the production control department and relevant parties as required; if necessary, actions can be taken first before reporting ； b) In the event of a power outage, water outage, or gas outage, measures must be taken to prevent the system from overheating, overpressuring, experiencing leaks, and causing damage to mechanical and electrical equipment ； c) In the event of an emergency stop, personnel engaged in maintenance, inspections, construction, and other activities at the production site should immediately cease their work and evacuate the area promptly ； d) In the event of fires, explosions, major leaks, or other accidents, the gas (material) supply should be cut off first, and the emergency response plan for such incidents should be activated as soon as possible. 8.2.4 After an emergency shutdown occurs, the construction (production) unit shall conduct a thorough analysis of the problems existing in aspects such as process technology, facilities and equipment, and control systems. It shall carefully evaluate the effectiveness and safety of various measures taken during and after the shutdown, and take actions to make improvements in order to avoid or reduce the occurrence of various emergency shutdown incidents. 9 Production Assessment 9.1 Commissioning Summary 9.1.1 The construction (production) unit shall ensure proper recording and accumulation of all original data related to commissioning. 9.1.2 In principle, the construction (production) unit should, within six months after the completion of the chemical plant commissioning trial (or within three months for medium and small-scale chemical plants), prepare a summary of the commissioning trial based on the organization, compilation, and analysis of the original records, and keep it on file. 9.1.3 The test run summary should primarily include the following contents: a) All preparatory work for production ； b) Actual trial operation steps and schedule ； c) Comparison chart between the actual test network and the planned network ； d) Difficulties encountered during the commissioning process and countermeasures ； e) Statistical analysis of start-up and shutdown accidents ； f) Stability and effectiveness of safety facilities, existing problems, and countermeasures ； g) Commissioning cost analysis ； h) Experience and lessons from testing ； i) Opinions and suggestions. 9.2 Stability Operation Tests 9.2.1 After the chemical feeding commissioning is completed, the chemical plant enters a phase in which the production load and product quality are increased, in order to test its ability to operate safely and stably over extended periods of time. Construction (production) units should gradually increase the system load, boost the capacity of the facilities, reduce raw material consumption, and optimize process operation parameters. They must subject various safety facilities to long-term operational testing, identify and rectify any existing problems, in order to achieve the goals of safe and stable operation of the facilities, high-quality and high-volume production of products, optimal process parameters, precise operation control, a comfortable working environment, and maximum economic benefits. 9.2.2 Main measures to be taken for the long-term operation of chemical plants: a) Further test, verify, adjust, and establish the process parameters of the chemical plant to ensure they meet the requirements of its actual operating conditions ； b) Based on the operating conditions of the chemical plant, develop plans for addressing defects, carrying out maintenance, and implementing upgrades, in order to optimize equipment and eliminate safety hazards ； c) Bring all automatic control systems into operation to evaluate their suitability, sensitivity, and safety ； d) Ensure the overall balance of utility systems to meet the requirements for the safe and stable operation of the chemical plant under different production loads over extended periods of time. 9.2.3 Points to note for the long-term operation testing of chemical processing units: a) The production load of the unit should be tested under three conditions – low load, medium load, and high load – to ensure stable operation; if the requirements for stable operation are not met in any given stage, the unit shall not proceed to the next stage ； b) For each load stage, it is necessary to conduct analyses of the equipment, processes, and utility systems required to proceed to the next load stage; measures should be taken to address any bottlenecks that may hinder the stable operation of the chemical plant in advance, so as to prepare for load adjustments ； c) The safe operating conditions for each load stage must be carefully examined and analyzed to identify any existing safety hazards; measures must be taken to eliminate them completely, with proper documentation kept ； d) During the operation of the chemical plant, the adjustment range should not be too large; it is necessary to gradually determine the optimal operating conditions for system stability, while also identifying the bottlenecks that prevent an increase in the system’s load, thereby providing a basis for system optimization. 9.3 Production Assessment 9.3.1 The main task of production assessment is to conduct a comprehensive evaluation of whether the production capacity, safety performance, process parameters, environmental protection standards, product quality, equipment performance, level of automation, and consumption quotas of chemical processing units meet the design requirements, including a thorough assessment of the capabilities of the supporting utility systems and auxiliary facilities. The production assessment for the introduced equipment is carried out in accordance with the contract. 9.3.2 Chemical construction projects shall not undergo completion acceptance without passing production assessment. 9.3.3 The construction (production) unit shall, in conjunction with research, design, construction and other units, carry out the following preparatory work prior to the production assessment: a) Form a production assessment working group led by the construction (production) unit, with the participation of research, design, construction and other units, prepare an assessment plan, and formulate an assessment work plan ； b) Study and familiarize oneself with the assessment materials to determine the calculation formulas and basic data ； c) Identify factors that may affect the proper conduct of the assessment ； d) Work together with the design department, as well as equipment and instrumentation suppliers, to calibrate the measuring instruments and analytical equipment required for assessment ； e) Prepare the assessment record form. 9.3.4 Production assessment should be carried out after the chemical feeding commissioning is completed, the chemical plant is operating at full capacity in a stable manner, and the following conditions are met: a) The problems that arose during full-load testing have been resolved, all process parameters are now stable after adjustment, and any issues that could affect the production assessment have been dealt with ； b) The production operation is safe and stable, with backup equipment in good condition and ready for use ； c) All automatic control instruments, on-line analysis instruments, and interlocks have been put into use ； d) The sampling points, analysis frequency, and methods for analytical testing have been determined ； e) The quality of raw materials, fuels, chemicals, lubricants, and spare parts meets the design requirements, and the stock levels are sufficient to meet the assessment needs ； f) The public utilities and auxiliary facilities operate stably and can meet the requirements of production assessments. g) The material flow between upstream and downstream units has been arranged, the packaging of products and by-products is satisfactory, and the transportation channels are unobstructed. 9.3.5 The main contents of production assessment are as follows: a) Plant production capacity ； b) Raw materials, fuel, and power indicators ； c) Main process parameters ； d) Product quality and cost ； e) Status of operation of automatic control instruments, on-line analysis instruments, as well as process interlocks and safety interlocks ； f) Operating condition of mechanical and electrical equipment ； g) Stability and effectiveness of safety facilities, as well as the status of safe production management ； h) Compliance with emission standards for the three types of waste ； i) Other items specified in the design contract to be evaluated. 9.3.6 The standard time for production assessment is 72 hours of continuous full-load production; in special cases, this period may be extended appropriately. 9.3.7 After the production assessment is completed, the construction (production) unit shall prepare an assessment report, which shall be signed and confirmed by all units that participated in the assessment. 9.3.8 When the results of the production assessment do not meet the design requirements, the construction (production) unit shall, together with the general contractor, designers, and feasibility study teams, analyze the reasons, propose solutions, and reach a consensus through consultation; generally, no further re-assessment will be conducted ； If re-assessment is indeed necessary, it should not exceed three times. If the performance of the introduced equipment does not meet the values guaranteed in the contract, the relevant contract provisions shall be applied, and this shall be specified in the annex to the performance assessment agreement, outlining the solutions and deadlines. 9.3.9 After the production assessment is completed, the construction (production) unit shall organize, summarize, and analyze the original records of the assessment, prepare a summary report on the production assessment, and keep it on file as an important basis for the project’s completion acceptance. 10 Supplementary Provisions: For chemical engineering projects that adopt general contracting or construction (project) supervision, the responsibilities of the general contractor at each stage as specified in these guidelines, as well as the responsibilities assumed by the supervisory unit on behalf of the project owner, shall be carried out in accordance with the contract signed between them and the project owner. Appendix A (Informational Appendix) Key Points for Preparation Work Prior to Commissioning Production Preparation work is one of the components of the overall control plan for the commissioning of chemical plants. The construction (production) unit should promptly organize the departments responsible for production preparation and engage experts in design, construction, and production to carry out this preparatory work in accordance with the \"Key Points for Preparation Work Prior to Commissioning\", ensuring that production preparation proceeds in parallel with the plant construction. The key points for the preparatory work prior to trial production are as follows: A.1 Basic requirements – the overall objectives, tasks, and planning arrangements for production preparation ； The main tasks related to production preparation for chemical engineering construction projects, including approval (authorization, registration), design, construction, project supervision, and quality control. A.2 Organizational Preparation Organizational preparation generally includes the leadership and working bodies for production preparation and trial operation, clarifying relevant provisions such as responsible persons, team members, job responsibilities, work standards, and work processes, as well as establishing and improving various management rules and regulations. A.3 Personnel Preparation A.3.1 Develop a staffing plan based on the approved staffing quota, with the main contents including: a) personnel categories, sources, and quality requirements ； b) The time it takes for managers, technical personnel, and skilled operators at all levels to be assigned to their positions. A.3.2 Personnel Training: a) Organization and management of personnel training ； b) Methods and steps for personnel training ； c) Selection of training institution and scheduling ； d) Training for managers at all levels, professional and technical personnel, and skilled operators ； e) Exams and assessments for various training stages and for different types of personnel ； f) Develop staff training plans. A.4 Technical Preparation A.4.1 Translation and printing of technical documents, drawings, and operation manuals. A.4.2 Formulate various technical regulations, job operation procedures, and safety operation procedures. A.4.3 Prepare various types of comprehensive technical documents. A.4.4 Formulate various rules and regulations for enterprise management. A.4.5 Prepare plans for the commissioning of large-scale units, as well as for system drying, purging, filling with three types of agents, and protection measures; simultaneously, work with the construction team to develop plans for system purging, airtightness testing, and chemical cleaning. A.4.6 Prepare commissioning plans for storage and transportation, utility systems, on-site generator sets, thermal power plants, boilers, fire protection, etc. A.4.7 Prepare plans for overall commissioning, unit commissioning, joint commissioning, chemical feeding commissioning, and production assessment. A.4.8 Computer simulation training technical equipment. A.4.9 Planning schedule for the preparation of various commissioning plans. A.4.10 Overall network plan for technical preparation. A.5 Safety Preparedness A.5.1 Establishment of safety production management organizations, as well as staffing, training, and assessment. A.5.2 Safety production responsibility system, safety management systems, and safety operation technical procedures. A.5.3 Comprehensive safety training program for all employees. A.5.4 Collection, compilation of safety accident cases from similar devices, and educational arrangements. A.5.5 Physical and chemical properties of each substance involved in plant commissioning, safety precautions, and emergency response measures. A.5.6 Procedures for the use, maintenance, and management of emergency facilities such as safety, fire protection, and first aid equipment, as well as information on the location and usage of fire protection facilities. A.5.7 Risk identification for chemical processing units and risk assessment during commissioning or Hazard and Operability Analysis (HAZOP), identification of major hazard sources, and safety instrument function evaluation reports (for units involving \"two key aspects and one major hazard\"). A.5.8 Emergency rescue plans, organization, and teams. A.5.9 Safety conditions of the surrounding environment and control measures. A.5.10 Area restrictions during the commissioning of chemical plants. A.5.11 Other safety conditions. A.6 Preparation of Materials and External Conditions A.6.1 Materials A.6.1.1 Main raw materials, fuels, and commissioning materials; auxiliary materials, three types of reagents, chemical substances, lubricants (greases). A.6.1.2 Domestic and international ordering plans for spare parts and components, as well as arrangements for the surveying, mapping, and trial production of imported spare parts and components. A.6.1.3 Domestic supply status of three reagents, chemical substances, standard gas samples, and lubricating oils (greases) for introduction devices. A.6.1.4 Special tools, equipment, pipes, pipe fittings, valves, etc. for production. A.6.1.5 Safety, occupational health, fire protection, gas protection, first-aid equipment and emergency medicines, etc. A.6.1.6 Transport vehicles. A.6.1.7 Production records, office and daily-use items. A.6.1.8 Communication equipment, packaging materials. A.6.1.9 Other materials. A.6.2 External Conditions A.6.2.1 Establishing the connection and supply timing for external power sources such as electricity, water, and steam. A.6.2.2 Connection of off-site roads, rainwater drainage, industrial wastewater, and other systems. A.6.2.3 Time for enabling external and internal telecommunications networking. A.6.2.4 Coordination of projects such as railways, docks, transfer stations, and material supply pipelines. A.6.2.5 Ensure compliance with requirements regarding safety, fire protection, occupational health, environmental protection, and special equipment. A.6.2.6 Implement community-based mechanical, electrical, and instrumentation maintenance capabilities as well as public service facilities. A.6.2.7 Declaration, approval, and certification of special equipment. A.6.3 Funds: Plans for various commissioning costs and working capital for production. A.7 Marketing and Product Storage and Transportation Preparation A.7.1 Marketing Preparation A.7.1.1 Compiling product manuals, designing and registering trademarks, promoting the quality, performance, and usage methods of products, as well as preparing safety data sheets and safety labels for hazardous chemicals. A.7.1.2 Implement the product flow and sales areas and sign agreements. A.7.2 Product Storage and Logistics Preparation A.7.2.1 Set up product storage facilities in accordance with **relevant standard requirements. A.7.2.2 Formulate specifications for product storage and handling, equipment maintenance, safety technical standards, and emergency response plans. A.7.2.3 Implement logistics transportation modes such as highways, railways, and waterways, and prepare the relevant approval procedures. A.8 Other preparations A.8.1 Preparation for logistical support services. A.8.2 Preparations related to technology provision, patent ownership, or contractor cooperation. A.8.3 Relevant preparations in cooperation with the design unit. A.8.4 Relevant preparations in coordination with the construction unit. A.8.5 Relevant preparations in coordination with equipment manufacturing and supply units. A.9 Comprehensive Network Plan for Production Preparation: The tasks related to production preparation, such as the commissioning of large-scale units, system purging, airtightness testing, drying, gas displacement, filling with the required chemicals, individual unit testing, integrated testing, and testing with chemical feedstocks, are analyzed in terms of key control points on an annual, quarterly, and monthly basis; these points are then incorporated into the overall control plan for the construction of the chemical plant. Appendix B (Informational Appendix) Outline for Preparing the \"Overall Commissioning Plan\" B.1 Project Overview B.1.1 Brief description of the project, accompanied by a flowchart (block diagram) ； The renovation project shall be accompanied by a general flowchart of the process before the renovation or the actual general flowchart (block diagram) from the previous year. B.1.2 Brief description of the scale of production facilities, utility systems, and auxiliary facilities, process flow, and construction status. B.1.3 Raw materials, fuel, power supply, and product flow. B.2 Basis and principles for formulating the overall commissioning plan B.3 Guiding principles and standards to be achieved during commissioning B.4 Conditions required for commissioning B.5 Organization and command system for commissioning B.5.1 Commissioning organization structure and command. B.5.2 Technical advisory group and driving team. B.5.3 Commissioning and operation maintenance system. B.6 Commissioning Plan and Schedule B.6.1 Overview of single-unit commissioning, joint commissioning, and chemical feeding commissioning plans. B.6.2 Test run schedule and its arrangement principles, as well as the time for feeding chemicals into the process and obtaining qualified products. B.6.3 Commissioning procedures, key control points, evaluation of chemical processing units, and schedule for trial production. B.6.4 Test run coordination schedule relationship diagram. B.7 Material balance B.7.1 Load during the commissioning with chemical feedstocks. B.7.2 Comparison of planned indicators for major raw material consumption with design values (or contract guaranteed values). B.7.3 Material balance sheet: a) Summary table of main product outputs ； b) Table of key raw material consumption indicators ； c) Chemical feed trial operation status table ； d) Economic and technical indicators ； e) Input-output diagram of main materials. B.8 Fuel and power balance B.8.1 Balance of fuel, water, electricity, steam, air, nitrogen, etc. B.8.2 Appendix: a) Fuel balance sheet ； b) Electricity usage schedule ； c) Heat load table ； d) Steam consumption balance sheet ； e) Using a water balance sheet ； f) Nitrogen balance sheet ； g) Others. B.9 Safety, Occupational Health, and Fire Protection B.9.1 Safety, fire protection, occupational health, and emergency rescue organizations, personnel, and responsibilities within the commissioning organization and command system. B.9.2 Basic tasks: a) Conducting safety assessments in accordance with the law, as well as carrying out safety reviews, reviews of special sections related to safety facility design, assessments of occupational disease hazards, and fire protection design reviews, etc ； b) Design review, major design changes, and the status of “three inspections and four confirmations” ； c) Availability of safety facilities, fire protection and occupational health facilities and equipment ； d) The development and improvement of management systems, safety technical regulations, and emergency response plans related to safety, fire protection, and occupational health ； e) Training and assessment results for personnel in safety, fire protection, and occupational health ； f) Identification of hazardous factors for major hazard sources, key commissioning stages, and difficult points. B.9.3 On-site safety management measures taken in accordance with regulatory requirements. B.10 Environmental Protection B.10.1 Environmental testing and treatment of waste gases, waste liquids, and waste solids. B.10.2 Measures, methods, and standards for the treatment of waste water, waste gas, and solid waste. B.10.3 Summary table of emissions and treatment of the three wastes. B.11 Difficulties in commissioning and countermeasures Analysis of difficulties in aspects such as commissioning procedures, chemical feedstock addition, load on chemical plants, and material balance, along with corresponding countermeasures. B.12 Calculation of commissioning costs The calculation of commissioning costs involves the accounting treatment during the commissioning phase of newly built, renovated, or expanded chemical plants, covering the period from when the plant starts commissioning until qualified products are produced. B.12.1 Methods for estimating commissioning costs, results and analysis, as well as the total amount of funds required and a distribution table. B.12.2 Measures to reduce commissioning costs. B.13 Other issues that require explanation and resolution C C Appendix C (Informational Appendix) Key safety considerations for preliminary testing and joint commissioning C.1 Pressure testing of pipeline systems C.1.1 Conditions for pressure testing of pipeline systems: a) Safety valves have been covered with blind flanges, and burst discs have been removed and also covered with blind flanges ； b) Expansion joints have been fitted with restraining devices ； c) Spring supports and hangers have been locked ； d) When testing is conducted using water as the medium, the load-bearing capacity of the relevant structure has been confirmed or calculated. e) The pressure gauge has been calibrated and found to be in good condition. C.1.2 The pressure testing of pipeline systems shall comply with the following provisions: a) Pressure testing using air and process media must be approved by the design unit and recognized by the production technology department ； b) Before the test, confirm that the test system has been effectively isolated from unrelated systems ； c) When conducting hydrostatic tests, clean fresh water shall be used as the testing medium; when austenitic stainless steel equipment or pipes are connected to the system, the chloride content in the water shall not exceed 0.0025% ； d) The test temperature must be higher than the material’s brittle transition temperature ； e) When conducting tests in cold seasons, anti-freezing measures must be taken ； f) The pipeline pressure test shall comply with the requirements of **relevant standard specifications ； g) After the test is completed, the water and air should be drained, and the system should be returned to its original state. C.2 Pipeline system leakage test C.2.1 Leakage tests must be conducted when transporting toxic media, flammable media, and other media for which leakage testing is required according to design specifications. C.2.2 The leak test should be conducted after the pipeline has been cleaned or purged successfully. C.2.3 When conducting a pressure test with air, it can be carried out simultaneously with a leak test; however, after the pipeline has been cleaned or purged successfully, a final leak test must be performed, with particular attention paid to the areas where the pipeline is reconnected. C.2.4 The leakage testing of pipeline systems shall comply with the following provisions: a) The test pressure shall be determined in accordance with the codes for inspection and testing of industrial pipelines ； b) The test medium is generally air ； c) The test pressure for the vacuum system’s leak detection should ensure safety ； d) Inspect using the method specified in the design documents. C.3 Water flushing C.3.1 Water flushing can be carried out only after the pressure test is successful, protective measures have been taken for the machinery, instruments, valves, etc. in the system, the temporary pipes have been installed, the flushing pump is operating properly, and a filter has been installed at the inlet of the flushing pump. C.3.2 Flushing work should not be carried out in extremely cold seasons; if it must be done, anti-freezing and anti-slip measures must be taken. C.3.3 During filling and draining, the piping system should be connected to the atmosphere. C.3.4 Before the pipes and machinery in the previous process have passed the flushing test, the flushing water must not enter the machinery in the subsequent process. C.3.5 The rinse water should be discharged to the designated location. C.3.6 After flushing, ensure that all drainage and exhaust pipes are unobstructed. C.4 Steam Purging C.4.1 Conditions for Steam Purging C.4.1.1 The pipeline system has passed the pressure test. C.4.1.2 Reserve the locations for pipe connections and splices as required by the design, and install temporary pipes ； Pipeline safety standards shall meet the requirements of relevant specifications. C.4.1.3 Effective protective measures have been taken for valves, instruments, and equipment. C.4.1.4 Ensure that there are no flammable materials on or near the pipeline system, and that the pipelines carrying flammable materials are properly isolated to prevent fires in the event of a leak. C.4.1.5 The steam supply system is operating properly, and the amount of steam available meets the requirements for purging. C.4.1.6 Fences have been installed around the restricted area, along with prominent signs. C.4.1.7 The test personnel are wearing the required protective clothing and shock-absorbing earplugs. C.4.2 The following regulations shall be observed for steam purging. C.4.2.1 Steam purging is strictly prohibited for pipeline systems without consideration for expansion. C.4.2.2 Before steam purging, warm the pipes by opening all drain pipes to remove condensate and prevent water hammer. C.4.2.3 Blow through each drain pipe one by one during purging. C.4.2.4 Conduct a thorough inspection of the reset process to ensure that the pipeline system has been fully restored, and that the connections between pipes and machinery are freely aligned in accordance with the specified standards. C.4.2.5 Blowing operations must have noise reduction measures. C.5 Chemical cleaning C.5.1 The inside of the piping system is free of debris and oil stains. C.5.2 The chemical cleaning solution has been analyzed by the quality control department and found to meet the standard requirements, confirming that it can be used for the system to be cleaned. C.5.3 Includes a chemical cleaning flowchart and a blind plate location diagram. C.5.4 The facilities, heat sources, chemicals, analytical instruments, tools, etc., required for chemical cleaning are all available. C.5.5 The chemical cleaning personnel are dressed in accordance with protective regulations and wearing protective equipment. C.5.6 If the pipeline system after chemical cleaning cannot be put into use temporarily, it should be protected with an inert gas. C.5.7 Wastewater must be treated to meet environmental standards before it can be discharged. C.6 Air Purging C.6.1 Pipes with a diameter greater than 600 mm should be cleaned manually. C.6.2 The system has passed the pressure test, and effective protective measures have been taken for the machinery, instruments, valves, etc. within the system. C.6.3 The position of the blind flange has been confirmed, and the air supply is guaranteed ； When purging oil-free pipelines, the air must be free of oil. C.6.4 Strict inspection should be carried out on the reset work after purging. C.6.5 Purging shall include measures such as shielding, warning, prevention of accumulation, and noise reduction. C.7 Pre-film treatment of the circulating water system C.7.1 Conditions for pre-film treatment of the circulating water system: a) The system has passed water flushing tests ； b) The circulating water system passed the joint commissioning test ； c) The chemical solution has been proven through tests to be suitable for the water quality at the site, exhibits good film-forming properties, and has a corrosivity level lower than the specified values ； d) Test pieces for monitoring the pre-film condition have been properly installed in the system ； e) Effective measures have been taken to handle waste liquid. C.7.2 The pre-coating of the circulating water system shall comply with the following provisions: a) Pre-coating operations should be carried out outside the cold season; if this is not possible, anti-freezing measures must be taken ； b) The pre-coating process of the system should be completed in one go; no pipes or equipment within the system should remain uncoated ； c) After pre-coating, drugs should be administered on time and in the correct dosage to keep the system in a coated state. C.8 System Purging C.8.1 Before starting up a chemical plant for feeding operations, it must be purged with an inert gas to ensure compliance. Before parking for maintenance, it must be replaced with a qualified one. C.8.2 System displacement conditions: a) Displacement flow diagram showing the locations of vent points, analysis points, and blind flanges ； b) The sampling and analysis personnel are in place, and the analysis instruments and reagents are ready ； c) Inert gases can meet the requirements of displacement work. C.8.3 The system replacement conditions shall comply with the following requirements: a) The oxygen content in inert gases shall not exceed the safety standards ； b) Verify that the quantity, quality, and installation location of the blind plates are satisfactory ； c) When performing displacement, attention should be paid to dead corners in the system; if necessary, repeated pressure increases and decreases can be used to dilute the displacing gas ； d) When the piping system is connected to a gas holder, the gas holder should be raised and lowered three times to completely displace the gas in the annular water seal ； e) The replacement work should be carried out sequentially, starting with the main pipes and then moving on to the branch pipes ； f) When taking samples, analysts should pay attention to the wind direction as well as the height and direction of the vent pipe, to prevent poisoning ； g) Analyze the data, requiring three consecutive successful tests, and have it signed off by the personnel in charge of production, technology, and safety ； h) After the replacement is complete, effective measures shall be taken to isolate the inert gas pipeline from the system. C.8.4 Qualification criteria
C.8.4.1 When replacing flammable gases with inert gases, the concentration of flammable gases in the gas mixture after replacement must meet the following requirements: when the lower explosive limit of the flammable gas is 4% or higher, a measured value not exceeding 0.5% (volume percentage) is considered acceptable ； When the lower explosion limit of the combustible gas is less than 4%, analysis and detection values not exceeding 0.2% (by volume percentage) are considered acceptable. C.8.4.2 When replacing inert gases with flammable gases, the oxygen content in the gas after replacement shall not exceed 0.5 %. C.8.4.3 When replacing air with an inert gas, the oxygen content in the gas after replacement shall not exceed 1%; if the gas is to be introduced directly into flammable or explosive media, the oxygen content shall not exceed 0.5%. C.8.4.4 When replacing inert gases with air, the oxygen content in the gas after replacement shall not be less than 20 %. C.9 Testing of general motor drive equipment C.9.1 Conditions for testing general motor drive equipment: a) The specified tests have been carried out at the supplier in accordance with the requirements of the contract ； b) The secondary grouting has reached the designed strength, and the foundation finishing has been completed ； c) The pipelines and equipment related to equipment commissioning have been purged or cleaned to specification ； d) A filter (device) is installed at the equipment outlet as required ； e) The pressure-lubricated seal oil pipelines and equipment have passed the oil washing process and been tested in operation ； f) The protective interlocks, early warning systems, indication devices, and automatic control devices for motors and equipment have been properly calibrated ； g) The safety valve has passed calibration ； h) The rotation direction of the motor has been checked, and the motor grounding is satisfactory ； i) The equipment protection cover has been installed ； j) The primary and secondary equipment such as motors and cables have undergone handover tests and passed. C.9.2 General motor-driven equipment shall comply with the following requirements: a) The medium used for testing shall be as specified in the design documents; unless otherwise specified, water should be used as the medium for pumps and mixers, while air or nitrogen should be used as the medium for compressors and fans ； b) Water should not be used as the testing medium for cryopumps; otherwise, the water must be completely drained after testing, and the pump must be thoroughly blown dry and inspected to ensure it is in good condition ； c) When the specific gravity of the testing medium is greater than that of the designed medium, attention should be paid to the motor current during testing to ensure it does not exceed the specified value ； d) The turbine must be rotated before testing ； e) The equipment can be tested only after the motor passes the test ； f) Equipment should generally first undergo a no-load test, followed by a load test ； g) During testing, attention should be paid to checking the temperature of the bearings (bushings) and packing, the machine’s vibration level, the current intensity, the outlet pressure, and the filter screen ； h) Instrument indications, alarms, automatic control, and interlocks shall be accurate and reliable. C.10 Commissioning of turbines and pumps C.10.1 Conditions for commissioning turbines and pumps: a) The supplier has carried out the specified tests in accordance with the contract requirements, and the supplier’s commissioning personnel are present on site (if specified in the contract) ； b) All steam and process pipelines leading to the machine have been properly purged ； c) The inter-compressor piping has been pressure-tested and cleaned or purged to specification ； d) The vacuum test of the condensing system passed ； e) The water cooling system is now operating stably and the pre-coating process has been successful ； f) The oil system is now operating properly ； g) The steam pipeline network is now operating properly, and the safety valves, pressure relief valves, and vent valves on the network have all been tested and found to be in good working condition ； h) The spring hangers have been adjusted and tested successfully ； i) All electrical and instrumentation systems of the unit have undergone static simulation tests ； j) The cooling system is now operating properly ； k) Safety devices such as protective covers have all been installed. C.10.2 The commissioning conditions for steam turbines and pumps shall comply with the following provisions: a) First, commission the auxiliary equipment (oil pumps, condensation systems, etc.), then commission the steam turbine, and finally conduct an overall commissioning ； b) The pipes should be warmed up first before starting up the turbine ； c) After the pipe heating is completed, the steam turbine is started up, with a rotation speed of generally 200 R/MIN ； d) If no abnormalities are found upon inspection, acceleration can be carried out according to the speed-up curve, while warming up is performed simultaneously ； e) When accelerating, pass the critical speed as quickly as possible ； f) Once the rated speed is reached, the governor should be put into operation ； g) Once the turbine is operating normally, increase its speed to the tripping speed to conduct a tripping test; if automatic tripping does not occur, stop the turbine manually immediately ； The tripping test should be performed three times ； h) Throughout the entire turbine commissioning process, close monitoring should be carried out of parameters such as oil temperature, oil pressure, bearing temperature, vibration levels, shaft displacement, rotational speed, inlet and exhaust temperatures and pressures, as well as the vacuum level in the rear cylinder ； i) Once the turbine test is successful, it should be connected to the compressor (pump) immediately ； j) The unit should first undergo a no-load test run; during speed increase, it is necessary to pass the critical speed as quickly as possible, and once the normal operating speed is reached, the voltage should be increased gradually in accordance with the voltage rise curve. A comprehensive inspection of the unit must be carried out before each pressure increase; only after it is confirmed that the unit is operating properly can the pressure be increased further until the design pressure is reached. C.11 Commissioning of reciprocating compressors C.11.1 Conditions for commissioning reciprocating compressors: a) The commissioning personnel are present, including those responsible for technical operations and electrical instrumentation (if necessary, technicians from the compressor manufacturer should also be on site). b) The water supply system is now operating properly. c) The circulating oil system and oil injection system have passed the trial operation. d) The inter-section pipes have passed the pressure test, and the inter-section pipes, water coolers, separators, and buffers have been cleaned or purged successfully. e) The safety interlocks and alarms have passed simulation tests, and the instrument readings are accurate. f) The safety valve has been calibrated. g) Important installation data, such as the clearance between various cylinder stages, the clearance between the crosshead and slideways, and the clearance between the motor rotor and stator, have been verified. h) The electric motor and turntable have been tested successfully, and protective covers have been installed. The main motor and the barring motor have been powered on, and the oil circulation test has passed. C.11.2 Reciprocating compressors shall comply with the following requirements: a) Air is preferably used as the medium for testing, and its pressure during load testing shall not exceed 25 MPA (gauge pressure) ； b) Before testing, the machine should be rotated manually first, and the testing should be carried out in the order of synchronous motor test, no-load test, and load test ； c) The motor testing time should be 2–4 hours, the no-load testing time should be 4–8 hours, and the load testing time should be 24–48 hours ； d) During the motor testing, the ventilation system should be turned on first, and the rotation direction of the motor should be checked ； e) During motor testing, the bearing temperature, vibration levels, and motor temperature rise should be checked ； f) The cylinder valves at all stages should be removed before no-load testing ； g) The interlock alarm device shall be simulated for calibration ； h) The load test should be conducted after the air valves of each cylinder have been reset ； i) After the cylinder valve is reset, conduct a load test for half an hour; then increase the pressure in 3–5 steps to the specified test pressure, ensuring that the system remains stable at this pressure for 1 hour prior to each increase ； j) During testing, the bearings, slides, stuffing boxes, gas temperatures at the inlet and outlet of the motor as well as the cooling water temperature, oil supply, vibration levels, and the sealing conditions in all areas should be checked ； k) During testing, attention should be paid to draining oil and water, as well as checking whether there is any impact or other abnormal noises in the cylinders at each stage ； l) The pressure should be reduced gradually before stopping; under no circumstances should the system be stopped while under pressure, except in emergency situations ； m) Wait 10 minutes after parking before turning off the fuel and water supply ； n) The final adjustment of the safety valve should be carried out during testing. C.12 Oven Drying C.12.1 Oven drying conditions: a) When amorphous refractory materials are used, there must be preparation records and test reports available ； b) When using refractory cement for lining, its strength shall meet the requirements specified in the design documents ； c) The installed expansion indicator has been set to zero ； d) When there are heating and cooling pipes inside the equipment, measures such as circulating water and air have been taken to prevent the pipes from overheating ； e) Possesses an approved furnace heating curve ； f) Insulation measures have been taken on the equipment foundation ； g) The temperature measuring instruments have been installed in the specified locations and tested to meet the requirements ； h) The cooling water, demineralized water, boiler feedwater systems, and waste discharge facilities are in operation ； i) The heating, temperature control, and ventilation systems are now operational. C.12.2 The following rules shall be followed for furnace drying: a) Flammable gases in the furnace or equipment shall be analyzed before ignition, and the analysis results must be satisfactory ； b) Raise the temperature, maintain it at a constant level, and lower it strictly in accordance with the furnace heating curve ； c) The interior of the furnace or equipment should be heated evenly ； d) Pay attention to monitoring the temperature of various pipes and foundations within the furnace or equipment, and take strict precautions to prevent overheating ； e) When the ignition device shuts off on its own, the combustible gas must be completely replaced before re-ignition is possible ； f) Measures to prevent poisoning should be in place at the gas emission point after furnace combustion. C.13 Calcination Furnace C.13.1 Calcination conditions: a) The drying furnace has passed inspection ； b) The thermal instruments have been calibrated and found to be satisfactory ； c) The safety valve has been successfully calibrated after cooling ； d) The boiler fuel is in place, and the ignition system has been properly calibrated ； e) Chemical reagents and analyzers are ready. C.13.2 The boiler boiling process shall comply with the following provisions: a) In accordance with the requirements of the design documents and relevant regulations, the solution used for boiling the boiler must be analyzed and found to be acceptable before it can be put into use; ignition may only be carried out after it has been verified that all other conditions meet safety requirements ； b) Strictly increase the pressure in stages in accordance with the requirements of the boiler heating plan; carry out boiler heating, water addition, and sludge discharge in stages. During the low-pressure boiler heating stage (usually at 300 KPA), tighten all the flange bolts of the manway and access valve connections ； c) When the boiler approaches the specified test pressure, measures such as water replacement, adding water, and draining waste water should be taken until all process conditions are fully met ； d) Adjust the safety valve at the specified test pressure, and conduct a leak test at the operating pressure, as well as inspect the expansion of the steam drum and collectors ； e) Reduce pressure, shut down the boiler, flush, and inspect as stipulated in the boiler purging procedure. C.14 Filling of internals in towers and vessels C.14.1 Conditions for filling internals in towers and vessels: a) The pressure test of the tower and vessel system must be successful ； b) The interiors of towers, vessels, etc. are clean and free of debris; the concentration of toxic and flammable substances inside equipment that has undergone anti-corrosion treatment complies with relevant standards ； c) Towers and vessels with linings, whose lining inspection has passed ； d) The manholes and vent pipes are all open, ensuring good ventilation inside the tower and vessels ； e) The filler has been cleaned thoroughly ； f) Filling tools are all available ； g) The permit for working in a confined space has been obtained. C.14.2 The filling of internals in towers and vessels shall comply with the following provisions: a) Persons entering towers and vessels shall not bring items that are not related to the filling work ； b) Personnel entering the tower shall wear appropriate clothing and protective equipment as required, fall prevention measures shall be in place, and a dedicated person shall be assigned to supervise them ； c) Unqualified internal components and packing mixed with foreign matter shall not be installed ； d) When installing the tray, the installer should stand on the beam ； e) The installation of distributors, tray plates and their accessories, as well as the arrangement of the packing, must all be carried out in strict accordance with the provisions of the design documents; such work shall be reviewed by professional technicians and the results recorded for archiving ； f) Before sealing the tower or vessel, all tools and unnecessary items carried on one’s person must be removed. After sealing, a leak test should be conducted. C.15 Filling of catalysts, molecular sieves, etc. C.15.1 Filling conditions for catalysts, molecular sieves, etc.: a) The type, specifications, and quantity of the catalysts meet the design requirements, and they are stored in good condition ； b) The reactor and related systems have passed the pressure test ； c) The reactor with a heat-resistant lining passed the furnace drying test ； d) Cleaning and drying the interior of the reactor ； e) Before filling the cryogenic unit with molecular sieves and adsorbents, its containers as well as the associated heat exchangers and pipes have been thoroughly purged of trace substances and dried to meet the required standards ； f) Filling equipment and all facilities are fully available ； g) The permit for working in a confined space has been obtained. C.15.2 The filling of catalysts, molecular sieves, etc. shall comply with the following provisions: a) Persons entering the reactor shall not bring in items unrelated to the filling work ； b) When filling the catalyst, a dedicated person must be assigned to supervise the process ； c) Filling personnel must wear the required clothing and protective masks ； d) Unqualified catalysts (crushed, broken, etc.) must not be placed inside the container ； e) During filling, the free fall distance of the catalyst shall not exceed 0.5 meters ； f) The filling personnel must not stand directly on the catalyst ； g) The filling work shall be carried out strictly in accordance with the provisions of the filling plan ； h) Check the pressure drop in the parallel reactors to ensure uniform airflow distribution ； i) For the pre-reduced catalyst, it shall be protected with an inert gas after filling, and a dedicated person shall be assigned to monitor changes in the catalyst’s temperature ； j) A leak test should be conducted after the reactor is reset. C.16 Re-inspection of heat exchangers C.16.1 After the heat exchanger arrives at the site, a leak test must be conducted again; when specified, a core pull test should also be performed. C.16.2 The water or chemicals used for testing shall meet the requirements of the test. C.16.3 During testing, water should be injected between the pipes and pressure applied; special attention should be paid to the grooves or welds to ensure they remain within normal limits. C.16.4 If a leak is detected inside the pipe, a core pulling inspection should be carried out. C.16.5 When inspections using ammonia or other media are required as specified, the special provisions shall be followed. C.16.6 After inspection, the accumulated water should be drained and dried with air. C.17 Instrument system commissioning C.17.1 Preconditions for instrument system commissioning: a) The instrument air station is in proper operating condition, and the instrument air piping system has been properly purged ； b) The air conditioning and uninterruptible power supply in the control room are functioning properly ； c) The individual calibration of transmitters, indicating and recording instruments, interlock and alarm switches, control valves, as well as panel-mounted and rack-mounted instruments has been completed ； d) The relevant parameters of the automatic control system regulator have been preset; the feedforward control parameters, ratio values, and various correction ratio offsets have been calculated and preset based on the relevant data ； e) All types of analog signal generators, testing instruments, standard gas samples, communication devices, etc. are available ； f) All on-site instruments and control valves are in service. C.17.2 The following requirements shall be complied with: a) Before conducting mechanical joint tests, the detection and automatic control systems shall first undergo simulated debugging, that is, signals shall be input at the transmitters, and all functions such as indication, control, and alarm shall be checked on the control panel or secondary instruments ； b) The interlocking and alarm systems should be subjected to simulated testing prior to mechanical joint testing; that is, simulated signals should be input at the signal switches to check their logical correctness and operating behavior, and adjustments should be made until they meet the required standards ； c) When calibrating instruments in conjunction with mechanical tests, instrument technicians, electrical personnel, and process operators must work closely together in coordination ； d) For interlock devices that are undergoing their first trial run or cannot be put into use under load temporarily, they may be temporarily disconnected with the consent of the construction (production) unit, provided that the alarm devices are retained ； e) Before starting up the chemical plant with feedstock, the parameters of the feedforward control, proportional control, and control systems equipped with correctors should be readjusted based on the load level and the actual composition of the materials. C.18 Electrical System Commissioning C.18.1 Preconditions for electrical system commissioning: a) All installation work in the main substation and related commissioning tasks have been inspected and confirmed by the power supply department, and the procedures for receiving power have been completed ； b) Primary equipment such as isolating switches, load switches, high-voltage circuit breakers, switchgear, and transformers have undergone handover tests and passed them ； c) Secondary equipment such as relay protection has passed testing ； d) AC and DC operating power supplies have passed calibration ； e) Emergency power supplies such as UPS have been successfully tested and calibrated ； f) Test records of grounding resistance ； g) Possess records of successful electrical equipment testing ； h) Have records of successful interlock protection tests. C.18.2 The following requirements must be complied with: a) Power supply and distribution personnel must work with valid certificates and strictly adhere to operating procedures ； b) Before energization, the transformation and distribution substations must conduct simulation tests on the relay protection devices, automatic reclosing devices, alarm systems, and phase-sequence monitoring systems according to the system specifications ； c) The protection devices for the programmable logic controller should have the interlock and alarm parameters simulated one by one, and the correctness of the positive alarm values of their logic should be verified ； d) The emergency power supply system should be tested and verified ； e) Operations should be carried out in accordance with the prescribed procedures for power shutdown and restoration ； f) The electrical system should be inspected and accepted before power is supplied. C.19 Conditions required for the commissioning of key equipment such as large-scale units C.19.1 The unit has been installed and its quality has been approved. C.19.2 The system piping pressure test and the heat exchange equipment airtightness test have passed. C.19.3 The process and steam pipelines have been successfully purged or cleaned. C.19.4 The lubricating oil, seal oil, and control oil systems for rotating equipment have been cleaned successfully. C.19.5 The safety valve has been tested and found to be in good condition, and it has been sealed with lead. C.19.6 The electrical, instrumentation, computer, and other related systems for testing have been successfully calibrated and tested. C.19.7 The power required for commissioning, instrument air, circulating water, deionized water, and other fluids are in place. C.19.8 The commissioning plan has been approved, and the command, operation, and maintenance personnel are in place. Testing instruments, tools, protective equipment, and record forms are all ready. C.19.9 The testing equipment and the systems connected to it have been completely isolated. C.19.10 The testing area has been designated, and relevant personnel may enter with proper authorization. C.19.11 The engineering installation documents required for commissioning shall be compiled by the construction unit and made available for the commissioning personnel to borrow. C.19.12 Determination of commissioning technical specifications. Appendix D (Normative Appendix) Conditions Required for Chemical Feed-in Commissioning Chemical feed-in commissioning must be carried out to high standards and with strict requirements, in accordance with the approved commissioning plan and procedures. Before starting up the chemical plant following the material feeding process, it is necessary to thoroughly check and confirm that the following conditions are met: D.1 Trial production report – The construction (production) unit shall submit a written report to the relevant local authorities, including the trial production plan, the signed approvals of the design, construction, and supervision units as well as external experts regarding the trial production plan and the conditions for trial production, and the safety assessment report issued by a safety evaluation agency on the safety conditions for trial production. D.2 Completion of single-unit testing and interim project handover D.2.1 Preliminary quality assessment of the project is satisfactory. D.2.2 The issues identified under the “three inspections and four determinations” have been resolved, and all remaining items have been dealt with. D.2.3 The design change items affecting the feedstock have been completed. D.2.4 The single-unit trial run was successful. D.2.5 The project has completed the intermediate handover procedures. D.2.6 All temporary facilities for construction within the chemical plant area have been removed ； There are no cluttered items or obstacles at the site. D.2.7 The equipment tag numbers, as well as the names of the pipeline media and flow direction indicators, are all complete. D.2.8 The system has been purged and cleaned, and the airtightness test has passed. D.3 The joint commissioning has been completed. D.3.1 Drying, purging, filling with the three types of agents, and calibration of computer instruments have all been carried out and verified. D.3.2 The equipment is in good standby condition. D.3.3 The on-line analysis instruments and meters have been calibrated and are ready for use, and the industrial air conditioning system is in operation. D.3.4 The testing, control, interlock, and alarm systems of the chemical processing units have been calibrated, and the lightning and static electricity protection facilities are accurate and reliable. D.3.5 On-site fire-fighting, gas protection, and other equipment as well as tools for station personnel are fully equipped. D.3.6 The issues identified during the joint commissioning have been resolved. D.4 Personnel training has been completed. D.4.1 Training on similar domestic and international installations has been finished. D.4.2 Training has been carried out in terms of on-the-job training, simulation training, and accident prevention training, with the goal of achieving “three understandings and six skills” (three understandings: understanding the principles, understanding the structure, and understanding the procedures and plans) ； Six skills: the ability to read diagrams, operate equipment, perform maintenance, perform calculations, communicate, and troubleshoot faults); improving the “six types of capabilities” (thinking ability, operational and task-handling ability, coordination and organizational ability, accident prevention ability, self-protection and first-aid ability, and self-discipline ability). D.4.3 Personnel for various types of work and those engaged in special operations have passed the examinations and obtained their work permits. D.4.4 Accident cases of similar domestic and international installations have been compiled, and studies have been conducted*. An analysis and summary have been conducted on the accidents and potential accident incidents that have occurred since the commissioning of this device, in accordance with the principle of \"four no-passes\" (not passing until the cause of the accident is identified, not passing until those responsible are dealt with, not passing until corrective measures are implemented, and not passing until the relevant personnel have received education), so as to draw lessons from them. D.5 All production management systems have been established and implemented. D.5.1 Clear job responsibilities have been defined, and team production operation systems have been set up. D.5.2 The test operation command systems at all levels have been established, the command personnel are on duty, and a regular meeting system has been put in place. D.5.3 Production scheduling systems at all levels have been established. D.5.4 Relevant systems such as job responsibilities, routine inspections, and shift handovers have been established. D.5.5 All instructions and information transmissions have been put in written form, and original record data have been tabulated. D.6 The approved chemical feeding commissioning plan has been presented to the relevant personnel for study*. D.6.1 Operating procedures and similar documents are available to each individual, and the chemical feeding commissioning plan is also provided to all personnel holding positions above that of operator. D.6.2 A written plan exists for each testing step, and it is known to all, from the supervisors to the operators. D.6.3 “Kanban” or “wall-mounted” management has been implemented. D.6.4 The trial operation plan has been explained, studied*, and discussed. D.6.5 An emergency response plan for accidents has been developed and tested. D.7 The logistics arrangements have been finalized. D.7.1 The scope and responsibilities for logistics have been defined. D.7.2 The shipping team has been assembled. D.7.3 The handling personnel are on duty and wearing identification badges. D.7.4 The transportation equipment and tools have been secured. D.7.5 The shipping duty location has been designated and marked, with 24-hour duty in place. D.7.6 Backup personnel for freight handling have been arranged. D.7.7 Material supply services are provided on-site with 24-hour duty. D.7.8 Mechanical, electrical, and instrumentation maintenance personnel are on duty. D.7.9 Contracts have been signed with societal mechanical, electrical, and instrumentation maintenance services. D.8 The water supply and drainage system is operating normally. D.8.1 The pressure, flow rate, and water quality of the water network meet the process requirements, and the water supply is stable. D.8.2 The pre-film treatment of the circulating water system is qualified and the operation is stable. D.8.3 The chemical water, fire-fighting water, condensate water, and drainage systems are all in operation and function reliably. D.9 The power supply system is operating stably. D.9.1 The dual-power-source, dual-circuit power supply required by the process has been implemented. D.9.2 The instrument power supply is operating stably. D.9.3 The emergency power supply is in place, and the backup generator is in good standby condition. D.9.4 The power dispatch operator is on duty. D.9.5 The power supply system maintenance has been completed, and personnel have started rotating shifts for inspections. D.10 The steam system is supplying steam steadily. D.10.1 The steam system is operating normally according to the specified pressure levels, with stable parameters. D.10.2 No leaks, and good thermal insulation. D.11 The nitrogen and air supply systems are operating normally. D.11.1 The process air, instrument air, and nitrogen systems are functioning properly. D.11.2 Parameters such as pressure, flow rate, and dew point are within acceptable limits. D.12 Raw materials and lubricants (greases) are fully prepared. D.12.1 All raw materials and lubricants (greases) have arrived and passed inspection. D.12.2 The “three-dose” loading is complete. D.12.3 The three-stage lubricating oil filtration system has been implemented, and the lubrication points for the equipment have been identified. D.13 Complete spare parts and accessories D.13.1 The spare parts and accessories meet the requirements for testing; they are available on hand, and the inventory records match the actual items. D.13.2 The warehouse has implemented a day-and-night duty system; the storage staff are familiar with the specifications, quantities, and storage locations of the goods, ensuring that shipments are made promptly and accurately. D.14 Reliable operation of the communication system D.14.1 Uninterrupted communication in the command system. D.14.2 Positions and direct phone lines are available and in use. D.14.3 The dispatch, fire alarm, and emergency call services are reliable and functional. D.14.4 Clear calls via radiotelephones and telephones. D.15 The material storage system is in good condition and ready for use. D.15.1 The storage tanks for raw materials, fuels, intermediates, and products have all been purged, pressure-tested, made airtight, calibrated, dried, and sealed with nitrogen. D.15.2 The pump and pipeline joint commissioning has been completed, and they are in good condition ready for use. D.15.3 The anti-static and lightning protection facilities of the storage tank are in good condition. D.15.4 The breather valves and safety valves of the storage tank have been properly calibrated. D.15.5 The tank identification numbers, the names of the media in the pipelines and their flow directions are all clearly indicated, and there are obvious fire prevention signs in the tank area. D.15.6 The storage of hazardous chemicals in the warehouse complies with the requirements of GB 15603. D.16 The logistics transportation system is ready for use at any time. D.16.1 Railway, road, port, and pipeline transportation systems have been built and put into operation. D.16.2 Systems regarding the quality, quantity, and method of transfer for raw materials, fuels, intermediate products, and finished products have been established. D.16.3 Measures for handling non-conforming products have been implemented. D.16.4 The product packaging facilities have been tested using actual materials, and all packaging materials are available. D.16.5 The methods for product sales and transportation have been arranged. D.16.6 The product’s factory inspection, loading, transportation equipment, and personnel are all in place. D.17 Safety, fire protection, and first-aid systems are in place. D.17.1 Appropriate safety measures and emergency plans have been established following risk assessments. D.17.2 Complete safety production management systems, procedures, and records are in place; a safety management system has been established, and personnel work after receiving safety training and obtaining the necessary certifications. D.17.3 Safety management systems such as the hot work procedure, no-smoking policy, and vehicle management system have been established and published. D.17.4 Equipment identification, pipeline flow direction and medium identification, road traffic signs, radiation protection signs, and other warning signs are all in place. D.17.5 A fire inspection system has been established, an accident emergency plan has been formulated, fire access roads are unobstructed, and accident emergency drills have been conducted*. D.17.6 Fire-fighting, gas protection, and specialized safety equipment and tools are installed at the specified lower levels, in full accordance with the required specifications and quantities; they are clearly marked and in good condition ready for use. Employees are proficient in the use of these fire-fighting, gas protection, and safety equipment and tools, and have undergone relevant drills. D.17.7 On-site personnel wear protective equipment as required, and basic first-aid knowledge is widely known among the staff. D.17.8 Fire protection facilities must pass inspection by the fire department. The fire protection systems for the production units and tank areas, fire foam stations, steam curtains, water curtains, sprinklers, as well as smoke and fire detectors, combustible gas and toxic gas detection alarms have been put into operation, with a 100% availability rate. D.17.9 Explosion-proof panels, flame arresters, safety water seals, flare molecular seals, vacuum breakers, etc., must be properly installed or calibrated. The pressure testing, calibration, setting of the pressure value, and sealing of the safety valve have been completed. D.17.10 The special equipment has passed the inspection and testing by the quality and technical supervision department. D.17.11 A dedicated person is responsible for the management of blind plates, which is carried out on a dynamic basis; there are records kept, and signs are posted at the site. D.17.12 On-site first aid stations have been established, or emergency agreements have been signed with hospitals to ensure 24-hour duty. D.17.13 The static testing of interlock and alarm systems shall be carried out at least three times to ensure correct operation. D.17.14 The lightning protection and anti-static facilities, equipment, as well as the grounding systems for pipe racks must be properly installed; they must have been tested and come with valid certification reports. D.17.15 Stairs, handrails, safety covers for equipment, as well as protections for trenches, holes, etc., must be fully equipped and sturdy enough to ensure safety. D.17.16 The lighting in the plant area and within the buildings, as well as the ventilation equipment, shall be installed in accordance with the design documents and passed inspection. D.17.17 All unnecessary items unrelated to production within the plant area must be removed. Flammable and explosive materials, highly toxic substances, and radioactive materials must be stored in locations designated by the safety authorities, with dedicated personnel in charge of their management. D.17.18 Other relevant requirements. D.18 The production scheduling system is operating normally. D.18.1 A scheduling framework has been established, and all specialized schedulers have been assigned and qualified through assessment before taking up their duties. D.18.2 A normal order has been established for commissioning scheduling work, and a regular scheduling meeting system has been put in place. D.18.3 The dispatchers are familiar with various material transfer schemes; the relationships regarding material supply between different plants and units are clear, and the pipelines are in operation. D.18.4 During the commissioning period, the balance of raw materials, fuel, products, by-products, and power is all incorporated into the normal management of the scheduling system. D.18.5 Meteorological information is released regularly to facilitate timely response and adjustment in various tasks. D.19 Disposal: The facilities for treating the three types of waste have been built and put into use, or contracts have been established for the disposal of these wastes by qualified entities. D.20 Preparation for laboratory analysis is complete. D.20.1 Normal analysis and testing procedures have been established in the laboratories. D.20.2 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. D.20.3 The sampling points have been determined, and the sampling equipment and responsible persons have been assigned. D.20.4 Analog sampling and analog analysis have been performed. D.21 On-site security has been arranged. D.21.1 The organization, personnel, and transportation for on-site security have been arranged. D.21.2 Systems for access control and security measures for key areas such as control rooms have been established. D.21.3 Measures for joint local defense have been implemented and a notice has been issued. D.22 The logistical support for daily life has been arranged. D.23 The driving team and expert group members have arrived at the site. D.23.1 The driving team and expert group members have arrived as planned. D.23.2 The office locations, transportation, accommodation, and other arrangements for the driving team and the experts have been taken care of. D.23.3 When foreign experts are present, on-site translation is already arranged. D.23.4 The chemical feeding commissioning plan has been approved by the expert group, and the suggestions from the commissioning team members have been fully presented. Appendix E (Informational Appendix): Procedures for Hiring Technical Advisors and Operators. The commissioning of chemical plants involves a high level of technical complexity, significant risks, and considerable difficulties. To fully draw on the experience of identical or similar units and ensure the successful completion of the chemical plant commissioning in just one attempt, experts from home and abroad (or expert teams) can be hired during the commissioning phase, depending on the circumstances, to serve as technical advisors and operating personnel (teams) to assist with the startup process. The specific methods are as follows: E.1 Task Responsibilities E.1.1 Technical advisors or drivers, under the unified leadership of the test drive steering committee, assist in carrying out the test drive tasks. E.1.2 Technical advisors or expert groups are senior technical mentors who should participate in the work of the technical advisory group. E.1.3 Drivers can participate in trial runs in the workshop or at their posts depending on the specific circumstances. E.1.4 The operator should actively participate in the commissioning process, assist the hiring party in reviewing the commissioning plan and verifying the conditions required for chemical feeding during testing, and guide the operators hired by the hiring party during the commissioning; generally, the operator does not perform the operations directly. E.2 Personnel Composition E.2.1 Technical consultants are generally high-level experts in the relevant field, who can be hired on a case-by-case basis. E.2.2 The driving crew should be composed of skilled technical personnel with extensive practical experience in production, and a person who is proficient in technology and possesses organizational skills should be appointed to lead the team. E.3 Recruitment Methods The recruitment or organization of expert groups, technical consultants, or drivers (teams) should be carried out as early as possible during the production preparation phase, and employment agreements or contracts should be signed to ensure that these personnel participate in activities such as production preparation and trial runs, so that they can become familiar with and understand the actual conditions of the chemical processing facilities and their equipment. E.4 Other Matters E.4.1 The employing entity shall provide the employed personnel with necessary technical materials, office supplies, personal protective equipment, and daily necessities. E.4.2 The treatment of the employed personnel shall be determined through mutual consultation between the two parties. E.4.3 The employing entity should strengthen the management of the employed personnel to ensure their safety ； Employees shall abide by the management regulations of their employer and maintain strict technical confidentiality. E.4.4 Joint ventures or imported facilities shall be operated in accordance with the contract provisions, and special issues shall be resolved through consultation between the Chinese and foreign parties.