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What materials does a company need to prepare for the acceptance inspection after safe trial production?

2015-09-14View Original

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Dear colleagues: We are a chemical enterprise currently in the trial production phase, and an inspection will be conducted after that. What documents does the company need to prepare in order to pass this inspection?
Reply #22015-09-14
**Steps for obtaining permits for chemical construction projects: 1. **Review of safety conditions for chemical construction projects (project approval)**; 2. **Review of the design for safety facilities in chemical construction projects (special safety section)** ; 3. **Pilot production of chemical construction projects ; 4. **Safety completion acceptance for chemical construction projects. 5. Obtain the **Safety Production License for Chemical Construction Projects.** Thus, it can be seen that the trial production process is carried out prior to the final acceptance. Only when the trial production proceeds smoothly can an application for the “Safety Production License” be submitted.
Reply #32015-09-14
It seems that this is similar to the requirements stipulated in SH/T 3904-2005 “Regulations on the Completion Acceptance of Petrochemical Construction Projects”.
Reply #42015-09-14
Implementation Measures for the Completion Acceptance of Chemical Engineering Construction Projects, Ministry of the Chemical Industry. Completion acceptance is an important construction procedure for comprehensively summarizing and evaluating the results of construction, as well as assessing the quality of design and construction. It plays a vital role in ensuring that construction projects are delivered for operation in a timely manner, maximizing the return on investment, and improving the management level of chemical engineering projects. I. Scope and contents of completion acceptance: For all new construction, expansion, and renovation projects related to capital construction and technical upgrades, once they are completed in accordance with the specifications outlined in the approved design documents, are ready for operation and use, and meet the acceptance standards, it is necessary to organize a completion acceptance process promptly in order to handle the handover procedures for fixed assets. II. Basis for completion acceptance: The approved feasibility study report, preliminary design and construction drawings, current construction technical acceptance specifications, as well as any changes or adjustments approved by the superior competent authority. For new technologies, complete sets of equipment or individual units introduced from abroad, as well as Sino-foreign joint venture construction projects, acceptance shall also be carried out in accordance with the signed contracts and design documents and other materials provided by foreign parties. III. Completion and Acceptance Standards (1) The production facilities as well as the utility and auxiliary facilities have been constructed in accordance with the design requirements and are capable of meeting the needs of production. (II) Capable of producing the products specified in the design documents. Upon assessment, the economic and technical indicators such as production capacity, process parameters, product quality, consumption of major raw materials, key equipment, and level of automation have met the design requirements. (III) In accordance with **environmental protection requirements**, strictly implement the prescribed \"three simultaneities\" system. Along with the completion and operation of the project, the treatment of the three types of waste was also put into operation in accordance with the specifications outlined in the design. Labor protection, industrial hygiene, safety and fire protection facilities all meet the design requirements. (IV) The technical documents and archival materials are complete and thorough. (5) The implementation of living welfare facilities has been basically completed in accordance with the design requirements, enabling them to meet the needs during the initial stage of operation. (VI) The construction of chemical mines shall complete trial mining production and trial operation of mineral processing in accordance with the design specifications. (7) The acceptance criteria for the introduced equipment shall be implemented in accordance with the contract provisions. IV. Time and requirements for completion acceptance (1) Once the production facility has met its designed capacity as verified through trial operation, it is necessary to report the increased production capacity to ** in a timely manner and proceed with the completion acceptance procedures. For chemical manufacturing projects, a three-month trial production period is generally arranged starting from the time when products are produced during the commissioning phase with raw materials fed into the process. During the trial production phase, select an appropriate time to conduct a production assessment of the manufacturing facility (usually 72 hours). After completing the production assessment, the completion acceptance is carried out, and the procedures for handing over the assets for use are finalized. (II) If the production facility, as proven through commissioning tests, is capable of producing qualified products but still fails to reach its designed capacity, the competent authority shall organize relevant units to conduct an assessment; a new production capacity can be determined based on the actual capacity demonstrated in these tests, and this figure shall serve as the basis for the completion acceptance of the project. (III) For production facilities that, upon trial operation, are capable of producing qualified products and reaching their designed production capacity, but fail to do so after going into operation due to reasons such as raw materials, fuel, market demand, and economic efficiency, resulting in losses, the reasons must be analyzed and acceptance inspections must be organized on schedule; the additional production capacity shall still be calculated based on the designed capacity. (IV) After the completion of a few projects, if issues such as process technical and equipment defects arise during chemical feeding and commissioning, resulting in abnormal commissioning of the production facilities or the inability to produce qualified products, the project owner shall organize units responsible for design and construction to conduct an assessment, analyze the causes, and submit a report on responsibilities. Propose plans for rectifying and improving the existing issues, implement them after approval by the competent authorities, and achieve the required standards and production levels as soon as possible. The time period for rectification and improvement generally shall not exceed two years. Once the conditions are met, the project completion acceptance will be carried out, and the procedures for delivering and putting the assets into use will be handled. (5) In some construction projects, the main production facilities and supporting works meet the acceptance criteria; only a few minor civil engineering works and certain equipment have not yet been delivered or installed. However, this does not affect normal production, and acceptance procedures should still be carried out. The remaining workload will be reviewed once in accordance with the design specifications to finalize the project work, ensuring sufficient funding is allocated for its completion on schedule through a fixed-price arrangement. (6) For projects that have met the completion acceptance standards, all preparations for the acceptance process must be carried out promptly, so as to complete the project completion acceptance and the handover of assets as soon as possible. If the acceptance and asset handover procedures are not completed within one year, no new construction projects shall be launched. V. Organization of Completion Acceptance (1) In accordance with the relevant regulations, the acceptance of large and medium-sized infrastructure projects is carried out by the **Planning Commission, or by the industry authorities or local authorities entrusted by the **Planning Commission. Generally, large and medium-sized construction projects, as well as technical renovation projects above a certain scale, are inspected and approved jointly by the competent departments of the province, region, or city where the project is located, along with the Department’s Construction Coordination Division. (II) Construction projects of enterprises directly under the ministry are inspected and accepted by the Ministry’s Construction Coordination Department or the relevant departments. (III) Small-scale infrastructure and technological upgrade projects of local enterprises shall be handled in accordance with the regulations of respective provinces, autonomous regions, and municipalities. (IV) For key chemical engineering projects and large-scale construction projects that are subject to acceptance by the competent authorities or local comprehensive departments, their environmental protection facilities are subject to a preliminary acceptance organized by the Environmental Protection Office of the Ministry of Chemical Industry in conjunction with the local competent authorities. (5) Form an acceptance committee or an acceptance leadership team based on the scale and complexity of the project. The acceptance committee shall have 1 chairperson, 2–3 vice chairpersons, and several members ; The acceptance leadership team consists of one team leader, 1–2 deputy team leaders, and several members. The main entities to be invited to participate in the acceptance process include: the local construction committee, development and reform commission, finance department, banks, environmental protection authorities, labor departments, statistics agencies, fire safety departments, health authorities, archives departments, as well as the project owner. The units participating in the Ministry of Chemical Industry mainly include: the Department for Construction Coordination, the Planning Department, the Finance Department, and other relevant departments. Surveying, design, and construction units should also participate in the completion acceptance process. VI. Methods and Steps for Completion Acceptance Based on the characteristics of chemical engineering construction projects, completion acceptance can be divided into two types: acceptance of individual projects and acceptance of the entire project. (1) Acceptance of individual projects: Once an individual project has been completed in accordance with the design requirements and is ready for use after trial operation, the project owner should promptly organize the design and construction units to assess the quality of the project. Relevant construction technical documents and as-built drawings must be prepared in compliance with the original **Construction Commission’s ‘Interim Provisions on the Preparation of As-Built Drawings for Capital Construction Projects’ (Document No. Jianfa Shi Zi [1982] 50). Financial settlement for the individual project and the handover procedures for the assets put into use should then be carried out, after which the newly added production capacity should be reported on a project-by-project basis. For a single project carried out by several construction units, once the portion assigned to one of those units has been completed in accordance with the design requirements, it can submit the handover procedures to the project owner. (II) Final acceptance of the entire project: Since the entire construction project meets the acceptance standards specified in these regulations, final acceptance of the whole project should be carried out. The acceptance of the entire project can be carried out in three steps: 1. Preparation stage (1) Prepare the as-built drawings of the project in accordance with the original regulations set by the **Construction Commission ; (2) Conduct financial settlement, prepare the final accounts in accordance with relevant regulations, and submit them to the competent authorities for approval ; The final accounts for capital construction projects must be submitted to the higher-level audit authorities for review, while those for construction projects directly under the ministry need to be submitted to the ministry’s Finance Department and Audit Bureau for examination ; (3) Clean up the workload and any remaining tasks according to the approved design documents, and propose solutions ; (4) Carry out the handover procedures for the projects to be transferred, sort through the fixed assets, and prepare a inventory of them ; (5) Account for the usage and inventory levels of the ‘three materials’ in the cleanup project, and propose recommendations for handling them ; (6) Conduct quality assessment or verification of the design, construction, and quality of major equipment. For **key projects, the quality of the work must be assessed or verified by the Ministry’s Chemical Industry Quality Supervision Station or a quality supervision agency appointed by it; for ordinary large and medium-sized projects, assessment or verification is carried out by the chemical industry quality supervision stations in each province ; (7) Various completion documents, including treatment of \"three wastes\", industrial hygiene, and safety and fire protection. Organize and classify materials related to labor protection, etc., and bind them into volumes ; (8) Prepare the completion acceptance report ; (9) Draft the project completion acceptance report on behalf of the **acceptance committee. To carry out the various preparatory tasks, the project owner takes the lead in organizing units involved in construction, design, and production, and invites local banks to participate as well. Form a project completion acceptance team or office in a timely manner to be responsible for the specific preparatory work for the completion acceptance. 2. Document review phase: Once the preparatory work is completed, the completion acceptance report and other relevant documents are submitted to the competent authorities for review, while also being sent to the local relevant departments for examination. For the acceptance projects organized and participated in by the ministry, the completion acceptance reports and evaluation documents must be submitted to the Ministry’s Construction Coordination Department for review, and discussions shall be held regarding matters related to the organization of the acceptance process and the acceptance meetings. 3. Acceptance phase: The final acceptance of a project is generally carried out in the form of an acceptance meeting. The acceptance meeting is organized by the acceptance committee or the acceptance leadership group. **For key projects and large-scale chemical projects, a pre-acceptance can be organized before the formal acceptance; for ordinary projects, pre-acceptances can be carried out by relevant specialists in areas such as environmental protection, fire safety, and industrial hygiene. During the formal acceptance process, the acceptance committee or leading group for acceptance shall listen to the report on the completion acceptance of the project as well as a presentation on the progress of the preliminary acceptance work ; Review engineering documentation ; Inspect and accept the project site ; Provide a comprehensive evaluation of project construction, design, construction, equipment quality, economic efficiency, and other aspects ; Propose solutions for unfinished projects and remaining issues. Organize a discussion to approve the project completion acceptance certificate and sign for acceptance. Projects that do not meet the standards will not be accepted. VII. Others 1. A chemical engineering construction project can be put into production management only after it has passed the project completion inspection and obtained the **inspection certification. 2. The Construction Coordination Department of the Ministry of Chemical Industry shall be responsible for the interpretation of these measures. 3. These measures shall come into effect as of the date of issuance. The Interim Measures for the Completion Acceptance of Capital Construction Projects of the Ministry of Chemical Industry (No. [83] Hua Ji Zi 450) is simultaneously repealed. Appendix 1: Main Contents of the Completion Acceptance Report (I) Textual Description Section of the Completion Acceptance Report 1. Construction Details (1) Basis for project approval, construction scale, product specifications, and additional production capacity (2) Design details, including the basis for design, design agency, design stages, department responsible for design approval, and any significant design changes (3) Construction details, including the construction contractor, progress of construction over the years, and key events that occurred during construction (4) Analysis of the estimated design cost, final settlement amount, and total value of the assets delivered for use, along with their composition (5) For chemical mining projects, a report on changes in geological conditions and mineral reserves at the end of construction must be prepared separately. 2. Status of production preparation, including organizational structure, staff training, availability of raw materials, as well as the condition of water, electricity, and steam supply systems and safety measures. For mining projects, it is necessary to prepare tier-3 (tier-2) resource volume reports prior to commissioning. 3. Information on the commissioning tests, the results of these tests at various stages, and the results of assessments of various economic indicators. For mining projects, it is necessary to prepare reports on mining tests, the results of pilot production for ore processing, and various technical and economic indicators. 4. Overall evaluation of project quality. 5. Status of waste treatment projects and results of trial operations. 6. Conditions regarding labor protection and industrial hygiene. 7. Remaining issues related to the project and suggestions for their resolution. 8. Foreign affairs activities and contract implementation status. 9. Analysis of investment effectiveness. 10. Lessons learned
Reply #52015-09-14
See also the **Measures for the Safety Supervision and Management of Chemical Construction Projects** (Order No. 45 of the **State Administration of Work Safety**).
Reply #62015-09-14
It is currently in the trial production phase, and inspection will be required after the trial production. Through on-site inspection and document review by the expert panel.
Reply #72015-09-14
What documents are needed for the document review section?
Reply #82015-09-15
Order No. 45 issued by the State Administration of Work Safety provides a detailed list of required documents; each province also has its own corresponding regulations. It is sufficient to prepare the documents in accordance with these requirements and submit them for inspection. After the inspection, the application must be filed as per the requirements for obtaining a work safety license.
Reply #92015-09-16
The requirements outlined in the latest Order No. 77 include those stipulated by the provincial safety authorities: a safety completion inspection report for chemical construction projects, along with an evaluation of this report by experts appointed by the enterprise. The requirements vary from province to province; in Jiangsu, qualified professionals fill out the required forms, and there is one ‘A’ grade for acceptable items and three ‘B’ grades for unacceptable items. After passing the inspection, it is submitted to the local work safety authorities for processing.
Reply #102015-09-17
The requirements are more or less the same everywhere; it is possible to hire a safety assessment company for consulting services. They will provide a list of documents, and once everything is ready, experts will be organized to conduct an on-site inspection.
Reply #112015-09-19
If the trial production goes without problems, the acceptance process will be straightforward. The acceptance mainly involves an on-site inspection, and the documents required are similar to those needed for the trial production application.

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