Air separation Plants construction project commissioning process

Air separation construction project commissioning process:

The commissioning work must follow the principle of "early commissioning of a single machine, strict purging and air tightness, complete naked cold leak detection , stable feeding and commissioning, and good economic benefits" to achieve safety, stability, and success the first time.

Conditions that should be met:

-The equipment tag number, pipeline medium name and flow direction mark are completed;

-Utility water and electricity meters have been running smoothly;

- A job responsibility system has been established and announced;The technical staff, team leaders, and job operators have been determined, passed the examination and obtained employment certificates;

-A job responsibility system has been established and announced;

-The test process indicators have been determined;

-The DCS system is complete, and the interlocking values and alarm values have been determined;

- All record reports have been printed and sent to the post;

The communication system is open;

-Safety and sanitation, fire-fighting facilities, gas prevention equipment, temperature sensors, smoke sensors, toxic and hazardous gas alarms, TV monitoring, and protective facilities are in good condition;

1 System activation and purging.

-Molecular sieve filling should be carried out according to the filling plan,after the filling is completed, an inspection should be organized a           

-System activation and purging shall be prepared by the production unit according to the design requirements ;

-System activation and purging should be carried out according to the test run plan, and the test data meets the standards; after acceptance by the person in -Charge of the test run, protection work should be done.

-Purging should be carried out in accordance with relevant principles and standards.

2 Naked cold leak detection

(1) Conditions for naked cold leak detection

-The purpose of the naked cold leakage test is to check whether the performance and quality of the equipment, pipes, valves, electrical, instruments, etc. of the device meet the requirements of the design and specifications. Generally, you should start with a single system, such as water circuit , gas circuit , oil circuit , etc. Then expand to intermodal transportation of several systems or entire devices.

(2) " Naked Cooling Plan "

For naked cooling , production personnel are responsible for preparing plans and organizing implementation, with construction and design units participating. For naked cooling, the construction team is responsible for leak detection, and the project department is responsible for supervision and review.

 The naked cooling solution should include the following:

Test run purpose;

Organization and command of test runs;

Conditions that should be met for test run;

Commissioning procedures and progress network diagram;

Main process indicators, analysis indicators, interlocking values, and alarm values;

Key points for starting, stopping and normal operations, and accident handling measures;

Test run material quantity and quality requirements;

Commissioning and transportation guarantee system.

(3) Before the naked cold test run, personnel participating in the test run must be organized to study the plan carefully.

(4) Load sand , stop the machine to heat up, clean up water, and then the construction team is responsible for sand loading.

3. Test run and put into production.

Before the test run , the test run conditions should be checked, and work can only be carried out after passing the test.

(1) Standards that should be met during test run

The quality of the main

No major equipment, operation, fire, explosion, personal injury or death, or environmental accidents will occur;

Safety, environmental protection, fire protection and industrial hygiene are achieved at the same time, and monitoring indicators are in line with standards;

Good material balance and low power consumption;

Control the commissioning cost and achieve good economic benefits.

(2) " Testing Plan "

The production department shall be responsible for preparing the plan and organizing the implementation of the test run, with the participation of the design and construction units.

The basic contents of the device commissioning plan include:

Device overview and commissioning objectives;

Commissioning organization and command system;

Conditions that should be met for test run;

Commissioning procedures and commissioning progress;

Utility balance for commissioning;

Process technical indicators, interlocking values, and alarm values;

Key points for starting, stopping, normal operations and accident handling measures;

Environmental protection measures; safety, fire prevention, explosion-proof measures and precautions;

Test run and transportation guarantee system; test run difficulties and countermeasures; test run problems and solutions; test run cost plan.

(3) Test team

For the commissioning of production equipment, a commissioning team should be formed, with the production unit as the main body and the design unit, construction unit, and air separation manufacturer's driving team participating.

During the trial run with material feeding, a unified trial run command system should be established to lead and organize the trial run work.

The design unit should dispatch an on-site service team headed by the chief design representative to deal with the design problems discovered during the test run.

(4) Organize the transportation guarantee system and be responsible for the test run and transportation guarantee work.

Organize a strong leadership team with participation from construction, design and other units to provide unified command for the operation guarantee work during the commissioning period.

In line with the principle of "whoever installs the equipment is responsible for ensuring transportation", a transportation guarantee contract is signed with the construction unit. The construction unit should implement a consistent responsibility system for installation, commissioning, and transportation guarantee.

The transportation personnel should be on-site 24 hours a day, with complete types of work and tools, so that they can be on call and "track" the transportation.

3. Production assessment

Production assessment refers to a comprehensive assessment of whether the device's production capacity, process indicators, environmental protection indicators, product quality, equipment performance, self-control level, consumption quota, etc. meet the design requirements after the test run produces qualified products.

(1) Completion acceptance shall not be carried out without production assessment.

(2) Production assessment should be organized by the production unit and participated by the design unit.

(3) The production unit should work with the design unit to prepare for the following production assessment:

Form a production assessment working group with mainly production units and design units participating, prepare assessment plans, and comprehensively arrange assessment work;

Research and familiarize yourself with assessment materials and determine calculation formulas and basic data;

Find hidden dangers and problems that may affect the assessment;

Calibrate measuring instruments and analytical instruments required for assessment;

Prepare the assessment record form.

(4) The production assessment should be conducted after the device has been running stably for a period of time at full load or high load, and the following conditions are met:

The issues affecting production assessment have been resolved;

The equipment is operating normally and the backup equipment is in good condition;

Automatic control instruments, online analysis instruments, and interlocking have been put into use;

The sampling points, frequency and methods of analysis and testing have been confirmed;

The operation of public projects is stable and can meet the parameter requirements of production assessment;

The factory exit channels for products, by-products, etc. are now unblocked.

(5) Production assessment content

Device production capacity;

Energy consumption indicators;

Main process indicators;

product quality;

Automatic control instruments, online analysis instruments and interlocking status;

The operating conditions of electromechanical equipment;

Environmental noise intensity;

Other items to be assessed as specified in the design and contract.

(6) The duration of production assessment is generally stipulated to be 72 hours.

(7) After the production assessment is completed, the production unit shall submit an assessment report and all units participating in the production assessment shall sign it.

(8) Handling of issues left over from production assessment:

When the production assessment results fail to meet the design requirements, the production unit and the design unit should jointly analyze the reasons, put forward handling opinions, and negotiate a solution. Generally, no re-assessment will be organized; when an agreement cannot be reached, the assessment will be re-assessed, but the re-assessment is limited to one time. .

After the production assessment is completed, the production unit should organize, summarize, and analyze the original records of the production assessment, write a production summary, and report it to the headquarters.

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