First, the preparatory work of the project
The preparatory work of the project refers to all the preparatory work for the completion of the project:
1, document preparation
Commissioned a qualified unit for the feasibility study report and the preparation of the project application;
2, project project
To sign the relevant agreement with the local government;
Preparation of pre nuclear materials, according to the requirements of the relevant government departments to complete the name of the pre nuclear work;
The feasibility study report and project documents submitted to the level of development and Reform Commission, the NDRC approved the approval document.
3, supporting procedures
With the application of the project to start the simultaneous assessment of environmental impact assessment, safety evaluation;
In the EIA through after the pre land, planning and site selection, project application report and approval work, the final plan of soil and water conservation, water resources assessment, land pre-trial, engineering geological exploration, earthquake and other authorities approval documents;
Complete the company registration.
Two, the project preliminary work
The preliminary work of the project refers to the main work of the construction project approval to start the project. Project proposal is approved for the project.
1, the establishment of management institutions and the development of various rules and regulations and equipped with a certain number of engineering and technical personnel.
Determine the general contracting, construction supervision and other management methods.
The units undertaking the general contracting, construction and construction supervision of the project shall have the corresponding qualifications, so as to ensure the effective control of the progress, quality, capital and production preparation of the project.
2, the preparation of process and basic design.
Determine the design principles, design criteria, design scheme and major technical problems, such as the total process flow, production method, plant composition, transportation, water, electricity, gas supply and consumption, key equipment and instrument selection, fire protection, labor safety, industrial hygiene, environmental protection, project budget etc..
3, the preliminary design of the project after the completion of the preliminary design review.
Preliminary design is an important part of engineering design, is the basis for the preparation of construction plans, arrangements for the annual plan and the organization of major equipment orders. The preliminary design review of the project is to review the preliminary design of the project is in line with industry regulations, standards, whether it is practical, safe and applicable, advanced and reliable technology, economic and reasonable, is to further optimize the design process.
4, the organization of the main design, construction units for the overall construction of the overall control plan and the overall construction of the overall control plan.
The overall planning is the project started early and in the construction funds, construction, foreign affairs, production equipment and materials, preparation, testing, evaluation, acceptance, cooperation, organization construction work in accordance with the principle of system engineering into the plan, reasonable arrangement, overall consideration, to ensure the realization of the main control points and complete the overall schedule the.
5, the project construction, equipment, supervision should be carried out bidding work.
To give full consideration to the particularity and complexity of the chemical production equipment, strictly examine the qualifications of the bidding units, select the construction, equipment, and supervision units. In the evaluation, calibration, we must comprehensively inspect the quality of the team, management level, technical equipment, financial conditions, and so on, and should not simply be based on the number of quotations.
6, long cycle equipment procurement problems.
Long cycle equipment is determined according to equipment manufacturing cycle. For the manufacturing cycle of equipment such as tanks, reactors and other design units to be in the process package or the basis of the design of the initial design parameters, the project department to organize equipment ordering. Other equipment and materials can be purchased in accordance with the progress of the project after the completion of the basic design.
Do a good job in the construction of new projects can be started before the implementation of the construction.
Three, project construction period
1, the preparation of the project plan
Work out the project plan according to the overall planning of the network and the delivery of the design drawings, the delivery schedule of the equipment and materials, etc.. In the project construction, according to the actual situation to adjust the overall control plan, but must ensure the realization of the overall goal, and strive to put into operation within the specified period of time.
2, the establishment of quality management agencies
Project department and construction and supervision units to set up quality management mechanism, establish a sound quality management system, equipped with a number of engineering quality management personnel and the necessary means of monitoring, strict supervision and inspection of the quality of the project. The quality of the project must comply with the standards, specifications and design requirements. To strictly in accordance with the provisions of the assessment and acceptance, to ensure quality.
In the process of construction, we must accept the supervision of Engineering quality.
3, equipment acceptance
To the factory equipment and materials shall appoint a responsible person in charge of the inspection work, strengthen docking, inspection, transportation, leadership and management personnel, and to establish a strong sense of responsibility, familiar with the business personnel as the backbone of the professional management team, transportation and handling, inspection, warehousing and issuing work uniform. The inspection of equipment and materials shall be submitted to the local commodity inspection authorities and the labor department in accordance with relevant state regulations.
4, the construction process of capital control
In the implementation of the project, the project department should strengthen capital control, do everything possible to save money. In order to ensure the production function under the conditions of the preliminary design in total investment budget range, according to the actual situation of engineering project between the adjustment of idle cash, but to control in the design of the proposed budget. In the event of a breakthrough in the total budgetary estimate, the design unit shall be responsible for the adjustment of the budgetary estimate in accordance with the plan for the preparation of the budget adjustment plan for chemical engineering.
Strict control of the project budget is the responsibility of each constructor, the preliminary design budget estimates, generally do not make adjustments. The basic conditions for adjustments to the estimates is based on the design of construction budget, equipment quantity reached 80%, the volume reached 60%, installation works completed in 60%, the amount of civil engineering can be completed more than 80%.
Four, engineering intermediate handover
1, project finishing and single commissioning
In the end of the basic installation project, the construction unit should catch off, and in accordance with the requirements of design and commissioning, commissioning, reasonable organization, carefully cleaning the unfinished engineering and tail, and is responsible for the rectification of defects; the project department should grasp the test, promote the mop, coordination, cohesion and outstanding progress of the test organization of production personnel to enter the scene, found problems in a timely manner to the rectification as soon as possible.
Upon completion of the installation of the project according to the content of the design, the construction unit shall, after passing the examinationThe amount of supervision departments for quality evaluation, project design, organization of production, construction, quality supervision units according to the unit and system, professional “ three by ” (three check: check the design leak, check construction quality problems, check the unfinished project; by checking out the issue of a given task, personnel, measures, rectification time).
The test, control, interlock and alarm system of the pump, the unit and its related electrical, instrumentation, computer and so on. The purpose is to check the equipment manufacturing, installation quality and equipment performance is consistent with the specifications and design requirements.
The project team shall be established by the project department, and the test plan and implementation shall be prepared by the construction unit, and the production units shall cooperate with the design, supply and quality supervision units. If the construction unit is not enough strength, can be produced by the production of technical personnel program, and organize production personnel to cooperate with the construction unit for single test.
Single machine test need to increase the temporary facilities (such as pipelines, valves, blind plate, filter, etc.), by the construction unit plan, project audit, construction unit construction.
The water supply, electricity, steam, wind and other public works and raw materials, materials, etc. shall be supplied by the project department.
The single commissioning process in a timely manner to fill out the trial record. The single commissioning qualified after production, the project department organization project management, design, construction, quality supervision and other personnel to confirm and sign.
The unit test conditions:
Unit installation is completed, the quality evaluation;
System piping pressure test and cold exchanger air tightness test;
Process and steam piping purge or cleaning pass;
Cleaning of equipment lubricating oil, seal oil and control oil system;
Safety valve debugging qualified and seals;
The same test related electrical, instrumentation, computer etc. the joint debugging qualified;
The medium required for commissioning is in place;
The test program has been approved, command, operation, operation personnel in place; testing instruments, tools, protective equipment, ready to complete record form;
Test equipment and its associated systems have been separated from each other, with its own independent system;
Test area has been designated, the relevant personnel to enter the certificate;
Commissioning of the project installation information, the completion of the construction unit, to provide test personnel to borrow.
The test equipment for the physical needs of some material, can be left to the commissioning stage of single commissioning.
2, system cleaning, purging, air tightness
System cleaning, purging, air tightness by the production unit of the program, construction, production units, and ultimately confirmed by the production unit.
System cleaning, purging, air tight to strict quality control, the use of media, flow, flow rate, pressure and other parameters and inspection methods, must comply with the requirements of design and specification. System for purging, prohibited unqualified medium into the pump, heat exchanger, tower, reactor and other equipment, pipe orifice, flowmeter, control valve, temperature sensor in chemical cleaning or purging should be removed, the valve core welding should be removed or open.
Special requirements of the pipeline, equipment cleaning, cleaning should be in accordance with the relevant specifications for special treatment.
3, engineering intermediate handover
Interim project handover marks the end of the installation project construction, from single commissioning into commissioning phase, is a necessary procedure for the project construction units to transfer production units, but the preservation and use of intermediate transfer device does not terminate the transfer of responsibility, the construction unit of the project quality, completion and acceptance of responsibility, until final acceptance.
The conditions for the handover of the project:
Works according to the design content construction;
The quality of the project is qualified;
Process, power pipeline pressure test, the system cleaning, purging, air tightness, insulation basically completed;
Static strength test, nondestructive testing, cleaning;
The single test run of the equipment shall be carried out (except for the actual material or special medium but not the pilot);
Large unit load test, of interlock protection unit and alarm control system joint debugging qualified;
The joint qualified debugging device electrical instrumentation and computer system, gas fire and explosion;
Installation of temporary facilities in the installation area has been dismantled, the work is completed, the net is clean and the site is clear;
Have influence on the linkage test three check four project and design changes after treatment, the other to tail responsibility and completion time has been clear.
The contents of the project handover:
According to the content of the project to verify the transfer of physical quantities;
The quality of the project evaluation and audit information about debugging record verification and transfer;
Installation of special tools and spare parts and materials;
Confirmation of the cleaning and completion time;
Handover of random technical data;
4, engineering intermediate handover
The interim project handover project organized by the Ministry of production, construction and design units for intermediate acceptance according to the unit engineering, professional, finally the organization of production, project management, construction and design units in the intermediate and transition meeting signed the interim project handover agreement and accessories.
Five, production preparation
Production preparation work throughout the project construction. After the project has been approved, it is necessary to compile the outline of the production preparation work, so as to make the production preparation and commissioning work into the overall overall control plan of the construction project.
1, production preparation tasks
The production preparation mainly includes the organization preparation, personnel preparation, technical preparation, material preparation, fund preparation, marketing preparation and external condition preparation.
(1) organizational preparation
After the project is completed, it is necessary to set up the production preparation organization, according to the progress of the project construction, according to the principle of simplification, unification and efficiency, and gradually improve the organization, responsible for the preparation of production.
Second, according to the requirements of the overall test program, the establishment of the pilot organization in a timely manner, unified organization and command of the relevant units to do a single test, linkage test, commissioning and production assessment.
According to the design requirements and the progress of the project construction, all levels of production management organization should be set up in time to meet the actual needs of production management.
(2) personnel preparation
According to the approved staffing quota index, incoming plan, timely staffing.
Personnel should pay attention to the age structure, cultural level, technical level. Production management, technical staff of the basic design of the forward plant, other personnel in the device before driving into the factory 2 months.
Make a good training plan, earnestly do a good job of training, so that all levels of management personnel, technical personnelAfter strict training and assessment of workers to meet the conditions of appointment.
The training of managers at all levels should focus on the education of the major and related knowledge, improve the management level, and adapt to the needs of trial production and production management.
The technical staff, team leader and backbone of the main operating personnel training, should focus on the organization of professional knowledge, practice, computer simulation and similar devices, environmental protection, fire protection and labor safety and industrial hygiene knowledge training, through single commissioning and commissioning, improve service quality and technical level, to play the role of technology and in the commissioning of the production backbone.
The new workers into the plant three safety education, generally divided into five stages as follows: the whole process of training and professional knowledge education, similar devices internship, job training, simulation training, investment in the stock before the test. Through training, so that they are familiar with the process, master the operation essentials, do “ three (three &rdquo six will understand; understand: understand the principle and understand the structure and understand the solution procedures; six: knowledge map, operation, maintenance, will will be calculated, will contact and troubleshooting), improve & ldquo; six kinds of abilities (” thinking ability, operation, operation ability, coordination ability, anti accident ability, self protection ability, self-control ability). At the end of the training period, we must carry out a rigorous examination, and will be included in the examination results of personal technical files, as evidence of mount guard evidence.
To the production of similar devices to personnel training organized by the implementation of “ six ” (given task, time, position, personnel, training and regular assessment led) approach, and signed &ldquo and Daipei units; two packets of a ” (Daipei unit package package will teach, in operation, post training under the supervision of the master contract).
(3) technical preparation
The main task of technical preparation is to prepare various test plan, production technical data, management system, so that the production personnel to master the technology of the equipment.
The early establishment of production management system, by participating in technical negotiations and discussed the design scheme and design review of the technical preparatory work, the production management and technical personnel familiar with the technology, equipment, instruments (including computers), safety, environmental protection and other aspects of the technical ability, all kinds of technical problems independently.
Make the overall test plan, through repeated modification, deepening, optimization.
According to the design documents, referring to the relevant data of the same kind of equipment, timely completion of training materials, technical data, management system, all kinds of test plan and the preparation of the assessment program.
Training: the teaching of basic knowledge, professional knowledge, teaching materials, teaching material, process flow chart, production preparation manual, safety, industrial hygiene and fire protection materials, domestic and foreign similar equipment accident case and processing method of assembly.
Production technology: plan process flow chart, operation method, process cards, process, technical specification, technical specification for safety accidents (including key production equipment and key production jobs), analytical procedures, maintenance procedures, operating procedures, electrical main equipment operation regulations, operating procedures, instrumentation and computer interlocking setting etc.. At the same time should be prepared and printed position records and technical accounts.
Comprehensive information technology: the enterprise and equipment introduction, raw materials (three agents) manual, material balance manual, product quality manual, lubricating oil (grease) manual, “ waste ” emission manuals, equipment manuals, list method and gasket, and timely collected random data.
Various test schemes:
Power supply: including external power supply and uninterruptible power supply (UPS) and other programs;
Water supply and drainage system: water source to the plant (or deep water), raw water pretreatment, circulating cooling water system flushing, chemical cleaning, pre membrane and other programs;
Industrial wind, instrument wind: air compressor commissioning, equipment and pipeline purging program;
Boiler system: Boiler flushing, chemical cleaning (Zhu Lu), fuel system, oven, pressure relief valve, pipeline purging, etc.;
Storage and transportation system: raw materials, product storage, import and export program;
Fire system: fire water, fire extinguishers, combustible gas alarm, fire alarm system and other fire prevention facilities commissioning scheme;
Communication system scheme;
System cleaning, purging, air tightness, drying, replacement, etc.;
Three agent loading scheme;
Boiler system commissioning scheme;
Linkage test scheme;
Plant commissioning scheme;
Accident treatment plan.
The management system: the management system developed by the post responsibility system as the center, to select security system, three “ ten &rdquo ban; safety production management system as the foundation, the functional management departments should formulate corresponding management system.
(4) material preparation
According to the test requirements of the program, organize the preparation of the raw materials needed to drive, fuel, three agent, chemicals, standard sample gas, spare parts, lubricating oil (grease), plan and implement the variety and quantity (including a loading amount, test dosage, reserves), and supply unit signed agreement or contract.
A variety of chemical raw materials, lubricating oil (grease) should be properly stored and kept to prevent damage, loss, deterioration.
All the spare parts should do the classification, establish account, cards, shelves, do account card match, the strict implementation of the system of granting custody.
The ownership of all kinds of random data, special tools and measuring instruments shall be owned by the construction unit. In the device during the inspection, should carefully check, registration, record.
Safety, industrial hygiene, fire fighting, gas prevention, rescue, communications and other equipment, according to the design and test needs to be equipped with post. Labor protection articles shall be distributed in accordance with the design and relevant regulations.
(5) capital reserve
According to the estimated production cost in the design budget, prepare the production preparation fund plan, and put it into the investment plan of the construction project, to ensure the source of production preparation fund.
In the preparation of the overall test plan, should be prepared to produce liquidity plan, and pay close attention to financing.
The construction unit shall prepare the commissioning cost plan.
(6) marketing preparation
Establish sales network as soon as possible and make marketing strategy.
Pre sales of products, product flow, and usersSign a sales agreement or contract.
Prepare the product specification to enable users to understand the product quality standards, performance, use and storage methods.
Using a variety of promotional tools to enable users to understand the product, improve product market share in the market.
(7) preparation of external conditions
Water supply, power supply, communication and other agreements signed, and in accordance with the overall test program requirements, the implementation of the opening time, the number of use, technical parameters, etc..
The timely opening of factory roads, docks, transit stations, flood prevention and discharge of industrial sewage, waste, etc..
Implementation of labor safety, fire protection, environmental protection, industrial hygiene and other measures, the initiative to report to the local government, for the necessary approval procedures.
Relying on the three maintenance of social power and social public service facilities, and support units to sign agreements or contracts.
Six, the device commissioning work
Test work to follow the “ single machine test to be early, purge air tightness to be strict, linkage test run to the whole, feeding test run to be stable, economic benefit is better than ” principle, to be safe and secure, a success.
1, linkage test
(1) the conditions of linkage test run
The purpose of the test is to verify the performance and quality of the equipment, piping, valves, electrical, instrumentation, computers, etc..
The linkage system includes drying, replacement, filling agent, water, and three oil, etc.. It is generally necessary to start with a single system, and then expand into a number of systems or fully equipped.
Conditions required for linkage test run:
The middle of the device is over;
The number of the equipment, the name of the medium and the flow mark;
Public works have been running smoothly;
Post responsibility system has been established and published;
Technical staff, class leader, the position operator has been determined, after the examination and obtain a certificate;
The commissioning plan and relevant operation procedures have been issued to individuals;
The test process indicators have been identified;
The interlock value, the alarm value has been determined;
To produce records of printed statements have been complete, sent to the post;
The communication system has been smooth;
Safety and sanitation, fire facilities, gas equipment and anti temperature, smoke and poisonous and flammable gas alarm, TV monitoring and protection facilities have been in good condition;
Operation team has been formed and in place.
(2) linkage test scheme
Linkage test run by the production staff responsible for the preparation and implementation of the organization, construction, design units to participate.
The linkage test plan shall include the following:
Test purpose;
Organization and command of test run;
Conditions for commissioning;
Test procedure and schedule network diagram;
The main technical indicators, analysis indicators, interlocking values, alarm value;
The open parking and normal operation, accident treatment measures;
The test material quantity and quality requirements;
The test operation system.
(3) before the linkage test run, it must be organized to participate in the pilot training program.
(4) drying, displacement, and filling of the three agent
System drying, replacement, three loading by the production unit in accordance with the design requirements of the program;
System drying, replacement should be carried out according to the test plan, the test data in line with the standard; after the commissioning of the person in charge of inspection, do a good job of protection.
Three filling should be carried out according to the loading plan, there should be a person in charge; filling the organization should be completed, the pilot can be closed after the signature of the person in charge.
2, feeding test
The test condition of feeding test should be checked before the commissioning test, and then the material can be tested.
(1) the standard to be achieved in the commissioning test
The main control points of the feeding test run on time, the continuous operation of the output of qualified products, a successful commissioning test;
No major equipment, operation, fire, explosion, personal injury, environmental accidents;
Safety, environmental protection, fire control and industrial hygiene to achieve “ three at the same time, &rdquo, monitoring indicators meet the standard;
Good material balance, low fuel consumption, low power consumption;
Control the cost of trial run, good economic returns.
(2) commissioning scheme
The commissioning shall be responsible for the preparation and implementation of the plan by the production department.
The basic contents of the test plan of the plant feeding include:
General situation and test target;
Test organization and command system;
Conditions for commissioning;
Commissioning and commissioning;
Test load and raw fuel balance;
The utilities balance test;
The technical indexes, interlock and alarm value value;
The open parking and normal operation and accident treatment measures;
To safety and environmental protection measures; measures for prevention of fire and explosion and precautions;
The commissioning operation system; commissioning commissioning difficulties and countermeasures; problems and solutions; test cost plan.
(3) test team
The commissioning of the production plant shall be composed of the production unit, the design unit, the construction unit and the test team of the corresponding plant.
During the commissioning period, a unified test run command system shall be established to lead and organize the trial run.
The design unit shall send the field service team headed by the design general representative to deal with the problems found in the test run.
(4) the organization operation system, responsible for commissioning operation work.
The organization construction, design and other units to participate in the operation, strong leadership, unified command during commissioning operation work.
The spirit of “ who installed the &rdquo operation principle, who signed the contract; protection and construction units, the construction unit should carry out the installation, commissioning, operation consistent responsibility system.
The operation staff should be 24 hours on duty, work, tools and complete, so call &ldquo, &rdquo operation; tracking.
3, production assessment
Production assessment refers to the commissioning output of qualified products, the plant production capacity, process indicators, environmental indicators, product quality, equipment performance, automation level, consumption quota is to meet the design requirements of the comprehensive assessment.
(1) no completion inspection shall be carried out without the production examination.
(2) the production inspection shall be organized by the production unit and the design unit shall participate in the examination.
(3) the production unit shall, in conjunction with the design unit, do the preparatory work for the following production assessment:
Composed of production units, design units to participate in the production of the working group, the preparation of assessment programs, the overall arrangement of the assessment work;Second, research and familiar with the assessment data to determine the formula, the basic data;
Looking for potential problems and problems that may affect the assessment;
Calibration of measuring instruments and analytical instruments;
Prepare the assessment record form.
(4) the production assessment shall be carried out at full or high load for a period of time:
The influence of production assessment has been solved;
The equipment is operating normally, the standby equipment is in good condition;
Automatic control instruments, on-line analytical instruments, interlocking has been put into use;
The sampling point, the analysis frequency and the method have been confirmed;
Raw materials, fuels, chemicals, lubricating oil (grease), spare parts and other quality meet the design requirements, reserves can meet the needs of the assessment;
The utility is stable and can meet the requirements of production parameter assessment;
The products and by-products of the factory has been open channels.
(5) production assessment content
Plant capacity;
Raw material, fuel and power index;
Main technical indexes;
Product quality;
Automatic control instrument, on line analytical instrument and interlock;
Operation status of the mechanical and electrical equipment;
The &ldquo &rdquo emission standards; wastes;
The environmental noise intensity and poisonous and harmful gas and dust concentration;
The provisions of other projects to design and appraisal to the contract.
(6) the time of production assessment is generally defined as 72 hours.
(7) after the completion of the production assessment, the production unit shall present the assessment report, and participate in the examination of the various units of production inspection.
(8) the treatment of remaining problems in production assessment:
The production evaluation results can not meet the design requirements, shall be borne by the production units and design units to analyze the reasons, put forward opinions, consultation, the general organization is no longer re examination; examination to reach agreement, but when the re examination is limited to one time.
After the completion of the production assessment, the production unit shall organize, summarize and analyze the original records of the production assessment, and write a summary of the production and report to the headquarters.
This article source: chemical belated effort;

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