Project Commissioning & Equipment Training

1、 Project commissioning scheme

 

Inspection before commissioning

 

Before commissioning, organize relevant personnel to get familiar with the drawings and do a good job of technical disclosure to ensure the safety of equipment and personnel during commissioning.

 

After the wiring between the meter and each equipment is completed, first check and check the internal wiring and input / output wiring. Before the local control unit is powered on, the insulation of panels, cabinets and cables shall be checked. Confirm that it is correct and power on for static commissioning.

 

Static debugging

 

Conduct static commissioning through the controller and check the following: A. whether there is short circuit; b. Whether the signal display and alarm display on the analog screen are correct; c. Whether all output relays operate normally; d. Whether all feedback signals are normal; e. Whether all operation buttons and switches operate correctly; f. Whether the program design meets the required process control flow; g. Whether the signal and alarm functions are normal; h. Whether the simulation test of system process, simulation failure, accident shutdown process and other tests are normal; i. Whether the system linkage commissioning operation is normal; j. Check the correctness of each process and preliminarily determine the best cooperation time of each step;

 

No load and load commissioning

 

The system automatically controls the commissioning of the power system. After debugging the control circuit, the main circuit is debugged, then the load running program is carried out first.

 

The power on commissioning of the control circuit is to check whether the wiring of electric control and distribution equipment is correct. During the test, the main circuit does not send power, only the control power is connected, and then the corresponding buttons or other master components are connected in sequence according to the actual working procedures. Check whether the corresponding electrical components have acted according to the specified procedures every time (such as whether the corresponding signal lamp is on, whether the contactor is closed or separated, whether the action sequence and delay meet the design requirements, and whether there are other abnormalities, etc.) If necessary, artificially simulate the fault signal for inspection, such as pushing the contactor to check whether the interlocking is effective, simulating the action of the limit switch to check whether the protection is reliable, pressing the emergency stop button or connecting the power supply to check the emergency stop and fault breaking functions, etc. after several such power on tests, all electrical components operate normally and the fault diagnosis function of the equipment is normal; The system fault protection function is reliable; the simulation test of system process, simulation fault and emergency shutdown process are normal; it is proved that the wiring of control part is correct and no-load test can be carried out.

 

Before the main circuit is powered on, reconfirm the correctness of the main circuit wiring and conductor selection, and check whether the short-circuit and overload protection appliances meet the requirements. After no-load test, the computer program can control according to the required process control process, whether all output relays operate normally, whether all feedback signals feed back normally, and whether the signal and alarm functions are normal on the analog screen The signal display and alarm display of the motor are correct; the no-load current of the motor is normal, and the load test run can be carried out.

 

During the test run, check the electric control and distribution equipment, including whether the data of each indicating instrument and electrical components work normally, whether the conductor contact point is loose, overheating and other abnormalities. There are no abnormalities after inspection.

 

During the linkage load commissioning and operation of the system, determine the best cooperation time of each step, and further adjust and improve the system control program.

 

Online debugging

 

(1) The test requirements of electrical equipment shall be carried out in accordance with the construction and acceptance specifications of relevant specifications. For the controlled electrical control equipment, the program software shall be debugged after the analog signal is normal;

 

(2) No load test: after the installation of main equipment, no-load operation test shall be carried out. The no-load test shall meet the technical requirements of relevant specifications;

 

(3) Full load linkage commissioning (test): after the equipment and no-load test of all facilities (processing, power supply facilities and water and gas supply facilities) are completed, the system linkage commissioning shall be carried out under the guidance and participation of design technicians with production and operation experience.

 

(4) After the full load linkage commissioning is completed, the test report shall be issued, and the main parameters measured and observed shall be compiled into the equipment commissioning test report and submitted to the customer.

 

Commissioning

 

(1) After the system linkage commissioning is qualified, the system can be put into trial operation after being verified by the project leader.

 

(2) The commissioning shall be carried out with the participation of the customer.

 

(3) The main parameters of commissioning shall be measured and observed, and various records shall be made.

 

(4) The continuous operation time during trial operation shall not be less than 24 hours.

 

Conditions for equipment commissioning

 

The equipment and its auxiliary devices, pipelines, etc. have all been constructed. The auxiliary devices such as cooling water, gas, electrical (instrument) control, etc. have been secretly turned as required, meeting the requirements of test run.

 

The personnel participating in the commissioning must be familiar with the structure, performance and technical documents of the equipment, and master the operating procedures.

 

Clean the equipment and the surrounding environment, and do not carry out dusty or dangerous operations near the equipment.

 

Equipment commissioning includes the following contents and steps

 

① Adjustment test of control system and instrument.

 

② Joint adjustment test of each system.

 

④ Limit test of technical index parameters.

 

Commissioning requirements for equipment commissioning

 

(1) Requirements for adjustment test of electrical and its operation control system

 

① According to the electrical schematic diagram and installation wiring diagram, the internal and external wiring of the equipment are correct.

 

② Check or debug overvoltage, undervoltage, overcurrent protection, etc. according to the type, grade and capacity of the power supply, and the inspection or commissioning contents meet the specified values.

 

③ Check the correctness, sensitivity and reliability of process action, indication, signal and interlocking device with analog operation according to the electrical system adjustment method and commissioning requirements in the equipment operation manual.

 

(2) Equipment system adjustment test requirements

 

The joint commissioning starts from components to components, to single machine and to the whole machine (complete set of equipment) according to the instructions and production operation procedures, and meets the following requirements:

 

a. The operating parameters of each system meet the design index requirements, and the operating conditions of each subsystem are normal.

 

b. Safety device, protection device, alarm device and other signals are tested to be correct, sensitive and reliable.

 

c. The test indexes meet the requirements of technical agreement or national standards.

 

2、 Equipment training program

 

(1) I. purpose and objectives of technical training

 

The purpose of technical training is to make the maintenance and users of the project better familiar with the system equipment. Improve the technical and fault handling ability of the personnel in charge of the equipment, so that the trainees can understand the basic knowledge of the technology of the invested products; strengthen their hands-on ability; be familiar with the application skills; meet the job requirements through training. Fully master the design idea and all functions of the whole product Timely and orderly sorting and maintenance of system data; proficient in system operation and maintenance methods; cultivate a strong sense of responsibility and work awareness.

 

● finally understand the technical performance of the equipment and master the operation and correct maintenance of the equipment;

 

● be able to eliminate general faults of equipment and master equipment maintenance technology and daily maintenance.

 

● have a detailed and thorough understanding of the structure, performance, principle and operation of the equipment of the project;

 

● operate and use the equipment correctly and skillfully, complete daily maintenance and repair, and carry out some simple repairs to ensure the normal use of the equipment.

 

● timely and accurately find out the existing and hidden problems of the equipment, and contact our company in time to solve the problems in time.

 

(2) . objects and qualification requirements of technical training

 

The object of technical training is the main administrators and users of the project.

 

(3) Technical training personnel

 

In order to ensure the quality of training and provide high-quality technical training for the project, our company will arrange experienced technicians and trainers to serve as the teachers of this training.

 

(4) Main contents of technical training

 

Conduct three-day training at the user's location, and provide detailed training plans on equipment use and maintenance, including technical performance, installation, commissioning and maintenance of the provided equipment. After the training, Party A's users shall be assessed, and the users can be skilled in operation and maintenance.

 

(5) Mode and place of technical training

 

Training method: the training is based on the manual training and closely combined with the on-site physical training.

 

Training location: specified by user.

 

Training time: negotiate with users.

 

(6) Arrangement of technical training

 

As a comprehensive multi system combined industrial equipment, the higher the user's relevant staff master the performance of the whole system and equipment, the more fully they use the system and equipment in the process of use, the more obvious the benefits to the user unit, and the higher the user's satisfaction with the equipment, so that the user's relevant staff can effectively master the equipment The only way to prepare is to receive comprehensive and serious training.

 

In view of the above ideas, our company has summarized many years of user training experience, formed a complete set of complete, effective and feasible training ideas and methods according to the principles of comprehensive understanding, classified training and assessment feedback, and classified free training according to the different needs of leading cadres, management personnel and technical personnel on the basis of fully understanding the current level of customers At the same time, secondary training and continuous training are provided, so as to achieve twice the result with half the effort. In the training process, the training process is scientifically divided into stages, each stage is equipped with assessment, and the learning status of students is fed back in time, so as to effectively adjust the training progress, curriculum arrangement and teachers.

 

Our company divides the training work into the following three stages: preparation, training and assessment.

 

Preparation: in order to do a better job in training and understand the current situation of users, it is very necessary to prepare. Therefore, the trainees of users need to fill in the basic information form of trainers and training business demand form, which can be used as the basis for training course setting and class hour arrangement.

 

Basic information of trainees

Name	Age	Education	Major	Post	Jobs	Training level

Training business demand table

Curriculum	Existing business status	Training requirements

Hierarchical training: according to the user's role and role in the project, the training is divided into three levels: leadership and management level (a), management level (b) and technical specialist (c). Its purpose and curriculum are as follows:

 

Leadership and management level (a)

 

From the perspective of use, class a personnel are the organization, advocate and promoter of the application of the equipment. Comprehensive and general knowledge will enable them to have the vision of macro management.

 

Objective: to understand the basic knowledge of the invested product technology; Course: technical overview; Introduction to hardware equipment.

 

Class hours: 2 class hours (0.5 working days).

 

Management level (Level B)

 

Level B refers to the management personnel of the project, and their work is directly related to the normal operation of the equipment. In order to enable trainees to really use equipment, undertake corresponding business work and ensure effective work, comprehensive and detailed training must be carried out.

 

Objective: to make students not only understand the general knowledge of the equipment and the implementation technology of relevant subsystems, but also strengthen their practical ability; Familiar with application skills; Pass the strict assessment and meet the job requirements.

 

Course: hardware system of each subsystem (function and structure); System software (function and operation); Power on and power off procedures; Common fault maintenance; Actual operation; Management application software (structure, operation method, use skills, use training).

 

Class hours: 2 class hours for theory class and 2 class hours for practice class, a total of 1 working day.

 

Technical Specialist (Level C)

 

The technical specialist is the senior manager of the whole equipment. In addition to routine affairs, his work should also be able to deal with many unexpected situations, such as data errors, operating system and hardware equipment failures; The problems that cannot be handled shall be recorded correctly, contacted with relevant parties and solved with the least loss. Therefore, personnel at this level shall have sufficient knowledge of equipment software and hardware.

 

Objective: to fully master the design idea and all functions of the whole product; Timely and orderly sorting and maintenance of system data; Master system operation and maintenance methods; Cultivate a strong sense of responsibility and work awareness.

 

Course: layout, setting and maintenance of each subsystem; Hardware system fault analysis and troubleshooting; Software system fault analysis method; Software installation and maintenance; Data sorting method.

 

Class hours: 2 class hours for theory class and 2 class hours for practice class, a total of 1 working day.

 

Training: the whole training plan is 2.5 working days. The specific training contents are as follows:

Content	Target	Lecturer
Equipment structure	Composition of each subsystem	Professional engineer
Prohibitions and precautions for equipment	Safety of equipment, safety of test object, and precautions for various types of equipment.
Equipment principle	Composition principle of each system
Device software	Specific content, installation and setting of software
Equipment operation	Operating procedures and methods of equipment
Fault judgment	Phenomenon and troubleshooting of equipment failure
Equipment maintenance	How to maintain the equipment and precautions during maintenance

Assessment: assessment is an important part of the above training work, which directly reflects the effectiveness of the training work. Therefore, our company and users jointly abide by the following assessment principles:

 

In order to clarify the responsibility, our company and the customer shall jointly fill in the assessment schedule for the assessment of the course, which shall be signed by the speaker, the person in charge of our company and the person in charge of the customer

 

3、 Equipment acceptance scheme

 

After equipment installation and commissioning, the equipment shall be accepted according to the technical agreement signed by both parties and the unified acceptance outline formed by relevant national and industrial regulations and standards;

 

1. Static acceptance

 

The acceptance contents include the manufacturing quality inspection of the main parts of the equipment, the scope of supply of the equipment and the configuration inspection agreed by both parties. The acceptance methods shall be confirmed one by one by both parties on the site. The main inspection and acceptance contents are as follows:

 

◇ check whether the integrity and configuration of contract goods are consistent with the requirements of the agreement;

 

◇ equipment appearance inspection, such as structural system, operability, safety protection device should be safe and reliable;

 

2. Equipment performance acceptance:

 

According to national regulations, a qualified third-party testing unit shall conduct verification according to national standards and gb5170, meet the corresponding requirements of GJB150, GJB150A, GB / t2423, GB / t10586, GB / t10589, GB / t10592 and other standards, conduct dynamic acceptance, and obtain the testing and identification certificate.

 

Final acceptance items: temperature range; Temperature fluctuation; Temperature uniformity; Temperature deviation; Humidity range; Humidity deviation; Heating and cooling rate, etc.

 

A qualified third-party measurement and testing unit recognized by both parties shall be invited to measure and calibrate, and issue an identification certificate, which shall be taken as the payment term. The measurement and calibration costs of the third-party measurement and testing unit shall be borne by us.

 

If the equipment fails to pass the acceptance, we will unconditionally rectify the equipment.

 

3. Information provided:

 

We provide equipment technical data (equipment standard configuration, attached standard accessories and list, list of spare parts, operation manual, maintenance manual, electrical schematic diagram, refrigeration system schematic diagram, main component structure diagram, certificate of conformity, measurement report and other necessary technical data)

 

After the completion of the above projects, both parties shall sign the final acceptance certificate.