JT/T 1299-2019Technical regulations for combined commissioning of dry bulk terminal handling equipment (English PDF)

Foreword

This standard is in accordance with GB/T Draft the rules given in 1-2009.

This standard was proposed and managed by the National Port Standardization Technical Committee (SAC/TC 530).

This standard was drafted. China Communications Mechanical and Electrical Engineering Bureau Co., Ltd., Shanghai Zhenhua Heavy Industry (Group) Co., Ltd., Ministry of Transport Academy of Sciences.

1 Scope

This standard specifies the general provisions, overall plan, stand-alone test, linkage test, production performance test of dry bulk port equipment linkage test.

Requirements for nuclear, safe work and handover acceptance.

This standard applies to coal, ore, dry bulk cargo terminal equipment linkage test, cement, fertilizer and other terminals can be used as a reference.

2 Normative references

The following documents are essential for the application of this document. For dated references, only the dated version applies to this article Pieces. For undated references, the latest version (including all amendments) applies to this document.

GB 383.6. 1 Explosive atmospheres Part 1. General requirements for equipment GB 15577 Dust explosion safety regulations GB 17918 Dust explosion-proof safety regulations for port bulk grain handling system GB/T 26475 bridge grab ship unloader GB 50034 Design Code for Architectural Lighting GB 50008 Code for design of electrical installations in explosive atmospheres GB 5016 Code for Construction and Acceptance of Automatic Fire Alarm System GB Z 188 Technical specifications for occupational health monitoring JB/T 4149 Technical Specifications of Arm Bucket Wheel Stacker and Reclaimer JB/T 7015 rotary dumper JT/T 557 Lighting Illumination and Measurement Method for Port Handling Area JT/T 1073 Bulk Cargo Continuous Loader JT J 244 Quality Inspection Standards for Port Equipment Installation Engineering JT S 149-1 Code for Environmental Protection Design of Port Engineering JT S.2005-1 Technical Specifications for Safety Protection of Waterway Engineering Construction JT S 217 Technical Specifications for Port Equipment Installation Engineering JT S 257 Quality Inspection Standard for Water Transport Engineering

3 Terms and definitions

The following terms and definitions apply to this document.

Mechanical and electrical engineering construction period plan prozector schedule Master plan for construction period of mechanical and electrical engineering. Including pre-construction preparation, design, procurement and manufacturing, construction commissioning, production preparation, linkage the whole process planning of test run, production performance assessment, handover and completion acceptance, defect liability period, etc.

Stand-alone test commissioning commisioning After the installation project is completed, the commissioning of various stand-alone equipment and subsystems is performed on site before the linkage test. Including. electrical system JT/T 1299-2019 Commissioning, of control systems, commissioning of mechanical equipment, commissioning of large stand-alone equipment, commissioning of communication systems, commissioning of environmental protection facilities, safety equipment Commissioning, of occupational disease protection facilities, commissioning of fire protection facilities, commissioning of monitoring facilities, etc.

No-load linkage test drive comb d commisioning After the single machine test of each equipment or subsystem is qualified, the joint test run of various processes performed when the material conditions are not put into operation to check Production equipment performance and manufacturing, installation quality, control and interlocking relationship with upstream and downstream.

Heavy-duty linkage test run combed wet commission After the no-load linkage test is qualified, all production equipment will be passed through the production process with the materials specified in the design documents, and the upstream and downstream design will be carried out.

The material input and connection between the two ends of the equipment are linked to the test run to check all its performance except economic indicators.

3. Five

Production performance assessment After the heavy-duty linkage test is qualified, the production equipment has reached the conditions of stable operation, and the production capacity specified for the design documents and construction requirements is evaluated.

The operation and testing of the rated load or the maximum allowable load of the equipment.

4 General requirements

4.1 The construction unit organizes the relevant units for project implementation, compiles the overall test plan according to the design documents and construction requirements, and shall be subject to the construction order the person in charge of technology and the person in charge of the supervision unit shall implement it after approval.

4.2 The construction unit shall set up a production preparation organization at the appropriate time during the construction of the project, responsible for the production preparation work, compile the production preparation outline, and Meet the needs of commissioning.

4.3 The construction unit should be familiar with the design documents, construction requirements, production and loading processes before installation to ensure that the project quality and schedule meet the test run Claim.

4.4 The installation progress of the construction shall be completed on schedule in accordance with the schedule of mechanical and electrical engineering.

4.5 During the construction process, the construction unit shall install in accordance with the requirements of design documents such as technical data and construction drawings, and the installation quality shall meet the JT S the requirements of 257, JT J 244, and JT S 217 create conditions for commissioning.

4.6 Before the start of the test, it should reach 6. 1.7. 2 conditions; test run should include all content specified in the design documents; test run results should reach the design Documents and standards required for construction.

4.7 The commissioning work shall strictly implement the procedures stipulated in the overall scheme of commissioning. The previous procedure is unqualified and the commissioning of the next stage shall not be conducted.

4.8 The stand-alone test and no-load linkage test shall be undertaken by the construction unit, coordinated by the manufacturing unit, and supervised by the construction unit and the supervision unit.

Supervision; heavy-duty linkage test run and production performance assessment shall be led by the construction unit, coordinated by the construction (manufacturing) unit, and supervised by the supervision unit.

Process supervision.

4.9 Unless otherwise specified, the construction unit shall be responsible for completing the electricity, water, oil, materials, road, Communication, shipping, rail and road transport vehicles.

4.10 When a fault or accident occurs during the test run, the test run should be stopped immediately, the cause should be identified, and reliable safety measures should be taken to ensure that Keep personal and equipment safe; failures and accidents have not been ruled out, and commissioning should not be continued.

4.11 Environmental protection facilities, safety facilities, occupational disease protection facilities, and fire protection facilities shall be debugged simultaneously with production equipment. Emissions it shall meet the requirements of JT S 149-1.

4.12 Engineering-related engineering quality shall comply with the provisions of JT S 257, environmental protection facilities shall comply with the provisions of JT S 149 ~ 1, and safety facilities.

The facilities shall comply with the requirements of JT S.2005-1, the occupational disease protection facilities shall comply with the requirements of GB 8 188, and the fire protection facilities shall comply with the requirements of GB 5016.

Regulations.

JT/T 1299-2019

5 Overall plan

5.1 Establishment principles the general principles of the commissioning program are as follows.

a) In the process of preparing the commissioning plan, the construction unit shall fully listen to the opinions of relevant personnel of the participating construction unit, and the planned construction period shall be reasonable;

b) The overall plan for commissioning should be completed one month before the end of equipment installation.

5.2 Preparation requirements the overall test plan should include at least the following.

a) General provisions, mainly including engineering conditions and equipment description.

b) process flow.

c) The commissioning plan shall include the following.

1) Preparation of test conditions;

2) The commissioning time should be performed in accordance with the procedures of stand-alone commissioning, no-load linkage test, heavy-load linkage test, and production performance assessment.

After the previous procedure is qualified, proceed to the next procedure;

3) The main selection process of the test run. The selection of the process should cover all process equipment. The test run of each interrelated equipment should ensure the joint test.

Normal connection between upstream and downstream when driving;

4) Commissioning test content, including the operation steps of the commissioning process;

5) The detailed plan for the test of the heavy-duty linkage test shall be completed one month before the start of the heavy-duty linkage test;

6) The commissioning plan can be adjusted according to the actual situation on site, and the content can be gradually deepened, but the main commissioning procedures should not be arbitrary change.

d) Preparation of related equipment, tools, consumables and testing instruments, equipment operating instructions, environmental protection, safety precautions, occupational diseases Preparation of documents such as protection.

e) Configuration and post duties of test personnel.

f) Planning and preparation of external conditions such as electricity, water, oil, materials, roads, communications, ships, freight trains and transport vehicles.

g) Temporary facility plan and material supply plan for commissioning.

h) Contingency plans during commissioning.

i) Test drive inspection record form.

j) Existing problems and deficiencies in the test run, rectification and completion plan, including the responsible unit, responsible person, completion date, and opinions of the acceptance unit.

6 Stand-alone test run

6.1 The following conditions shall be met before the stand-alone test run.

a) All the projects within the test range have been constructed in accordance with the requirements of the construction requirements, design drawings and documents, and the construction and acceptance specifications.

All quality standards have been completed and passed the inspection, and the following information and documents are provided.

1) Product specifications, test records, and certifications provided by the manufacturer;

2) Construction drawings and design documents;

3) The construction records and inspection documents of each site equipment;

4) Hidden engineering record files;

5) Safe working procedures, operating procedures, safety technical measures, etc .;

6) All special equipment shall be inspected by a unit qualified for special equipment inspection, and an inspection certificate shall be obtained.

b) The testing tools, instruments and meters related to the stand-alone test run are qualified, and the test record form is complete.

JT/T 1299-2019

c) The approved overall plan for the test run.

d) The commissioning team has been established, and the commissioning operators should be qualified after training and familiar with the overall scheme of commissioning, and be able to correctly operating.

e) The construction unit is responsible for the fuel, lubricating grease, electricity, water, etc. required for the stand-alone test run, and can provide a stable supply.

f) Equipment manufacturers should cooperate with commissioning personnel to be on duty.

6.2 The stand-alone test run shall meet the following requirements.

a) Unrelated personnel in the test area shall not enter;

b) The stand-alone test run shall be equipped with corresponding safety protection and warning signs and other devices;

c) The operation shall be carried out in accordance with the overall plan of the test run, and shall not be in violation of command, operation or labor discipline, and prevent personal injury.

And equipment damage accidents;

d) A special person should be appointed to conduct the test and make a record;

e) After the stand-alone test is qualified, all inspection results shall be recorded, and the construction unit shall organize the supervision unit to sign the test records together.

Word confirmation, as archived completion data;

f) safety protection measures in explosion-proof areas shall comply with the provisions of GB 15577 and GB.19918;

g) Work lighting, accident lighting, and road lighting have been put into use, and the illuminance at the workplace should meet the requirements of GB 500034, JT/T 557.

Regulations.

6.3 The test run of the large-scale single-machine bridge grab ship unloader shall comply with the provisions of GB/T 26475, and the test run of the continuous bulk ship loader shall comply with JT/T According to the provisions of 1073, the commissioning of the arm bucket wheel stacker and reclaimer shall comply with the provisions of JB/T 4149, and the commissioning of the rotary dumper shall conform to JB/T 7015.

Provisions.

7 Linkage test run

7.1 The joint test run shall be carried out in the order of no-load joint test and heavy-load joint test.

7.2 The following conditions shall be met before the joint test run.

a) The overall commissioning plan has been declared and approved by the construction unit and the supervision unit;

b) The corresponding management organization of the construction unit has been established, the rules and regulations are perfect, the staff at all levels have been qualified for training, and the production responsibility system has been clear;

c) Various rules and regulations, process regulations, safety regulations, electromechanical maintenance procedures, operating procedures, and post Operation methods and overall test plan have been issued and implemented;

d) the stand-alone test run has been completed and passed the inspection;

e) The interface debugging between the systems has been completed and verified;

f) All the test personnel have participated in the technical communication, are aware of the risk of field operations, and are familiar with the escape routes and methods;

g) Equipment manufacturers cooperate with commissioning personnel to arrive at their posts;

h) The post operation records and test-specific forms are ready;

i) The electricity and water required for the test run can ensure continuous and stable supply;

)) Before the heavy-duty linkage test run, the materials have been arranged in accordance with the specifications and quantities specified in the design documents and the overall test run plan, and can ensure continuous stability supply;

k) normal operation of the storage and transportation system;

l) Test spare parts, consumables, lubricating grease, test instruments, tools, etc. are available and a normal management system has been established

m) On-site structures, machinery and equipment, pipes, valves, electrical panels and other signs are consistent with the design drawings, and the signs are complete and prominent;

n) the electromechanical maintenance personnel composed of the construction unit or production unit during the test run;

o) The communication facilities are unobstructed and can be used at any time by the commissioning personnel and various departments of the production command system;

p) safety and fire protection facilities are fully prepared, personnel are in place, and they comply with relevant regulations;

JT/T 1299-2019

q) The measurement device is qualified and within the validity period;

r) The roads in Hong Kong are clear and clearly marked, and the on-site illumination can meet the test needs;

s) Commissioning and commissioning of environmental protection facilities and commissioning of pollutant treatment equipment;

t) The sanitary facilities in the port area meet the needs of the test run;

u) The port guards have been employed, and security agencies and systems have been established.

7.3 The joint test run shall meet the following requirements.

a) Traffic and personnel controls are implemented in the test area. Undocumented personnel are not allowed to enter the test area. Test personnel must enter and accept with valid documents.

check;

b) the commissioning personnel should obey the command;

c) It shall be carried out according to the no-load and heavy-load linkage test plan, sequence and operation method, and a monitoring operation system shall be implemented during the test period;

d) During the test run, the inspectors regularly report the operation to the test lead group. In case of emergency, they should start the application in time.

Emergency plan

e) When the heavy-duty linkage test runs, the material shall be gradually reached the rated load and the maximum load in stages according to the design documents and construction requirements Capacity

f) each linked production equipment shall have the test conditions for upstream and downstream connection during the joint test;

g) All production equipment and auxiliary equipment related to the test run should be coordinated, connected end to end, and test run simultaneously;

h) The data shall be measured in accordance with the overall plan of the joint test run, and a special person shall be assigned to make records;

i) Unless otherwise specified, the heavy-duty linkage test run shall be organized by the construction unit, coordinated by the construction unit, and carried out by the supervision unit Supervision

j) After the joint test is qualified, the main production indicators and operating parameters shall be recorded, and the construction and supervision units shall sign the test records together.

Word confirmation, as archived completion data;

k) During the specified test period, the production process is smooth and the equipment meets relevant standards, specifications and design documents, and construction requirements.

7.4 Before the heavy-duty linkage test run, the construction unit shall conduct a comprehensive inspection of each equipment, system, operating environment, and safety facilities, confirm each item, and construct the unit should cooperate with the completion, and the supervision unit should supervise the whole process.

7.5 After the no-load and heavy-load linkage test runs are qualified, the defects and exposure problems in the test run should be eliminated in time.

The joint design and manufacturing unit will solve the problem together; the heavy-duty linkage test run should gradually reach the rated load capacity of the equipment and create for production performance assessment condition.

8 Production performance assessment

8.1 The production performance assessment time should be carried out within 30 days after passing the heavy-duty linkage test.

8.2 Production performance assessment conditions shall meet the following requirements.

a) A production performance assessment plan has been formulated and the construction unit has approved it;

b) No-load and heavy-load linkage test run is completed and qualified;

c) The problems exposed under full-load test conditions have been resolved, and various process indicators are in a stable state after adjustment;

d) The production assessment organization is established, and the task division of testers has been implemented;

e) All necessary testing tools, wearing parts, spare parts, measuring equipment, etc. are available;

f) the assessment materials meet the requirements of the design documents;

g) The power, water, communications, ships, vehicles, and materials required for the assessment can ensure a continuous and stable supply;

h) The control system, alarm and interlocking devices have been operating stably.

8.3 The production performance assessment shall include the following items.

a) equipment quality and stability;

b) production capacity;

JT/T 1299-2019

c) measurement statistics;

d) energy consumption or consumption statistics;

e) main process indicators;

f) intact rate and failure rate;

g) Environmental protection facilities, safety facilities, occupational disease protection facilities, and fire protection facilities shall be assessed simultaneously with production equipment.

8.4 Production performance assessment shall meet the following standards.

The assessment and evaluation methods shall comply with the relevant design standards and specifications, design documents and construction requirements. The full or overload operating time shall be Contents that meet design documents and construction requirements.

8.5 Because the design, construction, and manufacturing units fail to meet the standards, the responsible unit should take effective measures to rectify.

8.6 After passing the production performance assessment, the main production indicators and operating parameters should be recorded, and the construction and supervision units should jointly record the test records.

Signed and confirmed, as archives of completed data.

8.7 After the production performance assessment is completed, the construction unit shall organize the relevant participating units to prepare an assessment report, which shall be subject to construction, design, construction, and supervision.

The units shall sign and take effect as the basis for final settlement. The production performance assessment report is archived as the completion acceptance data.

9 Safety requirements

9.1 The person in charge of on-site safety shall organize the preparation of corresponding safety work rules and systems according to the production characteristics and strictly implement them.

9.2 A safety and fire management agency shall be established prior to the commissioning of a single machine, and the division of labor shall be determined, and all safety regulations and systems shall be complete.

9.3 Entry personnel should be trained in safety and fire fighting. Production command, management, and operation personnel should be qualified only after passing safety training Get on the job.

9.4 The person in charge of on-site safety should conduct a safety check, including safety precautions, assess potential safety hazards, and formulate necessary responses.

Emergency measures.

9.5 All equipment and materials within the scope of the construction project shall have a product certificate and be re-inspected in accordance with relevant regulations to ensure the quality of the installation.

The quantity meets the requirements of design documents and construction and acceptance specifications, and meets the production process requirements.

9.6 The installation quality of the whole site equipment shall meet the requirements of JT S 257, and there shall be relevant inspection records.

9.7 The debugging of the alarm and interlocking system shall be carried out in accordance with the provisions of the design documents, and shall ensure that the operation is correct.

9.8 The fire extinguishers and fire extinguishers required to eliminate the initial fire shall be provided in accordance with the specifications, quantity and location specified in the design documents, and shall be clearly visible.

Sign.

9.9 Occupational health protection supplies, tools and appliances should be fully equipped according to the job type. Tools and appliances used in explosion-proof areas should comply with explosion-proof Claim.

9. The insulation tools and facilities required for operation and maintenance of the transformer substation and distribution room are fully equipped, and measures should be taken to prevent small animals from entering.

9. 11. The gro...