试车讲座(第三版)07 冷试车

遵循设备供应商的温度要求
Following the manufacturer’ s requirements for temperature cycles.
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设备热态试验 Hot testing equipment
适用于：Applies to： 必须在热态（运行温度）及常温下实施密
循环回路应与工艺溶剂的路径相同
The loop should ideally be the same loop that will be subject to solvent testing;
连续运行数日，为各班提供相同的操作机会
Tests should continue for several days in order to give all shifts a chance to conduct the same tests;
闭性试验的设备
equipment whose leak-tightness must be tested at operating temperatures and after temperature reversals;
采用热媒加热的固定床催化剂反应器，在 运行工况下当热媒泄漏时会污染催化剂的
Critical exchangers whose steam or cooling water is at a high pressure than the process fluid;
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模拟运行 Simulated Operations
在冷试车期间，将开展下列活动
钝化应在模拟试车结束，系统清洗合格 后进行，包括：
循环水设备、管道系统的钝化； 工艺设备、管道系统的钝化。
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蒸汽发生器的煮炉 Boil out
煮炉的目的 烘炉与煮炉的区别 煮炉应在有关系统具备投用条件，且
水、电、气（汽）、临时热源等确保 供应后，方可进行。 煮炉的操作主体
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冷试车的特点
惰性物料 物理模拟状态 一般无化学反应
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冷试车
Cold-commissioning
策划及准备
Preparation and Planning
预试车
Pre-commissioning
冷试车
Cold-commissioning
实施为产出产品所设计的各种单元操作
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冷试车的意义
尽可能接近实际工况的系统性模拟试验
Dummy Operation/Simulating Operation
工程设计质量的预检验 工程施工安装质量预检验 Manual及SOP质量的预检验 操作员工—装置人机接口的早期磨合 操作员工实地指挥操作的最后模拟演练 操作运行团队的最后战前检验 是否达到热试车要求的最后检验
To avoid thermal shock, the temperature of the heating medium may have to be raised gradually;
热态试验的时间长度要预先设定好
Time required for a hot test must be established in advance;
Fixed-bed catalytic reactors that in normal conditions are heated by heat transfer fluids where leakage would contaminate the catalyst;
蒸汽或冷却水侧的压力高于工艺介质侧压 力的关键换热器
A rough flow-sheet should be developed for air and water tests, predicting all information that normally appears on a process flow sheet - flow, temperature, pressure, heat transfer, power etc. will assist in alerting commissioning team to risks from over-pressuring, overloading, temperature-shocking and stressing equipment.
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模拟运行的原则 b
Principles for Simulated Operations b
一般以水、空气或惰性气体为介质进行
Closed loop dynamic testing with safe fluids consists of operating equipment systems with air, water, inert gases etc.
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模拟运行的步骤
1 向单元或系统引入安全模拟物料； 2 模拟开车操作； 3 在模拟工况下的试验运行及调整（水运、油运
、气或汽运、冷运、热运等）； 4 仪表及控制系统在模拟工况下的测试调整及报
警、联锁回路的逐一试验； 5 模拟停车操作； 6 模拟工况下各种原因引起的紧急停车操作； 7 模拟物料的退出及后处理。
各班均应得到闭路循环开车和停车的机会
All shifts should be given the opportunity to start up and shutdown each closed loop test.
应绘制简易的模拟运行流程图，标明流量、温度、压力、 热量及动力等参数，以警示试车人员超压、过负荷、热冲 击及热应力等危险
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Project Commissioning in Process Industry
流程工业建设项目的试车
第三版
第七章 冷试车
Chapter 7 Cold Commissioning
李达 daliopcw@
2016,03
IEC 62337 的定义
Phase during which the activities associated with the testing and operation of equipment or facilities using test media such as water or inert substances, prior to introducing any chemical in the system, take place.
During cold commissioning, we progress through:
安全流体模拟运行（水联运）
Safe Fluid Simulated Operations ;
溶剂流体模拟运行（油联运）
Solvent Simulated Operations
热运
Simulation at operating temperatures
向工艺系统加水（有特殊要求不允许加水的除பைடு நூலகம்）并煮塔
Water is pumped through the process (except where special conditions do not permit it) and boiled up in columns;
启动压缩机或风机送入空气或惰性气体
sieves, resins and desiccants 系统气密性试验 Tightness test of process system
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设备管道系统钝化
钝化 Passivation
在使用某种材料之前使其对另一种物质惰性化， 在其表面产生抑制或减缓腐蚀作用保护层的化 学处理过程。
如在运行工况下设备各部位温度的是均一的，则在试验时 也应保持其各部温度的均一性，以避免应力集聚
Establish a uniform temperature in all parts of equipment that are supposed to be uniformly hot during operation to avoid setting up stresses;
热试车
Hot-commissioning
试运行（运行调整及性能考核）
Trial operation Trouble Shooting & Performance Test)
试车讲座 7
试车后活动
Post Commissioning
公用工程引入 Utilities introducing 煮炉 Boil out 系统钝化 Passivation 干燥、置换 Dehydrating ，Purging 模拟运行 Simulated Operations 系统装填 Initial charge of catalysts，molecular
模拟运行结束后，排尽系统内的积水，并对设备实施干燥和置换
At the end of the simulation, water should be drained - equipment dried and purged;
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热态试验程序 Hot testing procedures
试验前必须设定各设备的热冲击允许值
The thermal shock tolerance of equipment must be determined beforehand;