On-site commissioning plan for plate heat exchanger units

On-site commissioning plan for plate heat exchanger units

• Preparations for the debugging stage

1.Equipment inspection: Check each piece of equipment such as plate heat exchangers, circulating water pumps, makeup water pumps, electrical control cabinets, filters, regulating valves, sensors, etc. Confirm that all equipment is installed firmly without damage, the wiring is correct, the terminals are not loose, the motor rotation direction meets the design requirements, and the equipment lubrication is adequate.

2. Pipeline Inspection: Inspect all connecting pipelines, flanges, and valves to ensure that the pipeline layout complies with the design specifications, the connections are tight and there is no looseness or damage; Check if there are any debris or water accumulation in the pipelines, and if necessary, perform flushing; Confirm that all valves are in the closed position (opened as needed during testing).

3. Safety Inspection: Verify that the electrical grounding and insulation are in compliance; check the sensitivity and effectiveness of the emergency stop buttons and protection devices in the electrical control system; prepare the necessary tools for debugging (pressure gauges, thermometers, wrenches, etc.) and emergency supplies (fire extinguishers, waterproof cloths, etc.); demarcate the debugging operation area and prohibit irrelevant personnel from entering.

4. Parameter Confirmation: Verify that the parameters of each equipment in the unit (such as heat exchange area, pump flow rate, head pressure, etc.) are consistent with the design parameters for the district heating system. Confirm that the parameter settings of the electrical control cabinet (such as temperature, pressure threshold, etc.) meet the design requirements.

• Interconnected trial operation and debugging

Objective: To verify the coordination of the operation of each equipment, ensuring the overall stability of the unit and meeting the parameter standards.

1. Start the unit: According to the working procedure, sequentially open the valves of the primary and secondary pipelines, start the circulating water pump and the makeup water pump, activate the automatic control mode of the electrical control cabinet, and Equipment linkage commissioning record.

2. Parameter Control: Real-time monitoring of the temperature, pressure and flow parameters of the primary and secondary sides. According to the design requirements, adjust the opening degree of the electric regulating valve and the rotational speed of the water pump to ensure that the water supply temperature of the secondary side and the pressure of the pipeline network remain within the set range (water supply temperature: 45 - 55℃, pipeline network pressure: 0.2 - 0.4 MPa).

3. Hazard Identification: During the operation process, observe the operating conditions of each equipment to identify any abnormal sounds, vibrations, leaks, etc.; check the reliability of the electronic control system's linkage, test whether the emergency stop and fault alarm functions are normal; observe whether there is any blockage or water accumulation in the pipelines to ensure smooth circulation of the pipeline network.

4. Long-term trial operation: After the linkage debugging is completed and normal, conduct a 24-hour continuous trial run. Record the operating parameters (temperature, pressure, flow rate) every 2 hours to identify any abnormal issues that arise during the operation. Make timely adjustments and optimizations to ensure the continuous and stable operation of the unit without any faults.

• Test Commissioning

1.After the debugging is completed, the debugging records should be sorted out, including equipment inspection records, water pressure test records, single-machine debugging records，Equipment linkage commissioning record and parameter adjustment records.

2.In accordance with the design standards and acceptance specifications, conduct a comprehensive inspection of the operating status of the equipment, the compliance of parameters, the coordination of the equipment, and the safety performance. Once the inspection is passed, issue a commissioning certificate, and only then can the heating system be officially put into operation.

3. If any hidden problems or abnormal parameters are detected during the debugging process, the machine should be stopped immediately for rectification. After the rectification is completed, the debugging should be restarted until it is qualified for acceptance.