Equipment Installation, Commissioning and Acceptance
Domain 6 - Equipment Installation, Commissioning and Acceptance
This domain tests the physical handover chain: foundation and arrival checks, alignment, pressure and electrical testing, trial runs in the correct sequence, and the distinction between intermediate handover and final acceptance.
Core rules
- Pre-installation. Foundation acceptance checks elevation, centreline, anchor-bolt hole position and depth, embedded plates and curing strength. Open-box inspection checks quantity, model, nameplate, certificates and transport damage; discrepancies are recorded jointly and claimed before installation begins.
- Installation. Setting-out and levelling with shims or shimless mounting; anchor bolts torqued to specification; coupling alignment checked for radial and angular deviation; secondary grouting only after alignment is confirmed and recorded.
- Pressure testing. Piping hydraulic strength test = 1.5 × design pressure (pneumatic 1.15 ×); pressure-vessel hydraulic test = 1.25 × design pressure corrected for the material stress ratio (pneumatic 1.15 ×). These rules differ and are a favourite item.
- Electrical and instrumentation. Insulation resistance, earthing resistance, loop check, and interlock and trip testing before energisation.
- Trial run sequence. 单机试车 (individual machine, no load) → 联动试车 (interlocked, with medium) → 负荷试车 → 性能考核. Conditions: approved procedure, trained operators, utilities available, spares and safety measures in place.
- Acceptance. 分项/分部/单位工程 acceptance → 中间交接 (custody transfer, not final acceptance) → 竣工验收 with complete as-built documentation.
Worked example
A centrifugal pump shows 7.1 mm/s rms vibration and 85 °C rolling-bearing temperature during a four-hour no-load run. Reasoning: both exceed typical limits (vibration roughly ≤4.5 mm/s for rigid support, rolling bearings ≤80 °C). Cause ranking follows the installation record: coupling alignment first, then soft foot and shim contact, then piping strain at the flanges, then suction cavitation. Re-running until readings "settle" conceals a mechanical fault. Correct action: stop, correct alignment and soft foot, re-run, record, and only then proceed to load testing.
Traps that cost marks
- Mixing piping and pressure-vessel test pressures.
- Treating 中间交接 as final acceptance, or accepting without as-built drawings and test records.
- Running load tests before interlock and trip tests are proven.
- Accepting a trial run without a signed, time-stamped parameter record.