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Jason@cleanroomequips.com
The company provides completed system commissioning services for clean room projects
Single machine test
Linkage commissioning
System comprehensive commissioning System performance diagnosis and analysis
Clean room system division
Air conditioning system comprehensive commissioning
Water system balance
Gas pipeline system related tests
Pure water system analysis and testing
Electrical test (below 35KV)
Chemical exhaust system balance and testing
After the completion of the clean room system, it did not meet the requirements of the design and specifications. The most important link to solve the problem is to find problems during commissioning. System commissioning includes two concepts: one is the adjustment of single machines and systems, and the other is the comprehensive performance test. The commissioning of the clean system should be carried out in three steps: single machine test-linkage commissioning-clean room performance test and comprehensive evaluation until the clean room operates normally.
Work preparation before clean room commissioning
1. Establish a commissioning team
Establish a commissioning team with the construction unit (owner) as the team leader and personnel from the design unit, construction unit, and supervision unit participating. The commissioning team leads the overall commissioning work, coordinates the relationship between all parties, and provides various soft and hard conditions for the commissioning work.
2. Preparation of commissioning plan
Under the leadership and organization of the commissioning team, prepare the commissioning outline. The commissioning outline is a guiding document for commissioning work. The contents of the commissioning outline include: organizational division of labor, personnel arrangement, material mobilization; commissioning projects, commissioning methods, commissioning instruments; commissioning procedures, commissioning progress, commissioning plan arrangements, etc. The preparation of the commissioning outline enables the commissioning personnel to have clear ideas, unified understanding, consistent steps, and neat actions, so that the commissioning work can proceed smoothly.
3. Joint inspection of construction site quality
Under the leadership and organization of the commissioning team, relevant leaders and technical personnel from the construction unit, design unit, construction unit, and supervision unit will participate in a comprehensive joint inspection of the construction site and construction quality. From the refrigeration station, heat exchange station, boiler room, substation, air conditioning room to cooling, heating, power supply system, air conditioning purification system and automatic control system. A comprehensive joint inspection of the construction quality of equipment (refrigerator, boiler, water pump, cooling tower, air conditioner, etc.), accessories (valves, vents, mufflers, etc.), pipes and pipelines to insulation, equipment foundation, pipe support and hanger, etc. Check whether the construction is carried out according to the drawings, check the discrepancies with the design drawings, find the unqualified construction quality items and check the reasons. Fill in the "defect list" one by one for the quality problems of construction, processing, installation, etc., and put forward rectification opinions, and complete the rectification within the deadline (before formal commissioning).
4. Cleaning of air-conditioning equipment and air-conditioning system
It is very necessary to clean the clean room comprehensively and thoroughly before commissioning. Carefully, comprehensively and thoroughly clean the floor, walls, ceiling, doors and windows of the clean room (it is best to ask a professional cleaning company); check, leak and wipe the air-conditioning equipment, air-conditioning ducts (supply ducts, return ducts, fresh air ducts), and air-conditioning accessories (silencers, valves, air outlets, etc.). Until the cleanliness requirements are met.
Install coarse and medium efficiency filters for the first air blowing. On the basis of thorough cleaning, install coarse and medium efficiency filters in the air conditioner. Air blow the entire purification air conditioning system for 24 to 36 hours to obtain preliminary purification of the entire system.
Install high-efficiency filters. High-efficiency filters can be installed after the system is air blown. Before installing the high-efficiency filter, it is required to check for leaks one by one, and plug the leaks if there are any. The leak detection is carried out on a temporary leak detection table, and the dust source uses atmospheric dust. Only the qualified high-efficiency filter can be installed. After the installation is completed, the installation seal of the high-efficiency filter is leak-checked again (using a dust particle counter to scan) to achieve qualified installation.
After the high-efficiency filter is installed and leak-checked, the purification air conditioning system is blown for the second time. The air blowing time is 24 hours, and then the debugging procedure can be carried out.
5. Preparation of test instruments, meters, and tools Before debugging, the instruments and meters used in the debugging must be debugged and calibrated (recalibration is required if the usage time exceeds)
The instruments used include instruments for measuring Wind speed, Air volume, temperature, relative humidity, pressure difference, noise, vibration, number of revolutions, time, atmospheric pressure and cleanliness. Preparation of equipment and tools used for debugging. Such as: electrician tools, plumber tools, metalworking tools, fitter tools, and ladders for climbing up and down. And please ask the construction unit to cooperate with electricians, plumbers, metalworking workers and fitters.
Preparation of drawings and record forms for debugging and testing.
a. Single-machine debugging
Single-machine commissioning is to test all equipment, accessories and other units in the project. The purpose of single-machine commissioning is to inspect and assess the installation quality of these equipment and accessories and the quality of the products delivered from the factory. The main contents of single-machine commissioning are: water and electricity first. That is, first inspect and assess the equipment and systems for water supply and power supply. Such as water pumps, transformers, distribution boxes, switches, etc. To ensure the normal and reliable water supply and power supply.
Then, conduct single assessments on cooling equipment (refrigerators, cooling towers, chilled water pumps, cooling water, etc.), heating equipment (boilers, heat exchangers, hot water pumps, etc.), air-conditioning equipment (surface coolers, heaters, humidifiers, filters, fans, etc.), automatic control equipment, instruments, valves and accessories of each system. See if they can meet the design requirements and operate normally. In particular, rotating equipment such as fans and water pumps should be tested to see if they are running smoothly, whether there are noises, collisions, and reversals; whether the wiring of electrical equipment is correct; whether the refrigerator and boiler can meet the design requirements; the cooling and dehumidification capacity of the surface cooler in the air conditioner, the humidification capacity of the humidifier, etc. should be checked and assessed individually. If a fault occurs or a problem is found, it should be eliminated immediately. For large equipment such as refrigerators, boilers, air conditioners, etc. (especially imported equipment), it is best to have the manufacturer's commissioning personnel on-site guidance during the single-machine test or the manufacturer is responsible for the test, and then hand it over to the user unit after it runs normally. The single-machine test prepares each unit for linkage debugging.
b. Linkage debugging
Linkage debugging is generally divided into two stages, namely the air volume balance distribution stage and the linkage debugging stage.
1. Air volume distribution: Air volume distribution is to adjust the supply air volume, return air volume, fresh air volume, and exhaust air volume of each clean room to the design air volume according to the design requirements. Because a clean workshop may have multiple air conditioning supply and exhaust systems, or an air conditioning supply system has to bear the air supply of multiple clean rooms. Therefore, the air volume distribution debugging work is a work with a large workload, long time, patience and meticulousness. The air volume distribution debugging work is also the key work of the entire debugging work. The commonly used air volume distribution debugging method adopts the standard air outlet method.
Standard air outlet method: A Clean Room may have several or dozens of air conditioning air supply outlets and return air outlets. Because they are all connected, when the air volume of a certain air outlet is adjusted, the air volume of other air outlets will also change with it. Therefore, the standard air outlet method is adopted. The so-called standard air outlet method is to find the most unfavorable air outlet (the air outlet with the smallest air volume) among all the air outlets before the air volume is distributed, and use this air outlet as the standard air outlet. A monitoring instrument is set on the standard air outlet to test the air volume changes of the standard air outlet at any time. Then adjust the air volume of all other air outlets. Because when adjusting the air volume of any air outlet, it will affect the change of the air volume of the adjusted air outlet; therefore, when adjusting the air volume of any air outlet, the air volume of the standard air outlet at that time should be used as the reference air volume, so that the air volume of all adjusted air outlets will change synchronously with the air volume change of the standard air outlet. When a purification air conditioning system is responsible for multiple clean room air conditioning, the debugging should be carried out from the end to the main trunk in the clean room as a unit. First, adjust the relative relationship of the air supply volume of each clean room, and then use the system's main valve to adjust the air supply volume of each air outlet and each clean room to the actual design air supply volume.
2. Linkage debugging Linkage debugging is carried out after air volume adjustment and single machine test run. Linkage debugging puts the purification air conditioning system and all systems serving the purification air conditioning system, namely: cooling system (refrigerator, cooling tower, water pump and all accessories on the cooling system), heating system (boiler, water pump and all accessories on the heating system), power supply system (distribution box, inverter...) and automatic control system into operation to assess the comprehensive performance and linkage performance of each system. If necessary, a certain amount of load is set artificially in the clean room to test whether the linkage of temperature and humidity probes, intermediate instruments and actuators is sensitive and coordinated; to test whether the temperature and humidity probes are accurate and whether the precision is qualified.
c. Performance test and comprehensive evaluation of clean rooms
On the basis of air volume adjustment and linkage debugging, the clean room air conditioning purification system and all systems serving it are in normal operation. Then the performance test and comprehensive evaluation of the clean room are carried out.
1. Performance test of clean room:
The performance test of clean room includes: cleanliness test, air volume test, positive pressure test, filter leak test, Wind speed test (unidirectional clean room) temperature, relative humidity test, noise test, etc.
Air volume or wind speed test: including the total air volume of the unit (supply, return, fresh air and exhaust), air volume of air outlet (supply, return and exhaust). Unidirectional clean room measures cross-sectional wind speed; non-unidirectional clean room measures its air volume, and uses its data to verify the number of ventilation times.
Measurement of cross-sectional wind speed: We use the advanced American Octopus TSI multi-point wind speed instrument for testing. Air volume test: Measure the air volume on the air duct or air outlet. The air volume measurement hole is set in the air duct according to the standard installation specifications; the terminal air outlet directly uses the advanced American TSI Electronic air volume hood to directly read the data, which is currently the most advanced and accurate instrument recognized by the industry. Positive pressure debugging: Pressure difference debugging is a tedious and meticulous work. In the end, the positive pressure of the clean room will be systematically checked with the door closed.
Cleanliness test: Each sampling point is sampled three times in a row, and the average of the three times is used as the cleanliness evaluation data of the point. The average value of the measured values of all measuring points is used as the cleanliness of the clean room (area) and the 95% UCL value (calculated when less than 9 points).
2. Comprehensive evaluation of clean rooms. On the basis of the clean room performance test, according to the test results of clean room cleanliness, temperature, humidity, positive pressure, air volume, noise, static electricity and sedimentation bacteria (involving pharmaceutical plants, operating rooms, laboratories), the construction and performance of the clean room are comprehensively evaluated for completion acceptance.
