2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16
At all times, industrial equipment has been quite complex from an engineering point of view. Starting with primitive presses and mixers from the point of view of a modern engineer, and ending with the completely automated production of the most complex parts for the space industry. In addition to the difficulties in the design of machines and assemblies, there is also the complexity of operation. In order to facilitate the work of maintenance personnel as much as possible, extend the life of the equipment, avoid the release of defective products and comply with all safety requirements, it is necessary to carry out commissioning before starting new machines.
Why commissioning is needed
Commissioning is almost more important than equipment installation. Modern machines and units can be serviced by people without special education. "Outside" it seems that it is worth pressing just two or three buttons, and the products will come out from under the machine by itself. However, for this statement to come true, commissioning must be taken seriously.
Commissioning should be planned in the project for the installation of equipment immediately after the installation of machines and units. The installers are usually qualified to verify that the unit settings are correct. Even before the start of production, commissioning will determine how correct the factory settings are, and identify installation and assembly errors, if any.
Qualification of specialists
Usually, the manufacturer of machine tools and equipment provides training for specialists in setting up the work of mounted industrial equipment. Most often, installation does not require high qualifications, since any specialist with a secondary specialized education can lay and connect cables. If you have some experience, you can generally talk about the lack of qualifications among the specialists involved in the installation.
The commissioning of electrical equipment is a completely different matter. Here you can no longer do without special knowledge and ideas about the structure of units, the ability to handle special programs, etc. In addition, if any errors are detected, the service technician will have to make a decision to eliminate errors right on the spot.
All this once again confirms the need for highly qualified specialists who carry out commissioning. Most often, the installation and start-up of equipment is carried out by different people. If we are talking about complex industrial equipment, then the manufacturer sends its specialists who have completed the coursetraining and know all the intricacies of the installed machines.
Warranty Service
The cost of modern equipment is quite high. Therefore, firms that install production lines strive to make the most of the warranty obligations of suppliers. Often, one of the conditions for fulfilling the guarantee is the commissioning by trained specialists. Only in the event that the start-up of the equipment was carried out by certified specialists, the manufacturer will sign warranty certificates. Upon completion of the adjustment work, the warranty documentation is filled in, to which the protocols of their implementation, diagrams of the studies carried out and schemes of individual settings are attached.
What does the commissioning consist of
The commissioning program consists of a set of measures to put the equipment into operation. In general terms, we can talk about several blocks of commissioning: checking the correct installation and identifying factory defects; introduction of individual customer settings and equipment operation for the agreed time; customer staff training.
If everything is relatively simple with the first and last item of the program, then the second requires special attention. The fact is that each manufacturer has its own nuances and features of production. The equipment comes from the supplier with the so-called factory settings. However, the specifics of production usually require changessetting up the operation of the equipment and checking its functioning in the new conditions.
Commissioning just involves the control of the release of new products or proper operation after installation. Most often, there is an agreement between representatives of the customer and the contractor to track the release of a small batch of products. It is possible that defects or failures will not be detected at the first moment, and then specialists will be able to quickly navigate and make the necessary adjustments.
Training as part of commissioning
When commissioning is underway, the training of personnel who will operate the new equipment is of the utmost importance. The quality of finished products directly depends on the ability of workers to manage machines and units. In addition, the faster the staff gets used to the new technical equipment, the more likely it is to win the competition, ahead of rivals with the release of a modernized product.
If we are talking about complex electrical equipment or gas boilers, then the safety of both people's lives and the enterprise as a whole literally depends on the ability of staff to use new equipment. Therefore, during commissioning, special attention is paid to instructing the employees of the customer company. Most often, at the end of such training, servicemen issue a certificate confirming the primary skills of workers.
How much does it cost
Every type of work must be valued at something. But since commissioning necessarily accompanies the installation of equipment, the costs for it are not allocated in a separate column. The cost of commissioning is usually already included in the total cost of equipment and its installation, since these works are carried out by the equipment manufacturer. In some industries, however, there is a different practice. In particular, when it comes to installing gas-fired boilers or conducting additional environmental and technological tests, the cost of commissioning may be prescribed specifically.
Particular cases of launch costs
In addition, a separate column in the price list can be staff training. It is common practice that all employees who will be exposed to new equipment receive a briefing. But situations are possible when, due to staff turnover or some other reasons, you have to constantly instruct new employees. In this case, the enterprise selling the equipment reserves the right to provide educational services for a fee.
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