Performing Test Runs

When a test run is performed using the actual materials for the toll, it is a prime opportunity for the toller and the client to document the capability of the equipment, instrumentation, and process steps. During such a test, frequency of sampling may be increased, additional analyses performed and yield capabilities checked to find the optimum setpoints and timing for the toll process. Health, safety and environmental staff may choose to provide close coverage of the test run to evaluate areas for improvement during the actual startup and long term operation. 

In an analogous manner, when powders are being formulated, tollers will substitute clay granules or other inexpensive inert materials to test the systems. 

In either type of test run, an opportunity exists to ensure the utilities for the process are capable of performing their function. 

Test runs also allow the primary steps of operating procedures to be validated and checked for logic or human factors aspects. 

Some tolled products can be reworked if they fail quality assurance tests. In these cases the production cost may go up, but the product is not a complete loss. However, other tolled products, some pharmaceuticals for example, could be completely ruined by similar processing mishaps. Losses in these cases can be quite extensive. Test runs and approved rework procedures for such products may help avoid these losses. 

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To evaluate the overall speed-up obtained as a result of the program restructuring we have performed test runs of the lOS program on the IBM 3090. Calculations have been carried out for the Li- HF reaction at one value of 7 and using two different values of the partial wave set dimension (NV). Detailed run times obtained for two values of the collision energy are reported in Table I. 

Generahzed correlations are available for each of the operations which make up the full filter cycle. This means that simulated operating conditions can be varied to obtain a maximum of information without requiring an excessive number of test runs. The minimum number of test runs required for a given feed will, of course, vary with the expertise of the experimenter and the number of operations performed during the filter cycle. If, for example, the operation invdves only the dewatering of a slurry which forms a cake of relatively low to moderate porosity, frequently sufficient data can be obtained in as little as six runs. For more difficult tests, more runs are usually advisable, and the novice certainly should make a larger number of runs as there is likely to be more data scatter. 

The instrumental analyzer procedure, EPA Method 3A, is commonly used for the determination of oxygen and carbon dioxide concentrations in emissions from stationary sources. An integrated continuous gas sample is extracted from the test location and a portion of the sample is conveyed to one or more instrumental analyzers for determination of O9 and CO9 gas concentrations (see Fig. 25-30). The sample gas is conditioned prior to introduction to the gas analyzer by removing particulate matter and moisture. Sampling is conducted at a constant rate for the entire test run. Performance specifications and test procedures are provided in the method to ensure reliable data. 

There are some considerations and planning that can assist in performing a successful test run. 

The tolling team has analyzed the hazards, addressed the risks and modifications using a management of change system, revised and written procedures, trained the workers, performed a PSSR, and completed any required test runs. The pre-startup phase is complete at this point. 

The turbine undergoes three basic tests, these are hydrostatic, mechanical, and performance. Hydrostatic tests are to be conducted on pressure-containing parts with water at least one-and-a-half times the maximum operating pressure. The mechanical run tests are to be conducted for at least a period of four hours at maximum continuous speed. This test is usually done at no-load conditions. It checks out the bearing performance and vibration levels as well as overall mechanical operability. It is suggested that the user have a representative at this test to tape record as much of the data as possible. The data are helpful in further evaluation of the unit or can be used as base-line data. Performance tests should be conducted at maximum power with normal fuel composition. The tests should be conducted in accordance with ASME PTC-22, which is described in more detail in Chapter 20. 

Before starting any performance test the gas turbine shall be run until stable conditions have been established. Stability conditions will be achieved... 

Spare rotors are frequently part of a new compressor contract. A deci sion must be made regarding the testing of the spare rotor. The recommended practice is to mechanically run spare rotors, using the same procedures used for the main. As a matter of logistics, the compressor is usually shipped with the last run rotor. If a performance test has been specified, it can be run before the rotors are changed and both rotors performance tested. This would not be economical, however. 

Normally the proper impeller selections and horsepower requirements are handled in a cooperative manner with the manufacturer of this equipment in order to obtain the best analysis of a given application. There is no substitute for performing the proper test runs to evaluate... 

The only proper way to monitor the performance of a cat cracker is by periodic material and heat balance surveys on the unit. By carrying out these tests frequently, one can collect, trend, and evaluate the unit operating data. Additionally, meaningful technical service to optimize the unit operation should be based on regular test runs. 

A test run is conducted to evaluate the performance of a 50,000 bpd (331 m /hr) FCC unit. The feed to the unit is gas oil from the vacuum unit. No recycle stream is processed however, the off-gas from the delayed coker is sent to the gas recovery section. Products from the unit are fuel gas, LPG, gasoline, LCO, and decanted oil (DO). Tables 5-2 and 5-3 contain stream flow rates, operating data, and laboratory analyses. The meter factors have been adjusted for actual operating conditions. 

The material balance test run provides a standard and consistent approach for daily monitoring. It allows for accurate analysis of yields and trending of unit performance. The reactor effluent can be deter-... 

Any (project yield improvements should be based on conducting a senes of operating test runs. The test runs should reflect typicar operating modes. The results should be material/heat balanced. Another test run should be performed just prior to the revamp. A comparison of the results, pre- and post-revamp, should reflect no major changes in the catalyst reformulation. 

Once the operation of the unit has lined out, it is time to conduct a series of test runs to compare performance and economic bend its of the unit with what was projected as part of the original project justification. The results can also be used to determine if the unit s performance meets or exceeds the engineering contractor s performance guarantee. 

Start-up start-up and test-run documents data on process performance first operation experience What-If, Checklist... 

All of the test runs at higher current densities in the pilot cells have been completed, or are presently ongoing, for just two months or so, the idea being to focus on the properties or the performance of the electrolyser and the membrane. The durability of... 

For the simulation of SMB-separations efficient software packages,based on the Triangle-Theory, are commercially available. The number of columns, the column dimensions, the theoretical number of plates in the columns, the feed concentration, the bi-Langmuir adsorption isotherm parameters and the number of cycles need to be defined by the user. Then the separation is simulated and values for the flow rate ratios, the flow rates, the switching time and the quality of the separation, purity and yield, are calculated. Based on these values an actual separation can be performed. However, some optimization/further development is usually necessary, since the simulations are based on an ideal model and the derived parameters and results therefore can only be taken as indications for the test runs. 

It is an usual practice to perform an actual-test-run over a sufficiently large range by employing the necessary prevailing expansion facility so as to ascertain fully whether or not the atomic absorption technique is reasonably applicable to a specific low-level estimation. Such a data may ultimately reveal the exact and true detection limit which is normally equals to twice the noise level. 

The LC control software, either stand-alone or as part of an overall data-handling system, should be tested by means of a separate OQ protocol. This protocol only needs to address the communica-tions/control integrity of the hardware (e.g., setting up a run/sequence with the proper instrument parameters, the ability to start and stop the pump, etc.). It should cover all the required instrument control functions listed as part of the protocol s functional specifications. It does not need to include specific hardware performance testing, such as linearity or flow rate. The latter tests are performed separately, as part of the individual hardware validation described below. 

Witnessed means that a hold shall be apphed to the production schedule and that the inspection or test shall be carried out with the purchaser or his representative in attendance. For mechanical running or performance tests, written notification of a successful preliminary test is required. 

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