To timely identify abnormal equipment status and prevent system shutdowns and accidents. In actual production, specific inspection requirements vary due to differences in industries and processes, but the core goal remains consistent: to accurately detect on-site abnormalities and possess basic disposal capabilities. Its scope covers equipment, pipelines, instruments, control points, etc., with the ultimate aim of ensuring the stable operation of the production system.
Firstly, inspectors must receive systematic theoretical training; secondly, they need to accumulate rich on-site practical experience. For transferred personnel with weak foundations, the difficulty is relatively greater. The inspector's familiarity and mastery of system relevance, sensitivity to changes in process indicators, and equipment operating status are a gradual process, which plays a key role in the quality of subsequent inspection work.
Although with the improvement of automation, on-site unattended operation can be realized under normal working conditions, personnel are required for on-site operations when handling abnormalities. Inspectors need to accurately locate abnormal equipment and carry out targeted disposal by identifying information such as changes in equipment odor and abnormal operating sounds.
Inspectors should strengthen their awareness of inquiry, frequently self-question on-site conditions, and analyze the causes behind phenomena. This process is essentially a manifestation of logical thinking; lack of thinking may lead to neglect of abnormalities. During the shift handover, they must ask the relieving shift in detail about the completion of work and unfinished matters in the current shift to ensure comprehensive information mastery. The relieving personnel must clearly explain all details to avoid accidents caused by handover omissions.
For equipment that can be touched by hand or with special inspection tools, inspectors should use touch or tools to monitor temperature changes and vibration status during equipment operation. Before operating equipment, they must first conduct dry-run simulation operations to confirm the accuracy of actions and procedures. Blindly touching equipment during operation should be avoided to prevent misoperations. Through systematic perception and analysis, timely capture the gradual parameter change process in the early stage of equipment failure, and take targeted control measures to ensure safe and stable operation of equipment.
The core lies in mastering production processes and equipment characteristics. It is necessary to regularly conduct in-depth on-site inspections, dynamically monitor equipment operating status and working conditions, strictly follow operating procedures, and implement differentiated equipment management strategies. The key is to enhance the refinement of inspections and accumulate practical experience through practical verification and logical analysis.
When working in the unit area, the primary task is to implement personal protective measures and ensure the standard wearing of labor protection articles. Maintain real-time communication with the central control room and timely feedback on-site conditions. In case of major leaks or leaks of toxic and hazardous substances, the reporting procedure must be prioritized; unauthorized disposal is strictly prohibited to avoid personal injury accidents.
The core goal of chemical plant equipment inspection is to identify and handle various safety hazards, specifically covering three dimensions: first, ensuring the personal safety of operators; second, ensuring the stable operation of production equipment; third, maintaining product quality safety.
1.General Hidden Danger Inspection: Focus on checking common problems such as medium loss, material overflow, fluid dripping/leakage, and seal leakage; verify whether the operating status of the equipment's basic instrument parameters is within the standard range.
2.Inspection of Key Parts of Important Equipment
Connecting components: such as the installation accuracy and operational stability of reducer couplings, and the tightness of base fixing;
Operating status: monitor whether there are abnormal sounds during the operation of the reducer;
Lubrication system: check whether the lubricating oil level meets the regulations and evaluate the aging degree of the lubricating oil.
3.Implementation of Inspection Methods
Look: Observe the equipment's operating conditions and the displayed data of relevant indicating instruments;
Listen: Monitor the noise during equipment operation to judge whether there are abnormal sounds;
Touch: Perceive the vibration of the equipment during operation; if necessary, use professional instruments such as vibration meters for quantitative detection to confirm whether the vibration value exceeds the standard.
1.Appearance Inspection: Check whether the equipment body has defects such as damage or deformation;
2.Inspection of Connecting Parts: Confirm the integrity and sealing performance of connecting parts;
3.Inspection of Instrument Operation: Verify the operating status and data accuracy of on-site primary instruments and other related instruments;
4.Leakage Inspection: Focus on checking for seal failure issues such as medium loss, material overflow, fluid dripping/leakage, and seal leakage.
1.Scope of Key Inspection Equipment
2.Inspection Differences Between Different Units
Due to differences in process characteristics, equipment types, and operating environments of various units, inspection priorities need to be adjusted according to unit characteristics, with targeted attention to equipment and parameters that have a greater impact on the production safety and efficiency of the unit.
If equipment defects can be eliminated by post operators and maintenance personnel, they should be eliminated immediately and recorded in detail in the log. Equipment defects that cannot be eliminated by post operators should be recorded in detail and reported level by level; meanwhile, operate carefully, strengthen observation, and pay attention to the development of defects. For equipment defects that cannot be eliminated in a timely manner, it must be discussed and decided how to handle them in the daily production scheduling meeting. Before arranging to handle each defect, corresponding measures must be formulated, and specific persons must be assigned to take charge to prevent the defect from expanding.
Dynamic management of equipment operation refers to enabling maintenance and management personnel at all levels to firmly grasp the operating status of equipment through certain means, and formulate corresponding measures based on the equipment's operating conditions.
Chemical production is continuous, and units operate for a long time. Strengthening inspections, timely discovering hidden dangers, and eliminating accidents in the bud are key to ensuring long-term stable operation. There are many misunderstandings in the inspection process. Regarding leakage: normal leakage is in the form of dripping; flowing out or even spraying out is abnormal. For pumps with oil cups, pay attention to whether the oil level in the oil cup is within the normal range. Check whether the outlet pressure is within the normal process range. For pumps with bearing cooling water, check whether the cooling water volume is normal. When checking vibration, focus on whether the anchor bolts are loose. Special reminder: it is strictly prohibited to wear gloves when operating or inspecting running equipment. Centrifugal pumps generally require water for sealing; checking the inflow and outflow of sealing water must not be omitted, as the seal will burn out without sealing water.
1.Liquid level of the inlet storage tank to prevent material from being emptied;
2.Pump outlet pressure or flow rate within the specified range;
3.Pump body leakage;
4.No abnormal noise or vibration in the pump body and bearing;
5.Integrity of the lubricating oil system;
6.For mechanical seals with flushing fluid and sealing fluid, check their pressure and flow rate, and judge whether they are unobstructed.
These inspections require a long time, and comparing and analyzing data will help understand the pump's operating status and expected service life.
1.Dress as required, wear a safety helmet, and carry necessary protective instruments;
2.Be familiar with the unit's unsafe factors, check unsafe status, and master the unit's safety status;
3.Report unsafe hidden dangers in a timely manner, make records, and report them promptly;
4.Determine the mandatory inspection route and try to implement a two-person system;
5.Pay attention to wind direction and avoid stepping on oil substances or chemical splatters;
6.Do not enter restricted areas without permission;
7.Do not walk on pipes.
Inspection aims to identify equipment abnormalities, prevent accidents, and ensure stable production. Inspectors must perform duties such as inquiry and standardized operation. Inspection requires mastering processes and equipment characteristics, focusing on various aspects of equipment and static equipment, emphasizing key equipment in inspections, handling defects in accordance with regulations, avoiding misunderstandings, and paying attention to safety outside the unit. TEFFIKO, which focuses on pump research, deeply understands the needs of chemical scenarios. Its pump body design is suitable for refined inspection, with stable sealing and controllable vibration, reducing hidden dangers from the source. Meanwhile, its stable parameters are easy to monitor, reducing inspection difficulty. Choosing TEFFIKO can lay a solid foundation for long-term stable operation of equipment and is a reliable choice to ensure production safety.
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