What are the situations in which manufacturing processes cause equipment problems?
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In the chemical production process, what causes equipment damage or abnormalities due to process issues? Thank you
The pump operates continuously, causing the equipment to run under excessive pressure and load; the heating furnace reaches excessive temperatures; and fuel continues to burn in the absence of any medium.
The question posed by the original poster is too broad! ! There are too many such cases! Changing the process flow caused the pump to become evacuated, led to severe vibration, and resulted in seal failures. The modified process in the tank area caused oil to flow into the steam system, and the oil-laden steam caught fire upon contact with high-temperature materials. Inadequate water injection during the process led to ammonium salts blocking the tube bundles. Various operational issues led to a disruption in the boiler feed water, causing the boiler to dry out and overheat until its tubes burst. The operators tried to adjust the feed rate, but made a mistake with one decimal place, which caused the feed rate to drop instantly below the interlock value; as a result, the plant stopped operating. Pressure built up in the heat exchanger heads, and hydrogen leakage resulted in small flames. . . If you think about it, there are many such cases; this topic is simply too broad to answer properly
Prolonged deviations from process parameters, operational errors, lack of experience in handling abnormalities, etc
That’s an overstatement. Equipment failures are caused by various factors (design, manufacturing, procurement, installation, operation, maintenance, repair, etc.), and all of these lead to equipment failures. It is necessary to conduct analyses and troubleshooting to identify the true cause of the failure in order to find an appropriate solution.
The problems with the equipment are generally either related to the raw materials or to the equipment itself; and the issues with the equipment are mainly caused by the raw materials, that is, process-related problems. For example, dirty raw materials, raw materials containing water, or substandard raw materials can all cause initial fluctuations. At a more advanced level, changes in the composition of the raw materials can lead to fluctuations in system pressure, resulting in vibrations in the compressor and other equipment; in severe cases, this can even cause the pipelines to break.