I have ordered a small pilot-scale device; how can I ensure its quality and how should it be inspected?
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The process engineers prepared the process diagrams, but not the detailed pipe diagrams or structural drawings. They then asked the procurement department to find a manufacturer (at the lowest price) to carry out the complete manufacturing process, including the installation of electrical components, instruments, pipes, brackets, and bases. During the inspection, the process engineers checked whether the process could be carried out smoothly, tested the water flow, as well as the pumps and instruments. Then, under pressure, the manufacturer arranged for logistics to deliver the items to the site urgently. Upon arrival at the site, it was found that many of the welding points on the brackets (structural elements) were severely damaged, to the point where the structures were almost falling apart. There were also components inside the control box that had come loose or broken, some instruments were damaged, and the tower was secured using only a few screws; moreover, the base steel plates were too thin, and the pipes used were also of poor quality. What I want to ask is, how can we do our preliminary work more thoroughly to avoid potential problems in the morning? What procedures should process engineers, procurement staff, etc. follow, and what responsibilities do they each have? Beyond those involved in general operations, is additional participation needed from others in the procurement process (since in pilot plants, people from other specialties often don’t get involved)? Are there any standardized processes that can be used as a reference? Are there any standards for acceptance checks, and what aspects need to be checked? How can we ensure that there are no problems with the device upon delivery to the site? Looking forward to your advice!
For such small devices or skid-mounted units, the design requirements need to be as clear as possible, and the PO should also be as detailed and accurate as possible (including specifications, models, materials, and even the designated manufacturer). Additionally, during the manufacturing process, designers must be on-site to oversee production (as only they know what is desired), and shipment is allowed only after a FAT test is passed prior to leaving the factory.
This designer has only expertise in processes, not in electrical or instrumentation equipment. What is PO FAT? Looking forward to your advice! Are there any procedures or documents required before leaving the factory, such as quality certification documents, leak and pressure testing reports, etc.? What about the materials used for welding and related inspections? Are there any standards that can be referred to? Acceptance procedure
When you order something at the lowest price, as long as you get it is enough; don’t worry too much about whether it will work or not, or how well it will function. For such customized medium or small-scale testing equipment, if one does not possess the necessary technical expertise, it is necessary to have skilled professionals carry out the design, or to find established manufacturers with such capabilities and provide them with the required specifications so that they can assist with the design. Safety and efficiency are not reflected in the lowest price from the outset; sometimes it takes failures and accidents to realize them.
This post was last edited by qugd on 2020-11-15 at 14:16. FAT stands for Factory Acceptance, which is an inspection and acceptance process carried out by the manufacturer before the product leaves the factory. Never mind, you’ve already purchased it at the lowest price; I hope it’s not a high-temperature and high-pressure device. If that’s really the case, let’s place a Bodhisattva beside it. The large equipment in the factory is installed on the outdoor ground, so there are places to run to in case of danger; the pilot and small-scale equipment is installed in the laboratory, where there’s no place to escape, so it’s better to offer prayers and be more careful in such situations.
PO, Purchase Order, a purchase order. FAT, Factory Acceptance Test, acceptance test upon leaving the factory. For process acceptance and pre-shipment inspection, reference can be made to the standard GB/T 25928-2010 \"Process Industry Automation Systems — Specifications for Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and Site Integration Testing (SIT)\"
If this is operated manually, and only some pumps use electricity, does this standard still apply?
It’s not in the laboratory, it’s outside the factory building
During the entire life cycle of this device, what responsibilities do process engineers, purchasers, and others need to fulfill? For example, if quality issues arise, is it the fault of the process engineers or of the purchasing staff?
1. First, check the PO to see if the design specifies what needs to be purchased 2. Check the purchase contract to see whether the supplier provided what was required according to the design specifications 3. Check the warranty certificate to see if the supplier has delivered the products as promised in it
At that time, the process design only provided a preliminary outline of the manufacturing procedures; the internal piping and layout were handled by the manufacturer. The problem was that the manufacturer used materials of thin thickness and the welding quality was poor. The process engineers were not experts in this field, so they couldn’t identify these issues. In the past, testing was carried out on-site by starting up the pumps to see if the system would work properly. No specific material specifications were given, nor was there any requirement regarding wall thickness. The base supports used also did not have specified dimensions or wall thicknesses. There were no professionals involved in the structural and electrical aspects of the design – everything was done by the manufacturer themselves. There were problems with the fixing of components in the control box, which led to those components falling off or getting damaged during transportation; this is the manufacturer’s responsibility. Is it a problem with transportation, the process engineers, or procurement?