Has there been an increase in failures due to the installation of interlock devices?

Let’s put it this way: the failure to establish a chain structure is due to cost savings, and it can’t be said that having a chain structure leads to more problems. First and foremost, the products purchased do not meet the standards required for a chain structure; so how can we ensure that there are no issues within such a chain structure?

Radar Madman, Ultrasonic Madwoman – use them in combination to create a chain reaction; there’s definitely something interesting to talk about with that. . . . . . {:3_51:} Brothers who agree, type 1111111 in a row – please reply to this post. Brothers who disagree, type 9999999 in a row – please also reply to this post. .

Analyzing the chains carefully and removing those that can be taken off is necessary, especially when it’s difficult to ensure high quality in terms of manufacturing and measurement； It is recommended to purchase equipment and components with high quality and guaranteed performance, as well as to implement cascade protection to prevent the occurrence of numerous secondary accidents.

The equipment quality is excellent, and the number of interlocks is moderate. There are too many interlocks, making it easy for production to come to a stop. Without interlocking, safety cannot be ensured, and safety inspections will not pass.

Understand well what SIS is.

Whether interlock is activated or not is actually a different concept from the device’s failure rate. Moreover, the purpose of interlocks is to protect the safety of the equipment and the operators, so it cannot be used as a factor for comparison

After participating in a HAZOP analysis, you will understand why alarms and interlocks are necessary. There are specific guidelines and standards for setting up these safety measures, and they are based on scientific principles – they’re not something that can be added or removed simply because one wants to

Who doesn’t want to work on interlocking? If certain interlocks severely disrupt normal production to the point where almost no production is possible, who would insist on putting them in use? Some interlocking systems cost hundreds of thousands or even millions yet still can’t be fixed – should we keep trying? If a company feels that it has spent a lot of money on trying to improve things multiple times without success, do you think it will still go ahead and try again? If we hire outside experts, where can we find those down-to-earth masters? This systematic solution cannot be achieved overnight, bit by bit, or through endless debates.

Firstly, in principle, the purpose of HAZOP analysis is to ensure the safety of production facilities and personnel; therefore, very strict rules are established. SIS is a safeguard mechanism designed to eliminate the hazard factors identified through analysis, and thus interlocks within SIS, along with the corresponding instrumentation and materials, are of great importance. Only by ensuring their safety and reliability can safe production of the facilities be guaranteed. Secondly, considering practical realities, even if a HAZOP analysis identifies risks and interlocks based on instrumentation cannot ensure normal production (whether due to fundamental design issues or manufacturing problems), it is necessary to adjust the measures taken to address those risks in a realistic manner. For example, other process measures can be employed to resolve safety issues while ensuring the safe operation of the facility. When production cannot proceed normally after interlocks are installed, it indicates that the measures taken to address the risks are not practical, and a realistic approach is needed. Therefore, when the situation described by the moderator occurs, simply removing the interlocks to ensure normal production is likely not in line with the current safety requirements ； An analysis from a process perspective should be conducted to determine whether other measures can be taken to address the safety assurance issues, after which the design should be modified; if necessary, solutions used in other devices within the same industry can be referenced. These are just my personal opinions for reference only.

If there’s a fault, fix it; if there’s no interlock, the inspection won’t pass, so production must be halted for repairs (unless safety supervision allows otherwise). Check how severe the damage is