What are the job responsibilities that instrument technicians must know?

Thread Content

General safety regulations: 1. Instrument technicians should be well-versed in the safety aspects related to electricity and toxic or harmful substances for the instruments under their responsibility. 2. Under normal circumstances, working on live equipment is not permitted. 3. In workplaces with dust and toxic substances, it is necessary to understand the nature of these substances and their hazards to human health, and to take effective preventive measures. 4. Operations inside towers, tanks, and other vessels shall be carried out in accordance with the safety regulations for work inside such vessels. 5. Equipment not under dedicated management must not be turned on or off arbitrarily. 6. Before starting work, the instrument technician must carefully check whether the tools being used, as well as various instruments and equipment, are in good working condition; otherwise, work cannot begin. 7. When servicing instruments, it is necessary to check in advance whether all safety devices are in good condition; otherwise, the servicing cannot begin. 8. When it is necessary to stop the meter or cut off power supply for on-site work, it is essential to contact the operators and obtain their permission before proceeding. Electrical operations are carried out by electrical professionals in accordance with established procedures. 9. When performing maintenance on instruments, the residual pressure and materials in the equipment must be released, water, electricity, gas, and supply sources must be cut off, the temperature must be brought to normal levels, and signs reading “Do not close switches” and “Under maintenance” must be posted. If necessary, a dedicated person should be assigned to supervise the process. Remove the safety device. 10. When using a soldering iron, never make electrical connections while the power is on; ensure all connections are made properly before powering on. It is strictly prohibited to use power tools that may generate sparks in areas where flammable and explosive materials are present. If such tools must be used, a hot work permit must be obtained in advance. 11. Instruments and their electrical equipment must have proper grounding. 12. Any instrument or equipment shall be treated as being powered until it is proven otherwise. Whenever the wiring at the terminals is not clear, it should be treated as a high-voltage power source. 13. The wires of instruments, electrical and lighting equipment, etc., must not be damaged or show signs of electrical leakage. 14. The instrument power switch and the lighting or power supply switch must not be shared; in explosion-proof areas, explosion-proof switches must be used. 15. For instruments and their auxiliary equipment, before power is applied, it is necessary to check whether the power supply and voltage levels match the requirements of the instrument. Then, inspect the insulation condition. Only after confirming that the wiring is correct and the connections are secure can power be supplied. 16. It is strictly prohibited to place conductors and magnetic items on instruments and electrical equipment. 17. It is strictly prohibited to touch any terminal of the transformer after it has been powered on. 18. It is strictly prohibited to disassemble or assemble instruments while they are energized. When live work is necessary, on-site personnel must contact the relevant departments or personnel; only after ensuring that it is safe and reliable can power be supplied. 19. For the instruments on site, as well as the intermediate junction boxes and distribution boxes, measures must be taken to protect them from water, moisture, freezing, and corrosion, in order to ensure their safe operation. 20. The enclosures of electric tools and electrical equipment used must be properly grounded. It is strictly prohibited to insert wires directly into sockets without plugs. 21. The voltage of electrical equipment should meet the requirements. If the equipment malfunctions during use, the power supply should be turned off first before notifying maintenance personnel. Non-professionals must not touch it arbitrarily. 22. Without the consent of the workshop equipment officer, the operating conditions of all instruments (differential pressure, pressure, or temperature ranges, etc.) must not be altered arbitrarily. After the scope of work changes, it is necessary to inform the equipment operator for record-keeping, and this should be clearly documented in the technical records. 23. Ammonia or liquid ammonia must never come into contact with mercury to avoid corrosion. 24. When working at heights, the “Safety Technical Operating Procedures for Work at Heights” must be followed. 25. When operating under high-temperature conditions, necessary protective insulation measures must be installed around the work area to prevent burns or scalds. 26. It is prohibited to stack chemical substances that produce corrosive gases around the instrument room (panel). Two Instrument Repair Workers 1. Comply with the “General Safety Regulations for Instrument Workers”. 2. When performing maintenance or troubleshooting, it is necessary to contact the main operator on duty, discuss safety measures, and work closely together. For critical processes where the interlock control system poses a risk of stopping the machine, work must be carried out only after contacting the workshop and dispatch. 3. When dealing with faults in automatic control systems, the interlock function must be disabled by the operator: the regulator needs to be switched from \"automatic\" to \"manual\" mode, and the transmitter processing unit, recorder, and alarm unit should have their power and gas supply cut off. However, the regulator’s power and gas supply must not be cut off in order to ensure proper operation in manual mode. 4. If it is determined that the fault originates from the regulator or actuator itself, after following the procedures specified in the previous point, have the operator perform manual operation on site to resolve the fault. 5. Maintenance personnel must have a clear understanding of the process flow, automatic systems, and the composition and structure of the detection systems; moreover, the terminal numbers must match those on the drawings before any work can be carried out. Safety preparations must be taken before dealing with faults; the resolution of major faults requires approval from the team leader or the shift supervisor, and a plan must be developed before any action can be taken. 6. When performing routine maintenance or accessing the control panel, careful handling is required – handle it gently, push and pull it softly, and avoid dropping any wires, plugs, or any components of the instruments. Knocking is strictly prohibited while driving normally, to prevent faults in the operation of interlocks, buttons, or relay contacts. 7. When removing or installing instruments on various pipelines and valves that are under pressure or contain materials, it is necessary to close the instrument valves to release the pressure; the materials must be completely removed before any removal or installation can take place. Such operations should always be carried out from the side. When dealing with on-site issues, all pipelines should be treated as under pressure. 8. If an abnormal operation of the instrument is detected and it resumes working on its own before the cause has been identified, the cause must be found before the instrument can be used again; otherwise, it should be disabled. If the gauge poses a direct threat to production and it cannot be stopped, contact the production chief scheduler. 9. When maintaining instruments, it is necessary to take measures to prevent them from freezing, so as to avoid accidents caused by frozen instrument pipelines. 10. When removing items from the electric furnace, it must be done after turning off the power. The voltage for local lighting must not exceed 36V. 11. The inspection, disassembly, and inspection of instruments on gas equipment must be carried out by two persons (one as supervisor), and should be done after the gas supply has been shut off for cleaning. When working with fire, it is necessary to go through the relevant procedures, and the work must be carried out under the supervision of a supervisor. 12. When working on the steam system, precautions should be taken to avoid burns and overheating of instruments. Oils and fireworks are strictly prohibited when in contact with oxygen or acetylene or when working in their vicinity. Three Instrument Installers 1. Comply with the “General Safety Regulations for Instrument Workers”. 2. Installing field instruments requires two people to work together. 3. When removing instruments that are exposed to hazardous substances such as alkalis, dust, and toxic gases, work may only proceed after proper cleaning and purging have been carried out. 4. Strictly enforce the management regulations regarding the issuance, storage, and keeping of flammable and explosive materials. 5. When mechanical equipment, welding equipment, as well as pneumatic and electric tools are used during installation and connection, the relevant safety operating procedures for such equipment must be followed. 6. It is strictly prohibited to store flammable and explosive materials around electric furnaces, ovens, and other heating equipment. Night operations must be carried out by two people. 7. The power supply and other wiring must comply with the requirements shown in the diagrams; no changes shall be made arbitrarily. If changes are indeed necessary, approval from the relevant departments is required. 8. When leaving the work area, the power supply and other relevant energy sources must be turned off. Electrical equipment must not be installed under doors or pipelines to prevent damage to the equipment due to drips. Four Instrument Calibrators 1. Comply with the “General Safety Regulations for Instrument Workers”. 2. It is necessary to understand the operating instructions, principles, and performance of the instrument being tested before operating it. 3. When using vibration tables, ovens, cryogenic equipment, or other devices for performance tests, the safety and technical operating procedures for those devices must be followed. Concentration is required during the experiment; one must not leave without permission, and should constantly monitor the progress of the experiment while keeping proper records. 4. When cleaning the instrument, turn on the ventilation equipment, pay attention to the surrounding environment, and the operator must not leave. Flammable solvents must not be used; if their use is necessary, special approval is required, and they must be stored in accordance with the regulations for flammable and explosive materials. 5. It is prohibited to use electric ovens or dryers to heat flammable materials such as oil ； Electric heating equipment should be under the supervision of a designated person. 6. During acceptance, the schematic diagram or other relevant documents should be carefully checked against the wiring list; testing may only begin after it is confirmed that everything is correct. 7. Any instrument that is in use must come with a certification of inspection and approval at the time of replacement; otherwise, its use is prohibited. 8. The removal of stopped instruments or field instruments must be recorded by the production workshop to prevent accidents caused by accidental operations by operators. 5. Thermal Instrument Operators: When performing work on live equipment, in environments with gas present, or at heights without shutting down the equipment, thermal instrument operators must first obtain approval. They need to be equipped with reliable safety tools, and one person should operate while another acts as a supervisor. 2. Before operating or maintaining the instruments, it is necessary to have a thorough understanding of the entire system as well as the instruments themselves, so as to be well-informed; after the maintenance is completed, relevant parties and users should be informed accordingly. 3. All equipment must not be operated or used beyond its \"specified range of use\". 4. The power must be turned off before items can be removed from the electric furnace. 5. It is prohibited to use temporary wires for instruments and electrical equipment, as well as to insert wires directly into sockets. 6. Inspections and the removal of instruments from gas equipment should be carried out after the gas supply is shut off and the system is flushed. When working with fire, it is necessary to notify the relevant departments and obtain approval from the safety and technical department, and the work must be carried out under the supervision of rescue personnel. 7. When adjusting or maintaining the instruments in the gas system, two persons are required (one of whom acts as a supervisor). Staff should be familiar with gas safety procedures. 8. When the steam system is in operation, burns and overheating of instruments should be prevented. Oils and fireworks are strictly prohibited when in contact with oxygen and acetylene or when working in their vicinity. 9. Flammable, explosive, and toxic substances should be kept under the supervision of a designated person, and stored in locked cabinets in well-ventilated areas where overheating can be prevented. The storage quantity must not exceed the specified amount. What are the precautions that instrument technicians should follow when working on site? 1. First and foremost, instrument technicians must be familiar with whether the workplace is a location prone to fire and explosion or one where toxic and harmful substances are produced ； 2. Then familiarize oneself with the tasks at hand, prepare the maintenance work order, and have two or more people participate ； 3. Before and during work, pay attention to the following points: ① Based on the work tasks, it is essential to conduct a thorough safety risk analysis, identify all potential harmful and dangerous factors, and take appropriate safety measures. Wear all necessary protective equipment; for work at heights, follow the relevant safety rules – wear non-slip shoes and use safety belts. Work is strictly prohibited in conditions of strong winds or heavy snowfall, etc ； For hot work, it is required to obtain the necessary work permits; after analysis and approval, work can proceed only with the presence of a supervisor ； When performing maintenance on enclosed containers such as towers, tanks, vats, and reactors, it is necessary to carry out analysis or gas displacement tasks; work can only proceed after confirmation that these steps have been completed successfully. Additionally, signs indicating that people are working inside must be installed ； When servicing measuring instruments and control valves used with toxic, harmful, and corrosive media, it is necessary to wear protective equipment such as gas masks or air respirators ； ②Instruments that require power shutdown must be prepared for such a shutdown. When maintaining interlocked or automatically controlled valves, it is necessary to inform the process engineers in advance, and they shall create the conditions for maintenance by disabling the interlocks or switching the automatic control circuits to manual mode ； ③During maintenance in the oxygen-enriched area, it is prohibited to use hammers or equipment that may generate sparks ； ④When disassembling or assembling instruments, stand to the side of them. Only after ensuring that the pressure medium has been completely drained can the instruments be removed. If the medium is toxic or harmful, it must be discharged in a designated location to prevent contamination. When reinstalling, degreasing must be carried out if oxygen-containing media measuring instruments are used ； ⑤When dealing with instrument failures involving high-temperature media, take measures to prevent burns from heat; proceed only after ensuring that both the primary and secondary valves are properly closed.