What are good **habits** in chemical operations?

1. Conduct regular inspections and frequently verify on-site with the DCs； 2. Think more about why; when observing fluctuations in indicators, consider the reasons behind them ； 3. Strengthen the understanding of the mutual influences among various indicators ； 4. Adjust the DCS slowly. 5. Think more about how to handle accident situations

I always ask the DCS staff to keep a notebook to record the main operations, so as to avoid forgetting them

Pay attention to every detail :) :) :)

Scroll through the images frequently and pay close attention to the changes. Pay more attention to trends and consult on-site personnel in conjunction with DCS.

In this regard, the Japanese are quite meticulous; for any action, they require pointing and naming, as well as careful verification

Excuse me, what does \"calling out positions\" upstairs mean?

Adjust frequently, make fine tweaks, and avoid rough handling. Keep proper process records, usually taking one record every 2 hours

DCS operation involves not only monitoring and adjustments on the machine’s display, but also regular verification with the site staff and an understanding of the actual conditions there. One must never neglect to maintain good communication and collaboration with the people on site just because they are a DCS operator.

*Over time, it becomes an instinct! Upon reaching a certain level of proficiency, one becomes fully aware of all valve positions; the valve position corresponding to any given load can be determined effortlessly, and the initial reactions and judgments in response to any fluctuations are accurate and decisive... This post was last edited by caojian725 on 2008-1-18 at 10:52

1. The first thing to do upon starting work is to check and confirm the overall status of the manufacturing process, including the operating conditions of all equipment and systems； Are parameters such as temperature, pressure, flow rate, and liquid level within normal ranges, and are the corresponding valve positions also within normal ranges? ； Whether various facilities and equipment such as devices and instruments are operating normally ； Spend about 10 minutes conducting a comprehensive check of all operational parameters to have a thorough understanding of the process status at the time of shift handover. 2. After taking over, carefully monitor the ongoing operations. For continuous processes, pay attention to whether the parameters are within normal ranges and if there are any abnormal changes, as well as watch for any changes in the valve positions – sometimes when fluctuations occur in the system, it is the abnormal reduction or increase in valve positions that is the first sign of such issues ； For discontinuous operations, it is best to keep a record to remind oneself when to complete each task. Operate strictly in accordance with the process operating procedures. 3. When an abnormal situation arises that needs to be addressed, it is necessary to make accurate judgments and carry out the operations skillfully. By conducting regular on-the-job training to become familiar with the procedures for dealing with common accidents, it becomes possible to handle any abnormalities that arise in production quickly and effectively. 4. During operations, strengthen communication with the shift leader and those in charge of outdoor tasks; obtain more information about the situation on site before proceeding with the work. This way, it’s not easy to make mistakes due to carelessness. 5. When operational fluctuations require adjustment, fine-tuning is generally carried out. If the operation shows significant fluctuations, this parameter can be set to MAN mode to manually control the valve position; once the parameters become stable, the auto (CAS) setting can be adjusted to be close to the PV value and automatic or cascade control can be enabled, after which the setpoint can be gradually adjusted back to the value required by the process. This allows the parameters to be stabilized quickly. 6. Develop the habit of recording operation details in a timely manner. Generally, operation records are required to be entered within 15 minutes after the operation is completed. However, it seems that many people don’t do it this way. This is unfortunate, as keeping timely records of your operations will help you summarize your experience and improve your skill level. 7. Be diligent in thinking, and regularly summarize the experiences and lessons learned from yourself and others.

A good *habit* can also be a bad *habit*. The best thing is to have no *inertial behavior. When everything becomes too *routine, problems are likely to arise, and they tend to be serious ones! ! ! Although practice makes perfect, it also makes one more prone to carelessness! ! ! Good chemical handling means avoiding the formation of *habits. Strictly abide by labor discipline, follow job specifications, and carry out tasks as required. Before carrying out an operation, it is essential to confirm it once again; not only should you think about it in your mind, but you should also say it out loud. Only after confirming can you proceed with the operation, and after that, you need to say it again and confirm once more before ending the task. This is what the Japanese call \"teisho kyoju\". In other words, chemical processing can be summed up in one sentence---------confirm, confirm, and confirm again. As for the methods of PID control, those are just some operational techniques; one needs proficient experience to make adjustments based on appropriate criteria. If there is a *habit that should be adopted, it is as everyone has said above: first, one must not only monitor and control things from the control room, but also spend more time on-site to become familiar with every minor change that takes place there. Only in this way can one have a thorough understanding of the site, and be able to make accurate judgments when problems arise, thus allowing for the resolution of issues using relatively reasonable methods. II. Think more; ask why about everything, think independently, and seek advice frequently.

DCS operators must possess the following qualities: 1. A strong sense of responsibility; without it, everything is in vain. 2. Excellent on-site operation skills; one who cannot serve as an assistant operator on site cannot effectively act as a chief operator either. 3. Knowledge of instruments, especially an understanding of instrument failures, their symptoms, and causes. 4. Familiarity with various parameters: their normal operating values, the factors that cause them to be too high or too low, and the solutions for such issues. 5. The ability to handle emergencies when the system fails, such as power fluctuations, water or steam supply interruptions, loss of instrument air, or DCS failures. 6. Good operating habits; sometimes even those who are busy throughout the shift still fail to maintain stability. Yet there are others who can do it with just a few adjustments. In other words, adjustments should be made in a rhythmic and moderate manner, depending on the characteristics of various parameters (such as adjustments to temperature and flow rate) as well as the role of those parameters within the system. 7. Another piece of experience for the main operator is to adjust continuously based on trends and identify problems, rather than making adjustments solely based on current values.

The person upstairs is amazing! Thank you!

But how can we achieve these things?

Well said! Another point: strictly follow the operating procedures