Questions about DCS operation? ?
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What do people think are the main responsibilities of a DCS operator? What do DCS personnel mainly do? What kind of operations should be performed? Is it better to recruit DCS operators from outside? Is it better to cultivate them from within? As a DCS operator, one must first understand the production site, right? But why do some factories recruit DCS personnel directly from outside and then train them, while others choose outstanding employees from within their own organization to serve as DCS personnel? Which manufacturers’ DCS systems are considered the most commonly used in the chemical industry? What qualities are necessary to become an excellent DCS operator? What do people think is the typical salary for a DCS operator these days? This post was last edited by qiwu9981 on 2008-4-18 21:35.]
DCS is just a control system. A DCS operator is primarily responsible for controlling and adjusting process parameters; in other words, it’s a type of operator, only one who uses the mouse more often than valves. In my opinion, ordinary DCS operators can be selected from workers who are familiar with the site. However, as a maintenance engineer for control systems, one still needs to have expertise in automatic control; this expertise can be developed through training or acquired by hiring external specialists. The salary of an ordinary DCS operator is only a little higher than that of an ordinary worker.
In fact, internal recruitment and external recruitment are the same; what matters is the ability to handle the job. Of course, if high standards are required, it would be better to hire people with relevant knowledge. But most manufacturers assign workers from their internal workshops who have good professional skills and comprehensive capabilities to work in the DCS room; under normal circumstances, these people can perform well as long as they understand the production processes and parameter control, along with having a strong sense of responsibility. There is no need to require DCS room staff to know everything related to the subject. This post was last edited by qiwu9981 on 2008-5-18 21:51.]
Agreed; it is necessary to master the indicators, principles, and control methods of the entire system in order to be able to handle emergencies.
I think it’s still better to select from outstanding internal employees, as they are very familiar with the processes. Training will also be faster, the quality will be higher, and their understanding of the manufacturing process will be much deeper. Moreover, DCS operations are closely linked to on-site operations, especially in emergency situations. If the person in charge is not familiar with the site, guiding those who are working on-site will lead to chaos. Handling accidents involves a race against time, and even gaining one minute can be extremely valuable at times. A secondary accident often occurs within this one minute.
New factories definitely need to hire people with work experience, while established companies should preferably promote outstanding field workers. One must be familiar with the site and the processes. DCS provides an overview of the entire process flow. Some experience in chemical operations is required; it’s best not to use newcomers. Currently, in China, DeltaV, Honeywell, and Yokogawa 3000 are widely used in large companies. There are many domestic companies in the small and medium-sized sector, such as Zhejiang University Zhongkong, HollySys, and Xinhua.
I joined the factory in 2005. Our unit installed a DCS control system from Zhejiang University Zhongkong at the end of 2005, but it was organized according to different positions. Basically, it’s the same as before – whoever used to do something still does that thing now. It’s just that it’s more intuitive and easier to use than the original dashboard. I don’t know what other units are like. We produce 80,000 tons of synthetic ammonia and 250,000 tons of small-scale alkali.
I work with DCS systems, and here are my thoughts on them: DCS stands for Distributed Control System. It allows the entire process of a chemical plant to be displayed on a computer screen, where it is possible to monitor and control various key process parameters, thereby enabling operators to oversee and adjust the system’s operation more easily. An excellent DCS operator must be highly familiar with and knowledgeable about the entire plant; they need not only extensive experience in operating the equipment on site but also a certain level of theoretical knowledge in chemical engineering, as well as the ability to respond to emergencies. It takes several years to train a qualified DCS operator, and some nuclear power plants in China even require a master’s degree for their DCS operators.
I think it’s better to train personnel internally; DCS control requires a good understanding of both the manufacturing processes and relevant theoretical knowledge, so that problems can be identified, analyzed, and resolved in a timely manner, thereby preventing accidents. The DCS of Zhejiang University Zhongkong is quite good.
What do people think are the main responsibilities of a DCS operator? What do DCS personnel mainly do? What kind of operations should be performed? Is it better to recruit DCS operators from outside? Is it better to cultivate them from within? As a DCS operator, one must first understand the production site, right? But why do some factories recruit DCS personnel directly from outside and then train them, while others choose outstanding employees from within their own organization to serve as DCS personnel? Which manufacturers’ DCS systems are considered the most commonly used in the chemical industry? What qualities are necessary to become an excellent DCS operator? What do people think is the typical salary for a DCS operator these days? Let me answer your questions (taking a synthetic ammonia DCS operator as an example). I believe the primary responsibility is to keep all the process parameters related to production within the limits set by the plant or departmental controls, to optimize operations as much as possible, and to produce qualified products. Secondly, DCS operators are primarily responsible for the control and adjustment of the entire process; they carry out routine maintenance tasks on a daily basis, and in case of an emergency, they can stop the equipment safely as quickly as possible. Thirdly, whether it’s recruitment from outside or internal training, I believe the key lies in whether the operator is dedicated, has an overall perspective, and is able to step up in critical moments. For the fourth question, I think there are several essential qualities that an excellent DCS operator must possess. First and foremost, one needs to have a flexible mind and a holistic understanding of the situation; when a problem arises somewhere, they need to be able to identify it and resolve it quickly. Additionally, they must be diligent, able to tolerate solitude, and capable of enduring the hardship of sitting at their post day after day. The average salary here is over 4,000. This post was last edited by INI99 on 2008-4-22 at 08:49.]
The presentation on the 11th floor was excellent. DCS operators indeed need to have a careful and thorough work attitude, especially when abnormalities occur in production, so as to be able to shut down the entire plant safely and ensure the safety of all equipment and personnel within it.
:'( :'( I am currently involved in DCS operations for ammonia synthesis, so I have some knowledge in this area. At work, I encounter all kinds of people, but I believe it’s most important to do one’s job well. It’s okay to have emotions outside of work, but emotions should not be allowed at work. We have had operational accidents here as well; each shutdown costs around 3 million, so the responsibility is quite significant
DCS operators generally need to be familiar with on-site operations, as they are responsible for directing the actions of personnel on site during system startup and shutdown processes. They must possess a holistic perspective, quick reflexes, solid theoretical knowledge, and a strong sense of responsibility; it is recommended to train them internally. The DCS operators at my workplace are between 3000 and 4000
For some information on DCS systems, one can refer to a book on distributed control systems written by the chairman of LSIT in China; I can’t remember the title of the book exactly, but it’s possible to ask about it. The systems developed by companies such as Yokogawa, ABB, Zhejiang University Control System, and LSIT in China are all quite good
Hehe. I agree with that. I wonder which region you are from.
I think in the chemical industry, a very high level of education isn’t necessarily required; here, even vocational school graduates are sufficient to handle the job
DCS is merely a control system; the operator’s main task is to control and adjust the process parameters. It is essential to understand the characteristics of control valves, such as air-operated open valves and air-operated closed valves, and to be able to respond quickly in emergency situations. The specific actions involved are turning on or off the control valves or notifying the crew to adjust the auxiliary valves. In my opinion, ordinary DCS operators can be selected from workers who are familiar with the site; all of the DCS operators in our factory are women, while all the men are on site. In terms of salary, DCS operators are paid less than those who work on-site. In small nitrogen fertilizer plants, as long as the process is stable, the DCS operators don’t need to make any adjustments. The field operators are responsible for inspections and carrying out drainage and flushing tasks. Moreover, the DCS environment here is much better than the field environment.
The DCS operators at our plant were all selected from their previous positions, and after simple training they were able to handle their tasks effectively; operating the system has become much easier than before!!
In our plant, the DCS operations are carried out by the main operators, who are responsible for regulating the key process parameters and coordinating with the relevant upstream and downstream units to ensure stable and continuous production. The main operator occasionally goes to the site as well, but generally uses a walkie-talkie to communicate with the workers on site in order to carry out operations. The salary for the main operator should be a bit higher
DCS is essential for ensuring the smooth operation of a process. DCS operators should: 1. Generally have a certain theoretical foundation (a vocational school education in a chemical-related field is sufficient); 2. To be competent in operating a DCS, one must be very familiar with the process pipelines, process parameters, valves, etc. on site, so as to be able to respond calmly and correctly in case of an emergency. 3. DCS personnel are generally trained through targeted programs, undergo on-site training, and are selected based on their performance to take up their positions. 4. The salary is 20% higher than that of regular operators.
DCS is the abbreviation for Distributed Control System; it displays the entire process of a chemical plant on a computer screen, allowing for the monitoring and control of various key process parameters, which facilitates operators’ supervision and adjustment of the system’s operation. The key to successful process operation lies not in the skill level of using the DCS, but rather in the operator’s expertise and experience in process management. A skilled operator should focus more on the actual process operations, with the DCS serving merely as a tool at their disposal