Equipment incident reporting

It is recommended to share accidents you have personally experienced, without limiting yourself to certain devices.

Let me introduce one case first: at the end of December 2008, the inlet valve of the condensate oil pump in a certain catalytic unit froze and cracked due to temperatures dropping below –11°C. A leak repair company was called in; while preparing to plug the leak, the operators used steam tape to blow on the valve during the process of depressuring the pipeline, which caused the leakage to worsen. The condensate oil sprayed as far as 6 meters away (with the valve being about 2.6 meters high), and the leakage persisted for over 25 minutes, forcing the shutdown of the unit.

In January 2005, I was on duty in the turbine area; the turbine blades were damaged and an alarm was triggered due to increased vibration. When I went to check it, the turbine was vibrating as if it were dancing, and smoke was leaking out – it was a terrifying sight that is still fresh in my memory. Fortunately, the emergency shutdown system was activated in time; otherwise, the turbine could have spun out of control, with consequences that would have been unimaginable. In the end, the shaft, moving blades, stationary blades, and bearing shells all had to be replaced. This post was last edited by redboy219 on 2009-2-4 at 22:20

I would like to send some photos of the damaged smoke extractor, but I’m unable to upload images; I can only describe it as follows: In May 2005, a loud noise was heard coming from the direction of the main fan unit of a certain catalytic device. The DCS system in the room showed that the vibration of the smoke extractor had increased to around 60 microns, and at the same time, a fire was detected in the area where the smoke extractor was located. Emergency shutdown handling by personnel. Inspection revealed that one blade of the exhaust fan had broken at its root, while an adjacent blade was bent due to impact; erosion marks were present at the roots of both blades, with depths exceeding 1.5 mm in some cases. The intense vibrations at the beginning caused the lubricating oil pressure gauge to fall off, and the lubricating oil sprayed out and ignited the smoke machine. I’ll continue later.........