Problems that occurred during construction
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I’d like to talk to you about the problems that arose during the recent installation of the equipment that has just been completed. To be honest about it: 1. For the 204 type seal used in the reaction vessel, in order to prevent the high temperature inside the vessel from affecting the seal, a cooling water jacket was installed beneath it. After welding, flanges were machined, but the weld seams were damaged as a result of this machining process. No pressure testing was carried out before installation； 2. The pipe extending inward from the flange of the reaction kettle is not welded to the upper head ； 3. During the adjustment test run, the circulating water in the mechanical seal cooling jacket was not turned on ； The above issues caused leakage inside the reactor during the trial production phase, as well as an excessive water content in the material. Fortunately, this did not result in product waste, but it was a very serious lesson for me as the person in charge of the construction. It shows that one must never take anything lightly. Last edited by laiqi on 2009-3-11 20:24.]
The general result. The confirmation system should be utilized to prevent things from happening that shouldn’t.
During the construction process, it is essential to be meticulous; if problems are not detected in advance, things will get complicated once production starts
Failure is the mother of success; learn from experience. Don’t make the same mistake again.
In fact, under formal construction management, there are nine control stages from the initial planning and briefing, through construction, team inspections, self-inspections, supervision, pressure testing, system integration, to the start of operation. If any one of these stages is handled carefully, problems can be identified. So why aren’t they detected? The more procedures there are, the more perfunctory the work becomes. Each step assumes that the other eight steps are being carried out more carefully than its own. Since all nine people end up doing a little too little, problems are bound to arise. It’s better not to reduce the number of procedures; when reduction is necessary, I usually ask one person to take responsibility and hold them accountable if anything goes wrong – they will definitely do their job diligently (and don’t forget to give them a treat afterwards). I think this method works pretty well, but it stops working once you get tired of using it. In short, every detail of the project needs to be under proper control in order for things to be done well; otherwise, even if something is completed, it will be done poorly.
Is the construction team mentioned by the poster the factory’s own maintenance workshop? There was no triple inspection for processing and welding, unit testing was not carried out, the requirements of the three inspections and four fixations were not met, and the combined testing was incomplete – it’s as if all these issues happened to coincide at once. It’s really unlucky.
Each step of the process must be subject to strict inspection, and work must be carried out in accordance with the established procedures; otherwise, unexpected problems may arise.
Strict construction management procedures must be followed; how can it work without proper supervision? Managers must stay on site at all times.
Thank the original poster for sharing their experience! In fact, every aspect of a project is important; even the slightest lack of attention can lead to mistakes, though these mistakes may vary in severity. To share a piece of advice from my mentor with everyone (especially those in management positions): treat each step of the process with care, implement every measure thoroughly, check each control point carefully, and take your work seriously – be responsible for yourself. :victory:
Strict management procedures for construction are required; management personnel must be present, and every step must be given due attention: victory:
Strict quality control is essential; critical quality processes must be under control. Otherwise, not only will there be direct losses such as rework and returns, but more importantly, there will be indirect losses for both the customers and the company itself (such as damage to the company’s reputation, financial losses due to downtime, etc.), which can be immeasurable.
:) :) It’s all the same now; one can’t be careless anywhere, especially when it comes to valuable equipment.
In terms of quality, management should be comprehensive, all-round, and involve all employees – this is what is meant by \"three-all management.\" There should be proper handover between different stages of production, with checks at each level, so as to avoid human errors. Learn from past mistakes and don’t lose heart.