Let’s talk about the safety issues that arise when driving after a long break
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Let’s talk about the safety issues that arise when driving after a long break. I’ll start first. We operate a small, specialized factory; last year, due to the financial crisis, one of our products stopped being produced. Recently, while operating the equipment, one employee forgot to open the valve for draining the liquid from the distillation tank. Fortunately, it was discovered in time; otherwise, an explosion could have occurred. When starting to use the equipment again, it’s necessary to conduct thorough inspections in the workshop. Ugh!!!!!!!!
Hey, don’t you guys have process technical specifications and job operation procedures? It contains the start-up and shutdown plans for the equipment. If the conditions do not permit it, I recommend that you still prepare a start-stop plan and distribute it to the team so that everyone can study it! The content includes the preparations and inspections before starting work, as well as the steps for commencing work.
Generally, there should be start-up and shutdown plans along with corresponding checklists, and personnel need to be trained before commencing work
After parking for an extended period, retraining is necessary; before driving, a check must be performed, and only after confirmation can driving proceed. I forgot to turn on the air supply valve when starting the air conditioner, which caused abnormal motor current and significant vibration – things returned to normal once the valve was turned on.
5.5.4.4 Before starting up the enterprise’s production facilities, inspections should be organized to verify the safety conditions. The safety conditions shall meet the following requirements: 1) The on-site processes and equipment shall comply with the design specifications ； 2) System airtightness test and no-load operation commissioning completed successfully ； 3) Operating procedures and emergency plans have been established ； 4) Prepared and implemented the plant commissioning plan ； 5) Operators have completed qualified training ； 6) All various hazards have been eliminated or controlled.
Before we drove, we organized a training session; there was also a plan, but the operators had not done it for a long time and had forgotten it
Employees should be trained before driving, **and those who have been away from their posts for more than 6 months are required to undergo safety training at levels two and three again.
Standard operating procedures should be established; in such situations, all tasks must be checked item by item using a specific checklist, and management personnel should pay close attention to this. That was close! :handshake
When starting the engine again, the condensate water in the steam pipes doesn’t drain properly, which causes water hammer effects – it’s quite terrifying
Chemical companies that are shut down for an extended period face many problems, such as employees losing their skills, which requires enhanced safety and operational training； A thorough cleaning and inspection of the system are necessary; over time, due to residual materials or water, rust forms, along with various crystals that can block the pipes, and in some cases even cause localized corrosion that leads to the pipes becoming damaged ； Steam pipes are not used for long periods, resulting in excessive condensate water, and so on. Therefore, I believe that chemical companies must proceed with caution when restarting operations after a long period of shutdown; employees need to be trained, and checks on the water, gas, and steam supply systems should be carried out systematically (and slowly). Checks on the power supply system as well as on the equipment itself are necessary, along with inspections for cleaning the systems. The production of the first batches of products should be carried out at a slow pace, so that any issues can be identified and resolved promptly. It can be said that the workload is also quite substantial, and it should basically follow the trial production procedures.
Starting work again, I think, is not much different from starting work for the first time: all rotating equipment needs to be tested in advance, manual doors need to be opened where necessary and closed where appropriate, and it’s necessary to check whether water, electricity, and gas from the utility systems can be supplied in a timely manner. Things like whether the pipes are unobstructed or not – it’s best to establish operating standards, with team leaders overseeing the inspections
Chemical companies that are shut down for an extended period face many problems, such as employees losing their skills, which requires enhanced safety and operational training； A thorough cleaning and inspection of the system are necessary; over time, due to residual materials or water, rust forms, along with various crystals that can block the pipes, and in some cases even cause localized corrosion that leads to the pipes becoming damaged ； Steam pipes are not used for long periods, resulting in excessive condensate water, and so on. Therefore, I believe that chemical companies must proceed with caution when restarting operations after a long period of shutdown; employees need to be trained, and checks on the water, gas, and steam supply systems should be carried out systematically (and slowly). Checks on the power supply system as well as on the equipment itself are necessary, along with inspections for cleaning the systems. The production of the first batches of products should be carried out at a slow pace, so that any issues can be identified and resolved promptly. It can be said that the workload is also quite substantial, and it should basically follow the trial production procedures.