After the new device was built, during the first test run, many problems arose!
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Our company’s newly installed equipment has finally begun trial operation after a period of intensive preparation work. However, there were quite a few unexpected problems that arose, such as clogged oil filters and inadequate heat transfer efficiency of the heat transfer oil. We hope that everyone can share the unexpected issues they encountered during their own trial operations, so that we can learn from each other and improve together!
It’s very difficult to have no problems at all during the testing of a new device; I just hope that the preparation work can be as thorough as possible! We’re about to start working too
First of all, one needs to learn from equipment that is identical or similar to one’s own. Learning from such experience is crucial; before starting work, it is necessary to discuss the relevant issues with experienced workers and develop detailed plans as well as step-by-step procedures for commencement of operations. It is also important to have the personnel from the equipment manufacturer present at the site, as they possess extensive experience and have encountered similar problems before, allowing them to offer sound advice. Most importantly, one should invite one or several experts – namely technicians who have worked with equipment similar to yours and who have experience in commissioning processes – as this is extremely important
Unexpected incidents occurred during the commissioning of the new equipment: gas mixed with oil, synchronous motors stopping for no apparent reason, breakage of the crosshead in the reciprocating machine, explosion of the main fan, pressure gauges catching fire, and so on.
We experienced significant oil leakage during oil discharge because the external pipelines had not been purged and pressure-tested； The valve leading to the tower was left closed, causing a leak in the heat exchanger ； I’m ashamed to admit it!
This issue is too broad, with too many uncertain factors; the characteristics of devices and apparatuses are even less likely to be the same. Let’s talk about the methods: First, I’ll discuss the need to understand the manufacturing process and its objectives, as well as the structural principles of the equipment and their control mechanisms. In terms of electricity, one needs to be able to read circuit controls; for instruments, it’s necessary to understand their logic. If that proves difficult, function block diagrams can be used. Additionally, knowledge of DCS operation and the principles of various valves is required. Since this involves starting up the system, some knowledge of installation and piping is also needed. With these as the foundation for dealing with problems, when issues arise, comparison and elimination are the main methods used. At the same time, it is essential to keep proper records of the parameters for each unit; this will serve as a reference for future joint tests or in case of other problems. Otherwise, you’ll be in a very awkward situation! Let’s talk about these first; everyone, share your ideas! This post was last edited by ljc9 on 2009-3-25 01:44]
For example, if a drain valve is forgotten to be closed, it suddenly becomes open during operation, causing a fire. Also, the blind plate was forgotten to be removed when starting up the machine