Reflecting on a device accident caused by a small switch
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This post was last edited by lovestory on 2011-5-22 at 22:46. A few days ago, the weather was very hot; around 11 a.m., the low-voltage switch located in the circulating water pump room tripped due to the high temperatures. As a result, the low-voltage electrical equipment in the power air compressor room, namely the oil pump and the computer controller, stopped working. Instantly, two axial flow air compressors driven by steam turbines and one small centrifugal compressor came to a halt. Although this shutdown was simple, its consequences and the problems that arose were quite significant. Firstly, it had a direct impact on our production of active pharmaceutical ingredients, as the operation of the utility equipment was affected by just one small switch – this was our mistake. If we had reacted promptly, we could have avoided losses of hundreds or even millions of dollars. However, unexpectedly, the small centrifugal compressor, which was usually in standby mode, encountered serious problems: firstly, its vibration level exceeded 80; secondly, its temperature rose above 90 degrees instantly; thirdly, there was severe oil leakage. Yet these issues did not draw enough attention from us. Is it really true that a device that is often left idle doesn’t deserve any attention? Obviously not; the oil leakage was so severe that there was still oil in the air being delivered. This could be detected by touch, and it represents a serious quality issue for fermentation products. Following the supervisor’s instructions, an inspection of the small compressor after opening it revealed that the two shaft bearings adjacent to the coupling were severely damaged; the oil seals failed to contain the oil, resulting in a serious equipment failure. The cause of the accident was simply the negligence of the management, who did not pay enough attention to the operating condition of the equipment. But in the end, the real culprit behind this accident was that small low-voltage switch – it’s unbelievable.
Then hold those in charge accountable, right? No? ? Well, forget it then; it seems like the problem is serious. But the solutions are all the same; clear responsibilities make things easier.
Which part on the machine is just for show? Who doesn’t matter? Not a single one may be missing!
Details determine success or failure; a typical example of poor quality.
In chemical plants, one should not underestimate the importance of electrical instrumentation – although it is considered a minor specialty. Things that we tend to overlook can pose serious risks, while the issues we pay close attention to usually do not cause any problems. Because there is a plan in place, issues can be dealt with promptly even if they arise.
The backup machine needs to be checked regularly, and maintenance can be carried out at any time – it’s better to be prepared!