How to be a good equipment engineer in a chemical company

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I. First of all, it is necessary to clarify the responsibilities and tasks of a workshop equipment engineer; 1. Develop equipment inspection, maintenance plans, and technical solutions. 2. Provide technical guidance and spare parts preparation for on-site equipment maintenance. 3. Manage the technical archives of various equipment in the workshop. 4. Responsible for the technical upgrading of workshop equipment and technological innovation, in order to improve the safety, reliability, and cost-effectiveness of such equipment. 5. Enhance technical support for equipment (spare parts) procurement by developing equipment technical specifications and signing technical agreements. 6. Responsible for identifying potential safety hazards at the equipment site and formulating technical solutions for addressing those hazards. 7. Organize or participate in the analysis of equipment accidents, and develop repair plans as well as preventive improvement measures for the affected equipment. 8. Responsible for providing professional technical training on equipment to workshop employees. 9. Responsible for external communications regarding equipment-related issues. 10. Assist the workshop equipment supervisor in equipment management tasks. II. To accomplish the above tasks, what knowledge, skills, and qualities do equipment engineers need to possess: 1. Basic professional techniques (the fundamental knowledge needed to solve problems). l Materials science: includes metallic materials and non-metallic materials. Mastering knowledge of a material’s chemical composition, microstructure, production processes, physical properties, and environmental impact provides a theoretical basis for the rational use of materials and for accident analysis of components. Highly recommended materials for study: university textbooks such as \"Materials Science of Metals\", \"Metals and Heat Treatment\", and \"Polymer Materials\" – in the edition by Gao Zhanxian, etc ； Relevant standards: Abroad: ASME-II, ASTM ； Domestically: the focus is on the standards for materials used in pressure vessels (tubes, plates, forgings, etc.). l Mechanics: It mainly consists of two parts: engineering mechanics and mechanics of materials. It is essential to master the basic concepts, fundamental principles, and calculation formulas related to forces and force systems, so as to be able to calculate and verify the strength, stiffness, stability, and other aspects of components (non-standard ones). l Mechanical Principles: Focus on mastering the types, characteristics, and applications of mechanisms. Have the ability to determine mechanical motion schemes and select mechanisms appropriately. I recommend \"Principles of Machinery\" by Sun Huan. -Operating equipment such as pumps is composed of basic components, and having a solid understanding of these components is crucial for selecting such equipment and analyzing faults. Such as the crank-connecting rod structure of typical reciprocating compressors, the gear structure of reducers, etc. l Machining technology: Mastering the process methods of machining, understanding the characteristics of new types of processing equipment (such as machining centers), knowing the processes for manufacturing accessories, and having the ability to assist with the redesign of equipment components, the quality inspection of spare parts, and accident analysis. For a gentler introduction, one can read “Fundamentals of Machining Processes”; for a more in-depth study, “Principles of Mechanical Manufacturing Processes” is recommended. 2. Professional technical applications in engineering – Moving equipment: Master the basic theories, design and calculation methods, main structures, selection, and usage of chemical engineering machinery for engineering applications. It is capable of performing thermodynamic and dynamic calculations on the unit (for design and under varying operating conditions), selecting appropriate equipment, verifying the strength of components, conducting technical analyses of equipment failures, and proposing improvements to the unit from a theoretical perspective. Key topics to study *Recommended materials: university textbooks such as \"Chemical Engineering Machinery\", Guan Xingfan’s \"Modern Pump Theory and Design\", Yu Yongzhang’s \"Technical Manual of Positive Displacement Compressors\", \"Turbine Compressors\", and \"Industrial Steam Turbine Technology\", etc. Foreign standards recommend API610, API612, API613, API617, API618, etc. (Domestic standards are essentially simplified versions of foreign standards, so they are not recommended; however, it is important to master them thoroughly, as domestic-made equipment operates in accordance with these domestic standards.) ) In addition, it is necessary to master equipment condition monitoring techniques; reading books such as \"Equipment Condition Monitoring, Fault Diagnosis Techniques and Applications\" is recommended. l Static equipment: pressure vessels, heat exchangers, boilers, pressure pipelines. Master design calculation methods, type and structural characteristics, design and manufacturing, inspection and testing, as well as key points for operation and maintenance. Standards or books related to this field include: GB150 \"Pressure Vessels\", GB151 \"Shell and Tube Heat Exchangers\", GB20801 \"Code for Pressure Piping\", GBT 9222-2008 \"Calculation of Strength of Pressured Components in Water Tubular Boilers\", and \"Technology of Large-Scale Circulating Fluidized Bed Boilers\". Foreign standards include ASME VIII-I and API 510. TEMA is a classic standard for heat exchangers; it is highly recommended. 3. Other specialized equipment: such as mixing equipment, lifting machinery, transportation machinery, etc., also need to be understood and mastered from aspects including design calculations, structure, selection, as well as fault diagnosis and handling. Study materials: Relevant professional books and standards. 4. Expandability: l Chemical engineering processes: Master the basic operating principles and methods of fundamental chemical engineering units; be capable of analyzing and diagnosing process-related problems; possess comprehensive analytical skills in accident analysis. Recommended learning materials: the university textbook “Principles of Chemical Engineering” and textbooks on chemical engineering processes for related majors. l Electrical and instrumentation knowledge: Learn to master the basic knowledge of electrical instruments, as well as the working principles and structures of the electrical instruments commonly used in one’s work environment. l Safety management: Learn to master the safety technical regulations and standards related to special equipment, as well as the analysis methods required by API587 \"Inspection Based on Risk\"; also learn from the analysis and prevention methods for accidents presented in \"Typical Accident Cases of Special Equipment\". Also keep in mind: the knowledge mentioned above serves as the foundation and guarantee for safety management as well. l Management skills: Mastering the concepts, basic knowledge, and methods of business management. Recommended readings include introductory management books such as \"The Common Sense of Management\" and \"Grove – The First Lesson for Managers\". Project management: It may not be possible to take on project management tasks, but learning to apply project management concepts and methods to manage one’s own work tasks will **improve our work efficiency. Recommendation: Harold Kerzner’s “Project Management”. In English: It is possible to obtain foreign teaching materials, standards, and other technical documents on a monthly basis, which enables one to keep up with the latest foreign technologies as soon as they become available ； Second, read the original text directly to prevent misinterpretation and translation errors. l Computers: Master a programming language to develop small computing management software on your own, **improving work efficiency. Promote the use of VB programming, small database language programming, and EXCEL function programming. For instance, I used VF to develop the “Team Information Management System”, and utilized EXCEL functions to create software for calculating compressor performance under varying operating conditions, as well as software for analyzing the flow pulsation at the outlet of reciprocating pumps. l Basic problem analysis and solution methods: The approaches to problem analysis and resolution in quality management are worth adopting and applying in addressing production issues across all workshops. It is recommended to read “ISO9001: Quality Problem Analysis and Resolution”. III. Development of good working methods and learning habits. 1. Go to the site in person and get familiar with the equipment. I mixed closely with the front-line maintenance workers and personally got involved in the inspection and repair of key components. Function: First, it enables enhanced communication with front-line workers and the establishment of a relationship of mutual trust, which facilitates cooperation and information exchange in future work. Secondly, by observing the internal structure of the equipment, one can gain a better intuitive understanding, figure out its operating characteristics and fault patterns, and improve their ability to diagnose faults and handle emergencies (through long-term on-site experience, it is entirely possible to accurately identify problems by simply listening, observing, and touching). Third, only by being familiar with the site and having strong practical skills to handle problems can one establish credibility within the maintenance team. 2. Knowledge management, improving quality. First, by going deep into the field and humbly learning from experienced technical workers. Among frontline workers, there are many talented individuals with special work skills and techniques as well as extensive experience. Their on-site experience is extremely valuable for conducting in-depth analysis and solving problems. Second, engage in technical exchanges through website forums and professional blogs to learn from peers in the industry. Third, learn from internal experts and technical authorities*. Fourth, stay informed about their new technologies and products by visiting the websites of reputable manufacturers. Fifth, develop the habit of keeping daily work notes; after completing each key task, it is also necessary to conduct a thorough summary in order to continuously accumulate work experience. Sixth, properly collect and organize technical materials (for details, see my blog “My Knowledge Management”). Seventh is to focus on the acquisition of knowledge in related fields. Practical production problems often involve various specialties and stages; mastering the various aspects of the \"expansion capability\" discussed in the previous section facilitates comprehensive analysis and judgment of such problems. 3. Master standards and make use of them. It represents a summary and refinement of the experience of industry experts over the years, based on standard norms. It provides specific working methods and standards; by following these standards in one’s work and striving to meet their requirements, it is possible to avoid unnecessary detours and improve efficiency. Common foreign standards used in the equipment industry include ASME API, DIN, TEMA, ASIM, AWS, EN, JIS, and other such standards. Among domestic standards, the GB standard is the most fundamental one. Professional standards represent a further development and refinement of the national standards; among these, the SH standards set by Sinopec are particularly strict and are closest to foreign standards. Other standards include NY, HG, SY, etc. 4. Strive for excellence and perfection. When formulating a technical solution, comprehensive factors such as technological advancement, safety, and cost-effectiveness should be fully considered to identify the best option. In the case of production problems or accidents, it is not sufficient to merely explain the phenomena as they appear; rather, it is necessary to analyze the root causes of the problems. By using modern statistical methods (such as radar charts, moving range charts, pie charts, scatter plots, etc.), analytical techniques (such as the SAMM method, Gordon method, KJ method, PERT network analysis method, matrix methods, etc.), theoretical calculations, and by referring to standard specifications, a scientific approach should be adopted to conduct thorough investigations and find solutions. 5. Be good at critical thinking and brave in innovation. Possesses an innovative spirit and way of thinking, and does not follow others blindly out of blind faith in authority. Everyone has different focuses of knowledge and ways of thinking, and with the rapid advancement of technology, it is difficult for any individual or organization to have complete knowledge in everything; this thus creates room for individual innovation. Think critically about issues on a daily basis; ask oneself about everything: Is there a better solution? (As in the case of my modifications to imported safety valves.) By carefully thinking about any abnormal issues that arise, one can develop independent insights and express their opinions effectively. This not only helps in self-improvement, but also enables one to stand out and achieve success more quickly. 6. Unlimited communication and collaborative progress. Communication includes interactions between superiors and subordinates, colleagues, various related specialties, as well as external partners (**regulatory agencies and collaborating organizations**), with the aim of obtaining information and resources to establish one’s own collaboration platform. Only by being willing to endure hardships and dedicating oneself to mastery in the field of equipment technology can one reach a new level of freedom, become a respected expert in the industry, and achieve success. September 16, 2017, Lunan, Zhang Fengkui