If the operator notices a sharp rise in the pump bearing temperature on the DCS, can an emergency shutdown be initiated?
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This post was last edited by Zhongyuanren on 2015-6-21 at 14:48. Dear colleagues: Recently, operators at a petrochemical plant detected through DCS monitoring that the temperature of a pump’s bearing had soared (exceeding the upper limit value within 7 minutes). The on-site operator immediately informed the field workers and the personnel responsible for maintaining mechanical equipment to go to the site to check things out. Upon arriving at the site, the field workers saw smoke coming from the pump and promptly shut it down. It took about seven minutes from the time the order was given until the issue was resolved. The supervisor still complained that it was too slow, arguing that the pump should have been shut down right away when the temperature started rising, and as a result, the operators and managers were punished. Is such a handling approach appropriate? Is it meaningful for equipment safety work? How should the equipment managers and operators involved improve their work in the future? Please discuss this with other sea friends, thank you!
If a temperature spike is detected, the operator has the authority to shut down the equipment urgently and activate backup equipment. Unless it involves issues related to the safety of the fluid being transported.
It’s the first time I’ve encountered this situation; it’s normal to lack experience! The leader never specified how things should be done; any problems that arose were only analyzed in hindsight……
I think you did the right thing; the program should work this way.
Alarm at 85° bearing temperature; shutdown immediately at 95°. When it reaches 95°, it indicates that the device’s bearings are damaged.
Friend: There are two reasons for the spike in DCS: 1. There is a real problem with the equipment； 2. DCS connection loss is an instrument issue ； Address the issue: It’s a device problem; a reward can be given afterwards ； If it’s a gauge issue and no judgment is made, an emergency shutdown will be initiated, resulting in losses. If you are a responsible leader, should you reward or criticize and punish the operators?
Friend: Please stay on topic; I hope we discuss how to handle things and our approach, not chain values.
The circumstances under which operators can shut down the equipment directly should be clearly specified in the equipment’s safety operating procedures. There should also be guidelines outlining the procedures that operators must follow in case of abnormalities; as long as the operators act in accordance with these procedures, there is nothing wrong with that. As for the punishment imposed by leaders, it should be carried out in accordance with relevant regulatory provisions; penalties cannot be imposed based on personal feelings...
It’s reasonable; they should be punished. Raising the temperature by 7 degrees over a period of 7 minutes without going to the site to check immediately is a dereliction of duty. If any signs appear at the beginning, the shift leader or the person in charge of outdoor operations should be notified to go to the site to check, use a thermometer to measure the temperature on site, and promptly decide to shut down the pump!
Does the operator not know to switch to the backup pump and shut down the main pump? :L
I’m sorry, no backup pump is designed for that area. Secondly, even if there is a backup pump in place, external personnel’s confirmation is still required; the machine cannot be shut down without the confirmation of such external personnel and maintenance staff. Problem: Where should the maintenance staff start to repair the equipment? ； Field work fails to truly grasp the key issues ； Equipment managers are unable to manage the equipment.