Eight essential martial arts and mental techniques for advanced appearance skills
Safety is something that every chemical instrument operator must always bear in mind! In chemical production, various materials often undergo various forms of physical or chemical changes in a liquid or gas state, continuously in closed containers and equipment, under different conditions such as high temperature, high pressure, and deep freezing; In addition, many media also have toxic, flammable, explosive, corrosive, and irritating odor properties. In addition, the scale of chemical production facilities is becoming increasingly large, and the production methods are highly automated and continuous; The production equipment has changed from an open type to a closed type; The production equipment moves from indoors to outdoors; Production operations have changed from decentralized control to centralized control, and have also evolved from manual manual operation to instrument automatic operation, and further developed into computer control. Production lacks elasticity. The stability of the equipment is difficult to grasp. Production equipment is prone to leakage, which not only pollutes the environment but also easily leads to fire and explosion accidents. Any defects in the design, material selection, manufacturing, and maintenance of equipment, instruments, pipelines, valves, and other aspects used in production can pose risks to production. Therefore, as a chemical instrumentation person, safety must be given top priority!
To practice divine skills, one must first protect oneself
The first introductory skill for chemical instrument practitioners is to identify hazards.
As a chemical instrument operator, it is necessary to analyze the hazards, predict and evaluate the hazards and harmful factors before work, grasp the patterns and changes of hazards, take corresponding preventive measures, and eliminate the hazards and safety hazards in their early stages. The basis for identifying hazards is to master certain knowledge of chemical production, understand the chemical and physical properties of various chemical substances in production, and have a certain understanding of chemical production processes, as well as the structure, working principles, and operating characteristics of various chemical equipment.
The second entry skill for chemical instrument practitioners is to master certain emergency rescue knowledge.
Firstly, it is necessary to master the knowledge of cardiopulmonary resuscitation and first aid for personnel who have been electrocuted. Because chemical instrumentation personnel often deal with electricity, the environment at the chemical production plant site is often harsh, and electric shock accidents are prone to occur in high temperature, humidity, confined spaces, and other environments. Therefore, it is particularly necessary to master the knowledge of cardiopulmonary resuscitation and first aid for personnel who are electrocuted; Secondly, it is necessary to master some self rescue knowledge in contact with hazardous chemicals. Chemical instrument personnel are prone to encountering the leakage of hazardous chemicals on the site of chemical production equipment. They should master some self rescue knowledge when in contact with hazardous chemicals, which is convenient for self rescue in the first time to minimize injuries; The third requirement is to master certain firefighting knowledge, including the use of fire extinguishers. Chemical instrumentation personnel often enter flammable and explosive device areas for work. When encountering initial fires caused by static electricity, mechanical impact, electrical sparks, etc., timely extinguishing the fire is extremely important for protecting themselves and production equipment! For fires that cannot be extinguished by oneself, one should use their own fire safety knowledge to urgently evacuate to a safe area and notify relevant departments for disposal.
As a chemical instrumentation person, it is important to firmly remember that survival comes first! Without the “1” of life, the rest are all “0”, so when entering the industry, everyone must remember: if you want to practice divine skills, you must first protect yourself!
Practicing boxing without practicing skills will lead to a stalemate
As a chemical instrumentation expert, after mastering two introductory skills, we will return to our old profession of instrumentation. A good appearance person should have a solid theoretical foundation, strong ability to analyze and solve problems, and not only know the nature of problems but also the reasons behind them. Some instrument technicians rely solely on deception when encountering problems, rather than calmly analyzing and solving them, often resulting in larger problems and even instrument scrapping.
The first basic skill for cultivating chemical instrument workers is the “four understandings and four skills” of instrument workers – understanding principles, structures, applications, performance, calibration, operation, maintenance, and troubleshooting.
As a chemical instrumentation person, we will come into contact with various instruments in the chemical production process. Common instruments can be divided into the following categories: temperature, pressure, flow rate, material level, composition analysis, as well as speed, vibration, etc.
A qualified instrument person should make great efforts to understand the measurement principles and structures of various instruments, understand the various operating conditions of instruments, and use and maintain them more reasonably, so as to ensure their long-term safe operation and safeguard the chemical production process. Instrument workers carry out daily maintenance and troubleshooting of detection and process instruments during the production process, involving a wide range of knowledge. They not only need to be proficient in the working principles and structural characteristics of detection instruments, regulators, and actuators, but also need to have certain knowledge of process control (automation). In the phenomenon of faults, there are not only instrument faults, but also mixed process and equipment faults. To analyze and judge faults, instrument workers must have certain knowledge of chemical processes and chemical equipment. For industries such as chemical and petrochemical industries, flammability, explosiveness, and toxicity are the characteristics of the industry. When dealing with faults, instrument workers must not take these issues lightly.
As a chemical instrument technician, it is not enough to only achieve the “four understandings and four skills” of instrument workers. In addition to daily maintenance, there are many technical renovation projects in enterprise production, including professional instrument renovation projects and process technology renovation projects, which require instrument cooperation for implementation. These large and small projects require a series of work such as design (large projects can be commissioned), construction preparation, installation, and driving. Instrument construction and installation knowledge is equally important knowledge as daily maintenance.
A qualified instrument person should have knowledge of chemical engineering drawing, be able to read process flow diagrams with control points, and also have knowledge of instrument construction, such as instrument wiring, pressure pipes, protective sleeve installation, anti-corrosion, explosion-proof, insulation, etc. They should also have knowledge of instrument debugging, such as single unit testing, single circuit testing, alarm, interlocking testing, etc. To understand the process flow diagram with control points, it is necessary to master the composition rules of instrument tag numbers. In measurement and control systems, each instrument that forms a circuit has its own instrument tag number, which consists of a letter code and a circuit number. The first letter represents the measured variable, and the following letters represent the function of the instrument; The circuit number can be compiled according to the device or section (area), usually represented by three to five digits, as shown in the following example:
A good appearance person should not only have a solid theoretical foundation, but also rich practical experience, broad vision, and broad knowledge. A teacher who teaches instrument knowledge may not have the same ability to handle instrument faults as a junior instrument worker. So, a qualified instrument person should listen, watch, and practice more, as well as communicate more with peers and visit the instrument circle more to enrich their knowledge in various aspects.
The third basic skill for chemical instrument practitioners is to be good at summarizing experience and transforming it into one’s own knowledge.
As a chemical instrument technician, we will encounter various problems in practical work. The process of solving problems is the process of accumulating experience. At a certain stage, we need to sort out and summarize these experiences, extract and summarize them, and form our own unique knowledge system. For example, a company asked me to help them solve a difficult problem. Their heating device cannot automatically control temperature, and the on-site instruments (thermal resistance and pressure transformer) have been verified without any problems. The self inspection of the regulating valve is also normal. The DCS manufacturer came to inspect the relevant cards and did not find any problems. Manually adjusting the steam valve can control the temperature of the heater well, but once it is changed to automatic, it cannot be controlled. Not only is it lagging, but the fluctuation is also increasing, and ultimately normal production cannot be achieved. After going there, I retrieved the historical curve and found that not only the temperature of the heater was lagging, but also the steam pressure was lagging. So I went to the site to check the root valve of the pressure transformer and found that only two wires were open. After opening them all, I reset the PID parameters and everything was normal!