Why is the instrument difficult to dry?

Why do you think your appearance is hard to dry? I sorted out some reasons and convinced you in minutes!

1, work attitude leads to repeated homework!

The difference of salary level leads to the decrease of work enthusiasm, and long-term depression is easy to become a lazy habit. Therefore, in the work, the obvious performances are as follows: First, the work can make do; Secondly, the work is not serious. For example, if you ask him to repair a transmitter and he doesn't tighten the cover after repair, it seems like a trivial matter. In fact, most problems in the instrument are accumulated by these trivial things; Therefore, working attitude makes instrument work more and more difficult, and safety accidents occur frequently.

2, product updates are fast, and learning is endless!

Another reason why the instrument doesn't work well is that the instrument products are updated quickly. At present, the instruments produced by various enterprises are different, especially the imported and domestic instruments are very different. Instrument workers may need endless study to do a good job, unlike people in the production workshop, so it is difficult to do their own work.

The instrument is roughly divided into eight blocks: temperature, pressure, liquid level, flow, analytical instrument, actuator, control system, instrument auxiliary equipment and so on. If four kinds of instruments are used in each block, an instrument worker needs to master 32 kinds of instrument skills, including instrument working principle, installation and maintenance.

3, the instrument does not understand the process, the process does not understand the instrument!

Whether the instrument works well depends not only on itself, but also on the cooperation with technicians. If you know your skills, the work will be much easier to do. There is basically no communication work for a week, otherwise every day is endless small work. Long-term work experience tells me that the working relationship with technology is much more important than your maintenance skills.

If the instrument doesn't know the craft, and the craft doesn't know the instrument, it is easy to have disputes, that is, wrangling, the work is not smooth, and the work is even more difficult to carry out!

4, female musical instruments do the work of male musical instruments, and male musical instruments do the work of pigs!

As an instrument worker, you must understand: design, selection, procurement, storage, picking, installation, debugging, use, maintenance, verification, overhaul, scrapping, laws and regulations, rules and regulations, operating procedures, implementation standards, instrument files, maintenance plans, maintenance records, verification plans, verification records, accident plans, flow charts, location maps, technical specifications, and so on. Inspection report, certificate of conformity, quality certificate, tool list, inventory list, work contact list, start-up confirmation list, operation application form, special operation operation certificate and accident description. ...

Instrument work is not only complicated, but also trivial, and complicated work makes instrument work more difficult!

For example, a simple instrument workflow:

I. Patrol inspection process: Instrument workers generally have their own responsibility areas for instrument maintenance, and determine the patrol inspection route according to the distribution of instruments in the responsibility area, and patrol inspection at least once a day. The main contents of the inspection tour:

1. Ask the technicians on duty about the operation of the instrument.

2. Check whether the instrument instructions and records are normal, whether the instructions of the primary instrument (transmitter) on site are consistent with those of the control room display instrument and dcs operation station, and whether the output of the regulating circuit is consistent with the valve position of the regulating valve.

3. Check whether the output of 24v power supply is normal (when the output voltage indicator light is dimmed, it is often abnormal) and whether the gas supply pressure reaches the required range (0. 14MP, 0.35MP, etc.). ). Whether the power supply voltage and torque of the electric regulating valve are normal.

4. Check the insulation and heat tracing status of the instrument (mainly in winter), and measure the temperature by hand.

5. Check the damage and corrosion of the instrument body and connector, including whether the hose connection is loose or damaged.

6. Learn about the operation of the instrument from the technical personnel on duty.

7. When the outdoor instrument environment is poor, protective measures such as plastic bags should be added in time, and the protection status should be checked to ensure that there is no damage or loss.

8, check the alarm interlock device, to ensure that the device is in good condition. Test the alarm interlock function regularly and make test records.

9, check the instrument in good condition. The intact instruments can be checked with reference to the Equipment Maintenance and Repair Regulations issued by the Ministry of Chemical Industry.

(1) The parts are complete and meet the technical requirements:

A, parts should be in good condition, complete and standard;

B, complete fasteners shall not be loose;

C, the connector should be in good contact;

D, terminal wiring should be strong;

E, adjustable parts should be in an adjustable position;

F, seal should be no leakage.

(2) It runs normally and meets the use requirements;

A, when running, the instrument should reach the specified performance index; The display and output should be normal, and the error should not be greater than the allowable error of the instrument.

B, under normal working conditions, the instrument said value should be between 20% and 80% of the full scale;

(3) The equipment and environment should be clean and tidy, and meet the work requirements;

A, the whole machine should be clean:

B, instrument pipes and lines shall be laid neatly, and shall be fixed for installation;

C, check whether the emergency cut-off valve power supply, battery, handle, fuel tank oil level and controller parameters are in normal state.

2. Regular blowdown and refueling process: With the rapid improvement of automation level, the number of pneumatic actuators has increased dramatically, and the air source treatment equipment should be regularly blowdown and refueled for daily maintenance.

Common components of air source treatment equipment:

1, filtering, filtering out solid impurities and partial moisture in the air source to provide clean compressed air.

(1) Manual drainage must be conducted before the water level reaches the water level below the filter element;

(2) Clean the filter element (soaking, scrubbing and backwashing) or replace the filter element. There are too many impurities to breathe.

2. The pressure reducer is used to reduce and stabilize the pressure of compressed air provided by the air source. When adjusting the pressure, it should be gradually and evenly adjusted to the required pressure value, and it cannot be achieved in one step. No trouble, no maintenance.

3. Oil mist device, which adds oil mist to the gas of gas equipment to lubricate the equipment. Come on, adjust the dripping speed. There is something at the top that can be twisted to adjust the dripping speed. The fuel quantity should not exceed eight full cups.

4. Maintenance at ordinary times: If the air source treatment equipment leaks, it is abnormal. Try sealing or replacing.

Third, regular lubrication and anti-corrosion technology: regular lubrication and anti-corrosion is also a part of the daily maintenance of instrument workers, but it is often overlooked in specific work. Lubrication period should be determined according to the specific situation. Instruments and components requiring regular lubrication and corrosion protection are as follows:

1, pneumatic cam deflection valve, pneumatic ball valve, pneumatic butterfly valve, rotating parts of electric actuator;

2. Fastening bolts for door shafts and junction boxes of protective boxes and incubators.

3. Fix the bolts and nuts of transmitter, regulating valve, valve positioner and electric converter in harsh environment to prevent the threads from rusting and being difficult to disassemble.

4. The rotating part of the feedback lever of the valve positioner in harsh environment.

5. Thermal resistance in harsh environment, bolt at thermocouple junction box or threaded part of upper cover.

6. Connection between hose and instrument in harsh environment.

Four. Anti-freezing inspection process: checking the anti-freezing measures of instruments is one of the daily maintenance contents of instruments, which is related to saving energy, preventing instruments from freezing and ensuring the normal operation of instrument measurement system, and is an item that cannot be ignored in instrument maintenance.

This work is seasonal, mainly to check whether the medium in the pressure guide tube of the liquid level transmitter of the gas holder is abnormal and whether the heat insulation material falls off. Individual instruments need heat preservation and heat tracing, check the heat tracing situation, and start and stop heat tracing in time according to the weather conditions to prevent icing and ensure the normal operation of instruments.

5. Fault handling process: Fault handling is an important part of instrument daily maintenance. Trouble shooting should be quick and effective, serious, leaving no hidden dangers, and problems that cannot be handled should be reported in time and handled in a coordinated manner. Troubleshooting requires the active learning and experience accumulation of instrument personnel, and provides the precautions (attachments) for daily maintenance reference. When dealing with faults and instrument maintenance, instrument personnel must put safety first, and personal safety and normal operation of production cannot occur. We must establish the idea of safety first and be familiar with the technological process before maintenance. The instrument and equipment can only be removed after contacting and being supervised by technicians. Avoid safety accidents. Basic analysis and treatment steps of field instrument system faults. The measurement parameters of field instruments are generally divided into four parameters: temperature, pressure, flow and liquid level. Now, according to the different measurement parameters, the faults of different field instruments are analyzed.

1. First of all, before analyzing on-site instrument failures, we should deeply understand the production process, production process and conditions of relevant instrument systems, and understand the design scheme, design intent, structure, characteristics, performance and parameter requirements of instrument systems.

2. Before analyzing and checking the on-site instrument system failure, it is necessary to know the changes of production load and raw material parameters from the on-site operators, check the record curve of the failed instrument, and comprehensively analyze and determine the cause of the instrument failure.

3. If the recording curve of the instrument is a dead line (the line without any change is called a dead line), or the recording curve was originally fluctuating, and now it suddenly becomes a straight line; The fault is likely to be in the instrument system. Because most recording instruments are DCS computer systems at present, the sensitivity is very high, and the change of parameters can be reflected very sensitively. At this time, you can change the process parameters artificially and see the curve change. If there is no change, it can basically be concluded that there is something wrong with the instrument system; If there are normal changes, it can basically be concluded that there is no major problem with the instrument system.

4. When changing the process parameters, it is found that the recording curve has a sudden change or jumps to the maximum or minimum value, and the fault at this time is often found in the instrument system.

5. Before the fault occurs, the recording curve of the instrument always behaves normally. After fluctuation, the recording curve becomes irregular or makes the system difficult to control, even manual operation. At this point, the fault may be caused by the process operating system.

6. When the DCS display instrument is abnormal, you can go to the site to check the indicated value of the same intuitive instrument. If there is a big difference, it is likely that the instrument system is out of order. In a word, when analyzing the causes of field instrument failure, we should pay special attention to the characteristics changes of the controlled object and the control valve, which may be the causes of field instrument system failure. Therefore, it is necessary to comprehensively consider and carefully analyze the field instrument system and process operating system to check the reasons.

Instrumental parking process: Instrumental parking is relatively simple, and the precautions are as follows:

1, working closely with technicians;

2, understand the process shutdown and chemical equipment maintenance plan;

3. According to the maintenance arrangement, dismantle the instruments or testing elements on the equipment to prevent the instruments from being damaged during equipment maintenance, and cut off the power supply and gas source before dismantling the instruments;

4. Dismantle the instrument in time according to the maintenance plan. When removing the flange transmitter, make sure that the material in the storage tank is empty.

5. Dismantle the thermal resistance, transmitter and other instruments, and wrap the signal cable with insulating tape and place it properly.

6. When removing the pressure gauge and pressure transmitter, pay attention to that the pressure inlet may be blocked, resulting in local pressure retention; If the material rushes out and causes personal injury, the correct operation is to loosen the mounting bolt, exhaust and discharge the residual liquid, and then unload the instrument after the gas and liquid are discharged;

7. For the electric valve positioner, remove it after turning off the air source;

8, remove the annular chamber orifice, pay attention to the orifice direction, to prevent reverse;

9, remove the instrument should be clearly marked, when installation, accordingly, to prevent similar instrument installation confusion caused by different range, resulting in instrument failure;

10, the instrument with interlocking control was manually unlocked with the consent of the technicians, and then the instrument was disassembled for maintenance.

Seven, instrument driving process:

1, instrument startup should be closely coordinated with the process. Install instruments in time according to the pressure test and leakage test of process equipment and pipelines, and the process start-up progress is not affected by instruments;

2, the installation of instruments must pay attention to the tag number, accordingly.

3. Instrument power supply. Turn on the corresponding power switch, and check whether the 24v power supply voltage is normal, and whether each dcs power supply module and UPS power supply are normal.

4. Air source emission. Water and impurities will appear in the air supply pipeline after running for a period of time, and there are more impurities and moisture due to the influence of start-up and shutdown. It must be removed before driving. Based on the principle of trunk to branch, remove the dirt one by one to prevent the gas source from blocking the orifice plate and causing instrument failure.

5, orifice plate and other throttling device installation should pay attention to the direction, to prevent the reverse. Ensure that the front and rear straight pipe sections are smooth and clean, and handle any dirt in time. The annular cavity should be in the center of the pipeline, and the pressure taking valve should be opened in time after installing the throttle device to prevent the pressure signal from being lost when driving. It is recommended that the handwheel be fully opened before returning to half a turn to open the pressure valve.

6. When installing the regulating valve, pay attention to that the arrow direction of the valve body is consistent with the flow direction.

7. When measuring the liquid level of full-scale negative migration, pay attention to filling the negative pressure connecting pipe with liquid.

8. When the differential pressure transmitter and the pressure transmitter are protected by isolation liquid, attention should be paid to filling the isolation tank with isolation liquid when restarting.

9, thermocouple compensation line wiring pay attention to the positive and negative polarity, to prevent the reverse. Thermal resistance should pay attention to the three wires can not be confused.

10. After maintenance, the instrument should be adjusted in linkage before starting, and the instructions of the instrument (transmitter, detection element, etc.) should be given once. ) and secondary instruments in the control room (disk installation, rack installation, computer display, etc. ), or the output value of the primary instrument is consistent with the input value of the rack-mounted instrument (distributor and dcs input card) in the control room; Check whether the regulator, dcs output, communicator output and valve position indication of regulating valve are consistent (or whether the input of electric valve positioner is consistent). The up-and-down stroke of electric valve switch should be consistent.

1 1. For the instrument with interlock, switch to the automatic interlock position after the instrument runs normally and the process operation is normal.

5, things are broken, changed, and the value is low!

After staying in the instrument circle for a long time, I gradually found a problem. The instruments in many factories are basically replaced! Not to mention the state-owned enterprises, they will be replaced if they are broken, and they will find manufacturers if they can't solve the problems, which will reduce the importance of the instrument department.

On-site work, because it is still a big pot system, you are busy with on-site instrument maintenance all day, and it may not be good to clean up the site properly. The salary is the same, so is the bonus. Nobody is stupid. It hurts to be busy all day, and it hurts my self-esteem. Playing in the office all day and laughing at you. You work and live. . . . In this atmosphere, it is difficult for you to solve the problem on your own initiative. Besides, the quality of the musical instrument you repaired is definitely not as long as the time it takes you to find a new one. But if you insist on repairing and reusing, others will say that your ability to repair quality and skills is not good. Look how long it has just been repaired, and there is another problem.

Therefore, the instrument departments of many factories are regarded as auxiliary departments and have never been taken seriously. Work is tired and dirty, toxic and harmful, and I dare not compliment it.

This is also a common problem at present. No value, no attention! Make the work harder and harder!

6, face project!

Most oil refining and chemical enterprises still use the original state-owned enterprise setup. Although the rules and regulations are perfect, most of them are face-saving projects, and they are busy making fakes all day, such as calibration records, maintenance records, inspection records, meeting records, safety records, training records, monthly manuscripts, monthly rationalization suggestions, monthly on-site maintenance, and monthly excellent team creation. And most of them are wasting their time making fakes there, not because there is no job at the scene. It's not that you fool around all day, but that your work can't be written in the above rules and regulations. Because what you wrote does not conform to the regulations, everyone is busy all day creating excellent teams and groups, excellent advanced workers and establishing perfect rules and regulations.

Face project makes our work more and more difficult! We didn't stop working, but did something we didn't want to do!

7, blame professional households!

To be an instrument, you must have a knowledgeable leader to make the following employees get twice the result with half the effort. If something goes wrong, you can also communicate with the leaders above, otherwise you will be accused. The field design of many important valves is by-pass. Interlocking adopts 2 out of 3, and the logic configuration needs to be delayed. Some essential technical means are adopted to solve the problem. It is difficult to avoid problems in daily inspection.

For example:

I am an instrument worker in fluorine chemical industry. Once again, the responsibility of the operator's "ignorance" suddenly ran to the instrument man's office. If the leader is willing to face the problem correctly, he can also explain it. If he meets a leader who doesn't understand, he will say, "Why don't you solve the problem for so many reasons?" This is no small blame.

Taking the blame for a long time has made our work more and more cautious and difficult!

8. The brain drain is great!

An instrument manager lamented: the difficulty of chemical instrument maintenance is that the income is lower than the production process, so it is not easy to lead the team; Brain drain is great, and one after another is sent away.

Like many jobs, the loss of instrument personnel is particularly large. In addition to geographical restrictions and family restrictions, instrument personnel often jump a lot because of salary and project problems. As the saying goes, there is no "future", at least there is a "way of money". Job-hopping can raise salary, and leadership job-hopping can raise salary! Secondly, the work of instrument personnel also needs to be run-in. Instrument work depends on technology and cooperation.

Long-term personnel flow is large, and it is difficult to carry out instrument work and implement it.

9, training is not in place!

Instrument training, the most training at present should be safety, but the technology is not in place, it is difficult to achieve safety!

Training employees is the responsibility and obligation of enterprises, especially chemical enterprises dealing in toxic and dangerous chemical raw materials. For the safety of enterprises and operation, it is necessary to strengthen the training of instrument staff. However, looking at the present situation of instrument staff training in Chinese enterprises, we can find that many enterprises are not active or even perfunctory in training instrument staff, and they do not realize the importance of instrument staff training.

Ask a few realistic questions:

Does your organization have systematic instrument training materials?

How often do you update the training materials?

10, the future of the instrument is bleak!

An instrument partner said: after working as an instrument worker for a while, I gradually feel that instrument maintenance has no future; At present, chemical process control is realized by DCS, which increases the maintenance of instrument workers. Because it is too closely related to the process, once there is a process operation problem, the operator's first push is the instrument failure. At this time, the instrument is busy checking whether there is any problem with the instrument, and then explaining it to the leader who knows something about the instrument, so it is easy to explain, otherwise the instrument will be responsible again; In addition, now all kinds of instruments are changing with each passing day, and instrument workers have to spend a lot of energy to learn and study new knowledge, with a heavy ideological burden, while operators basically rely on instruments to operate. The operation of this position has just begun to be familiar with, and there is basically no need to spend energy on learning in the future. The ideological burden is much lighter than that of the instrument worker, but the wages of the instrument worker and the operator are similar, which is extremely unfair to the so-called technical work of the instrument worker and consumes more energy than the operator. The consistent returns have dampened the enthusiasm of instrument workers. When they suffer hardships, others can't see them. What a thankless job. Recently, some people who have just come in are unwilling to be instrument workers. In addition, the first consideration for a unit to be promoted is technology, now equipment, and then electricity. Instruments are difficult to consider. It is generally believed that instruments are auxiliary work, which makes instrument workers very confused, have no future at all, and have no pride in doing it.

The instrument work is so difficult, why do we have to do it?

Some people say: I am an instrument worker, and I like the profession of musical instruments. I can only say: doing what I like is a kind of happiness!

Some people say: I have been working for 25 years and have been doing instrument maintenance for 20 years. I am proud that I can do this job. Because in the company, I was praised by my colleagues and leaders ~ ~ ~ because I am willing to learn! ! ! From a high school student to the present company, all kinds of instruments and automatic control equipment can be at your fingertips. This is the result of my own efforts. So ~ ~ friends ~ ~ efforts must be rewarded! ! ! No matter what job it is, it's the same! ! ! ! ! ! ! !

Some people say: it's different from another angle. Think of your present job as learning and accumulate wealth for yourself. Being an instrument worker needs a lot of knowledge support, such as process knowledge, electrical knowledge, equipment knowledge and mechanical knowledge. The instrument man on the fourth floor said it was hard to find a job, which was nonsense. That's because you are so good at it. For example, many DCS are now used to control between electrical appliances. You can't do well without knowing the routine control and contact of electrical appliances. The logic control in DCS comes from electrical appliances. If you don't know electrical appliances, you don't know what to do If you don't understand the problems of process equipment, you can't even analyze and explain to the leaders, or even find the reasons. Then you can earn immediate money by doing other majors, and earn future money by doing instruments and your long-term development.

Some people say that it is necessary to be flexible to engage in instrumental brain, and the premise of flexible brain is that the basic skills are solid and must be combined with theory. Every job can't cover everything. After working for several years, what needs to be improved is the ability to draw inferences from others. Everyone says that work experience is very important, but I personally value the ability to draw inferences from others, that is, understanding. I think it takes three years for an easy-to-understand field instrument. Instruments and meters belong to technical services and are in a secondary position. Now there is an accident sequence record (SOE), and you need to know the process knowledge. I think the strange process is not easy! Skills in life are equally important. If you can't be a man, at least there is no problem with food and clothing. The salary is not bad Several of my colleagues have been working for three years, and they are all on 10W. The key is to establish firm confidence in yourself.

Some people say: I think the future is still good? Another key depends on myself. Just graduated as a power plant instrument worker? However, what we did at that time was microcomputer protection and instrumentation. After two years of maintenance, we changed jobs and designed. Now I do electrical and instrument automatic control design at the same time? I've been doing it for five years. Do you feel okay? The experience accumulated in early maintenance is very important.

Some people say: I am a musical instrument. Some people say that the appearance of state-owned enterprises is not valued. I don't think so. A radish is a pit, and every post has the function of every post. Some people say that the future is not good, depending on their own level and opportunities. Since I worked in 2002, 90% of my colleagues in the instrument team have occupied an important position, and later merged with electric power to form electric power instruments, which is half of the country. We must catch them, dear brothers!