Preliminary Diagnosis and Emergency Handling Measures for Common System Faults

Preliminary Diagnosis and Emergency Handling Measures for Common System Faults

Any system may encounter sudden faults during operation. Mastering basic diagnosis methods and emergency handling principles can help you quickly stabilize the situation, prevent further losses, and create conditions for professional maintenance.

I. General Emergency Handling Principles

Before starting to troubleshoot any specific fault, the following safety principles must be followed:

Safety First, Immediate Shutdown: Upon detecting abnormal sounds, smoke, burning smells, leaks, or equipment malfunction, the first action is to immediately press the emergency stop button or disconnect the main power supply to stop the system.

Set Warnings to Prevent Accidental Actions: Set up clear "Do Not Operate" warning signs on the faulty equipment or area.

Initial Isolation: If possible, isolate the faulty part from other normal parts of the system (e.g., close relevant valves and switches).

II. Preliminary Diagnosis and Response to Common Faults

The following provides basic diagnosis methods for common system types:

1. Power System Failure (Equipment cannot start or suddenly stops)

Diagnosis: Pressing the start button has no effect, or the system suddenly stops operating.

Emergency Troubleshooting:

1. Power Supply Check: Check if the main switch and air switch have tripped, and ensure the power supply line is normal.

2. Protection Check: Check if the motor thermal protection has tripped due to overload; try resetting it after it cools down.

3. Fuel/Lubrication Check: For diesel engines, check if the fuel is depleted and if the engine oil is insufficient.

2. Abnormal Operation (Abnormal Noise, Vibration, Overheating)

Diagnosis: The equipment emits a harsh friction or impact sound, or vibrates violently, and the local temperature is abnormally hot to the touch.

Emergency Handling:

Stop the machine immediately.

Check Fasteners: Focus on checking whether the anchor bolts, couplings, pulleys, fan blades, and other high-speed rotating parts are loose or broken.

Check Lubrication: Suspect that bearings or other parts are overheating due to lack of lubrication.

Do not force the machine to start, as this may cause further damage.

3. Performance Degradation (Insufficient Output, Low Efficiency)

Diagnosis: The equipment is running but at a slow speed and with weak power (e.g., a drilling rig not advancing, a brick-making machine with insufficient pressure).

Preliminary Investigation:

Transmission Check: Inspect belts and chains for looseness or slippage.

Media Check: Check for insufficient or severely contaminated hydraulic oil; check for clogged air intake filters in the blower/air compressor.

Load Check: Check if the load exceeds the equipment's normal capacity due to excessively hard raw materials or excessive load.

4. Leakage Faults (Oil, Water, Gas Leaks)

Assessment: Continuous leakage of liquid or gas is found on the ground or equipment surface.

Emergency Handling:

Identify the Leak Point: Locate the source as much as possible (e.g., oil pipe joints, seals, water tank cracks).

Control the Leak: If possible, close relevant pipeline valves.

Prevent Contamination and Slippage: Catch the leaked material with containers; lay absorbent pads on the ground or set up anti-slip warning signs.

No Open Flames: For fuel or lubricating oil leaks, all nearby sources of ignition must be eliminated.

5. Control System Malfunction (Unresponsive Operation, Abnormal Display)

Assessment: Operation buttons and touchscreen are unresponsive; the controller displays garbled characters or a black screen.

Emergency Handling:

Attempt Restart: Turn off the power to the control system, wait one minute, then turn it back on and observe if the problem is resolved.

Check Wiring: Quickly check if the main control line connectors are loose or disconnected.

If the problem persists, proceed with a shutdown procedure to avoid unauthorized operation.

III. Recording and Reporting

After taking emergency measures, the following should be done:

Record Information: Record the time of the fault, the symptoms, and the measures taken as detailed as possible.

Preserve Status: Unless it is an emergency, preserve the fault scene as much as possible to facilitate diagnosis by professionals.

Report Promptly: Report the fault situation, recorded information, and preliminary judgment to the equipment administrator or professional maintenance personnel promptly and accurately.

Summary: Stay Calm and Orderly, Uphold Safety First

When handling faults, remaining calm is more important than technical skills. Remember the process of "stop first, then assess, then handle." Your core task is not to immediately repair complex faults, but to safely stop the system and prevent the fault from escalating. A clear description of the fault symptoms and a record of the process are the most effective support for subsequent professional maintenance work.