The main body of the air compressor was operated under fault conditions without any preventive measures being identified or relevant monitoring and operational procedures being established.

I. Risk Manifestations

The air compressor’s main unit has been operating with a fault undetected, typically manifesting as inadequate routine inspections, failure to recognize abnormal signals, unaddressed alarms, or temporary masking of the fault. Without established monitoring and operational safeguards, the equipment may continue to run under abnormal conditions, increasing the risk of component damage, gas supply interruptions, and secondary safety hazards.

• Abnormalities such as unusual noises, vibrations, temperature rises, and pressure fluctuations were not detected in a timely manner.
• The status of lubrication, cooling, sealing, venting, and other systems lacks continuous monitoring.
• Fault handling is limited to verbal handovers, with no written records or assigned responsible parties.

II. Enhance Routine Inspections and Condition Monitoring

A checklist should be established to cover pre‑startup, in‑operation, and post‑shutdown inspections, with particular attention to operating noise, vibration, temperature, pressure, oil level, leaks, and alarm records. For critical air compressors, trend analysis can be performed by correlating instrument readings, operational curves, and historical fault data, thereby avoiding reliance solely on empirical judgment.

• Clearly define inspection frequency, inspection items, and record-keeping procedures.
• An “first‑encounter responsibility” system shall be implemented for abnormal signals; the person who discovers such a signal shall report it and follow up on its resolution.
• Incorporate historical faults, maintenance records, and operating parameters into the shift handover.

III. Clarifying Fault Diagnosis and Deactivation Boundaries

Executable criteria for identifying abnormalities shall be established in accordance with the equipment’s technical documentation, process requirements, and on-site safety conditions. For situations such as threats to the main unit’s safety, failure of cooling or lubrication systems, sustained escalation of pressure anomalies, or malfunction of protective devices, clear thresholds for immediate shutdown or derating shall be defined to prevent continued operation under fault conditions and mitigate further losses.

• Distinguish between observable operation, time-limited operation, load-reduction operation, and situations requiring mandatory shutdown.
• Zero tolerance will be enforced for cases of failure of safety protection devices.
• The decision to deactivate and the conditions for resuming operation shall be verified by authorized personnel.

IV. Formulate Measures for the Operation of Guardianship

For equipment that cannot be shut down immediately but is experiencing abnormalities, a written plan shall be developed.Supervisory Operation PlanThe plan shall include an anomaly description, risk level, operational restrictions, monitoring items, monitoring frequency, responsible personnel, emergency response procedures, and termination criteria. No abnormal equipment may be left unattended for an extended period without prior assessment and approval.

• Designate personnel to conduct scheduled inspections and record key operating parameters.
• Clearly define the anomaly escalation path, and immediately shut down for maintenance when predefined conditions are met.
• During operation under supervision, overloading, prolonged continuous operation, and unattended operation should be avoided.

V. Closed-Loop Repair and Recovery Confirmation

Upon detection of a fault, a closed-loop record shall be established, encompassing reporting, diagnosis, remediation, acceptance, and system re‑commissioning. Completion of maintenance does not necessarily eliminate all risks; prior to resuming operation, it must be confirmed that the root cause has been resolved, relevant components have been reset, protective devices are functioning properly, and operating parameters have returned to normal.

• Conduct root-cause analysis for recurring anomalies to prevent merely addressing surface-level symptoms.
• Operations such as component replacement, parameter adjustment, and protection reset shall be logged.
• After the equipment is restarted, schedule a period of focused monitoring; only after confirming stability should it be transitioned to routine inspections.

VI. Training and Accountability Implementation

Operators, maintenance personnel, and management staff should be familiar with the common symptoms of compressor malfunctions, the reporting procedures, and the emergency response requirements. Training should draw on real-world field cases, with a particular focus on enhancing awareness of abnormal noises, unusual odors, leaks, alarm signals, and parameter drift.

• Clearly define job responsibilities to prevent situations where no one follows up after issues are identified.
• Incorporate inspection quality, anomaly reporting, and response timeliness into daily management.
• Regularly conduct drills for abnormal scenarios to enhance collaborative response capabilities.