When determining the ratio of instrumentation and electrical personnel in a chemical plant, aside from quantitative factors, the following non-quantitative factors must also be considered:
1. Characteristics of the Production Process
1.1 Process Complexity:
If the production process in the chemical plant is highly complex, involving multiple chemical reaction steps, special equipment, and strict control requirements, the dependence on the instrumentation and electrical systems will be higher. For example, in the fine chemicals field, some products require precise control of parameters such as temperature, pressure, and flow. This necessitates high-performance instruments and reliable electrical systems for support. In such cases, more professionals may be needed to ensure the proper operation and timely maintenance of the instrumentation and electrical equipment.
On the other hand, if the production process is relatively simple, with more conventional equipment and less stringent control requirements, the number of personnel needed might be less. For instance, in some traditional chemical production processes, the equipment operates relatively stably, with lower requirements for the instrumentation and electrical systems, thus requiring simpler maintenance work.
1.2 Process Safety:
Some chemical production processes carry higher safety risks, such as high temperatures, high pressure, flammability, explosiveness, or toxicity. In these cases, the reliability and stability of the instrumentation and electrical systems are crucial, and sufficient professionals are needed to conduct strict monitoring and maintenance to ensure production safety. For example, in the petrochemical industry, the production process involves large amounts of flammable and explosive substances, and any failure of the instrumentation or electrical equipment could trigger serious safety incidents. Thus, enough professionals are required for routine inspections, troubleshooting, and emergency repairs to ensure production safety.
For production processes with relatively low safety risks, the personnel ratio can be more flexible. For example, in the production of some daily chemical products, the safety risks are relatively low, as are the requirements for the instrumentation and electrical systems, so the number of maintenance personnel can be appropriately reduced.
2. Equipment Condition and Maintenance Requirements
2.1 Equipment Age:
New equipment usually has higher reliability and stability, with a relatively low failure rate and less maintenance work. In such cases, the number of instrumentation and electrical personnel can be reduced. For instance, in a newly built chemical plant with advanced equipment and automation systems, the equipment tends to run stably during the early stages of operation, with fewer maintenance needs, allowing for personnel adjustments based on actual conditions.
Old equipment, on the other hand, may have more potential issues, a higher failure rate, and increased maintenance work. For chemical plants using older equipment, more instrumentation and electrical personnel may be required to ensure normal equipment operation. For example, in some chemical plants that have been in operation for many years, equipment aging is severe, leading to frequent failures, so enough professionals must be available for timely repairs and replacements to ensure continuous production.
2.2 Equipment Brand and Quality:
Different brands of equipment may vary in quality, reliability, and maintenance difficulty. Some well-known brands usually offer better quality and after-sales service, resulting in lower failure rates and easier maintenance. In such cases, the personnel allocation can be reduced. For example, in chemical plants that use internationally renowned brand equipment, the quality is reliable, and maintenance is relatively simple, so the personnel ratio can be adjusted accordingly.
In contrast, equipment from lesser-known or lower-quality brands may have more potential issues and require more maintenance personnel. For example, some smaller chemical plants may use equipment of questionable quality to save costs, which might encounter various problems during operation, thus requiring sufficient personnel for timely repairs.
2.3 Maintenance Strategy:
If a chemical plant adopts a preventive maintenance strategy, regularly inspecting, maintaining, and repairing equipment, the failure rate can be effectively reduced, and the workload for emergency repairs can be minimized. In such cases, the number of personnel can be reduced. For instance, some chemical plants have established comprehensive maintenance plans, regularly inspecting, calibrating, and maintaining instrumentation and electrical equipment to detect and address potential issues in time, thereby reducing equipment failure risks and decreasing the need for professional personnel.
If the plant adopts a reactive maintenance strategy, only repairing equipment after failures occur, more personnel may be needed to handle emergency repairs. For example, some chemical plants, due to financial or management reasons, may not have an effective preventive maintenance mechanism, resulting in equipment failures being addressed only after they happen, which requires sufficient personnel to be on standby for timely troubleshooting and restoring production.
3. Corporate Management and Culture
3.1 Management Model:
Different corporate management models also affect the personnel ratio. For instance, some chemical plants adopt a centralized management model, with instrumentation and electrical personnel managed under a single department. This approach optimizes resource allocation and improves work efficiency. Under such a management model, the personnel ratio can be determined based on the overall number and complexity of the equipment.
In contrast, some chemical plants may use a decentralized management model, distributing instrumentation and electrical personnel across various production workshops or departments. This model better meets the needs of the production site but may lead to personnel being spread out, increasing management complexity. In such cases, the personnel ratio should be determined based on the specific conditions of each workshop or department, while also considering collaboration and communication among personnel.
3.2 Training and Development Opportunities:
If the company emphasizes employee training and development, offering ample learning opportunities and career advancement for instrumentation and electrical personnel, it can attract and retain more professionals, boosting their work motivation and efficiency. In such cases, the personnel number can be reduced, as employees’ professional competence and abilities are enhanced, allowing them to better handle various challenges at work.
On the contrary, if the company does not prioritize employee training and development, the employees’ professional skills and work motivation may be impacted, necessitating an increase in personnel to compensate for skill gaps. For example, in some chemical plants, due to financial or management reasons, employees may not receive sufficient training, leaving them feeling underprepared when faced with complex maintenance tasks, thus requiring more personnel to ensure smooth operations.
3.3 Corporate Culture:
Corporate culture can also influence personnel ratios. If the company values teamwork and collaboration, encouraging employees to support and help one another, work efficiency can improve, reducing the need for a large workforce. For example, in some chemical plants, a strong corporate culture fosters mutual trust and respect among employees, allowing them to solve problems together, which can reduce personnel allocation to some extent.
However, if the company suffers from poor communication or collaboration issues, more personnel may be needed to ensure smooth operations. For instance, in some chemical plants, due to conflicts of interest between departments or poor management, employees may lack a spirit of cooperation, leading to low work efficiency, which requires more personnel to make up for the lack of teamwork.