DCS operation training organized for the renovation project of the fixed-bed gas generation unit for synthetic ammonia production in Guizhou Hongsheng

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Organization of DCS operation training for the renovation project of the fixed-bed gas generation unit for synthetic ammonia production in Guizhou Hongsheng – Author/Source: Zhongke Synthetic Gasification Co., Ltd. Date: 2020-02-01 Clicks: 593 As the construction progresses, the renovation project of the fixed-bed gas generation unit for synthetic ammonia production in Guizhou Hongsheng, carried out by Zhongke Hefei Gasification Technology Co., Ltd. (hereinafter referred to as “Zhonghe Gasification”), has entered the intensive phase of DCS system debugging. In accordance with the work plan, on the afternoon of December 26, the Guizhou Hongsheng project team took the lead in organizing training on the operation and maintenance of the DCS system. A teaching team composed of engineers from Zhonghe Gasification & Instrumentation and instrument engineers from the DCS system manufacturer conducted the training for more than ten personnel, including operators and maintenance workers from the client side, with the Zhonghe Gasification Commissioning & After-sales Service Center assisting in carrying out related tasks. To help the owner become familiar with the on-site equipment and processes as soon as possible and master the relevant operating systems, the project team arranged for the owner’s operators to be involved in the entire debugging process right from the preparation stage. Prior to this training, the relevant staff from the owner’s side already had a basic understanding of the process flow of the entire circulating fluidized bed system as well as the locations of the equipment on site. The engineer from Zhonghe Gasification & Power Equipment provided a systematic overview of all the aspects of the operating system. Drawing on his own practical experience, he explained the important parameters and adjustment methods for each aspect, offering a clear and straightforward analysis of the operation process, from principles to structure to control. The instrument engineers from the manufacturer provided an in-depth explanation of the relevant theoretical knowledge. By taking into account the current status of the operating units, they explained in detail the typical problems that arise in the operation and maintenance of systems such as thermal control and safety protection, as well as the optimization strategies for addressing these issues, thereby achieving a \"seamless integration\" between theoretical training and practical operations. During the Q&A session, the instructor carefully answered each of the questions raised by the attendees, creating a lively learning atmosphere on site. After the interaction, the participants reinforced what they had learned through a practical assessment and all received a passing grade. Through this training, the participants have mastered the routine operations of control systems, developed a thorough and concrete understanding of DCS control systems, and are now ready to hand over the commissioning work to the owners. At present, the DCS commissioning work for the Hongsheng project has been completed, and the rectification of issues in various specialties is essentially finished; the conditions for high-temperature furnace heating and system startup are now met. In line with the owner’s overall schedule, it is expected to come online within this year, contributing to the company’s performance in 2019. Project Profile: Guizhou Hongsheng Chemical Co., Ltd. is located in Daxiqiao Town, Xixiu District, Anshun City, Guizhou Province. It is a traditional coal chemical enterprise that previously used intermittent fixed-bed gasifiers to produce raw material gas, resulting in high energy consumption, significant pollution, and low efficiency. In accordance with the owner’s requirements and the actual conditions on site, the designers used local anthracite as raw material and adopted advanced circulating fluidized bed gasification technology to upgrade the gas production unit. The system consists of 2 gasifiers, each with a capacity of 60,000 Nm3/h; once completed, it will significantly increase the level of automation in the gasification process, help reduce energy consumption and emissions, and meet the needs of current ammonia synthesis production.