Baling Petrochemical completed the major maintenance of its gasification unit and related facilities ahead of schedule

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Baling Petrochemical Completed Major Overhaul of Gasification Unit and Associated Facilities Ahead of Schedule Author/Source: Gasification World Date: 2021-12-16 Clicks: 6 On December 9, the gasification unit in Baling Petrochemical’s coal chemical division was successfully brought online after the overhaul; qualified synthetic ammonia was produced at 22:35 that day. Subsequently, the unit’s effective gas processing capacity increased steadily, reaching 92% of its maximum capacity by the following day. Thus, the company’s originally planned 35-day major maintenance campaign for the gasification unit and related facilities was completed 4.5 days ahead of schedule, achieving the goals of \"zero injuries, zero pollution, zero accidents\" as well as a successful restart of operations right after the maintenance was finished. On November 8, the company’s gasification unit and associated facilities were shut down as scheduled for major maintenance. There are a total of 2,062 maintenance tasks in this project, with over 20 contractors involved. All units must strictly control the admission of contractors and supervise the on-site direct operation processes, while strengthening oversight by third parties as well as inspections by the safety and environmental protection inspection teams ； Strictly adhere to the requirement of “80% preparation and 20% implementation”; make thorough preparations in advance for all aspects of maintenance and construction work. Vigorously oversee the quality management of contractors’ construction efforts, strengthen the review and approval process for maintenance plans, and conduct inspections and acceptance checks at quality control points in accordance with hierarchical management requirements ； Key equipment (critical heat and cold exchange equipment) is tightened using flange fixed torque ； The third-party maintenance quality consulting service personnel hired by the company conduct daily inspections of construction quality. The Equipment Department randomly checks the records related to the maintenance quality process, publicly exposes typical quality issues, and enforces strict evaluations. Led by the Company’s Equipment Management Department, all units are implementing their local responsibilities to ensure proper control over the safety, quality, and progress of key maintenance projects. Priority will be given to carrying out maintenance on 25 key projects, including the maintenance of gasification furnaces, the replacement of elbows in the crude syngas pipelines, the maintenance of syngas compressors and ammonia refrigerators, as well as the rectification of hazards associated with high-risk pumps. Corrosion prevention measures were taken concurrently; a corrosion survey was conducted on the units undergoing overhauls, and it was found that certain sections of the pipelines carrying crude gas, shift gas, and synthesis gas were severely corroded. These sections were replaced taking advantage of this overhaul opportunity, thereby eliminating significant safety hazards.