Huajin Group’s Jintianhua ammonia synthesis plant achieved 500 days of continuous operation at Class A level

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Jintianhua’s ammonia synthesis plant of Huajin Group achieved 500 days of continuous operation at Class A status – Author/Source: China North Industries Group Huajin; Date: 2022-01-25; Clicks: 9. On January 20, Jintianhua’s ammonia synthesis plant in Huajin Group managed to operate continuously at Class A status for 500 days across different calendar years, breaking the previous records of 300 days set in 2014 and 2018. This represents the longest operating period for such a plant since the company began operations 30 years ago, indicating that Jintianhua’s production and operation management has reached a higher level. Since the plant was restarted following its major overhaul in September 2020, Jintianhua has made strenuous efforts to coordinate with external parties in order to promptly resolve major issues affecting the plant’s operation, such as natural gas shortages and power restrictions imposed by the electricity grid ； In light of the serious problems associated with the aging of Neike equipment and the various difficulties faced by production facilities throughout the seasons, we adhere to the goals of high efficiency, low consumption, and stable operation, and make every effort to improve all aspects of management. The staff in the control room operate with care, paying close attention to equipment management. Earnestly implement the safety responsibility system for individual units of equipment as well as predictive equipment management to enhance the intrinsic safety of the equipment ； Taking equipment management improvements as an opportunity, actively engage third parties to conduct safety diagnostics on the issues existing in the installations ； Specialized teams are established to strengthen the assessment of critical equipment and key components; special attention is given to potential hazards such as cracks in gas turbine rotors, with real-time monitoring in place to ensure that such hazards remain under control ； Increase the renewal and technical upgrading of electrical and instrumentation equipment to reduce the failure rate of such equipment ； It has successively completed safety upgrades to the compressor unit control system and enhancements to the gas turbine control system, addressing the bottleneck issues that affected the long-term stable operation of the facility and enabling optimal performance of the same. They carry out technical upgrades to equipment to improve its efficiency, and they strengthen on-site management. On the basis of thorough implementation of the “five key systems” in chemical production, emphasis is placed on on-site management, with a combination of self-inspection and professional inspections. Incentive mechanisms such as “reward for each issue resolved” are used to encourage employees to identify potential hazards and apply the principle of learning from one instance to address similar problems. As a result, more than 1,300 serious hazard issues were detected, including abnormalities in the AC102 control valves, the 100CGT1 turbine, and leaks in the lubrication pipelines of the synthetic air compressors; all of these issues were addressed, thereby preventing multiple shutdown incidents. They strengthen on-site inspections to address potential equipment issues promptly, and implement strict process management as well as employee training. Strictly manage deviations from process specifications, promptly assess the main risks and potential hazards associated with plant operation, and formulate corrective actions and prevention plans ； Increase efforts in employee training, focus on cultivating operators with multiple skills for different tasks, and develop emergency response plans in a timely manner to address extreme weather conditions and any abnormalities that occur during plant operation. Strengthen training on these plans as well as emergency drills, thereby improving the operators’ ability to handle emergencies and ensuring the stable and continuous operation of the plants.