Kaiyue Coal Chemical leverages collective intelligence to tap potential and resolve faults in online gas composition analyzers
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Kaiyue Coal Chemicals Pooles Ideas to Tap Potential and Resolve Issues with Online Gas Composition Analyzers Author/Source: Kaiyue Coal Chemicals Date: 2022-05-20 Clicks: 11 In chemical manufacturing enterprises, the use of online analyzers enables timely feedback on process control, improves production conversion rates, facilitates optimization of automatic control during production, helps achieve high quality and high yields, reduces costs and increases efficiency, thereby enhancing economic benefits and ensuring safe production. It is reported that Kaiyue Coal Chemical Company currently has four analysis booths and 20 online analysis instruments. Due to the long-term operation of the online analyzer and the high impurity content in the process sample gas, the chromatograph used for online analysis of the gas composition at the outlet pipeline of the scrubber in Vaporization Furnace B frequently experiences malfunctions. After thorough inspections by the technicians and maintenance staff in the electrical and instrumentation workshop, it was finally determined that there was a fault in the chromatography system software. When contacted, the after-sales engineers all said that due to technical reasons, a technician needed to be on site to handle it. After careful consideration, the workshop decided to have the personnel from the instrumentation team first switch the sample gas from Furnace B to online monitoring using the chromatograph AT-13004, and then mobilize everyone to brainstorm solutions. Through discussions and exchanges with related organizations, as well as by contacting installation manufacturers and Siemens technical trainers for advice, the solution proposed was to restore the AMD files on the system. Several colleagues in the instrumentation team worked overtime voluntarily, reviewed various documents, and finally located the original AMD files for the equipment. With the online video guidance of the manufacturer’s technical staff, the workshop crew used chromatography installation software to import the new files into the chromatograph, and re-calibrated the AT-13003 chromatograph multiple times. After introducing the sample gas, the methane measurement values were within the acceptable range.
Chromatography failures occurred frequently – systematic troubleshooting revealed that the software of the chromatography system was at fault – a support engineer was contacted (but could not arrive on site) – collective brainstorming – the solution was to restore the AMD files originally installed – extra hours were spent searching for those AMD files – technical support from the manufacturer provided online video guidance – and the problem was resolved. Do you know what I’m thinking of? Internet cafe 20 years ago: Player: Boss, the computer has a blue screen. Boss: Restart it! Player: It still doesn’t work! Boss: Well, this is a pretty serious issue; we need to reinstall the system. Network administrator: Wow, this is tricky. We definitely need a system drive. Boss: Do it. Network administrator: I also need to contact the computer store by phone; they’ll guide me on how to install it. Boss: Do it. Player: Wow! In such a high-tech environment, isn’t the archive room used to store files without any random attachments? The operator hasn’t even read the basic instrument manual? Let’s also pool our ideas… 20 watches with frequent problems, and no one issued any warning reports? Is the instrument calibration not done by a metrology institute? Is it enough to say that the error is within acceptable limits? What potential is being tapped? A complete mess!