Regarding gasifier burner failures

Regarding the slurry pipeline: I believe that before feeding the material in, the high-pressure slurry pump should be pressurized to the normal operating pressure or slightly higher, in order to check for internal leaks in the pump’s outlet drain valve, circulation valve, and the slurry discharge valve located before the furnace. After the pressure testing is complete, the blind flange on the slurry discharge valve should be reinstalled. After the material has been fed in, it is also necessary to promptly check for internal leaks in those same valves; if any leaks are detected, the system should be stopped immediately for repairs. While driving, a no-operate sign must be attached to the above three valves; it is strictly prohibited to operate these three valves. Before feeding material, the safety system must be tested in a no-load mode at least three times to ensure that the valve operation meets the requirements of the safety system before material feeding can proceed.

The large interlock test must be conducted three times, and the slurry pipeline and oxygen pipeline need to be purged with steam before feeding material. The three-level verification before each material feeding must be properly carried out: ensuring no items are missed and that the verifications are accurate. Enforce strictly!

Regarding oxygen pipes: The assembled oxygen delivery pipes must be purged with dry nitrogen and subjected to a leak test. During this test, grease-free soapy water should be applied to all fittings and connections; no bubbles should appear within 1 minute. When testing or putting the oxygen delivery system into operation, the valves should be opened slowly, with the flow rate adjusted gradually. It is strictly prohibited to open and close the valves rapidly to avoid adiabatic compression or excessively high flow rates. For pipes that are in use for a long time, it is necessary to remove fittings such as valves, elbows, and tees before starting the machine, and check for any signs of wear, thinning, or accumulation of iron particles; if such issues are found, they must be cleaned up promptly.

The poster’s last sentence is really well put. It’s a good idea to do a cold start test before driving. Although our plant has startup confirmation forms for the gasification furnace, which cover various valves, pipelines, instruments, and other aspects, the lack of a strict and well-established management system as well as proper procedures for starting up and shutting down operations is a problem. In particular, there are many young people in our plant – people like me who have just graduated but are already given the title of gasification engineer – and their experience in chemical production is limited. As a result, numerous problems arise after the plant starts operating; issues that should have been identified and resolved before startup. Of course, behind each problem there are usually multiple causes. However, I increasingly believe in the importance of mature management systems, as the stability of chemical production often relies on such systems. Furthermore, the testing before driving the vehicle doesn’t seem to be such an easy task either; the instruments at our factory keep claiming that it’s impossible to conduct tests, using my lack of knowledge about these instruments as an excuse. Ugh!

I’m stunned! Before starting the production process in my factory, none of this existed at all. Wouldn’t everyone be terrified if they came here? ;P ;P ;P