Safety Operating Procedures for Gas Generators

Safety Operating Procedures for Gas Generators (I) Preparation before Ignition A. All moving parts have passed normal cold-state tests. 1. Check whether oil has been added to each reducer and other areas that require lubrication. 2. The gray disk rotates normally ； Is the rotation direction correct? 3. The fan starts and stops properly ； Whether the steering is correct. 4. Automatic coal feeding system: Hopper feeding, rising, discharging, and descending all operate normally. 5. Check that all bolts are tightened and that there are no leaks in the system. 6. Check whether the stroke of the bell cover and its sealing are satisfactory. 7. Check that all valves open and close smoothly without any faults. B. All instruments show normal readings. It provides sensitive and accurate responses. C. The water level of each water seal is normal ； The water jacket is filled with water; the water level gauge shows clearly, and the liquid level displays properly during water inflow and outflow. D. The steam system is operating normally in its cycle. 1. The automatic pressure relief device is functioning properly with no blockages. 2. Ensure the steam pipeline is unobstructed, and open the steam relief valve. E. Furnace lining: Line the furnace with slag having a particle size of 30–70 mm, to a height of about 100 mm above the furnace grates, and level it out. (II) Ignition 1. Ignition: Add wood, with the amount sufficient to ensure the coal layer catches fire. The wood chips should be distributed evenly throughout the furnace. Light the wood chips and ensure they burn completely; when lighting them, open the exhaust valve, lower the bell cover, and use the feeding cart to push open the coal bin lid. 2. Once the firewood is burning well, a small amount of coal can be added to sustain the flame. Start the primary fan to supply a moderate amount of air to aid combustion; if there are areas where the fire has not caught, reduce the air flow or stop it altogether, and use a stick to stir the contents appropriately so that the entire furnace burns evenly. If even then the fire does not burn evenly, it should be lit again. Stop the air supply to observe whether the furnace is burning evenly; if the burning is good, the ignition process is complete. 3. Add coal gradually; once the coal layer reaches a certain height, gas can be produced normally. 4. Once gas production is normal, proceed to the gas supply procedure. (III) Gas Supply 1. Before igniting the heating furnace, it is necessary to open the secondary air valve on the nozzle first in order to purge the furnace chamber and remove any residual gas that may be present inside the furnace and in the flue ducts. 2. Close the secondary air valve. 3. Place the ignition rod at the nozzle, then slowly open the gas valve to ignite the gas. Be sure to wait for the gas to ignite; avoid letting too much smoke accumulate in the stove, as this can cause an explosion. 4. When lighting the fire, one should not be facing the furnace door directly; it is strictly prohibited to stand near the furnace door or any of its openings. 5. After the nozzles are ignited, observe the combustion situation, gradually increase the amount of secondary air, and adjust the air distribution valves for each nozzle to ensure stable combustion in all of them. 6. If the nozzle does not ignite, it indicates that the quality of the gas is poor or the amount of gas supplied is insufficient. The gas valve should be closed immediately, and additional secondary air should be used to blow out any remaining gas in the furnace. After waiting for 5 minutes, attempt to ignite the furnace again by following the steps outlined above. 7. When the temperature in the furnace chamber of the heating furnace is below 500°C, it is necessary to constantly check whether there is a flame outage inside the furnace. If a flame outage occurs, the gas valve should be closed immediately, the furnace door opened, and ignition should be attempted again following the established procedure. 8. It is strictly prohibited for any water seal area or water jacket to run out of water at any time; the water in the water jackets should be added frequently in small amounts. 9. During operation, pay regular attention to the readings on the instruments in the electrical control cabinet; the temperature at the gas outlet must not exceed 400°C, and coal should be added promptly. 10. If water seeps from the upper and lower water seals during operation, reduce the primary air volume. 11. The layer height should be maintained between 700 and 800 mm; if it is too low, it affects the quality and output of gas, and in severe cases, ignition may not be possible. 12. The combustion temperature of the heating furnace is related to the amount of gas, as well as the amounts of primary and secondary air and the draft force from the chimney; it is necessary to adjust the sizes of various valves in a timely manner during production. 13. The particle size of the coal must meet the required standards to avoid affecting gas production; coal particles that are too large, too small, or prone to caking can all impact gas production, and in severe cases, it may be impossible to ignite the fire. 14. Oil deficiency is strictly prohibited in all reducers and rotating parts. 15. Stewards must undergo professional training before taking up their duties; it is strictly prohibited for unauthorized personnel to operate switches and valves. 16. Non-staff members are not allowed to enter the work site. 17. Maintenance is strictly prohibited while the gas generator is in operation, and flames are strictly forbidden within 2 meters of the gas generator. (IV) Shutdown of the furnace: The shutdown of the furnace can be categorized into the following situations: ① Shutdown based on the user’s requirements; ② Shutdown for major repairs; ③ Shutdown due to a sudden power outage, with the latter being treated as a power outage incident. The shutdown procedure for the hot gas system is summarized as follows: 1. Before shutting down the system during normal operation, first check the coal layer height; then gradually reduce the amount of primary air to lower the reaction temperature inside the furnace, and maintain a positive pressure at the furnace bottom. Open the exhaust valve to isolate the gas generator from the heating furnace, subsequently close the primary air valves and stop the fans. Open the steam valves, and finally turn off the main power supply to the electrical control cabinet. 2. Shutdown for maintenance: When it is planned to shut down the gas furnace for maintenance, coal feeding can be stopped 1–2 hours before shutdown. During shutdown, the air flow should be gradually reduced, the release valve should be opened to isolate the gas generator from the heating furnace, the door of the heating furnace should be opened or the carriage pulled out of the furnace, and then the fan should be turned off. The furnace must not be opened within 8 hours after it is shut down, to prevent air from entering the furnace and causing an explosion. 3. Sudden power outage or furnace shutdown: During operation, in the event of a sudden power outage, quickly open the release valve and increase the amount of steam supplied to the bottom of the furnace, so as to maintain positive pressure inside the gas furnace; use a water seal to prevent communication between the gas generator and the heating furnace. At the same time, open the furnace door. (5) Continuous-operating gas generators can eliminate the steps of preparing the furnace and lighting it with firewood. Warning: Do not light the furnace when the air and dust inside it are murky; use secondary air to clean the furnace chamber until it is clear and free of any turbid gases before supplying gas to ignite it. Notes: User Manual for Wolong Brand CG Series Gas Generators, Nanyang Wolong Towerless Water Supply Equipment Manufacturing Factory. Table of Contents: I. Overview……………………………………………………………………………………………… (1) II. Main Structure………………………………………………………………………………………… (1-2) III. Gasification Principle ………………………………………………………………………………… (2-3) IV. Technical Parameters ………………………………………………………………………………… (3-4) V. Operating Procedures for the Gas Generator …………………………………………………………………… (4-6) VI. Common Problems, Causes of Failures, and Solutions…………………………………………………………… (7-8) VII. Precautions and Tips ………………………………………………………………………… (8-10) VIII. Appendices ……………………………………………………………………………………… (10) I. Overview Coal accounts for 70% of China’s energy mix; using coal in a clean manner is the best way to address the country’s energy challenges. Coal gasification is one of the main methods for promoting clean coal technology. The Wolong brand gas generator is the result of years of research by experts, and it is a patented product. It uses bituminous coal and non-caking bituminous coal as raw materials, with time and steam as gasifying agents, to produce gas for use in catering, stoves, boilers, and various heating devices, thereby replacing fuel and enabling users to save a significant amount of money at low costs. During operation, it is airtight and pollution-free, improving the working environment for workers and reducing their workload, which has made it very popular among users. It is currently widely used in hotels, guesthouses, bathhouses, government agencies, schools, and enterprises. II. Main Structure The CG series gas generator is composed of a furnace body, a coal feeding mechanism, an ash discharge mechanism, a dust collector, a power distribution and control system, an air supply system, a steam system, and an operation platform. 1. Furnace body section: It features a steel plate cylinder structure with a water jacket circulation system, which can generate steam for use as a gasifying agent. The lower part contains a primary air passage that oxidizes the fuel. 2. Coal feeding mechanism: A mechanically driven coal feeding mechanism transports coal to the coal bin at the top using a trolley, where it is added to the furnace as required by production needs. 3. Blowing system: Primary air is blown in using a centrifugal blower, and the temperature of the primary air is measured with instruments to keep the generator in its optimal operating condition. The secondary air is delivered through a separate air duct to the furnace; there it mixes with gas inside the burner before combustion. At the same time, the secondary air can also be preheated using an air heat exchanger installed in the flue to achieve further energy savings. 1. Ash discharge mechanism: Uses a rotating grate for wet automatic slag discharge. 2. Dust removal device: An adjustable water seal dust collector with high dust removal efficiency is used; as the gas passes through this dust collector and is washed with water, most of the dust in the gas settles, resulting in clean gas that can be used in furnaces. The gas can also be burned directly without washing. This device is equipped with a drain valve and a water seal isolation mechanism, which allow the residual gas in the gas furnace to be released when the furnace is shut down, thereby isolating the heating furnace from the gas generator. 3. Power distribution control system: The power supply, operation controller, and temperature display of the entire device are placed in the control cabinet for centralized control and monitoring. 4. Steam system: includes water jacket heat circulation, automatic pressure relief safety devices, valves, pipes, etc. The steam generated meets the needs of the gas generator itself, eliminating the need for a separate steam boiler. 5. Operating platform: The working platform of the steel structure. For workers to carry out operations such as operation and maintenance on it. III. The gasification principle of gas generators In a gas generator, coal moves from top to bottom, while the gasifying agent moves from bottom to top. Coal and the gasifying agent move in opposite directions and undergo physical and chemical reactions; we refer to this process as gasification. The reaction process is divided into 5 levels. (1) Ash layer: The ash layer is located above the grate and consists of the residues left after coal gasification; its height is 150~250 mm above the grate. Its functions are: (1) Since the ash settles as an oxide layer and is at a relatively high temperature, heat exchange occurs when the gasifying agent passes through this ash layer, preheating the gasifying agent to over 200°C; this creates favorable conditions for the thermochemical reactions in the oxide layer, thereby accelerating combustion ； (2) The ash layer acts as a protection for the grate due to being cooled by the gasifying agent. (3) The ash is distributed in a loose manner on the grate, and as the gasifying agent passes through this layer of ash, it helps to redistribute the airflow evenly. (II) Oxidation layer: The oxidation layer, also known as the combustion layer, is located above the ash layer. In this layer, oxygen from the blower reacts with carbon, resulting in complete combustion that produces large amounts of carbon dioxide along with a significant amount of heat. The thermochemical reaction of gas relies on this to provide heat. (III) Reduction layer: The reduction layer is the area where coal gas is produced. Once the carbon dioxide generated in the oxidation layer rises to the reduction layer, it undergoes endothermic chemical reactions with the hot carbon: (1) to produce carbon monoxide, (2) water vapor reacts with the hot carbon to produce carbon monoxide and hydrogen, and (3) carbon monoxide reacts with excess water vapor to produce carbon dioxide and hydrogen, releasing heat in the process that raises the temperature inside the gas stove. (IV) Carbonization layer: The carbonization layer is located above the reduction layer. At temperatures of 400–550°C, coal loses its volatile components and other pyrolysis products (CH4, CmHn) to become coke; the coke then moves from the pyrolysis zone to the reduction zone where chemical reactions take place. (5) Drying layer: The drying layer is the topmost layer of the material stack; the moisture in the raw coal is evaporated in this layer, preparing the material for carbonization in the layer below. IV. Technical Parameters 1. Furnace diameter: 0.6–3.0 meters 2. Applicable fuels: anthracite, coke, and weakly caking bituminous coal, with particle sizes of 6–13 mm, 13–25 mm, and 25–50 mm. 3. Gasifier type: Air + water vapor. 4. Gasification intensity: ≥200 kg/m2.h. 5. Gasification rate: 3.5 Nm3/kg. 6. Calorific value of the gas: 1250–1500 kcal/Nm3. 7. Outlet temperature of the gas furnace: ≤400°C. V. Safety operating procedures for gas generators (I) Preparation before ignition A. All moving parts function properly when tested in a cold state. 1. Check whether oil has been added to each reducer and other areas that require lubrication. 2. The gray disk rotates normally ； Is the rotation direction correct? 3. The fan starts and stops properly ； Whether the steering is correct. 4. Automatic coal feeding system: Hopper feeding, rising, discharging, and descending all operate normally. 5. Check that all bolts are tightened and that there are no leaks in the system. 6. Check whether the stroke of the bell cover and its sealing are satisfactory. 7. Check that all valves open and close smoothly without any faults. B. All instruments show normal readings. It provides sensitive and accurate responses. C. The water level of each water seal is normal ； The water jacket is filled with water; the water level gauge shows clearly, and the liquid level displays properly during water inflow and outflow. D. The steam system is operating normally in its cycle. 1. The automatic pressure relief device is functioning properly with no blockages. 2. Ensure the steam pipeline is unobstructed, and open the steam relief valve. E. Furnace lining: Line the furnace with slag having a particle size of 30–70 mm, to a height of about 100 mm above the furnace grates, and level it out. (II) Ignition 1. Ignition: Add wood, with the amount sufficient to ensure the coal layer catches fire. The wood chips should be distributed evenly throughout the furnace. Light the wood chips and ensure they burn completely; when lighting them, open the exhaust valve, lower the bell cover, and use the feeding cart to push open the coal bin lid. 2. Once the firewood is burning well, a small amount of coal can be added to sustain the flame. Start the primary fan to supply a moderate amount of air to aid combustion; if there are areas where the fire has not caught, reduce the air flow or stop it altogether, and use a stick to stir the contents appropriately so that the entire furnace burns evenly. If even then the fire does not burn evenly, it should be lit again. Stop the air supply to observe whether the furnace is burning evenly; if the burning is good, the ignition process is complete. 3. Add coal gradually; once the coal layer reaches a certain height, gas can be produced normally. 4. Once gas production is normal, proceed to the gas supply procedure. (III) Gas Supply 1. Before igniting the heating furnace, it is necessary to open the secondary air valve on the nozzle first in order to purge the furnace chamber and remove any residual gas that may be present inside the furnace and in the flue ducts. 2. Close the secondary air valve. 3. Place the ignition rod at the nozzle, then slowly open the gas valve to ignite the gas. Be sure to wait for the gas to ignite; avoid letting too much smoke accumulate in the stove, as this can cause an explosion. 4. When lighting the fire, one should not be facing the furnace door directly; it is strictly prohibited to stand near the furnace door or any of its openings. 5. After the nozzles are ignited, observe the combustion situation, gradually increase the amount of secondary air, and adjust the air distribution valves for each nozzle to ensure stable combustion in all of them. 6. If the nozzle does not ignite, it indicates that the quality of the gas is poor or the amount of gas supplied is insufficient. The gas valve should be closed immediately, and additional secondary air should be used to blow out any remaining gas in the furnace. After waiting for 5 minutes, attempt to ignite the furnace again by following the steps outlined above. 7. When the temperature in the furnace chamber of the heating furnace is below 500°C, it is necessary to constantly check whether there is a flame outage inside the furnace. If a flame outage occurs, the gas valve should be closed immediately, the furnace door opened, and ignition should be attempted again following the established procedure. 8. It is strictly prohibited for any water seal area or water jacket to run out of water at any time; the water in the water jackets should be added frequently in small amounts. 9. During operation, pay regular attention to the readings on the instruments in the electrical control cabinet; the temperature at the gas outlet must not exceed 400°C, and coal should be added promptly. 10. If water seeps from the upper and lower water seals during operation, reduce the primary air volume. 11. The layer height should be maintained between 700 and 800 mm; if it is too low, it affects the quality and output of gas, and in severe cases, ignition may not be possible. 12. The combustion temperature of the heating furnace is related to the amount of gas, as well as the amounts of primary and secondary air and the draft force from the chimney; it is necessary to adjust the sizes of various valves in a timely manner during production. 13. The particle size of the coal must meet the required standards to avoid affecting gas production; coal particles that are too large, too small, or prone to caking can all impact gas production, and in severe cases, it may be impossible to ignite the fire. 14. Oil deficiency is strictly prohibited in all reducers and rotating parts. 15. Stewards must undergo professional training before taking up their duties; it is strictly prohibited for unauthorized personnel to operate switches and valves. 16. Non-staff members are not allowed to enter the work site. 17. Maintenance is strictly prohibited while the gas generator is in operation, and flames are strictly forbidden within 2 meters of the gas generator. (IV) Shutdown of the furnace: The shutdown of the furnace can be categorized into the following situations: ① Shutdown based on the user’s requirements; ② Shutdown for major repairs; ③ Shutdown due to a sudden power outage, with the latter being treated as a power outage incident. The shutdown procedure for the hot gas system is summarized as follows: 1. Before shutting down the system during normal operation, first check the coal layer height; then gradually reduce the amount of primary air to lower the reaction temperature inside the furnace, and maintain a positive pressure at the furnace bottom. Open the exhaust valve to isolate the gas generator from the heating furnace, subsequently close the primary air valves and stop the fans. Open the steam valves, and finally turn off the main power supply to the electrical control cabinet. 2. Shutdown for maintenance: When it is planned to shut down the gas furnace for maintenance, coal feeding can be stopped 1–2 hours before shutdown. During shutdown, the air flow should be gradually reduced, the release valve should be opened to isolate the gas generator from the heating furnace, the door of the heating furnace should be opened or the carriage pulled out of the furnace, and then the fan should be turned off. The furnace must not be opened within 8 hours after it is shut down, to prevent air from entering the furnace and causing an explosion. 3. Sudden power outage or furnace shutdown: During operation, in the event of a sudden power outage, quickly open the release valve and increase the amount of steam supplied to the bottom of the furnace, so as to maintain positive pressure inside the gas furnace; use a water seal to prevent communication between the gas generator and the heating furnace. At the same time, open the furnace door. (5) Continuous-operating gas generators can eliminate the steps of preparing the furnace and lighting it with firewood. Warning: Do not light the furnace when the air and dust inside it are murky; use secondary air to clean the furnace chamber until it is clear and free of any turbid gases before supplying gas to ignite it. VI. Common Problems, Causes of Failures, and Solutions
Common Problems | Causes of Failures | Solutions
Difficulty in ignition | Excessive combustion air | Reduce the secondary air valve opening
Insufficient gas supply | Adjust the conditions inside the gas burner | Coal layer is tilted or not fully burned; remove coal from the furnace and re-ignite, ensuring even ignition
Coal slag formation in the furnace | Change the type of coal used | Extinguish the fire after closing the furnace door
Insufficient secondary air, unstable flame combustion | Increase the secondary air supply; close the furnace door only after the combustion is stable | Excessive or insufficient chimney draft | Adjust the chimney draft
Flame goes out easily | Unstable quality of gas | Add more coal or increase the primary air flow | Obstructions in nozzles or pipes | Clear the obstructions in nozzles or pipes
Coal layer is tilted or not fully burned | Remove coal from the furnace and re-ignite, ensuring even ignition | Severe coal slag formation | Change the type of coal used | Coal layer is too low | Raise the coal layer level
Red sparks in the flame | Impurities in the fuel or medium | Screen out coal dust | Furnace explosion when adding coal | Coal layer is too low; raising it can prevent this issue | Excessive black coal in the coal slag | Lower the gas outlet temperature | Increase the height of the gas outlet
Excessive slag removal | Reduce the frequency of slag removal | Fuel particles are too large or have uneven sizes | Use coal of uniform particle size | Furnace lid is lifted up or down | Water leakage from the water seal | Excessive primary air flow | Reduce the primary air volume | Coal layer is too low | Raise the coal layer level | Excessive pressure inside the furnace | Clear the pipes and increase the opening of the gas valves ； Adjust the draft in the heating furnace chimney. The fuel particles are too large; use coal with an appropriate particle size. Water is leaking from the lower water seal. The amount of primary air is too high; reduce the amount of primary air. The coal particles are too small or there is too much coal dust; adjust the coal particle size. Coal caking or sticking occurs; change the type of coal. The water jacket is leaking. The water jacket is damaged due to lack of water; shut down the furnace, remove the coal from it, and repair it again. VII. Precautions: (1) Before ignition, it is necessary to purge the heating furnace and flue pipes of any residual gas. Start the fan to blow air into the furnace chamber, thereby clearing any gas that may remain in the chamber after the furnace has been shut down. The fan must operate for 5 minutes before air can be introduced for ignition. Avoid accumulating too much smoke, and ignition by explosion is prohibited. (II) Gas supply and ignition of the heating furnace: Place the ignition rod next to the ignition hole; wait for the gas to arrive, after which it should be ignited in the heating furnace, causing a flame to emerge from the nozzle. If the nozzle does not ignite, it indicates that there is insufficient gas or the quality of the gas is poor. Immediately close the gas valve, adjust the operation of the gas generator, and use secondary air to blow out any remaining gas in the heating furnace before attempting to ignite it again. Once the nozzle ignites, gradually adjust the secondary air valve to maintain stable combustion. (III) Operation 1: Pay attention to the readings on the instruments in the electrical control cabinet; the temperature at the gas outlet should be ≤400°C. If slag formation is detected inside the furnace, the steam control valve should be opened further to increase the temperature of the primary air. The amount of primary air should be adjusted according to the gas consumption. If the firepower from the nozzles is insufficient or the temperature at the gas outlet is too low, the amount of primary air should be increased. 2. Maintain the coal seam height at 800–1000 mm. 3. Coal must be added when the gas outlet temperature approaches 400°C, and coal must also be added when the amount of gas in use is insufficient. 4. Slag removal ； Slag can be removed once the slag layer reaches a certain thickness. If there is too much ash, slag should be removed frequently, but the slag layer must remain at least 200 millimeters thick to prevent the fire layer from damaging the grate. 5. Steam system: Maintain the water level; it is strictly prohibited to have a lack of water in the water jacket. 6. Maintain a certain water level in each water seal area, and remove any foreign objects that fall into the water seals promptly. 7. Regularly lubricate all mechanical transmission parts to maintain good lubrication. 8. Tar condensation can clog nozzles and pipes. If the nozzle fails to spray fire properly, it is necessary to promptly inspect and remove tar from the nozzle and valves; the pipes should be cleared regularly, and regular inspections of the equipment should be carried out. 9. Operating a gas stove in either a hot or cold state will reduce the quality of the gas. The so-called hot state refers to a gas outlet temperature exceeding 400°C, while the cold state refers to a gas outlet temperature below 100°C. 10. When discharging slag, it is necessary to check whether the motor and reducer are operating properly. If there are foreign objects or coal slag in the furnace, this can cause the slag discharge tray to get stuck; in such cases, forced rotation for slag discharge should not be attempted. 11. Regularly check whether the automatic pressure relief device is reliable. (IV) Shutdown and shift handover: When shutting down the furnace, it is necessary to isolate the pipes connecting the gas generator to the heating furnace to prevent backflow. During the shift handover, it is essential to clearly exchange information about everything that has happened, any existing problems, and the current status, while keeping proper records of the handover. Special note: Soft water should be used in the water jacket of the gas generator, and scale should be removed promptly in accordance with relevant boiler standards. The water jacket must never be without water at any time. The slag discharge mechanism should rotate in the direction indicated by the arrow; reverse rotation is strictly prohibited. Maintain the slag layer thickness to prevent the grate from being damaged. Within 8 hours after the furnace is shut down, it is strictly prohibited to turn on the gas stove for use to avoid an explosion inside the furnace. The slag pool at the bottom of the gas generator must be cleaned regularly to prevent it from becoming clogged; otherwise, it will affect slag removal and damage the grate drive system. The driving parts of the gas generator (such as bearings, rollers, pins, etc.) must not be lacking in oil. VIII. Attachments: 1. Fire probe (1 piece); 2. Shovel (1 piece)

Please refer to the \"GB6222-2005 Safety Regulations for Gas Use in Industrial Enterprises\" by the original poster