Emergency Plan for Ammonia Synthesis Purification

Is it an emergency rescue plan, or a production accident handling plan?

It’s an emergency plan, right? We have different roles assigned to us. Why can’t it be stuck on?

Our factory also uses the wet oxidation method with tannin for desulfurization. I’m not sure if our emergency response plan will be useful to you Accident name: Explosion of anti-explosion plate for desulfurization electrostatic coking removal 1. Occurrence conditions: ① Excessive dosage in this position. 　 ② The oil is being compressed and discharged too quickly and forcefully. ③ Emergency shutdowns and trips due to compression result in a sharp increase in pressure at this position. ④ The explosion-proof panels have not been inspected for a long time, resulting in lower explosion-proof standards. ⑤ The inlet and outlet valves were closed, the hot wash steam flow was set too high while the vent flow was set too low, resulting in excessive pressure inside the tower. ⑥ Inadequate purging before maintaining the electrostatic defouling device led to exposure to an open flame during the maintenance. 2. Hazards that may occur: ① Due to the explosion-proof panel being located close to the high-voltage electrostatic defouling device, fires and explosions are likely to occur. ② This leads to a sharp drop in system pressure; delays in reducing the machine speed can potentially result in negative pressure in the system. ③ This leads to a significant reduction in machine operation, or even shutdowns. ④ Shards from an exploded blast shield can cause injury. 3. Control measures: ① The amount added at this position should be increased in a uniform and gradual manner, with strict control to keep the fan outlet pressure ≤45 Kpa. ② Strengthen communication with the low-pressure machine operators and strictly control the inlet pressure of the low-pressure machine. ③ Regularly inspect the static electrostatic defouling explosion-proof plates, and replace them promptly if any issues are found. ④ During the replacement before servicing the electrostatic defouling unit, the vent valve of the electrostatic defouling unit should be opened wide to ensure that the internal pressure within it is ≤0.05 Mpa. 4. Emergency response measures: ① After the explosion-proof plate bursts, first shut down the electrostatic coking system and maintain a positive pressure in the desulfurization system. ② Notify of compression, scheduling for gas release, reducing machine capacity and output, and shutdown if necessary ； ③ Close the corresponding static electrostatic defouling inlet and outlet valves, open the hot wash steam valve and the vent valve, and arrange for a fitter to carry out the replacement. ④ After the inlet and outlet valves for electrostatic defouling are closed, contact the dispatch team to start increasing the flow rate of the low-pressure pump. ⑤ After replacing the static electrostatic defouling explosion-proof plate, continue to pass steam for displacement, and open the inlet valve of the static electrostatic defouling system to allow air to be vented. Gradually close the steam valve, take samples at the vent location for analysis; once the semi-water gas meets the required standards, open the outlet valve and close the vent valve. 5. Persons responsible for control: Level monitor, shift supervisor, blacksmith. II. Name of the accident: Failure to prepare when starting the standby fan. 1. Conditions under which the accident occurs: ① The fan has not had its waste removed or its shaft rotated as required over an extended period after it was taken out of use, resulting in the fan being unable to rotate. ② After the fan stops, foreign objects such as coal tar fall in, preventing the fan from rotating. ③ Faults in the fan’s electrical components and wiring. 2. Hazards incurred: ① It leads to a reduction in output and machine usage, affecting normal production. 3. Control measures: ① Rotate the fan every hour and drain it once starting from the time it is shut down; after 24 hours of shutdown, rotate it every 2 hours and drain it once ； ② Fitters need to carry out regular maintenance on the fans ； ③ To prevent debris such as coal tar from entering the fan, the inlet and outlet valves should be closed after shutdown. ④ Electricians regularly inspect the fan’s electrical components and wiring to check the insulation condition. 4. Emergency response measures: ① Activate other backup fans. 5. Person in charge of control: Fan operator, fitter, electrician. 3. Name of accident: Breakage of the safety water seal at the system outlet. 1. Conditions under which it occurs: ① The water supply valve for the safety water seal is closed, and frequent fluctuations in production pressure result in a low liquid level inside the water seal. ②The workload for this position has increased too much and too quickly. ③Compressed emergency shutdown; the gas return or oil discharge is too rapid. ④Corrosion and internal leakage in the safety water seal inner sleeve have caused a low liquid level inside the water seal. ⑤Internal leakage in the safety water seal drain valve has caused a low liquid level inside the water seal. 2. Hazards incurred: ① It causes fluctuations in the production volume of subsequent processing stages, leading to a decrease in output. ②Once the pressure drops, the system may draw negative pressure. ③After the safety water seal is flushed, water from the jacket enters the fan, damaging it. 3. Control measures: ① The increase rate for this position should be appropriate ； ②Strengthen connections with positions related to compression ； ③Regularly check the level of the safety water seal ； ④Stabilize system pressure. ⑤Check the water seal drain for leaks regularly, and replace it promptly if any leakage is detected. ⑥Regularly check the liquid level in the external jacket of the water seal; if any abnormalities are detected, shut off the drain valve of the external jacket promptly. While ensuring the proper liquid level in the internal jacket, add water to it. 4. Emergency response measures: ① Immediately after flushing with a water seal, contact the low-pressure pump to restore air supply, adjust the desulfurization large circulation system, and maintain positive pressure in the system. ②Immediate power shutdown for electrostatic defouling ； ③Immediately close the water seal outlet valve based on the system pressure, shut off the drain line of the water seal’s external jacket, and add water to the water seal. ④Contact the dispatch team to further investigate the cause and prevent similar accidents from occurring. 5. Persons responsible for control: Fan operator, Level controller, Blacksmith. 4. Name of the accident: Breakage of the foundation bolts of the Roots blower (or motor). 1. Conditions under which it occurs: ① The blower (motor) operates with defects for a long time, resulting in poor stability. ② The bearings of the fan (motor) are poorly maintained and are severely worn. ③ The foundation bolts of the fan (motor) are not securely fixed and are loose. ④ The fan and motor shaft are not aligned. ⑤ The quality of the foundation bolts for the fan (motor) is poor. 2. Hazards that may occur: ① If the foundation bolts break, the stability of the equipment is reduced, which can easily lead to misalignment between the fan and the motor, resulting in serious equipment failures that pose a risk to human safety or severely disrupt production. 3. Control measures: ① The increase in dosage should be slow and gradual. ② Strengthen routine inspections of operating equipment to promptly detect abnormalities such as vibration and noise. ③ Strengthen the maintenance of fans by regularly tightening the foundation bolts. ④ Strictly inspect the materials entering the factory to ensure that the quality of the anchor bolts is satisfactory. 4. Emergency response measures: ① Maintain contact with the dispatch team and compression unit, and shut down the faulty fan to start the backup fan. ② If the inlet and outlet valves of the fan are leaking, blind plates need to be installed on them. 5. Person in charge of control: Fan operator, Blacksmith. 5. Name of accident plan: Gas entering the liquid-rich tank. 1. Conditions for occurrence: ① The circulation rate of the desulfurization pump is low, and the pressure at this station is high. ②The outlet valve of the desulfurization tower is opened too wide. ③The low-pressure pump stopped operating, resulting in high pressure at this station and causing the solution in the desulfurization tower to be emptied. 2. Hazards that may occur: ① Gas leakage leads to a drop in system pressure, preventing adequate supply and affecting production in subsequent stages. ② It is easy for people to suffer from gas poisoning, creating potential accident hazards. ③ It is prone to severe explosion accidents when exposed to an open flame. ④ Production in the latter stage decreases, while production costs rise. 3. Control measures: ① Strengthen routine inspections to maintain the liquid level in the desulfurization tower. ② Increase the circulation rate promptly and reduce the system pressure. ③ Control the desulfurization tower outlet valve in a timely manner. 4. Emergency response measures: ① Close the outlet valve of the desulfurization tower; once the liquid level rises, adjust its opening degree to the normal level. 5. Person in charge of control: Shift supervisor of the regeneration unit. 6. Name of accident plan: Severe excess of H2S at the first outlet. 1. Conditions for occurrence: ① Excessively high H2S content in the incoming raw gas (use of high-sulfur coal). ②The solution does not regenerate well over time. ③Improper operation. ④The bypass valve of the desulfurization tower was opened too wide. ⑤The solution concentration was diluted too much, resulting in a decrease in desulfurization efficiency. 2. Hazards that may occur: ① Corrosion of the equipment in the relevant section affects the control of H2S at the second dehydration outlet; in severe cases, this leads to reduced machine capacity and output, resulting in substandard product quality. 3. Control measures: ① Contact the gas production and dispatching teams promptly to reduce the H2S content in the feed gas ； ②Increase the solution circulation rate to raise the composition of the solution ； ③Increase the solution temperature to enhance regeneration. ④When taking a shortcut to the desulfurization tower, drive slowly. ⑤When diluting the solution, do it slowly and steadily. 4. Emergency response measures: ① Shut down the bypass of the desulfurization tower and increase the solution circulation rate. ②Notify to increase the solution circulation rate in Stage 2. ③Increase the temperature of the regeneration solution to enhance regeneration. ④If the hydrogen sulfide level at the second outlet still exceeds the specified limit, reduce the dosage or reduce the operating capacity of the machine. 5. Person in charge of control: Recycling worker, Analyzer. 7. Name of accident plan: Accident due to excessive oxygen content in feed gas. 1. Conditions for occurrence: ① The oxygen content in the semi-water gas supplied from the gas generation unit is above the allowable level. ② Negative pressure is created at the fan inlet to introduce oxygen. ③ The fan tripped, causing the extraction system to draw negative pressure and oxygen. 2. Hazards that may occur: ① High temperature in the converter, which can damage the coal contactors ； ② Resulting in reduced output, fewer machines in operation, or even shutdowns ； ③ Electrostatic defouling explosions have caused severe accidents. 3. Control measures: ① Strengthen inspections to prevent the fan from operating in reverse mode ； ② If the fan stops operating, immediately notify the compression system to reduce air supply and activate the backup fan ； ③ Strengthen the monitoring of the composition of semi-water gas: reduce output and operating speed when O2 ≥ 0.5%, and shut down immediately when O2 ≥ 1.0%. 4. Emergency response measures: ① If the vacuum issue cannot be resolved immediately, or if the oxygen level reaches the limit that requires shutdown, the machine should be shut down right away. 5. Responsible persons for control: Fan operator, analyst, fitter. 8. Name of accident plan: Water ingress into the water seal at the gas holder outlet, resulting in blockage and shutdown. 1. Conditions under which it occurs: ① Blockage of the drain pipe of the water seal at the gas holder outlet ； ② Severe corrosion of the gas pipes inside the gas holder, with water infiltration ； ③ The gas holder is under negative pressure; water has entered the gas pipelines ； ④ Internal leakage in the water seal make-up valve at the gas holder outlet; water is entering the water seal ； 2. Hazards that may occur: ① Excessive oxygen content, which can lead to severe explosion accidents in extreme cases ； ② Transformation coal contact overheating ； ③ Reduce volume, reduce machinery, or even shut down. 3. Control measures: ① Ensure that the height of the gas tank is within the specified range. ② Regularly inspect the coal gas pipeline at the gas holder outlet. ③ Pay attention to changes in system pressure. 4. Emergency response measures: Stop the machine immediately. 5. Person responsible for control: Fan operator, team leader. 9. Name of accident plan: Gas poisoning of people indoors. 1. Conditions under which it occurs: ① The room is too airtight, resulting in poor air circulation ； ② Air is leaking from outdoor pipelines and entering the interior ； 2. Hazards that may occur: ① Operators may be poisoned, which affects production and can even be life-threatening in severe cases ； ② When the explosive limit is reached, a severe explosion can occur ； 3. Control measures: ① Improve indoor ventilation ； ② Strengthen the inspection of process pipelines, and address any issues found promptly ； ③ Strictly follow the interval inspection checklist and conduct inspections in a timely manner. 4. Emergency response measures: ① Immediately transfer the poisoned person to a well-ventilated area; provide first aid if necessary, and pay attention to keeping them warm ； ② Contact the staff hospital ； (8012) ③ Notify the dispatcher to call 120 to rescue the person who has been poisoned. 5. Person responsible for control: All personnel who are not on duty at that time. 10. Name of accident plan: Sudden spontaneous shutdown of the Roots blower. 1. Conditions under which it occurs: ① The load on the blower exceeds the rated pressure, causing the power supply to be cut off. ②Fault in the fan itself or motor failure. ③Fault in the electrical wiring. 2. Hazards that may occur: ① Significant fluctuations in production, even leading to shutdowns ； ② The pressure dropped rapidly, even pulling the desulfurization system into a negative pressure state, which led to an excessive oxygen level in the subsequent sections and triggered a severe explosive accident ； ③ The fan reversed, causing damage to the equipment. 3. Control measures: ① Instrument technicians, electricians, and fitters should regularly check the operation of the equipment ； ② Strictly implement the routine inspection system to ensure that equipment does not operate under overload conditions or while faulty ； ③ Regularly service the check valve to ensure its sensitivity and reliability. 4. Emergency response measures: ① Immediately close the inlet (outlet) valves of the faulty fan to prevent it from rotating in reverse ； ② Start the standby fan ； ③ Promptly notify to reduce the intake and exhaust air, as well as lower the machine speed and volume, in order to prevent the desulfurization system from going into negative pressure. 5. Persons responsible for control: Fan operator, shift supervisor. 11. Name of accident plan: High desulfurization resistance leading to negative pressure in the compressor. 1. Conditions under which the accident occurs: ① High resistance in the desulfurization system, pressure buildup at the fan outlet, and extremely low pressure at the inlet of the compressor (this problem is likely to occur when the system resistance exceeds 20 Kpa). 2. Hazards caused by the accident: ① It can cause the compressor to operate in a vacuum condition, leading to an excessive oxygen level; in severe cases, this can result in catastrophic explosions ； ②Transformation catalyst overheating ； ③Reduce volume, reduce machinery, or even shut down ； ④Negative pressure deformation of the equipment. 3. Accident control measures: ① Ensure proper purification of the gas entering the desulfurization tower ； ②Control the regeneration process to increase sulfur production ； ③Strictly control the solution components to minimize suspended sulfur and reduce negative reactions to the lowest level ； ④Strictly control the solution temperature to prevent the filler from being damaged or deformed due to excessive heat ； ⑤Strengthen regular inspections and address any leaks promptly (including valve and pipeline gas leaks) ； 4. Emergency response measures for accidents: I) When the inlet pressure for compression is extremely low and pressure buildup occurs at the fan outlet, ① first open the bypass route to the desulfurization tower, simultaneously stop the desulfurization pump to reduce the circulation volume, and inform the compression unit to resume gas supply and reduce its operation ； If the situation improves, normal production adjustments should be gradually restored ； II) When compression is in negative mode: ① Start the large circulation system of the plant, activate the short-circuit routes for the new and old desulfurization towers; at the same time stop the desulfurization pumps to reduce the circulation volume, and inform the compression unit to resume gas supply and reduce its operation ； If the pressure still does not decrease after implementing the above measures, the machine should be stopped immediately ； ②Once the pressure issue is resolved as a result of these measures, normal production operations should be gradually restored ； 5. Person in charge of control: Shift supervisor, Supervisor of the regeneration operation post. 12. Name of accident plan: Fire accident in the desulfurization section. 1. Conditions for occurrence: ① Air leakage from the oil seal of the fan, exposure to an external open flame ； ② Static electrode removal of fouling, explosion-proof plates; arcing occurs in transformers ； ③ Sulfur in contact with an external open flame ； ④ During hot work, the pipeline catches fire ； ⑤ During air displacement, coal tar in the pipeline caught fire. 2. Hazards that may occur: ① Reduction in machine operation, decrease in output, or even shutdown of the equipment ； ② In severe cases, fatal accidents occur ； ③ When sulfur catches fire, it produces the toxic gas sulfur dioxide, which can cause respiratory damage or even death ； ④ If a pipeline catches fire, losing control can lead to damage to the equipment and pipelines. 3. Control measures: ① Strengthen the maintenance of fans ； ② Check the explosion-proof panels regularly and maintain a record book ； ③ Fire is prohibited in areas where sulfur is stored ； ④ During hot work, the pipelines should be isolated, and hot work analysis should be strengthened ； ⑤ When replacing the air, it should be done slowly to maintain normal circulation of water and solution as much as possible. ⑥ When performing hot work at a workplace, sufficient fire-fighting equipment must be prepared, and preventive measures must be established. 4. Emergency response measures: ① In the event of a fire, select appropriate fire extinguishing equipment based on the specific circumstances to put out the fire. ② Start the standby fan, shut down the faulty fan, and apply grease to the shaft seal of the faulty fan ； ③ After the electrostatic defouling explosion-proof plate explodes, the power supply should be cut off immediately, its inlet and outlet valves should be closed, and the steam replacement valve should be opened to introduce steam inside; at the same time, contact the dispatch team and the compression department ； After an explosion of the electrostatic defouling explosion-proof plate, contact the dispatch team; if it is necessary to shut down the compressor, do so, but if the situation can be handled without shutting down the compressor, proceed with treatment without stopping it ； ④ If a pipeline catches fire, the power supply should be cut off immediately to lower the temperature at the point of ignition. 5. Person in charge of control: On-duty operator, shift supervisor. 13. Name of accident plan: Solution deterioration. 1. Conditions for occurrence: ① The solution temperature remains above or below the specified limits for an extended period. ② The extraction and separation of sulfur foam are not timely. ③ The solution components are not appropriate. ④ Long time difference in gas medium. ⑤ The amount of regenerative air is low, resulting in poor regeneration efficiency. 2. Hazards caused by the accident: ① The suspended sulfur in the solution is higher than 1.0 g/L, resulting in tower blockage ； ②Desulfurization efficiency decreases, and the H2S level at the outlet exceeds the limit ； ③Sulfur foam is difficult to separate, and the amount of sulfur produced is low with poor quality. 3. Accident control measures: ① Control the solution temperature within the specified range ； 　 ② Enhance the extraction and separation of sulfur foam to ensure that sulfur particles are separated from the solution in a timely manner. 　 ③ Adjust the solution components in a timely manner. 　 ④ Increase the amount of recycled air to enhance the regeneration process. 4. Emergency measures in case of an accident: 5. Person responsible for accident control: Regeneration worker 14. Name of the accident plan: Severe excess of H2S at the second outlet 1. Conditions under which it occurs: ① Severe excess of H2S at the inlet ； ②The solution circulation rate is low ； ③The solution regeneration system is malfunctioning. 2. Hazards incurred: ① Severe impact on the process conditions in subsequent units (urea, synthesis, methanol) ； ②Equipment in the section after corrosion ； ③Reducing machines and quantities affects production. 3. Control measures: ① Contact the first-stage separation unit and the dispatch department in a timely manner to carry out adjusted control based on different situations ； ②Increase the components of the solution ； 　 ③Increase the solution circulation rate. 4. Emergency response measures: ① Immediately increase the circulation rate. 5. Responsible persons for control: shift leader, regeneration worker. 15. Name of the accident plan: Sudden power outage of the desulfurization pump. a. Power outage at this workstation. 1. Conditions under which it occurs: ① Power outage due to severe weather conditions ； ②A power outage occurred due to a malfunction at the substation. ③110,000 units malfunctioned ； ④Misoperation. 2. Hazards caused by the accident: ① Liquid spillage, as a failed check valve can cause the pump to operate in reverse, leading to damage to the desulfurization pump, turbine, and motor ； ②If the liquid level in the flash tank becomes too low, the shift gas will leak out through the ejector, affecting production and environmental protection; in severe cases, it can pose a threat to human safety ； ③The H2S at the outlet could not be controlled, resulting in severe excess levels of H2S at the outlet and causing a shutdown of the entire system. ④The liquid level in the lean liquid tank is too high, resulting in solution loss. 3. Control measures: ① Take the opportunity to service the check valve to ensure its sensitivity and reliability ； Responsible person: Charter fitter ； ②Regularly maintain all valves to ensure they remain lightweight and flexible ； Responsible person: Charter fitter ； ③Strengthen the management of open flames ； ④Control the liquid levels in each tank and column at appropriate levels ； Responsible person: On-duty operator ； ⑤Strengthen operational training. Responsible person: Shift supervisor ； 4. Emergency measures in case of an accident: ① Quickly shut down the turbine and the outlet valve of the desulfurization pump, closely monitor the liquid level in the lean liquid tank, and start the backup desulfurization pump ； When the backup pump fails to start: Responsible person: Shift leader, Regeneration worker ； ②Quickly close the flash tank outlet valve ； 　Responsible person: Recycling Worker ； ③The team leader promptly contacted the dispatcher to take further action. ④Contact the electrician to find a solution ； ⑤Temporarily reduce H2S at one outlet ； ⑥If it cannot be resolved in a short time, the vehicle should be stopped immediately. 　 b. Plant-wide power outage 1. Conditions under which an emergency power shutdown occurs: ① Severe weather (lightning, strong winds, thunderstorms, etc.) ； ②, main power distribution control failure ； ③, 110,000 units malfunctioned ； ④, misoperation. 2. Hazards caused by the accident: ① Liquid spillage, as a failed check valve can cause the pump to operate in reverse, leading to damage to the desulfurization pump, turbine, and motor ； ②If the liquid level in the flash tank becomes too low, the shift gas will leak out through the ejector, affecting production and environmental protection; in severe cases, it can pose a threat to human safety ； ③The H2S at the outlet could not be controlled, resulting in severe excess levels of H2S at the outlet and causing a shutdown of the entire system. ④The liquid level in the lean liquid tank is too high, resulting in solution loss. 3. Measures to control accidents: ① Take the opportunity to service the check valve to ensure its sensitivity and reliability ； Responsible person: Charter fitter ； ②Regularly maintain all valves to ensure they remain lightweight and flexible ； Responsible person: Charter fitter ； ③Strengthen the management of open flames ； ④Control the liquid levels in each tank and column at appropriate levels ； Responsible person: On-duty operator ； ⑤Strengthen operational training. Responsible person: Shift supervisor ； 4. Emergency measures in case of accidents: ① Quickly close the turbine and desulfurization pump outlet valves, and closely monitor the liquid level in the lean liquid tank ； Responsible person: Team leader, Recycling worker ； ②Quickly close the liquid outlet valve of the desulfurization tower ； Responsible person: Recycling Worker ； ③Quickly close the flash tank outlet valve ； 　Responsible person: Recycling Worker ； ④Close the system inlet and outlet valves, and stop the machine while maintaining pressure ； ⑤The team leader promptly contacted the dispatcher to take further action. C. Compression power shutdown 1. Conditions for emergency power shutdown: ① Severe weather (lightning, strong winds, thunderstorms) ； ②, main power distribution control failure ； ③, 110,000 units malfunctioned ； ④, misoperation. 2. Hazards caused by the accident: ① It leads to a decrease in system pressure, an increase in the liquid level in the desulfurization tower, resulting in resistance and the formation of air blocks ； ②Lowering the liquid level in other equipment, such as an empty flash tank level, can cause the conversion gas to leak out through the ejector, affecting production and environmental protection; in severe cases, it can pose a risk to human safety, as can an empty liquid level in the lean liquid tank, which can lead to the desulfurization pump running dry ； 3. Accident control measures: ① Maintain appropriate liquid levels in each tank and tower ； Responsible person: On-duty operator ； ②Strengthen operational training. Responsible person: Shift supervisor ； ③Regularly maintain all valves to ensure they remain lightweight and flexible. Responsible person: Charter fitter ； 4. Emergency measures in case of accidents: ① Contact the dispatch team to reduce the number of units in operation; if necessary, decrease the circulation volume of the solution ； Responsible person: Team leader ； ②Strengthen the monitoring of the liquid level in each tank ； Responsible person: Recycling worker, computer operator

Are there any emergency plans for transformation and decarbonization?