Oxygen tube valve tuning

The air separation unit regulates the pressure in the main oxygen pipeline. A dry run must be conducted before feeding material in; after resetting, the oxygen flow rate is adjusted to the operating value (note: at this point, oxygen is being vented). Finally, the material is fed in. After successful feeding, the gasification furnace gradually increases pressure; at this point, the oxygen flow rate remains more or less constant, but the opening degree of the oxygen valve changes.

I’m not quite sure what the original poster means – are they referring to pressure testing of the oxygen pipelines or the large-scale interlock tests?

The oxygen pipe valve is tested for leaks before actual installation, and a logic test can be conducted prior to commissioning to check whether the valve position changes as required by the timing sequence.

Before feeding the material, oxygen must first be directed to the furnace tip to reach the amount of oxygen required for feeding. Once the programmable valve position is adjusted, oxygen can be supplied to the burner immediately

Considering introducing clean nitrogen into the oxygen main, conducting simulated feeding trials should enable safe data collection and personnel training as required by the original poster, while also allowing the interlock functions to be tested

Is this the moderator’s idea, or is there really a precedent for this? Also, if we’re just imagining this, could someone with expertise analyze whether there are any differences between the data obtained under such conditions and the oxygen-related data?

First, conduct a no-load test to ensure there are no issues before applying load.

I have a test plan that was developed during the initial testing, the tests that must be carried out before driving the vehicle originally. Wait until I find and paste the work plan arrangements and requirements related to air separation: 1. Purging of oxygen pipelines: Timing: 10.1–10.3. Purging requirements: Start with the main pipes, then the branch pipes; the purge must pass the leak detection test. Purging pressure: 5–7 bar. Flow rate of purge gas: greater than 20,000 m3/h. 2. Airtightness testing of oxygen pipelines: Timing: 10.4–10.5. Airtightness requirements: First test airtightness using medium-pressure nitrogen, then increase the pressure to 80 bar using the liquid nitrogen pump from the air separation unit; there should be no leaks at the flanges of the oxygen pipelines. 3. Wet test plan for nitrogen pipelines: Timing: 10.4–10.6. Test requirements: The air separation unit must maintain a pressure of 120 bar in the high-pressure nitrogen tanks, with continuous supply of nitrogen. Test plan: Refer to the test plan. 4. Oxidation test of oxygen pipelines: Timing: 10.7–10.8. Test requirements: All valves in the oxygen pipelines must be kept open; when oxygen is supplied by the air separation unit, the pressure must be increased gradually to 80 bar, after which the pressure should be reduced after 24 hours to conclude the oxidation test. 5. Wet test plan for oxygen pipelines: Timing: 10.9–10.11. Test requirements: Refer to the test plan. 6. Test plan for the backup system of the air separation unit: Timing: 10.12–10.13. Test requirements: Refer to the test plan. Last edited by Comrade Li on 2009-3-5 08:04.]

Test Plan for the Air Separation Backup System 1. Purpose of the test: To simulate a situation in which, during the operation or feeding process of the gasifier, the liquid oxygen pump of the air separation unit stops suddenly; in such a case, the liquid oxygen pump of the backup system should start immediately. The test aims to monitor fluctuations in the pressure in the oxygen main pipeline as well as the oxygen flow rate and pressure within the operating gasifier. Adjustments are made based on the results of these tests to ensure that the gasifier can operate stably in similar situations during normal production. 2. Test conditions: (1) The oxygen pipeline oxidation test was successful, and all three gasification furnaces are equipped with the necessary conditions for introducing oxygen. (2) The air separation liquid oxygen pump and the backup system liquid oxygen pump have passed testing and are ready to supply oxygen. 3. Test Method ⑴ A gasification furnace was operated under semi-load conditions, with an oxygen pressure of 8.1 MPa and an oxygen flow rate of 10,000 Nm3/h. The liquid oxygen pump in the air separation unit stopped suddenly, and the backup liquid oxygen pump started automatically; the fluctuations in the pressure of the main oxygen pipeline as well as the oxygen flow rate and pressure in the operating gasification furnace were measured. ⑵ A gasification furnace was operated under simulated full load conditions, with an oxygen flow rate of 20,000 Nm3/h and an oxygen pressure of 8.1 MPa. The liquid oxygen pump in the air separation unit stopped suddenly, and the backup liquid oxygen pump started automatically; this was done to test the fluctuations in the pressure of the main oxygen pipeline, as well as the oxygen flow rate and pressure within the operating gasification furnace. ⑶ One gasification furnace was operated under full load conditions, with an oxygen flow rate of 20,000 Nm3/h and an oxygen pressure of 8.1 MPa. The other gasification furnace was operated under partial load conditions, with an oxygen flow rate of 10,000 Nm3/h and the same oxygen pressure of 8.1 MPa. When the liquid oxygen pump in the air separation unit stopped suddenly, the backup liquid oxygen pump started automatically; this was done to test the fluctuations in the pressure of the main oxygen pipeline, as well as the oxygen flow rate and pressure in the operating gasification furnaces. ⑷ Two gasification furnaces were operated under simulated full load conditions, with an oxygen flow rate of 20,000 Nm3/h and an oxygen pressure of 8.1 MPa. The liquid oxygen pump in the air separation unit stopped suddenly, and the backup liquid oxygen pump started automatically; this was done to test the fluctuations in the pressure of the main oxygen pipeline, as well as the oxygen flow rate and pressure in the operating gasification furnaces. ⑸ One gasification furnace was operated under full load conditions, with an oxygen flow rate of 20,000 Nm3/h and an oxygen pressure of 8.1 MPa. The other two gasification furnaces were operated under partial load conditions, with an oxygen flow rate of 10,000 Nm3/h and the same oxygen pressure of 8.1 MPa. When the liquid oxygen pump in the air separation unit stopped suddenly, the backup liquid oxygen pump started automatically; this was done to test the fluctuations in the pressure of the main oxygen pipeline, as well as the oxygen flow rate and pressure in the operating gasification furnaces. 4. Test procedures: During the test, the instrumentation staff must supply simulated signals from behind the control panel. (1) Send a forced operation signal to the instrument of the high-pressure slurry pump P1201. ⑵ The burner cooling water system is operating normally after reset. ⑶ When the pressure in the high-pressure nitrogen system is greater than 13 MPa, the manual valve in front of XV12005 opens, the manual valve behind HV12002 opens, the manual valve behind XV12006 opens, the manual valves in front of and behind XV12021 and XV12022 close, and the manual valve in front of XV12004 closes. ⑷ Notify to equalize the pressure in the oxygen pipeline; once the pressure PI12008 of the main oxygen pipeline exceeds 8.0 MPa, the control room operator shall press the reverse pressurization button PB12009 to pressurize the oxygen pipeline in reverse. After the reverse pressurization is completed, button PB12009 is reset, and the zone oxygen valve HV12003 is opened. The control room then verifies that all valves are operating properly. ⑸ After manually turning on HV12006 from the control panel, it is confirmed that all conditions for step A1 of the startup procedure are met; then the initialization button PB12001 is pressed, causing XV12007 to open. The control panel adjusts the oxygen control valve FV12009 so that the oxygen flow rate matches that required during testing. Once the oxygen flow rate and pressure stabilize, all relevant parameters are recorded. Appendix: Test Data Record Sheet for Backup Systems
Condition 1: Furnace A is operating at partial load; the liquid oxygen pump from the air separation unit stops suddenly, and the backup liquid oxygen pump starts automatically.
Series Number: A
Tag Number: PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa – before automatic start, after automatic start

Condition 2: Furnace A is operating normally; the liquid oxygen pump from the air separation unit stops suddenly, and the backup liquid oxygen pump starts automatically.
Series Number: A
Tag Number: PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa – before automatic start, after automatic start

Condition 3: Furnace A is operating normally, while Furnace B is operating at partial load; the liquid oxygen pump from the air separation unit stops suddenly, and the backup liquid oxygen pump starts automatically.
Series Number: A, B
Tag Number: PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa, PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa – before automatic start, after automatic start

Condition 4: Furnace A is operating normally, and Furnace B is also operating normally; the liquid oxygen pump from the air separation unit stops suddenly, and the backup liquid oxygen pump starts automatically.
Series Number: A, B
Tag Number: PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa, PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa – before automatic start, after automatic start

Condition 5: Furnace A is operating normally, Furnace B is operating at partial load, and Furnace C is also operating at partial load; the liquid oxygen pump from the air separation unit stops suddenly, and the backup liquid oxygen pump starts automatically.
Series Number: A, B, C
Tag Number: PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa, PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa, PT12009 MPa, FT12009 Nm3/h, FV12009 %; PT12008 MPa – before automatic start, after automatic start

It is an instance; the pressure does not require correction. After correcting the flow data deviations, there is almost no difference from the actual operation

We conducted tests on gasification using high-pressure air, including load tests