Initial cooling inspection operation

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Process Operating Procedures for the Drum Cooling Unit 1 Technical Specifications: 1.1 Initial cooling section: 1.1.1 Temperature of raw gas before the cooler: 78–82℃； 1.1.2 Set temperature: 20～22℃ ； 1.1.3 Suction pressure before the device: ~2000 Pa 1.1.4 Resistance of the pre-cooler: ≤1000 Pa ； 1.1.5 Temperature difference of coal gas at the outlets of each primary cooler: ≤2℃ 1.1.6 Temperature of circulating water entering the equipment: ~32℃ ； 1.1.7 Circulating water return temperature: ~45℃ ； 1.1.8 Temperature of low-temperature water entering the equipment: ~20℃ ； 1.1.9 Low-temperature water return temperature: ~22℃ ； 1.1.10 Tar content in the spray liquid in the lower section of the primary cooler: 30–40% ； 1.2 Electrostatic tar catcher section: 1.2.1 Oxygen content in gas: ≤ 1.0 % 1.2.2 Gas treatment capacity: 32500 m3/h per unit ； 1.2.3 Tar content in the gas captured by the electrostatic precipitator: ≤50mg/Nm3 ； 1.2.4 Secondary current: 200～500mA ； 1.2.5 Secondary voltage: 33～36kV ； 1.2.6 Nitrogen filling rate for insulated box: 50～80m3/h ； 1.2.7 Nitrogen pressure: ~20kPa ； 1.2.8 Insulation box temperature: 90～110℃ ； 1.2.9 Electrostatic capture resistance: ≤500Pa ； 1.3 Blower section: 1.3.1 Gas pressure behind the blower: 5～20kPa ； 1.3.2 Gas temperature after blower: ~53℃ ； 1.3.3 Suction pressure in front of the fan: 3～5kPa ； 1.3.4 Pressure in the coke oven gas collection duct: 80–120 Pa 1.3.5 Temperature of the unit’s bearing shells: <75℃ ； 1.3.6 Reducer bearing temperature: ~75℃ ； 1.3.7 Bearing outlet oil temperature: ≤60℃ ； 1.3.8 Motor lubricating oil pressure: 0.117～0.177 MPa ； 1.3.9 Starting oil pressure for auxiliary oil pump: 0.08MPa ； 1.3.10 Critical speed: 2965rpm ； 1.3.11 Axial displacement of blower rotor: ＜0.5mm 1.3.12 Rated current of main motor: ≤61.52A ； 1.3.13 Main motor stator temperature: ~130℃ ； 1.3.14 Main motor bearing temperature ~80℃ ； 1.3.15 Blower oil station oil level: 740～1300mm ； 1.3.16 Blower oil station oil temperature: ~35℃ ； 1.3.17 Volume of high-level fuel tank: 320L ； 1.3.18 Gearbox gear ratio: 1.537 ； 1.3.19 Inlet oil temperature of the hydraulic coupler: 50～55℃ ； 1.3.20 Outlet oil pressure of the hydraulic coupler: 0.05～0.35MPa ； 1.3.21 Oil temperature after blower oil cooler: ~35℃ ； 1.3.22 Blower casing temperature: ≤70℃ ； 1.4 Condensation section 1.4.1 Outlet pressure of the circulating ammonia water pump: 0.25～0.3MPa ； 1.4.2 Outlet pressure of high-pressure ammonia water pump: 2.5～3.0MPa ； 1.4.3 Tar pump outlet pressure: ~0.4MPa ； 1.4.4 Temperature of each motor: ≤65℃ ； 1.4.5 Remaining ammonia water volume: ~15t/h (water volume for 600,000 t of coke per year) ； 2 Equipment Overview
Standard equipment:
| No. | Name | Unit | Quantity | Specifications |
|-----|------|------|----------|----------------|
| 1 | Condensate circulation pump | Unit | 2 | Q=25 m³/h, H=50 m; Model: IH65-40-200. Equipped with motors: 2 units, Model: Y160M1-2, N=11 kW |
| 2 | Condensate pump | Unit | 2 | Model: IH80-50-200; Q=50 m³/h, H=50 m. Equipped with motors: 2 units, Model: Y160M1-2, N=15 kW |
| 3 | Hot water pump | Unit | 3 | Model: 122H-6B; Q=720 m³/h, H=67 m. Equipped with motors: 3 units, Model: JS136-4, N=220 kW, Voltage: 6000 V |
| 4 | Residual ammonia water pump | Unit | 2 | Model: IH80-50-315; Q=50 m³/h, H=125 m. Equipped with motors: 2 units, Model: Y225M-2, N=5 kW |
| 5 | Circulating ammonia water pump | Unit | 2 | Model: 12Sh-6B; Q=720 m³/h, H=67 m. Equipped with motors: 2 units, Model: JS136-4, N=220 kW, Voltage: 6000 V |
| 6 | Circulating ammonia water pump | Unit | 1 | Q=360–612 m³/h, H=65.1 m; Model: 10Sh-6. Equipped with motor: 1 unit, Model: Y315M-4, N=132 kW |
| 7 | Exhaust gas washing wastewater pump | Unit | 2 | Model: IS80-50-315; Q=15–30 m³/h, H=32.5–31.5 m. Equipped with motors: 2 units, Model: Y132S-4, N=5.5 kW |
| 8 | Submersible pump | Unit | 2 | Model: 50Y-40; Q=14.4 m³/h, L=2450 mm, H=40 m. Equipped with motors: 2 units, Model: Y32s-2, N=7.5 kW |
| 9 | Water-containing tar oil pump | Unit | 2 | Model: CHZO25-200C; Q=9 m³/h, H=36 m. Equipped with motors: 4 units, Model: Y132S1-2, N=5.5 kW |
| 10 | Gas valves | Unit | 6 | Model: DN1000, Type: Z942W-1. Equipped with electric actuators: 6 units, Model: AZH90, N=8 kW; explosion-proof |
| 11 | Bellows compensator | Unit | 3 | Model: 2.5DHE1000XBF-1500, DN1000 |
| 12 | Manual monorail crane | Unit | 2 | Model: SDX-3. Equipped with hand chain hoists: 2 units, Model: HS3, Load capacity: 3 t |
| 13 | Exhaust fan with motor | Unit | 2 | Q=824 m³/h, H=3660 Pa; Motor: Model Y90L-2, N=2.2 kW |
| 14 | Forklift for tar residue handling | Unit | 1 | Model: CPCD5 |
| 15 | Steam pressure recovery unit | Unit | 1 | Model: QH-1 |
| 16 | Ammonia water clarification motor | Unit | 3 | N=1.5 kW |
| 17 | Pressure tar separator motor | Unit | 3 | N=1.5 kW |
| 18 | Thick oil pump | Unit | 2 | Model: TLBW-16/1.6 |

Non-standard equipment:
| No. | Name | Unit | Quantity | Specifications |
|-----|------|------|----------|----------------|
| 1 | Horizontal pipe primary cooler | Unit | 3 | Volume: 3750 m³ |
| 2 | Water seal tank | Unit | 3 | Diameter: Dg600 mm, Height: 3700 mm |
| 3 | Water seal tank | Unit | 1 | Diameter: Dg600 mm, Height: 3700 mm |
| 4 | Condensate tank | Unit | 2 | Diameter: DN2400 mm, Length: 5000 mm |
| 5 | Full-flow tank | Unit | 3 | Diameter: Dg500 mm, Height: 1360 mm |
| 6 | Exhaust gas washing tower | Unit | 1 | Diameter: Dg1000 mm, Height: 17500 mm |
| 7 | Liquid seal tank | Unit | 1 | Diameter: Dg500 mm, Height: 650 mm |
| 8 | Underground venting tank | Unit | 1 | Diameter: Dg1800 mm, Length: 6500 mm, Volume: 15 m³ |
| 9 | Mechanized ammonia water clarification tank | Unit | 3 | Volume: 130 m³ |
| 10 | Pressure tar separator | Unit | 3 | Volume: 80 m³, Diameter: DN2600 mm, Length: 1600 mm |
| 11 | Water-containing tar filter | Unit | 3 | Diameter: DN500 mm, Height: 900 mm |
| 12 | Intermediate tank for circulating ammonia water | Unit | 1 | Volume: 170 m³, Diameter: DN6000 mm, Height: 6965 mm |
| 13 | Emergency intermediate tank for ammonia water | Unit | 1 | Volume: 170 m³, Diameter: DN6000 mm, Height: 6965 mm |
| 14 | Intermediate tank for residual ammonia water | Unit | 1 | Volume: 280 m³, Diameter: DN7700 mm, Height: 6965 mm |
| 15 | Hot water tank | Unit | 1 | Volume: 280 m³, Diameter: DN7700 mm, Height: 6965 mm |
| 16 | Tar residue cart | Unit | 1 | — |

Inspection route for primary cooling operators:
Under normal operating conditions, inspections should be carried out along the following route:
Mechanized ammonia water clarification tanks → Tank area → Circulating ammonia water pump room → Primary cooler condensate pump room → Flotation oil remover and primary cooler → Mechanized ammonia water clarification tanks, intermediate tank for circulating ammonia water, emergency tank for circulating ammonia water, residual ammonia water tank → Circulating ammonia water pump room, flotation oil remover, underground venting tank → Condensate water seals, oil distribution in condensate tanks, cooling water channels, primary cooler pump room, condensate spraying from primary coolers, temperature gradient of circulating cooling water.
Check whether the inflow and outflow volumes at the mechanized ammonia water clarification tanks remain balanced; inspect the operation status of scrapers; check for any leaks in the tanks; verify whether the oil level meets technical specifications; assess the condition of oil residues.
Timely remove residual oil at the bottom of tar intermediate tanks and circulating ammonia water tanks; check dehydration and temperature conditions of tar storage tanks; monitor liquid levels in all tanks.
All standby pumps in the tank area pump rooms must be rotated once per shift; inspect for any leaks or malfunctions in equipment and pipelines; check operational status of all pumps.
Assess oil removal efficiency of flotation oil removers; monitor pressure within containers and operational status of container pumps; check liquid level in the underground venting tank; verify water pressure in channels and detect any leaks.
Examine condensate distribution and oil allocation in water-sealed condensate tanks; monitor liquid levels and blockage prevention measures in condensate vents; ensure uniform condensate spraying from primary coolers; check water volume, temperature, gas temperature, and condensate discharge status; evaluate temperature differences across primary coolers.
For blowers: Rotate standby blowers; inspect sight glasses on elevated oil tanks; monitor on-site pressure and temperature; check return oil temperatures at bearings before and after blowers; monitor current flow and motor operation; assess overall blower performance and coupling operation.
Monitor inlet/outlet oil temperatures in hydraulic coupling oil cooling systems; inspect sight glasses on elevated oil tanks; check oil pressure and level in oil stations; monitor oil temperature; evaluate kidney-shaped oil filters and oil heat exchangers; verify water channel pressure and detect any leaks.
Check whether condensate vents are unobstructed; monitor liquid levels in condensate tanks and blockage prevention measures in vents; monitor steam pressure within the blower system.
For electrostatic tar precipitators: Measure oxygen content in gas, nitrogen pressure, preheating temperature of nitrogen, gas pressure, water seals, and ensure that drain pipes remain unobstructed.
1. Measure gas temperatures at the inlet and outlet of primary coolers; adjust the volume of chilled water accordingly to ensure that the outlet gas temperature complies with technical specifications. Adjust the outlet water temperature, flow rate, and pressure at each section to meet the specified requirements, ensuring an adequate amount of condensate is sprayed. 2. Check whether the drain pipe and water seal of the primary cooler are unobstructed. 3. Check the circulation and spraying of the condensate in the primary cooler, observe any changes in the resistance of the primary cooler, and clean it using hot ammonia solution based on the resistance levels. 4. Check the status of updates to the condensate system, and adjust the amount of condensate used for updating based on the liquid level in the condensate tank. 5. Check whether the ammonia in the three mechanical ammonia clarification tanks is uniform through the observation ports of these tanks; regularly verify that the oil-water interface in the mechanical ammonia clarification tanks meets the required standards, and promptly feed tar into the tar intermediate tank. 6. Check the liquid level in the circulating ammonia tank, and adjust the ammonia flow rate in the residual ammonia tank based on that level. 7. The amount of ammonia in the residual ammonia tank is not less than 2/3 of the tank’s height, ensuring a continuous and stable supply of residual ammonia to the ammonia vaporization tower. 8. Periodically pump oil into the intermediate tanks for circulating ammonia water, ammonia water in case of accidents, and excess ammonia water, to keep the liquid levels within the ranges specified by the process. 9. Continuously add tar to the system used for spraying condensate in the primary cooler, to ensure an adequate amount of condensate is sprayed. 10. Regularly check the operation of the scraper machine in the mechanized ammonia clarification tank. Check the discharge of tar residues, and be responsible for coordinating with the forklift to transport them to the coal yard. 11. Check whether there are any abnormal noises from the pumps in the circulating ammonia water pump room and the condensate pump room while they are operating normally; verify if there are any leaks in the sealing devices; check whether the base foot bolts are loose; and observe whether the oil level in the oil cups is sufficient. Check whether the current and voltage of each motor, as well as the flow rate, pressure, and temperature parameters of their pumps, meet the required standards; also measure the bearing temperature. Address any abnormalities promptly. 12. Conduct regular inspections of the air flotation oil removal unit to ensure its effective oil removal capacity. 13. Frequently check whether there are any leaks or other issues with the equipment and pipelines, and address any abnormalities promptly. Blower inspection route: When production is operating normally, conduct inspections along the following route: blower ammeter, suction gauge in front of the machine, condition of the machine’s operation, high-level oil tank, pressure gauge behind the machine, oil pump station, oil cooler, drain pipe, mist catcher, water seal tank, underground vent tank. 1. Regularly check the suction pressure in front of the machine and the pressure behind it. When the pressure change exceeds the specified limits, the cause should be identified promptly. Regular checks should be carried out on the temperature of various components, the current levels, and the operation status of the unit; any abnormalities detected must be addressed immediately, with reports submitted to the section chief and the dispatch officer. 2. Regularly inspect the oil system, oil coolers, and oil tank level to maintain normal pressure. In case of blockages in the oil circuits, oil leaks, drops in oil pressure, or a decrease in the oil tank level, these issues must be addressed promptly, and the situation reported to the dispatcher and section chief. 3. Regularly clean the drainage pipes to ensure their unobstructed flow, and promptly remove any condensation from within the blower unit and its pipelines; address any blockages immediately once they occur. 4. Rotate the standby unit during each shift to check whether its rotation is smooth.