Issues regarding the safety operating procedures for ammonia synthesis gas tanks,
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Who can tell me the safety operating procedures for ammonia gas storage tanks? Thank you firstI. Tasks of the Gas Tank Position
II. Preparatory work before receiving coke oven gas and startup procedures
III. Normal operation, operation under special conditions, and routine maintenance
IV. Shutdown procedures
V. Common faults and preventive measures
VI. Safety precautions
VII. Shift handover system for gas tanks
VIII. Handling of major accidents
IX. List of equipment
X. Table showing the relationship between gas tank height and the amount of gas stored
XI. Process flow diagram of the gas tank
I. Tasks of the Gas Tank Position: Store a certain amount of coke oven gas supplied by the chemical production unit, maintain the proper height of the gas tank, and ensure stable inlet pressure for the 6MD32‑314╱25 type compressor; However, when the gas supply for coking is suddenly interrupted or a fault occurs in a preceding process, it ensures that the compressor can operate at reduced load for a certain period of time or shut down properly. II. Preparatory work and startup steps before accepting coke oven gas (I) Preparation work 1. The equipment, pipelines, and valves have been installed in accordance with the design requirements. 2. The stairs and safety railings have been installed. 3. The water supply and drainage pipes, as well as the steam pipes, are unobstructed and leak-free. 4. The instruments are fully installed and are sensitive and functional. 5. Fill the water seal groove with water until it overflows, and conduct a settlement test. Observe the results of this test to check whether the settlement is uniform, and to detect any signs of tilting or leakage. 6. Introduce air for lifting tests to check the fit between the idler wheels and guide rails. Observe whether the lifting speed of each tower meets the requirements, and check for any tilting or derailment. While conducting the lifting tests, examine the airtightness of the gas tank and verify that the automatic alarm system functions properly, accurately determining the altitude at which the alarm is triggered ; When lifting or lowering the gas holder, the pressure inside the holder should be measured for each section of the tower lifted, to check whether it matches the design specifications. 7. The inlet and outlet pipes of the gas holder must be purged before accepting coke oven gas. 8. Before accepting coke oven gas, displacement is required; nitrogen is used as the displacement medium. The vent valve of the gas holder is utilized to raise and lower the pressure intermittently several times until the analyzed oxygen content is less than 0.5%, at which point it is considered acceptable. (II) Startup procedures: ⑴ Fill the sink with water until it overflows, fill the drain device (water seal) with water, and conduct a thorough inspection. ⑵After checking and confirming there are no issues, open the gas inlet valve; at the same time, open the vent valve at the top of the gas tank. Be careful not to allow too high a pressure of gas to enter the tank, so that the vent valve can function properly. ⑶After the gas is introduced into the gas holder (using gas as the displacement medium), nitrogen is expelled through the vent valve; samples are taken for analysis at the base of the vent valve located on the top of the holder. When the oxygen content is less than 0.5%, the vent valve is closed. When taking samples or closing the valve, it is necessary to wear an oxygen respirator and stand upwind to prevent poisoning or suffocation. ⑷After closing the vent valve, wait until the height of the gas tank rises above six meters, then open the outlet valve to supply gas to the 6MD32─314╱25 compressor. ⑸When driving in winter, the water temperature in the tank should be kept around 5°C. (It is advisable to keep it from freezing.) ⑹ When there is gas stored in the gas holder, and gas is supplied again after the coking process stops, it depends on the capacity of the holder; if the height of the holder is less than five meters, the inlet valve should be opened first. Only when the gas tank rises above six meters should the outlet valve be opened to release the gas. III. Normal operation, operation under special conditions, and daily maintenance: (I) Daily maintenance and normal operation: 1. The drain should be kept at the overflow level, with checks performed four times per shift. 2. Keep the sink, water circulation, and water seal in good condition; check them once per hour during winter. Steam should be passed through the steam pipes (at a level that prevents freezing). 3. During strong winds and in summer, the height of the gas tank should be reduced appropriately; on snowy days, the snow accumulated on the top of the tank must be removed to prevent slipping. 4. The drain valve at the bottom of the gas holder must be carefully managed and must not be tampered with. 5. Conduct regular inspections of the tower walls of the gas holder to check for any signs of friction, jamming, tilting, or debris in the tracks, in order to prevent accidents resulting from inadequate inspections. Number of inspections per shift: four times for the day shift, and two times for the middle-night shift. 6. Smoking, open flames, and throwing heavy objects are strictly prohibited within the gas holder area. 7. The valve room must be locked, and unauthorized persons are strictly prohibited from entering. 8. The idler wheels of the gas holder should be lubricated regularly to ensure proper lubrication. 9. The valve room is well-ventilated, with the fan running continuously. 10. Record the gas pressure inside and outside the cabinet once per hour; check and record the cabinet height every four hours; record the oxygen content in the gas inside the cabinet every four hours. Sampling and analysis are to be carried out by the laboratory, while the shift supervisor is responsible for making the arrangements. 11. Use an electric control valve to maintain the storage volume of coke oven gas in the gas tank between 5000 m3 and 25000 m3, ensuring normal gas supply from the compressor. (II) Operations under special circumstances: 1. When the oxygen content in the gas supplied for coking exceeds the specified limits: Upon receiving a notification from the laboratory or the control room responsible for desulfurization that the oxygen content is too high, the inlet and outlet valves of the gas tank should be closed immediately, and the bypass valve should be opened. If the oxygen content exceeds 0.8%, the bypass valve should be closed again, the vent valve at the inlet of the gas tank should be opened, and the main outlet valve of the gas tank should also be opened. The 6MD32 compressor should be instructed to reduce its load to the lowest level possible or to stop operating. The shift supervisor should inform the laboratory to take samples immediately to analyze the oxygen content in the gas inside the tank, and appropriate actions should be taken based on the results. 2. When the gas tank fails and cannot be used for maintenance, the bypass valve should be opened to supply gas; the inlet and outlet valves must be closed, and water seals should be installed at these ports. Once the water seals are filled, the vent valves on the inlet and outlet valves should be opened. The inlet and outlet valves must remain tightly closed. IV. Shutdown procedures: 1. When the gas holder needs to be isolated from the outside world for major or routine repairs, the bypass valve should be opened, and the inlet and outlet valves should be closed ; If necessary, fill the gas inlet and outlet pipes inside the cabinet with water to serve as a substitute for a water seal. 2. When draining water from the tank, it is necessary to first open the vent valve at the top of the gas holder to connect it to the atmosphere, and then open the drain valve at the bottom of the gas holder; meanwhile, the rate of water drainage should be checked regularly. Be careful not to release water too quickly, to prevent a negative pressure from forming inside the cabinet and causing the gas tank to collapse. 3. When parking temporarily, close the outlet valve as needed. When there is a temporary shutdown of gas supply for coking or chemical production, close the inlet valve, and depending on the situation, inform the compressor to reduce its operation rate or shut down ; If the gas holder height reaches the lower limit, the outlet valve should be closed to stop gas supply, and the bypass valve should be opened. V. Common faults and preventive measures: (I) Deflation of the bell jar: Causes: 1. When draining water from the gas tank’s water seal groove, the vent valve of the gas tank is not opened or is blocked by debris, resulting in negative pressure inside the gas tank. 2. The guide wheels at the upper and lower parts of the bell cover have come off their tracks, causing the bell cover to tilt and be unable to move. 3. The volume of coke oven gas entering the gas holder decreases, and adjustments are not made in a timely manner. Prevention measures: 1. Before draining water from the cabinet, check whether the drain valve is open and unobstructed; the water should not be drained too quickly. If any noises are heard from the top of the cabinet, stop draining water immediately. 2. Regularly check the sliding condition and lubrication of the guide rails; if severe wear is detected, adjustments or replacements should be made promptly. 3. Adjust the amount of coke oven gas in the vent tank in a timely manner; if necessary (when it is below 5 m), shut down the system. (II) Bell jar top flipping: Cause: The gas holder is too tall and the weather is too hot. Prevention measures: Operators should maintain regular communication with upstream and downstream processes, and strengthen inspections to prevent the gas tank from reaching an excessive height. Reduce the height of the gas holder appropriately when the temperature is too high. (III) Inflexible lifting of the bell cover or deviation of the bell cover: Cause: The guide wheel surfaces are not parallel, and there is severe friction on the guide wheels. The bell jar tilts, or the lift cabinet rises too high and is deflected by strong winds. Prevention measures: When looseness of the guide wheels is detected during production, or when the gap between the guide wheels and the guides increases or they become worn out, detailed records should be kept, and the workshop shall organize adjustments and repairs. (IV) When the oxygen content in the gas tank is higher than 0.8%, the vent should be opened and the tank filled with safe and qualified gas. VI. Safety Precautions: 1. When draining the water in the tank for maintenance of the gas holder, it is necessary to first fully open the vent valve. 2. Welding is strictly prohibited within 15 meters of the work area. If welding is necessary, a welding permit must be obtained and safety measures taken; welding may only proceed once all precautions have been ensured. 3. The workstation must be equipped with complete fire protection equipment, and the operators must be familiar with how to use it. 4. When maintaining the gas tank, be sure to close the inlet and outlet valves tightly, open the vent valve inside the tank and install a water seal; if necessary, use blind plates for isolation. 5. The valve room must be well-ventilated; a carbon monoxide mask should be worn when entering it. 6. It is strictly prohibited to enter the gas holder wearing iron shoes; persons who are not authorized for this gas holder are strictly forbidden from entering it. 7. When repairing equipment on the gas tank or in restricted areas, tools must be handled with care; no metal objects should be used for striking. Where necessary, butter should be applied or the area should be wetted with water. 8. Fire protection systems should be checked regularly to ensure that fire hoses and extinguishers are in good working condition. Fire-fighting equipment must be stored in designated locations. 9. Regular checks for leaks should be carried out, and any leaks found must be addressed promptly. Open flames must not be used in areas where there is a risk of coal gas. 10. When personnel from external organizations are involved, the department’s approval is required, and they must be accompanied by someone on duty. 11. Flammable, explosive items, as well as items unrelated to work, must not be stored in the control room. VII. Gas Tank Shift Handover Procedure 1. Before handing over the shift, the person leaving duty must conduct a thorough inspection of the gas tank and all associated equipment. Special attention should be paid to the overflow pipes, water supply valves, and the water collection tanks for inlet and outlet pipes, with records to be kept. 2. Before handing over the shift, the person handing over the shift carefully counts and records all tools and fire-fighting equipment. 3. During the handover, the person handing over the duties must provide a thorough and detailed account of all aspects to the person taking over, without any omissions. 4. During shift handover, if an emergency occurs or the maintenance of the equipment for the current shift has not been completed, the person handing over the shift must handle the situation together with the person taking over, or obtain the latter’s permission before filling out the shift handover record and leaving the post. 5. The person taking over the shift should be in good physical condition; they must arrive at their post 10 minutes ahead of the scheduled time, conduct a thorough inspection of the gas tanks and all equipment, and get ready to take over the shift. 6. Conduct a thorough inventory of tools and fire-fighting equipment, and check to ensure they are in good condition. Any missing tools or fire-fighting equipment should be noted on the record sheet, with signatures from both parties. 7. The person taking over should listen carefully to the instructions given by the person handing over the shift regarding the gas tank and all equipment, and also examine the operation records thoroughly. 8. When taking over the shift and encountering an unexpected incident or finding that equipment repairs have not yet been completed, the person taking over should proactively understand the situation, assist in resolving it, and keep proper handover records. VIII. Handling of Major Accidents 1. Roof collapse of the gas holder – Causes ; It is caused by excessive pressure, lack of water in the water seal, freezing in winter, etc. Treatment method ; Control the intake air to replenish the water seal in a timely manner, or automatically fill it with water after the level drops naturally. 2. Reasons for water shortage in the gas holder ; It is caused by natural evaporation or freezing in winter. Treatment method ; Regular observation is necessary; water should be added daily during spring and autumn, heating should be provided in winter to maintain warmth, and water can be added twice a week in summer to keep the water level at an appropriate level. 3. Reasons for vacuuming the gas holder ; The water tank of the gas holder discharges a large amount of water or gas, resulting in insufficient gas supply. Treatment method ; Perform emergency adjustments 4. Handling methods for water ingress in gas tanks ; The large water seal should be opened, the vent blind plates removed, air should be vented out of the cabinet, and then each tower should be placed into the water tank. Management needs to be strengthened to prevent such accidents from occurring. IX. Key operating points for the gas tank: 1. This gas tank can withstand winds of force 7; its volume is 30,000 cubic meters. In cases of winds stronger than force 7, the height of the gas tank shall not exceed that of its first section, and its volume shall not be more than 10,000 cubic meters. 2. Adjust the height of the gas holder appropriately according to weather and wind speed. 3. Alarm when the gas holder volume exceeds 25,000 m3. (1/2 height of Section 3) 4. The height of the gas tank is controlled by an electric valve on the main gas pipeline.