Safety Measures for NCG Transportation in Fuel Reuse Application

Safety Measures for NCG Transportation in Fuel Reuse Application

The transportation process of non-condensable gas (NCG) for fuel reuse needs to focus on three core objectives: leakage prevention, overpressure prevention and flashback prevention, and implement the following safety measures:

Pipeline and Material Selection

The conveying pipelines shall be made of corrosion-resistant and pressure-resistant materials such as carbon steel or stainless steel, which are suitable for NCG medium containing trace hydrogen sulfide, so as to avoid pipeline leakage caused by corrosion perforation. Meanwhile, the pipelines shall be designed in accordance with relevant pressure standards, and their pressure resistance rating shall be more than 1.5 times the normal working pressure to prevent rupture due to overpressure.

Pressure and Flow Control

The pipeline system shall be equipped with pressure regulators and flowmeters to stabilize the NCG conveying pressure within the safe range of 0.05–0.1 MPa, avoiding valve erosion due to excessive pressure and insufficient energy supply of burners due to insufficient pressure. Pressure gauges shall be installed at key nodes of the pipelines to monitor pressure changes in real time, and issue early warning signals promptly in case of overpressure or underpressure.

Configuration of Safety Protection Devices

Emergency shut-off valves shall be installed at the positions of pipelines close to the heating chamber and storage tanks, and the valves shall have both manual and automatic control functions, which can quickly cut off the gas supply in the event of leakage, overpressure or flameout.

A flashback arrester shall be installed at the end of the pipeline near the burner to prevent flame from backfiring into the pipeline and causing deflagration, thus ensuring the safety of the gas source side.

Flammable gas leak detectors shall be arranged in areas where pipelines are prone to leakage (such as flanges and valve interfaces). The detectors shall be linked with audible and visual alarms, and once the gas concentration exceeds the standard, the alarm shall be triggered immediately and the shut-off valve shall be linked to close the gas supply.

Laying and Maintenance Requirements

Pipeline laying shall avoid passing through densely populated areas; protective supports shall be set for overhead laying, and anti-corrosion layers and warning signs shall be provided for underground laying. Regular air tightness testing and maintenance shall be carried out on pipelines, valves and flanges, and aging seals shall be replaced in a timely manner to eliminate leakage hazards.

Emergency Disposal Supporting Facilities

The transportation system shall be equipped with emergency vent pipelines connected to the torch system. During equipment startup/shutdown or fault overpressure, the surplus NCG can be safely discharged and incinerated to avoid safety risks caused by direct venting.