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Hazard Visualization Case √ Background: A polysilicon enterprise's chlor-alkali workshop and cold hydrogenation workshop faced significant issues such as large process fluctuations and frequent maintenance, posing great accident risks and hazards. The biggest challenge they encountered was the inability to timely detect hidden dangers and see risks, leading to ineffective control measures. √ Solution: The Danger Vision system was deployed at three key points: the hydrogen washing and compression in the chlor-alkali workshop, the secondary brine electrolysis system, and the silicon powder feeding in the cold hydrogenation workshop, to comprehensively monitor production process risks. √ Results: Within one month of the system going live, the customer successfully identified 480 potential incidents, including unauthorized operations (such as changing alarm values without permission), equipment malfunctions, discrepancies between actual configurations and HAZOP reports, design errors (such as interlocks being triggered but still considered normal due to alarms + manual intervention), and abnormal operating conditions. By examining and confirming each discovered protective layer event, analyzing problems, and implementing corresponding corrective actions, the identified hazards were promptly and effectively addressed, significantly improving safety management levels.
The wireless intelligent safety valve condition real-time monitoring system Case √ Background: An industrial gas company encountered issues with abnormally increased torch flames over a period of time. This phenomenon not only resulted in material loss and energy consumption but also posed safety and environmental risks. √ Solution: XiaoAn-Digital's wireless intelligent safety valve status real-time monitoring system was installed across the entire torch system (45 monitors). After one month of observation, analysis, and supporting verification methods, a preliminary judgment was made on which valves might have leakage issues. √ Results: The system achieved comprehensive monitoring of the torch system valves, enabling immediate identification and precise location of leaking valves. Through monitoring and analysis, it was identified and confirmed that 12.5% of the safety valves had leaks.
The wireless intelligent safety valve condition real-time monitoring system √ Background: A domestic polysilicon enterprise has thousands of safety valves and an equal number of supporting ball valves spread across its production site. Traditional management methods such as manual inspection, tagging, and lead sealing are challenging to keep up with the real-time status of fully open/not fully open valves when dealing with such a large number of valves, posing significant safety hazards (e.g., if the manual stop valves upstream and downstream of safety valves or bursting discs are closed, they are considered major hazards). √ Solution: To address this issue, the company installed a pilot remote monitoring system for the manual worm gear ball valve positions before and after certain safety valves in the cold hydrogenation workshop. √ Results: Within three months, the system successfully monitored 28 instances of unauthorized operations leading to state changes and promptly notified relevant managers through SMS alerts, visual displays on the master control unit, and log records. The introduction of the system allowed the company to grasp the valve status in real time, laying a solid foundation for the successful experience of this project to be promoted throughout the plant.
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