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Question Bank for the Reaction Shift in Coaxial Catalytic Cracking Units
Table of Contents
Chapter 1: Probation Assessment Questions and Answers for the Reaction Shift
1. Probation Test Paper A
2. Probation Test Paper B
3. Probation Test Paper C
4. Probation Test Paper D
5. Probation Test Paper E
6. Answers to Probation Test Paper A
7. Answers to Probation Test Paper B
8. Answers to Probation Test Paper C
9. Answers to Probation Test Paper D
10. Answers to Probation Test Paper E

Probation Assessment Test Paper A for the Reaction Shift in Catalysis Workshop II
Name:　　　　Score:　　　　

I. Definition of Terms (4 × 5’ = 20’)
1. Regenerated catalyst:
2. Catalyst bridging:
3. Catalyst activity:
4. Dry pot:

II. Fill-in-the-Blank Questions (30 × 1’ = 30’)
1. The air supply to the auxiliary combustion furnace is divided into two streams, referred to as _____ and _____ respectively. One stream enters the furnace chamber, while the other enters the jacket surrounding the reactor shell. During the start-up heating process, it is required that the furnace chamber temperature does not exceed _____, and the outlet temperature of the furnace does not exceed _____. 2. During normal production, the main method for adjusting the reaction temperature is to adjust ; auxiliary methods involve adjusting . 3. The reserve in the stripping section is mainly adjusted. 4. Before entering the lift pipe, the raw materials are heat-exchanged with , , , respectively. 5. Inside the regenerator, there is a group of parallel-stage cyclone separators. 6. The pressure control method for the settler is normal when it is . 7. Petroleum is a complex mixture, primarily composed of and compounds; the former accounts for , while the latter accounts for . It also contains , , , and trace metal and non-metal elements. 8. The opening and closing of the valve are referenced to the direction of the handwheel; counterclockwise means opening. 9. The regeneration temperature of the reaction catalyst is at ℃ ； The pressures of the two devices, in order from highest to lowest, are >. 10. The solids referred to in the solid content of the oil slurry are . 11. Secondary combustion refers to combustion in the dilute phase of the regenerator. III. Short-answer Questions (4×6′=24′) 1. What are the purposes of periodic discharge and continuous discharge? 2. What are the hazards of secondary combustion? 3. What precautions should be taken when igniting furnace 2101? 4. What are the principles for handling accidents at reaction stations? IV. Essay Questions (26′) 1. How is fuel injection performed at the start of operation? Precautions? (8′) 2. What are the causes and symptoms of sudden interruptions in reaction raw materials, and how are such incidents handled? (8′) 3. List the main steps involved in starting up this position, as well as the precautions for each step. (10′) Test Paper B for the Reactor Operator Position in Catalyst Production Workshop II Name:　　 　Score:　　　　 　I. Term Explanations (4×5′=20′) 1. Reaction time: 2. Spent catalyst: 3. Catalyst collapse: 4. Catalyst circulation rate: II. Fill-in-the-Blanks (30×1′=30′) 1. The purpose of adding an oxidizer is to prevent and eliminate the occurrence of … caused by the dilute phase in the regenerator. 2. The inventory in the stripping section is mainly adjusted. 3. The valve model and code are indicated as: Z ； J ； H ； A ； T. 4. The opening and closing of the valve is referenced to the direction of rotation of the handwheel; counterclockwise is . 5. The reaction catalyst regeneration temperature is at ℃ ； The pressures of the two devices, in order from highest to lowest, are >. 6. Completely burning CO to CO2 inside the regenerator; this type of regeneration is called . 7. Activity reflects the performance of a catalyst. 8. The fuel-to-oil ratio refers to the ratio to it. 9. The reaction steam pressure is generally controlled at MPa, the regenerator pressure at MPa, and the settler pressure at MPa. 10. The function of a metal passivator is . 11. The reactor inventory mainly refers to the inventory of and ; generally, the inventory of is at the zero-level operation state, while the inventory is primarily concentrated in . 12. The function of the pre-lifting section is . 13. A valve that closes when there is signal pressure and opens when there is no signal pressure is called a . 14. After enabling self-protection, one should go to the site to check and turn it off. 15. My plant’s process control utilizes a system, and to ensure the safe operation of the plant, a system is also used. III. Short-answer Questions (4×6′=24′) 1. What are the purposes of periodic discharge and continuous discharge? 2. What is the function of the primary and secondary air in furnace 2101? 3. Briefly describe what factors influence the reaction temperature? 4. Under what conditions should feeding be stopped urgently in the device? IV. Essay Questions (26′) 1. How is fuel injection performed at the start of operation? Precautions? (8′) 2. What is the phenomenon of water in the crude oil? How to handle it? (8′) 3. What emergency measures should the response personnel take in case of a sudden power outage? (10′) Test Paper C for Qualification Assessment of Reaction Operators in Catalyst Production Workshop 2 Name:　　 Score:　　　　 I. Term Explanations (4×5′=20′) 1. Equilibrium catalyst: 2. Secondary combustion: 3. Reaction time: 4. Fuel-to-oil ratio: II. Fill-in-the-Blanks (30×1′=30′) 1. The purpose of adding an oxidizer is to prevent and eliminate ＿＿ in the dilute phase of the regenerator, which leads to ＿＿＿＿. 2. During normal production, the main method for adjusting the reaction temperature is to adjust ＿＿＿＿＿＿＿ in order to regulate ＿＿＿＿＿＿； auxiliary methods involve adjusting ＿＿＿＿＿＿＿. 3. The air supply to the auxiliary combustion furnace is divided into two streams, named ＿＿＿ and ＿＿＿； ＿＿＿ enters the furnace chamber, while ＿＿＿ goes into the jacket of the cylinder. During the startup and heating process, it is required that the temperature in the furnace chamber not exceed ＿＿℃, and the temperature at the furnace outlet not exceed ＿＿℃. 4. Before entering the lift pipe, the raw materials exchange heat with ＿＿, ＿＿, ＿＿, and ＿＿ respectively. 5. The catalytic unit is used in the ＿＿ processing process; it generally uses heavy oils such as ＿＿＿＿＿, ＿＿＿＿, and ＿＿ as raw materials, and under the action of a catalyst, cracking reactions take place. The end products are ＿＿, ＿＿, ＿＿, ＿＿, etc. 6. The main driving forces for fluidization in the two reactors are ＿＿＿＿, ＿＿＿＿＿ ； The reaction temperature is generally ＿＿＿＿＿ °C. 7. When the storage capacities of the two devices overlap, it will cause ＿＿＿＿＿＿＿＿＿＿＿＿＿＿; if this situation is difficult to control, one should immediately ＿＿＿＿＿＿＿＿＿. 8. The function of the pre-lifting section is ＿＿＿＿＿＿＿＿＿＿＿＿＿＿＿＿＿. 9. The function of the stripping section is ______________________________________. III. Short-answer Questions (4×6′=24′) 1. Why does secondary combustion occur? How to prevent and handle it? 2. How to carry out the injection of combustion oil at the start of operation? Precautions? 3. What is the role of an oxidizer? 4. What are the hazards of a boiler being full of water? What is the handling method? III. Essay questions (26 points) 1. Briefly describe the factors that affect reaction pressure? (8′) 2. Catalyst bridging (reasons and treatment methods). (8′) 3. List the main steps for starting up this position, as well as the precautions for each step. (10′) Test Paper D for Qualification Assessment of Reaction Operators in Catalyst Production Workshop 2 Name:　　 Score: I. Term Explanations (4×5′=20′) 1. Oil-to-catalyst ratio: 2. Regeneration catalyst: 3. Carbon deposition: 4. Catalyst circulation rate: II. Fill-in-the-blank Questions (30×1′=30′) 1. The inventory in the stripping section is mainly regulated by . 2. The depth of the catalytic cracking reaction is expressed in terms of . 3. Before entering the lift pipe, the raw materials are heat-exchanged with , , , respectively. 4. The pressure control method for the settler is normal when it is . 5. Regenerator pressure control methods and . 6. The catalytic unit is a processing facility in which heavy oils such as , , and others are used as raw materials; under the action of a catalyst, cracking reactions take place, resulting in products such as , , , and others. 7. Seamless steel pipe Ø159×5 indicates that the inner diameter of the pipe is: mm ； The wall thickness is: mm. 8. Completely burning CO to CO2 inside the regenerator – this type of regeneration is called . 9. The higher the regeneration pressure, the faster the charring rate. 10. The regeneration process mainly involves burning off the substance on the catalyst. 11. Secondary combustion refers to combustion in the dilute phase of the regenerator. 12. If water is supplied to the boiler when it is severely underwater, it will happen. 13. The purpose of using a metal passivator is . 14. A valve that closes when there is signal pressure and opens when there is no signal pressure is called a . 15. The purpose of regular sewage discharge is . The purpose of continuous wastewater discharge is . 16. After activating self-protection, go to the site for inspection and shut it down. III. Essay Questions (4×6′=24′) 1. What is catalyst poisoning? 2. Describe the working principle of a cyclone separator? 3. Why is atomizing steam needed for the reaction feed? 4. When installing the catalyst in the reactor, why is it necessary to do it quickly at first, but then slowly after some time? IV. Essay questions (26 points) 1. What is the phenomenon of water being present in crude oil? How to handle it? (8′) 2. When is the regenerator burn oil activated? What should be kept in mind when enabling it? (8′) 3. List the main steps involved in starting up this position, as well as the precautions for each step. (10′) Test Paper E for the Reactor Operator Position in Catalyst Production Workshop. Name:　　 Score: I. Term explanations (4×5′=20′) 1. Reaction time: 2. Reconversion ratio: 3. Complete regeneration: 4. Total catalyst inventory: II. Fill-in-the-blank questions (30×1′=30′) 1. Catalyst selectivity is the ability of the catalyst to convert the feedstock into . 2. During normal production, the main method for adjusting the reaction temperature is to adjust ; auxiliary methods involve adjusting . 3. The reserve in the stripping section is mainly adjusted. 4. The regenerator contains groups of parallel cyclone separators. 5. The pressure control method for the settler is normal when it is . 6. Regenerator pressure control measures and. 7. The catalytic unit is a processing system that uses heavy oils such as , , and others as raw materials; under the action of a catalyst, cracking reactions take place, resulting in products such as , , , and others. 8. The opening and closing of the valve are referenced to the direction of the handwheel; counterclockwise means opening. 9. The measures commonly taken to prevent secondary combustion are and . 10. The solids referred to in the solid content of the oil slurry are . 11. In the stripping section, the catalyst comes into contact with the stripping steam through contact. 12. The function of the flap valve in a cyclone separator is . 13. Activity reflects the performance of a catalyst. 14. The function of the water seal tank on the flue pipeline is . 15. The phenomenon where the catalyst circulation is interrupted in an inclined pipe is called. 16. If water is supplied to the boiler when it is severely underwater, it will happen. 17. The function of using metal passivators is. III. Short Answer Questions (4×5′=20′) 1. What is the function of a cyclone separator? 2. Under what circumstances should a waste heat boiler be shut down urgently? 3. What precautions should be taken when igniting furnace 2101? 4. What are the principles for handling accidents at reaction stations? IV. Essay Questions (4×5′=20′) 1. How is the injection of combustion oil carried out at the start of operation? Precautions? (8′) 2. What are the hazards of low water level in a boiler? What is the method for dealing with a boiler running low on water? (8′) 3. What emergency measures should the response personnel take in case of a sudden power outage? (10′) Answers to Test Paper A for the Qualification Assessment of the Reaction Operator in Catalyst Production Workshop 2 Name:　　 Score:　　　　 I. Term Explanations (4×5′=20′) 1. Regenerated catalyst: A catalyst that has been regenerated and comes out of the regenerator, with most of the carbon deposits removed from it. 2. Catalyst bridging: refers to the interruption of catalyst circulation in the regenerated inclined tube (or the upcoming vertical tube). 3. Catalyst activity: Reflects the catalyst’s ability to accelerate reaction rates. 4. Dry furnace: A severe water shortage in a boiler that occurs when the temperature in the furnace is too high or the water supply is insufficient, resulting in more gas being produced than water entering the system. II. Fill-in-the-blank questions (30×1′=30′) 1. The air supply to the auxiliary combustion furnace is divided into two streams, known as primary air and secondary air. The primary air enters the furnace chamber, while the secondary air enters the jacket of the cylinder. During the startup and heating process, it is required that the temperature in the furnace chamber not exceed 950°C, and the temperature at the furnace outlet not exceed 680°C. 2. During normal production, the main method for adjusting the reaction temperature is to control the opening degree of the regeneration slide valve in order to regulate the catalyst circulation rate; an auxiliary method is to adjust the preheating temperature of the feedstock. 3. The inventory in the stripping section is mainly adjusted by the opening degree of the raw material stop valve. 4. Before entering the lift pipe, the raw material exchanges heat with top circulation fluid, diesel, intermediate fluid, and slurry respectively. 5. The regenerator contains seven sets of parallel two-stage cyclone separators. 6. When the pressure control methods for the settler are functioning properly, it involves controlling the opening degree of the oil and gas butterfly valve at the top of the fractionation tower and the speed of the air compressor. 7. Oil is a complex mixture primarily composed of C and H compounds, with the former accounting for 83-87% and the latter for 11-14%. It also contains trace elements of N, O, S, and metals and non-metals. 8. The opening and closing of the valve are referenced to the direction of the handwheel; counterclockwise means open. 9. The reaction catalyst regeneration temperature is 650–700℃ ； The pressures of the two units, in order from highest to lowest, are regenerator pressure > settler pressure. 10. The solid content in the slurry refers to the amount of catalyst present in the slurry. 11. Secondary combustion refers to the combustion of CO in the dilute phase of the regenerator. III. Short-answer Questions (4×6′=24′) 1. What are the purposes of periodic discharge and continuous discharge? Answer: The purpose of regular sewage discharge is to remove the sludge and sediment formed inside the furnace or drum, and to adjust the quality of the water within them. The purpose of continuous discharge is to prevent an increase in salt content and maintain stable water quality. 2. What are the hazards of secondary combustion? Answer: Secondary combustion occurs because the mechanical strength of the equipment materials decreases at high temperatures, leading to the rupture of the lining, damage to the cyclone, deformation of the gas collection chamber, and severe damage that results in accidents. Additionally, at high temperatures, the catalyst can be damaged or fail. 3. What precautions should be taken when igniting furnace 2101? Answer: ① The O2 content in the gas must be <1% to enable ignition ； (20% of the total score) ② Install a gas heater to prevent gas from carrying liquid ； (40% of the total score) ③ After igniting the burner, adjust the primary air flow immediately to prevent overheating of the furnace. (40% of the total score) 4. What are the principles for handling accidents at reaction sites? 1) Under any circumstances, the catalyst reserves of the reaction-regeneration systems must not exhaust each other. (15% of the total score) 2) A fluidizing medium must be introduced into the reaction-regeneration system to prevent collapse or dead bed. (10% of the total score) 3) Once the main air supply is interrupted, the feed must be stopped immediately, and the combustion oil supply must also be halted. (15% of the total score) 4) Under feeding conditions, the exit temperature of the lift pipe must not be lower than 450°C; if it is not possible to raise it at that time, the feed should be stopped. (15% of the total score) 5) When the main fan is stopped and the feed is cut off, the temperature of both reactors must remain above 400°C; if it drops below this level, the catalyst should be removed. (10% of the total score) 6) When there is catalyst circulation in the reaction-regeneration system, oil slurry circulation must be maintained. If the slurry circulation is interrupted for an extended period, it should be switched to single-regenerator fluidization or, depending on the circumstances, the catalyst should be discharged. (10% of the total score) IV. Essay question (26 minutes) 1. How is fuel injection performed at the start of operation? Precautions? (8′) Answer: ① First, direct the burning oil to circulate in front of the control valve to separate water ； (20% of the total score) ② Combustion oil can be injected when the temperature of the regenerator bed reaches 380°C and the bed level is 2.2 m above the combustion nozzle. (20% of the total score) Notes: ① Make sure to drain the water completely before use ； (10% of the total score) ② The injection amount should not be too large ； (20% of the total score) ③ If a spray does not succeed, close the fuel valve and wait until the bed temperature rises before attempting to spray again. (30% of the total score) 4. What should be noted after injecting fuel into the lift pipe? Answer: ① Control the reaction temperature properly; it is not advisable to adjust the reaction temperature by changing the feed rate ； (30% of the total score) ② There is rich gas after fuel injection; the reaction pressure is controlled by the flare valve at the inlet of the compressor ； (30% of the total score) ③ Be careful to avoid burning; reduce the amount of fuel used for combustion in a timely manner to prevent carbon buildup. (40% of the total score) 2. What are the causes and symptoms of sudden interruptions in reaction raw materials, and how should such accidents be handled? (8′) Cause of the accident: 1) The crude oil pump is damaged or has an unrecoverable fault. (10% of the total score) 2) The crude oil contains a high level of water. (10% of the total score) Handling method: Indoors: 1) Activate the feed self-protection system, and cut off the feed as well as the two devices. (10% of the total score) 2) Use a flare at the outlet of the pressure compressor, as well as stripping steam, etc., to balance the pressure in the vessels. (10% of the total score) 3) Control the liquid level in the external heat exchanger drum properly. (10% of the total score) Outdoor: 1) Quickly close the second hand valve of the feed nozzle, as well as the hand valves for the slurry, pre-heated dry gas, and terminator. (10% of the total score) 2) Change the regenerative slide valve and the unregenerated plug valve to manual shut-off mode. (10% of the total score) 3) Check the operation of the self-protection functions; if they are not functioning, carry out the operations manually. (10% of the total score) 4) Open the pre-boost steam manual valve. (10% of the total score) 5) Introduce the burning oil to the nozzle for dehydration, and control the temperature of the regenerator properly. (10% of the total score) 3. List the main steps involved in starting up this position, as well as the precautions for each step. (10′) Answer: I. Conduct a thorough inspection – it is essential to be careful and meticulous, and to keep proper records ； (10% of the total score) II. System purging and airtightness testing: Steam must not be introduced into the regenerator; the pressure should be increased to 0.18–0.2 MPa as much as possible. (15% of the total score) III. Ignition of furnace 2101 and heating of the two reactors: The heating process must be carried out strictly in accordance with the specified temperature rise curve to prevent large fluctuations in temperature ； (15% of the total score) IV. Loading the catalyst: First, quickly install the sealing legs; ensure that the pressure in the settler is slightly higher than that in the regenerator. (15% of the total score) V. Removing air from the reactor: Ensure proper drainage of steam, and introduce steam slowly. (10% of the total score) VI. Establishing fluidization in both reactors: Ensure normal fluidization in both reactors; proceed slowly at the beginning of the fluidization process to maintain an appropriate pressure difference between the two reactors. (15% of the total score) VII. Removing the large blind flange for oil and gas: Maintain a slight positive pressure in the settler, and work closely with the distillation team to prevent catalyst from entering the distillation tower ； (10% of the total score) VIII. Reaction injection, startup, and adjustment of operations. Feeding material must be carried out only after the injection conditions are met. (10% of the total score) Answer Key for Test B – Reactor Operator Position, Catalysis Workshop II Name:　　 Score:　　　　 I. Term Explanations (4×5′=20′) 1. Reaction time: The time during which the raw materials are in contact with the catalyst and undergo a reaction. 2. Catalyst to be regenerated: refers to the catalyst that has undergone a catalytic reaction and comes out of the stripping section of the settler, with carbon deposits on its surface. 3. Catalyst collapse: refers to the sudden decrease in the amount of catalyst present in the regenerator (or settler). 4. Catalyst circulation rate: The amount of catalyst that flows from the regenerator into the reactor per hour is called the catalyst circulation rate. II. Fill-in-the-blank questions (30×1′=30′) 1. The purpose of adding an oxidizer is to prevent and eliminate secondary combustion caused by CO in the dilute phase of the regenerator. 2. The inventory in the stripping section is mainly adjusted by the opening degree of the raw material stop valve. 3. The valve model and code are indicated as: Z gate valve ； J shut-off valve ； H check valve ； A safety valve ； T-regulating valve. 4. The opening and closing of the valve are referenced to the direction of the handwheel; counterclockwise means opening. 5. The reaction catalyst regeneration temperature is 650–700℃ ； The pressures of the two units, in order from highest to lowest, are regenerator pressure > settler pressure. 6. The CO is completely burned to CO2 inside the regenerator; this type of regeneration is called complete regeneration. 7. Activity is a property that reflects a catalyst’s ability to accelerate reaction rates. 8. The catalyst-to-oil ratio refers to the ratio of the catalyst circulation rate to the total feed rate. 9. The reaction steam pressure is generally controlled at 1.0 MPa, the regenerator pressure at 0.24 MPa, and the settler pressure at 0.20 MPa. 10. The role of using metal passivators is to suppress the degradation of catalyst activity and selectivity caused by heavy metals. 11. The reactor inventory mainly refers to the inventory in the settler and the stripping section; generally, the inventory in the settler is at zero level during operation, with the inventory being concentrated primarily in the stripping section. 12. The pre-raising section serves to provide the reaction with a regenerated catalyst in a well-fluidized state. 13. A air-to-close valve is one in which the valve closes when there is signal pressure and opens when there is no signal pressure. 14. After activating the self-protection function, go to the site to check the self-protection valve and shut down the feed nozzle. 15. The process control of my plant utilizes a Distributed Control System (DCS), and an Emergency Shutdown system (ESD) is employed to ensure the safe operation of the plant. III. Short-answer Questions (4×6′=24′) 1. What are the purposes of periodic discharge and continuous discharge? Answer: The purpose of regular sewage discharge is to remove the sludge and sediment formed inside the furnace or drum, and to adjust the quality of the water within them. The purpose of continuous discharge is to prevent an increase in salt content and maintain stable water quality. 2. What is the function of the primary and secondary air in furnace 2101? Answer: The primary air flows through the furnace; its function is to supply air for combustion and to regulate the furnace temperature ； The secondary air mixes with the high-temperature flue gas at the furnace outlet within the annular jacket, which can lower the furnace outlet temperature and prevent damage to the distribution pipes; it can also raise the temperature of the main air. 3. Briefly describe what factors influence the reaction temperature? 1. Variations in the opening degree of the single-acting slide valve (accounting for 10% of the total score)
2. Changes in the total feed rate to the reactor (accounting for 10% of the total score)
3. Variations in the temperature of the preheated feed (accounting for 10% of the total score)
4. Changes in the temperature of the regeneration bed (accounting for 10% of the total score)
5. Presence of water in the raw materials (accounting for 5% of the total score)
6. Excessive amount of steam used for pre-lifting or feed atomization, or presence of water in such steam (accounting for 5% of the total score)
7. Activation of the small-scale feeding system (accounting for 10% of the total score)
8. Blockage or coking in the riser (accounting for 5% of the total score)
9. Presence of water in the quench agent or liquid in the dry gas used as quench agent (accounting for 10% of the total score)
10. Variations in the quantity and temperature of the quench agent (accounting for 5% of the total score)
11. Changes in the amount of dry gas used for pre-lifting (accounting for 5% of the total score)
12. Significant fluctuations in the differential pressure between the two reactors (accounting for 10% of the total score)
13. Malfunction of instruments or single-acting slide valves (accounting for 5% of the total score)
Under what circumstances should the feed be urgently cut off in the unit? (1) Main blower shutdown due to malfunction. (10% of the total score) (2) The catalyst stops flowing or flows in reverse. (15% of the total score) (3) Severe carbon buildup prevents production from continuing. (15% of the total marks) (4) The feed flow rate is too low and cannot be remedied. (10% of the total score) (5) The catalyst loss is too high and cannot be controlled, making it impossible to maintain normal production. (15% of the total score) (6) Prolonged interruptions of water, electricity, steam, and air supply. (Accounting for 10% of the total score) (7) When critical equipment suddenly experiences irrecoverable malfunctions, or accidents such as explosions and fires occur, making it impossible to maintain production. (10% of the total score) (8) When the lift pipe is in use with feed, its outlet temperature is below 440°C, preventing normal operation. (15% of the total score) IV. Essay questions (26 points) 1. How should the operation of spraying fuel oil be carried out during startup? Precautions? (8′) Answer: ① First, direct the burning oil to circulate in front of the control valve to separate water ； (20% of the total score) ② Combustion oil can be injected when the temperature of the regenerator bed reaches 380°C and the bed level is 2.2 m above the combustion nozzle. (20% of the total score) Notes: ① Make sure to drain the water completely before use ； (10% of the total score) ② The injection amount should not be too large ； (20% of the total score) ③ If a spray does not succeed, close the fuel valve and wait until the bed temperature rises before attempting to spray again. (30% of the total score) 4. What should be noted after injecting fuel into the lift pipe? Answer: ① Control the reaction temperature properly; it is not advisable to adjust the reaction temperature by changing the feed rate ； (30% of the total score) ② There is rich gas after fuel injection; the reaction pressure is controlled by the flare valve at the inlet of the compressor ； (30% of the total score) ③ Be careful to avoid burning; reduce the amount of fuel used for combustion in a timely manner to prevent carbon buildup. (40% of the total score) 2. What is the phenomenon of water being present in crude oil? How to handle it? (8′) Answer: The symptoms of water being present in the feedstock oil are: unstable total feed flow rate, increased reaction pressure, and a decrease in the riser outlet temperature. When water is present in the crude oil, the feed rate should be significantly reduced, and the preheating temperature of the crude oil should be appropriately lowered to decrease the amount of vaporization. When there is severe water contamination in the crude oil, the feed should be cut off. At the same time, timely contact should be made with dispatch and the tank farm to carry out tank switching or other measures. 3. What emergency measures should be taken by response personnel in the event of a sudden power outage? (10′) (1) The individual relief valves are activated one after another; pay close attention to the feedback from the various control valves involved in the self-protection mechanism. (Accounting for 15% of the total score) (2) Immediately fully open the main torch valve and Valve B to prevent pressure buildup in the reaction system; close Anti-surge Valve C. (15% of the total score) (3) Increase the amount of stripping steam to drive out all the oil and gas from the settler, thereby preventing coking due to temperature drops caused by prolonged power outages. (15% of the total score) (4) Depending on the steam and wind pressure levels, slowly close the main accident steam valves, as well as the valves used for loosening, backflow control, and focus prevention ； Close the F2201 primary and secondary air valves. (15% of the total score) (5) The blowout preventer uses an accumulator to track the contraction of the riser, thereby preventing accidents caused by backflow of oil and gas due to riser contraction. (15% of the total score) (6) Shut off the emergency steam to the startup sleeve. (10% of the total score) (7) Redirect the feed oil and slurry to the return line at the nozzle; close the pre-lift dry gas hand valve and the terminator hand valve, and reset the feed self-protection system. (15% of the total score) Answer Key for Test C – Reaction Operator Position in Catalyst Production Workshop 2 Name:　　 Score:　　　　 I. Definition of Terms (4×5′=20′) 1. Equilibrium catalyst: After being used for a certain period of time, the activity of a fresh catalyst gradually decreases. At this point, a small amount of catalyst should be added gradually to maintain a relatively stable level of activity – the equilibrium activity. The catalyst at this stage is called an equilibrium catalyst. 2. Secondary combustion: At certain temperatures, if the oxygen content in the flue gas from the regenerator is too high, it can lead to further combustion of CO present in the flue gas. This type of combustion, in which CO is converted into CO2 within the dilute flue gas, is known as secondary combustion. 3. Reaction time: The duration for which the raw material is in contact with the catalyst and undergoes reaction. 4. Catalyst-to-feed ratio: the ratio of the catalyst circulation volume to the total reaction feed volume. II. Fill-in-the-blank questions (30×1′=30′) 1. The purpose of adding an oxidizer is to prevent and eliminate secondary combustion caused by CO in the dilute phase of the regenerator. 2. During normal production, the main method for adjusting the reaction temperature is to control the opening degree of the regeneration slide valve in order to regulate the catalyst circulation rate; an auxiliary method is to adjust the preheating temperature of the feedstock. 3. The air supply to the auxiliary combustion furnace is divided into two streams, referred to as primary air and secondary air. The primary air enters the furnace chamber, while the secondary air enters the jacket of the cylinder. During the startup and heating process, it is required that the temperature in the furnace chamber not exceed 950°C, and the temperature at the furnace outlet not exceed 680°C. 4. Before entering the lift pipe, the raw material exchanges heat with top circulation fluid, diesel, intermediate fluid, and slurry respectively. 5. The catalytic unit is a secondary processing step; it generally uses heavy oils such as vacuum distillate oil, atmospheric residue oil, and wax oil as raw materials, and carries out cracking reactions under the action of catalysts. The end products are gasoline, diesel, liquefied gas, dry gas, and other substances. 6. The main driving force for fluidization in the two reactors is the pressure difference between them and the static pressure of the catalyst ； The reaction temperature is generally between 500 and 530°C. 7. If the storage volumes of the two vessels overlap, it can lead to backflow of oil and gas along with air, resulting in severe explosion accidents; if this situation cannot be controlled, the feed supply should be cut off immediately, as well as the connection between the two vessels. 8. The pre-rising section serves to provide the reaction with a regenerated catalyst in a well-fluidized state. 9. The function of the stripping section is to strip off the oil and gas carried by the raw catalyst, thereby increasing the product yield and reducing the coking load on the regenerator. III. Short-answer Questions (4×6′=24′) 1. Why does secondary combustion occur? How to prevent and handle it? Answer: The carbon monoxide contained in the flue gas rising from the regenerator’s dense phase undergoes secondary combustion when exposed to high temperatures and high excess oxygen. (30% of the total score) Measures to prevent secondary combustion include: (1) Adding a carbon monoxide oxidizer, controlling a high level of excess oxygen, and ensuring that carbon monoxide burns completely in the dense phase of the regenerator. (15% of the total score) (2) When partial regeneration occurs, control the excess oxygen and regeneration temperature at lower levels. (15% of the total score) (3) Adopt efficient regeneration methods in the regeneration process, such as coking tank regeneration. (10% of the total score) When secondary combustion occurs, measures such as reducing the main air flow (thereby decreasing the excess oxygen content) and lowering the regeneration temperature are usually taken. In the case of using carbon monoxide as a combustion aid, if secondary combustion takes place, it is necessary first to add more carbon monoxide and increase the main air flow, so that the carbon monoxide can burn up within the bed. (30% of the total score) 2. How is the injection of combustion oil carried out at the start of operation? Precautions? How to carry out the injection of combustion oil at startup? Precautions? Answer: ① First, direct the burning oil to circulate in front of the control valve to separate water ； (20% of the total score) ② Combustion oil can be injected when the temperature of the regenerator bed reaches 380°C and the bed level is 2.2 m above the combustion nozzle. (20% of the total score) Notes: ① Make sure to drain the water completely before use ； (10% of the total score) ② The injection amount should not be too large ； (20% of the total score) ③ If a spray does not succeed, close the fuel valve and wait until the bed temperature rises before attempting to spray again. (30% of the total score) 3. What is the function of an oxidizer? Answer: Eliminate and prevent secondary combustion in the dilute-phase section of the regenerator. 4. What are the hazards of a boiler being full of water? What is the handling method? Answer: Hazards: A full boiler with water will result in a large amount of water being carried in the steam. In boilers equipped with superheaters, the water, after being superheated, causes salt deposits to form inside the furnace tubes. The water level issues can be severe in some cases and less severe in others. If the water level is above the highest water mark but is still visible, it constitutes a moderate level of flooding. If the water level exceeds the visible edge at the top of the gauge, so that the water level can no longer be seen inside the gauge, it constitutes a severe case of overfilling. (40% of the total score) Handling method: (1) Check whether the water level gauge is accurate ； (20% of the total score) (2) If the regulating valve fails, switch to manual control ； (20% of the total score) (3) Increase pollutant discharge. After the above treatments, if the water level in the boiler drum still rises, the boiler should be shut down immediately. (20% of the total score) III. Essay questions (26’) 1. Briefly describe the factors that affect reaction pressure (8′) 1) Change in total feed volume. (5% of the total score) 2) Change in reaction depth. (5% of the total score) 3) Changes in steam volume or water carryover in each section of the reactive distillation. (5% of the total score) 4) Changes in the termination dose or presence of water. (5% of the total score) 5) Changes in the properties of the crude oil. (5% of the total score) 6) Excessive fractional distillation cold reflux or water contamination. (5% of the total score) 7) The compressor stopped due to a malfunction. (5% of the total score) 8) Change in the reaction momentum of the compressor. (5% of the total score) 9) Variation in the flare opening at the compressor inlet. (5% of total score) 10) The liquid level in T2201 is high, submerging the inlet of the oil and gas pipeline. (5% of the total score) 11) The air-cooling and water-cooling effects of T2201 are poor. (5% of the total score) 12) The flare system contains a large amount of condensed oil. (5% of the total score) 13) Variation in the opening degree or jamming of the T2201 top oil and gas butterfly valve. (5% of the total score) 14) Entry of terminator into the lift pipe, changes in dry gas volume, or liquid in the dry gas stream. (5% of the total score) 15) Severe coking in the large oil and gas pipelines and external gas collection chambers. (5% of the total score) 16) The compressor presses oil too quickly or pressures air. (5% of the total score) 17) Tower flooding, tower submersion, mist entrainment, etc. in distillation towers. (5% of the total score) 18) Change in compressor speed, change in steam pressure at 3.5 MPa. (5% of the total score) 19) The liquid level in V2203 is too high. (5% of the total score) 20) Failure of instruments and control valves. (5% of the total score) 2. Catalyst bridging (reasons and treatment methods). (8′) Cause of the accident: 1) Pressure pulsating changes in the two devices. (5% of the total score) 2) Excessive amount of loose air or loose steam, along with water content. (10% of the total score) 3) The stripping steam temperature is low, resulting in severe water carryover. (10% of the total score) 4) Changes in the flow properties of the catalyst, such as severe carbon buildup in the raw catalyst, oil contamination in the raw catalyst, and changes in the sieve analysis composition of the catalyst. (5% of the total score) 5) There is foreign matter blocking in the system, such as coked blockages or accumulation in the raw material risers in the stripping section. (10% of the total score) 6) The check valve and slide valve are malfunctioning, with an insufficient opening degree. (10% of the total score) Handling method: 1) Keep the pressure of the stabilizer at normal levels. (5% of the total score) 2) Adjust the amount of loose air and steam, address any blockages, and drain all condensate. (10% of the total score) 3) Increase steam temperature and remove moisture. (10% of the total score) 4) Adjust the amount of stripping steam and the amount of loosening agent to deal with carbon accumulation and replace the catalyst. (5% of the total score) 5) Adjust the opening degree of the control slide valve and plug valve, as well as the differential pressure between the two devices, to address any blockages. (10% of the total score) 6) Manual operation, open the large slide valve, plug valve. (10% of the total score) 3. List the main steps involved in starting up this position, as well as the precautions for each step. (10′) Answer: First, conduct a thorough inspection. It is essential to be careful and meticulous, and to keep proper records ； (10% of the total score) II. System purging and airtightness testing: Steam must not be introduced into the regenerator; the pressure should be increased to 0.18–0.2 MPa as much as possible. (15% of the total score) III. Ignition of furnace 2101 and heating of the two reactors: The heating process must be carried out strictly in accordance with the specified temperature rise curve to prevent large fluctuations in temperature ； (15% of the total score) IV. Loading the catalyst: First, quickly install the sealing legs; ensure that the pressure in the settler is slightly higher than that in the regenerator. (15% of the total score) V. Removing air from the reactor: Ensure proper drainage of steam, and introduce steam slowly. (10% of the total score) VI. Establishing fluidization in both reactors: Ensure normal fluidization in both reactors; proceed slowly at the beginning of the fluidization process to maintain an appropriate pressure difference between the two reactors. (15% of the total score) VII. Removing the large blind flange for oil and gas: Maintain a slight positive pressure in the settler, and work closely with the distillation team to prevent catalyst from entering the distillation tower ； (10% of the total score) VIII. Reaction injection, startup, and adjustment of operations. Feeding material must be carried out only after the injection conditions are met. (10% of the total score) Test Paper D – Answers for the Reaction Operator Position in Catalyst Plant 2 Name:　　 Score: I. Term Explanations (4×5′=20′) 1. Catalyst-to-feed ratio: The ratio of the catalyst circulation volume to the total reaction feed volume. 2. Catalyst to be regenerated: refers to the catalyst that has undergone a catalytic reaction and comes out of the stripping section of the settler, with carbon deposits on its surface. 3. Carbon buildup: When the feedstock becomes heavier and there is insufficient air for combustion, it leads to a **decrease in the catalyst’s activity and selectivity**. This, in turn, increases the amount of carbon generated within the reactor, creating a vicious cycle that results in exponential carbon buildup. As a result, the amount of carbon deposited on the catalyst rises to very high levels. This phenomenon is known as carbon buildup; it causes a **decline in the efficiency of catalyst regeneration**, leading to a reduction in both the quantity and quality of gasoline produced. If not addressed properly, it can also lead to secondary combustion. 4. Catalyst circulation rate: The amount of catalyst that flows from the regenerator into the reactor per hour is called the catalyst circulation rate. II. Fill-in-the-blank questions (30×1′=30′) 1. The inventory in the stripping section is mainly adjusted by the opening degree of the raw material stop valve. 2. The degree of catalytic cracking reaction is expressed in terms of conversion rate. 3. Before entering the lift pipe, the raw material exchanges heat with top circulation fluid, diesel, intermediate fluid, and slurry respectively. 4. When the pressure control methods for the settler are functioning properly, it involves controlling the opening degree of the oil and gas butterfly valve at the top of the fractionation tower and the speed of the air compressor. 5. Regenerator pressure control methods: double-acting slide valve opening and flue damper opening control. 6. The catalytic unit is a secondary processing step; it generally uses heavy oils such as vacuum distillate oil, atmospheric residue oil, and wax oil as raw materials, and carries out cracking reactions under the action of catalysts. The end products are gasoline, diesel, liquefied gas, dry gas, and other substances. 7. Seamless steel pipe Ø159×5 indicates that the inner diameter of the pipe is: 149mm ； The wall thickness is: 5mm. 8. Complete combustion of CO to CO2 takes place inside the regenerator; this type of regeneration is known as complete regeneration. 9. The higher the regeneration pressure, the faster the charring rate. 10. The regeneration process mainly involves burning off the coke on the catalyst. 11. Secondary combustion refers to the combustion of CO in the dilute phase of the regenerator. 12. If water is supplied to the boiler when it is severely underwater, an explosion will occur. 13. The role of using metal passivators is to suppress the degradation of catalyst activity and selectivity caused by heavy metals. 14. A air-actuated valve is one that closes when there is signal pressure and opens when there is no signal pressure. 15. The purpose of regular slag discharge is to remove the sludge and sediment formed inside the furnace or drum, and to adjust the quality of the water within them. The purpose of continuous discharge is to prevent an increase in salt content and maintain stable water quality. 16. After activating the self-protection function, go to the site to check the self-protection valve and shut down the feed nozzle. III. Essay Questions (4×6′=24′) 1. What is catalyst poisoning? Answer: It refers to the situation where raw materials contain high levels of heavy metals such as iron, nickel, copper, and vanadium, which can **reduce the activity and selectivity of the catalyst**. A decrease in the yields of gasoline and diesel leads to an increase in the yields of carbon and gases; this phenomenon is known as catalyst poisoning. 2. Describe the working principle of a cyclone separator? Answer: It works by the high-speed rotation of the gas flow, which generates centrifugal force on the catalyst particles; this force throws the catalyst against the wall of the device, separating it from the gas and thus achieving gas-solid separation. 3. Why is atomizing steam needed for the reaction feed? Answer: Catalytic cracking is a gas-phase reaction. It is important to rapidly vaporize the feed entering the lift pipe. Introducing atomized steam can ensure a uniform mixing of oil, gas, and catalyst. At the same time, atomized steam can reduce the partial pressures of oil and gas, preventing rapid coking of the catalyst. In the event of a supply interruption of the raw material, the atomizing steam can also prevent the nozzle from clogging. 4. When installing the catalyst in the reactor, why is it necessary to do it quickly at first, but then slowly after some time? Answer: Before the catalyst is installed, the regenerator is empty. When the catalyst is installed, the feed leg of the cyclone separator lacks a material seal, so it cannot function properly, resulting in a large amount of catalyst being carried out of the regenerator. To this end, a material seal must be established promptly to ensure the proper operation of the cyclone separator and reduce catalyst loss. So, generally, the rate at which the catalyst is installed is quite fast. Once the cyclone separator is operating properly, the main challenge at this point is to raise the dense-phase temperature as much as possible in order to inject the combustion oil earlier. At this point, if a large amount of cold catalyst is added, it becomes difficult to raise the dense-phase temperature (note that insufficient amount can cause overheating in the auxiliary combustion chamber). Therefore, the speed at which the catalyst is added should be slow. IV. Essay questions (26 points) 1. What is the phenomenon of water being present in crude oil? How to handle it? (8′) Answer: The symptoms of water being present in the feedstock oil are: unstable total feed flow rate, increased reaction pressure, and a decrease in the riser outlet temperature. When water is present in the crude oil, the feed rate should be significantly reduced, and the preheating temperature of the crude oil should be appropriately lowered to decrease the amount of vaporization. When there is severe water contamination in the crude oil, the feed should be cut off. At the same time, timely contact should be made with dispatch and the tank farm to carry out tank switching or other measures. 2. When is the regenerator burner fuel activated? What should be kept in mind when enabling it? (8′) Answer: At startup, once the catalyst in the regenerator is heated by the flue gas-air mixture from the auxiliary combustion chamber to a temperature higher than the auto-ignition point of the burning oil, it is then possible to start injecting the burning oil. During the production process, when the amount of raw coke is low and the thermal balance between the two units is insufficient, burning oil can be used to supply the necessary heat. After the reactor’s feed is cut off, burning oil can also be used to supply heat. When using combustion oil, it is important to ensure that the dense-phase temperature in the regenerator is higher than the auto-ignition point of the combustion oil; the adjustment range should be small, and the water must be removed before use. Furthermore, another important condition is that the catalyst in the bed must submerge the nozzle. 3. List the main steps involved in starting up this position, as well as the precautions for each step. (10′) Answer: I. Conduct a thorough inspection; it is essential to be careful and meticulous, and to keep proper records ； (10% of the total score) II. System purging and airtightness testing: Steam must not be introduced into the regenerator; the pressure should be increased to 0.18–0.2 MPa as much as possible. (15% of the total score) III. Ignition of furnace 2101 and heating of the two reactors: The heating process must be carried out strictly in accordance with the specified temperature rise curve to prevent large fluctuations in temperature ； (15% of the total score) IV. Loading the catalyst: First, quickly install the sealing legs; ensure that the pressure in the settler is slightly higher than that in the regenerator. (15% of the total score) V. Removing air from the reactor: Ensure proper drainage of steam, and introduce steam slowly. (10% of the total score) VI. Establishing fluidization in both reactors: Ensure normal fluidization in both reactors; proceed slowly at the beginning of the fluidization process to maintain an appropriate pressure difference between the two reactors. (15% of the total score) VII. Removing the large blind flange for oil and gas: Maintain a slight positive pressure in the settler, and work closely with the distillation team to prevent catalyst from entering the distillation tower ； (10% of the total score) VIII. Reaction injection, startup, and adjustment of operations. Feeding material must be carried out only after the injection conditions are met. (10% of the total score) Answers to Test Paper E for the Qualification Assessment of the Reaction Position in Catalyst Production Workshop 2 Name:　　 Score: I. Term Explanations (4×5′=20′) 1. Reaction time: The time during which the raw materials react upon contact with the catalyst. 2. Re-refining ratio: In the re-refining process, the total feed to the reactor consists of fresh raw material and re-refined oil (including slurry). The ratio of reprocessed oil to fresh feedstock is called the reprocessing ratio. 3. Complete regeneration: The process of completely burning CO to CO2 inside the regenerator is called complete regeneration. The complete regeneration methods are: first, high-temperature complete regeneration; second, complete regeneration with an oxidizer. 4. Total catalyst inventory: The amount of catalyst available throughout the entire reaction regeneration system. II. Fill-in-the-blank questions (30×1′=30′) 1. Catalyst selectivity is the ability of the feedstock to be converted into the desired product. 2. During normal production, the main method for adjusting the reaction temperature is to control the opening degree of the regeneration slide valve in order to regulate the catalyst circulation rate; an auxiliary method is to adjust the preheating temperature of the feedstock. 3. The inventory in the stripping section is mainly adjusted by the opening degree of the raw material stop valve. 4. There are seven sets of parallel two-stage cyclone separators inside the regenerator. 5. When the pressure control methods for the settler are functioning properly, it involves controlling the opening degree of the oil and gas butterfly valve at the top of the fractionation tower as well as the speed of the air compressor. 6. Regenerator pressure control methods: double-acting slide valve opening and flue damper opening control. 7. The catalytic unit is a secondary processing stage; it typically uses heavy oils such as vacuum distillate oil, atmospheric residue oil, and wax oil as raw materials, and carries out cracking reactions under the action of catalysts. The end products are gasoline, diesel, liquefied gas, dry gas, and other similar substances. 8. The opening and closing of the valve are referenced to the direction of the handwheel; counterclockwise means opening. 9. The measures commonly taken to prevent secondary combustion are reducing the main air flow and regeneration temperature, as well as adding CO as a combustion aid. 10. The solid content in the slurry refers to the amount of catalyst present in the slurry. 11. In the stripping section, the contact between the catalyst and the stripping steam is a counter-phase contact. 12. The flap valve of the cyclone separator serves to prevent gas from flowing back into the leg. 13. Activity is a property that reflects a catalyst’s ability to accelerate reaction rates. 14. The function of the water seal tank on the flue duct is to cut off the flue gas. 15. The phenomenon of interruption in catalyst circulation within the inclined tubes is called bridging. 16. If water is supplied to a boiler when it is severely underwater, an explosion can occur. 17. The role of using metal passivators is to suppress the degradation of catalyst activity and selectivity caused by heavy metals. III. Short Answer Questions (4×5′=20′) 1. What is the function of a cyclone separator? Answer: It works by the high-speed rotation of the gas flow, which generates centrifugal force on the catalyst particles, pushing them toward the wall of the device and separating them from the gas to achieve gas-solid separation. The recovery efficiency of the centrifuge is required to be 99.98%. When installed in the regenerator and reactor, this device serves to recover the catalyst and reduce catalyst loss. 2. Under what circumstances should a waste heat boiler be shut down urgently? In any of the following situations, an emergency shutdown of the furnace may be carried out ； 1) The boiler water level has reached an extremely low level ； (10% of the total score) 2) A fault in the water supply system prevents water from being supplied to the boiler ； (10% of the total score) 3) Both the water level gauge and the safety valve fail ； (10% of the total score) 4) Combustion equipment is damaged; furnace walls become red-hot or collapse, posing a serious threat to the safe operation of the boiler ； (10% of the total score) 5) The boiler experienced a water-overflow accident; although the drain valve was opened to release water, it had no effect ； (10% of the total score) 6) Interlocked operation of various protective measures to shut down the furnace ； ( accounting for 10% of the total score) 7) Other abnormal conditions occur that jeopardize the safe operation of the boiler. (In 10% of all cases) When the aforementioned conditions occur, the fuel supply must be cut off immediately; the superheater drain valve should be opened and the main steam valve closed. If there are no faults in the forced draft system, a purging process should be carried out for 5 minutes. In case of any faults in the forced draft system, nitrogen purging should be performed instead. After purging, the nitrogen valve must be closed ； At the same time, the boiler water level must be maintained. The furnace is temporarily shut down. Due to operational requirements or in case of an emergency, it is shut down following normal or emergency shutdown procedures. It will be restarted once the operating conditions return to normal or the incident has been resolved. (30% of the total score) 3. What precautions should be taken when lighting the furnace 2101? Answer: ① The O2 content in the gas must be <1% to enable ignition ； (20% of the total score) ② Install a gas heater to prevent gas from carrying liquid ； (40% of the total score) ③ After igniting the burner, adjust the primary air flow immediately to prevent overheating of the furnace. (40% of the total score) 4. What are the principles for handling accidents at reaction sites? 2 Under no circumstances should the catalyst inventories in the reaction-regeneration systems be completely depleted. (15% of the total score) 3 The reaction-regeneration system must be fed with a fluidizing medium to prevent collapse or dead bed. (10% of the total score) 4 Once the main air supply is interrupted, the feed must be stopped immediately, and the combustion oil supply must also be ceased. (15% of the total score) 5 Under feeding conditions, the outlet temperature of the riser must not be lower than 450°C; if it is not possible to raise it at that time, the feed should be stopped. (15% of the total score) 6 When the main fan is stopped and the feed is cut off, the temperature of both reactors must remain above 400°C; if it drops below this level, the catalyst must be removed. (10% of the total score) 7 When there is catalyst circulation in the reaction-regeneration system, slurry circulation must be maintained. If the slurry circulation is interrupted for an extended period, it should be switched to single-regenerator fluidization or, depending on the circumstances, the catalyst should be discharged. (10% of the total score) 8 In the event of severe overheating in the regenerator or a fire accident in the regeneration system, the feed should be shut off. (10% of the total score) 9. Even when the feed is cut off and the main blower is shut down, if there is still catalyst present in the system, it is necessary to ensure that the reverse blowing air and fluidization air (steam) continue to flow without interruption. (15% of the total score) IV. Essay questions (4×5′=20′) 1. How should fuel injection be carried out at the start of operation? Precautions? (8′) Answer: ① First, direct the burning oil to circulate in front of the control valve to separate water ； (20% of the total score) ② Combustion oil can be injected when the temperature of the regenerator bed reaches 380°C and the bed level is 2.2 m above the combustion nozzle. (20% of the total score) Notes: ① Make sure to drain the water completely before use ； (10% of the total score) ② The injection amount should not be too large ； (20% of the total score) ③ If a spray does not succeed, close the fuel valve and wait until the bed temperature rises before attempting to spray again. (30% of the total score) 4. What should be noted after injecting fuel into the lift pipe? Answer: ① Control the reaction temperature properly; it is not advisable to adjust the reaction temperature by changing the feed rate ； (30% of the total score) ② There is rich gas after fuel injection; the reaction pressure is controlled by the flare valve at the inlet of the compressor ； (30% of the total score) ③ Be careful to avoid burning; reduce the amount of fuel used for combustion in a timely manner to prevent carbon buildup. (40% of the total marks) 2. What are the hazards of low water level in a boiler? What is the method for dealing with a boiler running low on water? (8′) Answer: Severe water shortage in a boiler is a serious fault during its operation; if water is added under such conditions, it will exacerbate the fault and lead to the explosion of the boiler. This is because the steel plates (or steel pipes) have overheated (or become red-hot) due to a lack of water in the boiler. The higher the temperature, the greater the expansion of the metal. If water is introduced when there is a water shortage, due to the large temperature difference between the water and the overheated steel plates, the areas that come into contact with the water first will contract rapidly as a result of the cooling effect, leading to tearing or cracking. Under pressure, these cracks will widen into large openings, through which steam and water burst out, causing a severe explosion. Boiler water shortage is divided into severe water shortage and mild water shortage. Using the \"water calling method\", when water appears in the water level gauge, it indicates a slight water shortage; in such cases, the boiler feed water can be increased, while also paying attention to restoring the water level ； If water still does not appear in the water level gauge even when using the \"water calling method,\" it indicates a severe water shortage; feeding water to the boiler is strictly prohibited, and the boiler must be shut down immediately. 3. What emergency measures should be taken by response personnel in the event of a sudden power outage? (10′) Handling method: 1) Activate the respective safety valves one after another; pay attention to observing the feedback from each control valve involved in the self-protection mechanism. (15% of the total score) 2) Immediately fully open the main torch valve and Valve B to prevent pressure buildup in the reaction system; close Anti-Surge Valve C. (15% of the total score) 3) Increase the stripping steam flow to purge all oil and gas from the settler, thereby preventing coking due to a drop in temperature caused by a prolonged power outage. (15% of the total score) 4) Depending on the steam and wind pressure levels, slowly close the main accident steam valves, as well as the valves used for loosening, backblowing, and protecting the focus holder walls ； Close the F2201 primary and secondary air valves. (15% of the total score) 5) The standby choke valve utilizes an accumulator to follow any contraction of the riser, thereby preventing accidents caused by backflow of oil and gas due to such contraction. (15% of the total score) 6) Shut off the emergency steam for the spent sleeve. (10% of the total score) 7) Reroute the flow at the feed oil and slurry nozzles back to the return line; close the manual valves for the pre-lift dry gas and terminator; reset the feed emergency shutdown system. (15% of the total score)