【JST-030】Gasoline Hydrogenation Lecture and One-on-One Q&A Office

Chapter 1: Commencement Process Section 1: Three Checks and Four Determinations “Three Checks and Four Determinations” is a process that must be undertaken in the petrochemical industry prior to the handover of a project. The “three checks” refer to checking for design omissions, assessing the quality of the work and any potential hazards, and examining the amount of work that remains unfinished”； “The “four fixations” refer to assigning tasks, designating personnel, setting deadlines, and determining measures for the problems identified, with a requirement to complete them within a specified time frame. 　　　“In simple terms, the “three checks and four determinations” that we operators need to carry out involve checking whether the pipelines on site and their specifications correspond to the process flow specified by the design team ； Check whether the devices at the site are safe and easy to operate in the future ； Check whether the on-site construction quality meets the technical requirements ； Monitor the project progress based on the completion timeline and quality requirements set by the company.

Section 2: Water Flushing I. Purpose of Water Flushing 1. To flush out dirt, slag, and other debris from the equipment and its pipelines, to inspect the quality of the construction work, and to eliminate potential hazards. 2. Check the operation of mechanical equipment under load to test the performance of pumps and motors. 3. Train operators in skills to familiarize them with on-site procedures and equipment. II. Water flushing method and precautions 1. Before water flushing, the device should be in a state where the through-blowing process has been completed. When switching to the water flushing procedure, thorough inspections are necessary to prevent cross-contamination. 2. When flushing equipment and pipelines, start from the higher points before moving to the lower ones, and proceed from the main lines before dealing with the branch lines; longer pipelines should be flushed in sections. 3. Before flushing, valves that are prone to clogging such as the sampling valve, pressure gauge hand valve, and level gauge should be closed; flushing should take place only after the pipelines and equipment have been thoroughly cleaned. 4. Accessories such as flow meters, control valves, safety valves, check valves (or their valve cores), orifice plates, and filter elements that were removed during purging should not be reinstalled yet; they should be put back in place only after the water flushing is complete. 5. The special valves in the device must be installed in place and subjected to water flushing only after the upstream pipelines have been thoroughly flushed. 6. The vent valve of the tower or container should be opened before water is introduced; any excess water must be drained before it enters the equipment, and the water can only be allowed to enter once it is clean. 7. When filling the tower with water, the bottom drain valve should be kept fully open; once the water is clear, it should be closed. Then, starting from the top of the equipment, the pipelines should be flushed gradually from top to bottom. 8. For cooling equipment equipped with a bypass line, it is advisable to use the bypass line first during flushing, and then remove the inlet flange to allow discharge, thereby preventing debris from entering and clogging the pipes. Once the water quality is clean, the flange can be reattached and flushing of the main pipeline can continue. 9. Before flushing with water, contact the instrumentation team to close all instrument outlet valves, and inform them to flush the instrument pipelines as appropriate. 10. During the flushing process, if a pump is to be used for flushing, the inlet pipeline of the pump must first be flushed properly; thereafter, the inlet filter screen should be installed before starting the pump for flushing. At the same time, pay attention to the ammeter on the motor – overloading is strictly prohibited. 11. To ensure sufficient water pressure and flow for system flushing, each discharge point should be opened one by one, and it should be closed promptly once the water quality is clean. 12. The external pipelines of the device can be flushed only after coordinating with the dispatch team. 13. All equipment and pipelines must be flushed; temporary lines should be connected if necessary, and all low-point vents and sampling ports must be opened regularly for discharge. 14. Check regularly to ensure the drainage system is unobstructed. 15. During water flushing, if the weather is cold and the water at the equipment inlet at higher elevations cannot be drained, a temporary filter screen can be installed at the equipment inlet. After flushing the water equipment, it is discharged from its bottom. 16. Depending on the temperature conditions, be careful to prevent freezing. After the water flushing is complete, drain all the water from the equipment and its pipelines as soon as possible; if necessary, use air to push out the water in order to prevent the equipment from being damaged by freezing. 17. Each system shall keep proper water flushing records in accordance with regulations. III. Quality requirements for water flushing 　　　For pipes flushed with water, unless there are special requirements, they are generally considered to meet the standards if the color and transparency of the water, as observed visually, are roughly the same as those at the inlet. Appendix: Water flushing routes
1. Fresh water → D1101 → P1101(A,B)
2. Fresh water → Startup gasoline → P1102(A,B) → C1101 → P1201(A,B)
3. Fresh water → Startup gasoline → D1102 → P1102(A,B)
4. C1101 → Entrance to P1103(A,B) → E1107 → C2101
5. Fresh water → D1301 → P1301(A,B) → C1301 → E1301 → E1302 → D1302 → P1302(A,B)
6. C1101 → P1201 → E1301 → E1303 → C1301
7. Fresh water → Light gasoline → Transfer → Light gasoline to etherification process → C2101 → R2101 pipeline → E2101 → E2102
8. C2101 → Reverse methanol pipeline → Transfer → Startup methanol → D2102 → P2103(A,B) → C2102 → P2104 → E2101 → E2103
9. C2101 → Reverse methanol pipeline → Transfer → Startup methanol → D2103 → P2106(A,B) → C2103 → P2105(A,B) → E2106 → E2110 → C2104 → E2106 → E2107
10. Fresh water → Temporary pipeline → D2101 → P2101(A,B)
11. Fresh water → D2104 → P1202(A,B)

Section 3: Airtightness I. Purpose of Airtightness Testing After the installation is completed or after maintenance work, it is necessary to check for any leaks at the joints where equipment and pipelines are connected; therefore, airtightness testing is required. Additionally, during the operation of the installation, the entire system gradually experiences increases in temperature and pressure. This is especially true for high-temperature and high-pressure equipment, where thermal expansion and contraction occur significantly, so airtightness tests must be conducted at each stage of pressure increase. II. Airtightness acceptance criteria: At low temperatures, soap water can be used to check for bubbles in order to determine whether there is any leakage. At high temperatures, leak detection can be performed using a combustible gas detector. For **Lan connectors that are difficult to detect, cover their surface with a layer of sealing tape, drill a small hole in it, and then apply soapy water to check. Appendix: Airtight routes
1. Nitrogen injection point: D1101; nitrogen pressure used: 0.6 MPa, with pressure increased to 0.3 MPa. Airtight section: Catalytic gasoline → D1101 → P1101
2. Nitrogen injection point: D1102; nitrogen pressure used: 0.6 MPa, with pressure increased to 0.3 MPa. Airtight section: C1101 → A1101 → D1102 → P1102; E1104 → C1101 → P1103 → E1107
3. Nitrogen injection point: K1201; nitrogen pressure used: 2.5 MPa, with pressure increased to 2.0 MPa. Airtight section: E1201 → R1201 → F1201 → R1200 → E1201 → E1102 → A1201 → D1201 → D1203 → C1201 → D1202 → K1201 → reverse circulation line of the pre-distillation section → E1102 → E1105 → E1106 → R1101 → E1105
4. Nitrogen injection point: D1301; nitrogen pressure used: 0.6 MPa, with pressure maintained at 0.6 MPa. Airtight section: C1301 → A1301 → D1301 → P1301; E1301 → E1303 → C1301 → E1301 → E1302 → D1302 → P1302
5. Nitrogen injection point: D2101; nitrogen pressure used: 0.6 MPa, with pressure increased to 0.4 MPa. Airtight section: D2101 → P2101 → R2101 → E2101 → E2102
6. Nitrogen injection point: C2103; nitrogen pressure used: 0.6 MPa, with pressure decreased to 0.1 MPa. Airtight section: E2108 → C2103 → P2105 → E2106 → E2110; C2103 → A2102 → D2103 → P2106
Nitrogen injection point: Etherification filter; nitrogen pressure used: 0.6 MPa, with pressure increased to 0.4 MPa. Airtight section: E2105 → C2102 → P2104 → E2101 → E2103; C2102 → D2102 → P2103
7. Nitrogen injection point: C2104; nitrogen pressure used: 0.6 MPa, with pressure maintained at 0.6 MPa. Airtight section: C2104 → E2106 → E2107
8. Nitrogen injection point: C2101; nitrogen pressure used: 0.6 MPa, with pressure increased to 0.4 MPa. Airtight section: C2101
9. Nitrogen injection point: D1204; nitrogen pressure used: 0.6 MPa, with pressure increased to 0.3 MPa. Airtight section: D1204 → P1202
10. Other common areas: Airtightness shall be ensured according to actual conditions. Such as fuel gas tanks, nitrogen tanks, purge air tanks, 1.0MPa steam pipelines, 3.5MPa steam pipelines, etc.

Section 4: Water Transportation I. Purpose of Water Transportation 1. To further flush the pipelines and equipment. 2. Check the operating conditions of pumps, equipment, pipelines, valves, flanges, instruments, etc. under load. Familiar with DCS operation. 3. Familiarize operators with the device’s process flow through simulation operations. II. Preparations and precautions for water intermodal transport 1. Ensure that the equipment and pipelines have been successfully purged, pressure-tested, and washed with water, and that individual pieces of equipment have passed their trial operations. 2. The issues related to the pipelines, equipment, and instruments involved in the water intermodal transport have been resolved. 3. The preparation work for the pumps involved in water intermodal transport is complete, and relevant units are required to make preparations to ensure smooth operation. 4. When using water intermodal transport, it is necessary to strictly prevent equipment from experiencing overpressure and motors from operating under overload conditions. The liquid level must be well controlled to avoid pump cavitation. Control valves should not be set to automatic mode at first; they can be switched to automatic mode once operations stabilize, depending on the circumstances. 5. Before starting the water interconnection process, it is necessary to check whether blind flanges have been installed on the inlet and outlet valves of each system, in order to prevent water from leaking into external systems. 6. Water transportation operations must be carried out in accordance with established procedures; generally, important processes and equipment are required to participate in such water transportation operations as per the regulations. 7. When water passes through the cooler, heat exchanger, and control valve, it first flows through the bypass line and then through the main body. 8. If blockages are detected in filters and pipelines, they should be cleaned promptly; towers, containers, heat exchangers, and coolers must be emptied. Appendix: Revised water transfer route D1101→P1101→E1102→E1105→E1106→R1101 cross-line→E1105→C1101→P1201→transfer oil to high pressure→E1301→E1303→C1301→E1301→E1302→D1302→P1302→stripping cycle line→transfer to main cycle line→D1101 Revised water transfer route

Section 5: Nitrogen displacement system – Pre-occupied building

Section 6: Catalyst Loading and Soaking in the Etherification Reactor – Xianzhan Building

Section 8: Catalyst Loading in Hydrogenation Reactors The quality of catalyst loading affects the production efficiency of the reactor as well as the quality of the product; uneven catalyst distribution can lead to uneven distributions of fluid flow and reaction temperature. Loading and unloading catalysts should be avoided on rainy days. Dust-containing material, that is, crushed catalyst, should not be fed into the reactor to avoid excessive pressure drop in the catalyst bed or blockages in the pipelines, heat exchangers, or high-pressure separators. I. Inspection of the reactor’s components before catalyst loading 1. Check whether there is water, dust, rust, debris introduced during construction, or old catalyst particles inside the reactor. 2. The stainless steel wire mesh on the collector at the bottom outlet of the reactor should be fitted tightly against the wall of the outlet fitting, with a gap width of less than 3 mm. 3. The pores of the stainless steel wire mesh wrapped around the outlet collector should be free of any obstructions (including ceramic balls or catalyst fragments), to ensure that 100% of the pores remain unobstructed. The stainless steel wire mesh showed no signs of bending or broken wires. If the steel wires bend or break, causing the diameter of some mesh openings to increase, they should be repaired. 4. There is no accumulation of catalyst, ceramic ball fragments or particles, nor any dirt on the inner wall and internal components of the reactor, ensuring that all parts have been thoroughly cleaned. 5. Verify that the cold hydrogen tube and its nozzle are unobstructed and not clogged by foreign objects. 6. The levelness of the distribution disc installation meets the design requirements. 7. Verify that all sealing materials such as O-rings or asbestos gaskets are properly installed and meet the design requirements, and that the water seal test of the distribution panel is satisfactory. Special attention should be paid to ensuring that the gap seals between the discharge pipes between the catalyst beds and equipment such as support plates, distribution plates, and cold hydrogen plates meet the required standards; if any gaps exist, they should be sealed using asbestos rope. 8. Conduct a quality inspection on the installation of the stainless steel wire mesh covering the catalyst support plate in accordance with the requirements in items 1 and 2 above. 9. Check the levelness and watertightness of the cold hydrogen tank to ensure that the errors are within the specified range. II. Steps for loading the catalyst 1. Ensure that all preparatory work before loading is complete; before installing the catalyst, verify its dimensions once again. 2. First, fill a layer of asbestos strips in the discharge pipe at the bottom of the reactor, and then fill the remaining space of the discharge opening with porcelain balls. 3. Add the ceramic balls at the bottom of the reactor layer by layer, from bottom to top, according to the specified specifications and dimensions; after adding each type of ceramic ball, level it out with a rake ； Record the quantity of each type of ceramic ball added and their actual location within the reactor ； After installing the ceramic balls at the bottom, add the catalyst as specified in the filling diagram. 4. Add the catalyst to the height left by the upper ceramic balls, and fill the upper part of the bed with ceramic balls in accordance with the specified requirements. 5. Install in a timely manner the internal components of the reactor at this level, such as thermocouples, distribution plates, cold hydrogen tanks, cold hydrogen pipes, and support grids ； After the internal components have been installed, remove any debris promptly; no tools shall be left inside the reactor. 6. Fill the discharge pipes between the bed layers with ceramic balls ； Load the ceramic balls and catalyst in the upper layers up to the top of the reactor; install various types of protectants, scale baskets, and ceramic balls for covering the top at the predetermined heights as specified in the loading diagram ； Install the reactor top distribution panel and cover. 7. Organize the quantities of various catalysts and ceramic balls of different specifications, verify and record the total amount of catalyst added, and check the remaining quantities of various catalysts and ceramic balls on site.

Section 9: Catalyst Drying – Xianzhanlou