Can any expert explain in detail the procedures for starting up the oil refining unit?
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Recently, a very loud sound of purging equipment was heard from the Qingdao refinery area. Some say the purging lasts a week. Others say that this is the boiling of various heaters and heat exchangers during the commissioning and start-up of the device. According to the Qingdao refinery start-up deadline, the 10 million tons Qingdao refinery should start trial operation in the near future. I have just entered the petrochemical industry and don't know much about this. Can any senior give a systematic introduction to the start-up procedures of Qingdao Oil Refining? Are there any other issues that require specific attention?
If you can tell me a small detail that you know, that's fine. I'll give it a thumbs up. Thank you.
What you are talking about is steam pipeline purging and target shooting. The power system is built first, and then the purging equipment is installed.
Strength test, stand-alone test run, purging, water flushing, sealing test, water combined transportation, these are all common chemical plants. Others need to be divided into separate devices. For example, the hydrogenation unit also has hydrogen gas tightness, emergency pressure relief test, quenched hydrogen test, cold oil transportation, hot oil transportation, catalyst loading, catalyst drying, catalyst sulfurization, catalyst passivation, reactor drying, low nitrogen oil start-up, raw oil cutting, etc.
Thank you for such a comprehensive reply. I guess the start-up procedure for a device is quite complicated. Only if you have worked in this industry for more than five or six years can you figure out the general path. As far as I know, Qingdao oil refining has atmospheric and vacuum pressure, kerosene, diesel and gasoline hydrogenation, catalytic reforming, catalytic cracking, delayed coking, aromatics extraction equipment, etc.
A week of purging is still preliminary. If you fail to pass the target, you have to start over. I don't know how long it has been. The oven should not make such a big noise. The main reason is pipeline purge. The so-called target practice is to set up an aluminum sheet at the outlet of the purge pipeline and blow it for a period of time to see how many traces of blown debris are left on the aluminum sheet. It must be less than a few per square centimeter to be considered qualified.
The initial start-up procedures of the catalytic device are as follows for reference. The first step is a comprehensive inspection of the quality of the device project. The second step is to introduce the common medium. The third step is steam purging, penetration, fourth water flushing, pressure test, and water combined transportation. The fifth single unit trial operation, the trial operation of the centrifugal pump, the trial operation of the metering pump, the trial operation of the air-cooling fan, the standby main fan, the single unit trial operation, the load trial operation, the sixth drying lining and boiling furnace, the three-vessel drying lining, the auxiliary combustion chamber F-101 operation, the extra-legal heater and steam generator, the drum boiling furnace plan, the seventh light oil trial operation plan, the eighth unit started construction
Routine start-up procedures for atmospheric and vacuum distillation: 1. Final inspection and confirmation of the installation process, and contact the crude oil tank area to prepare for oil delivery. 2. The system introduces crude oil to replace water and establishes an open circuit cycle. 3. The decompression oil collection tank collects wax oil, and the wax oil in the side line system replaces water. 4. Change open circuit cycle to closed circuit cycle ； 5. The crude oil is kept at a constant temperature of 90°C and dehydrated under vacuum. 6. Cycle temperature and use residual oil water cooler. 7. The outlet temperature of the atmospheric pressure furnace reaches 150℃. 8. The outlet temperature of the atmospheric pressure furnace reaches a constant temperature of 250℃. Check the condition of the on-site equipment. 9. The outlet temperature of the normal pressure furnace is 300°C, the closed-circuit circulation is changed to open-circuit circulation, and the normal pressure is turned on when changing oil. 10. Normal pressure is normal, turn on decompression. 11. Decompression is normal and operation is fully optimized.
Chapter 1 Comprehensive inspection of the device 1. Inspection requirements 2. Inspection content (1) Process inspection (2) Equipment inspection Chapter 2 Public project commissioning plan 1. Prerequisites and requirements for public project commissioning 2. Commissioning of 1.0MPa and 3.5MPa steam systems 3. Commissioning of circulating water 4. Commissioning of fresh water, demineralized water, domestic water and purified water Chapter 3 Device connection , Purge plan 1. Purpose of penetration purge 2. Purge method and requirements 3. Purge penetration precautions 4. Purge penetration quality requirements 5. Purge penetration process Chapter 4 Device water flushing, water intermodal transport plan 1. Water flushing 1. Water flushing purpose 2. Water flushing method and precautions 3. Water flushing quality requirements 4. Water flushing steps 5. Water flushing process: Section 2 Water Intermodal Transport 1. The purpose of water intermodal transport 2. The conditions for water intermodal transport 3. Precautions for water intermodal transport: 4. Control valve adjustment plan 5. Water combined transport process Chapter 5 Pump test run plan 1. Purpose of single machine test run 2. Trial run precautions 3. Single machine test run content Chapter 6 Compressor test run plan Section 1 Test run purpose Section 2 Preparation for test run Section 3 Lubricating oil system cleaning and oil running and trial operation 1. Circular oil running flush of the lubricating oil system 2. Trial operation and commissioning of the lubricating oil system Section 4 Single test turbine 1. Test run purpose: 2. Overall work that should be carried out during the trial operation of a single machine 3. Various interlocking and self-protection debugging of the unit 4. Turbine regulating system test 5. Turbine single machine test Section 5 Air test run of the unit 1. Test run purpose 2. Test run conditions 3. Inspection and confirmation before start-up: 4. Unit start-up Chapter 7 Hydraulic decoking system trial operation plan Section 1 Inspection before the first start of construction 1. Purpose and requirements of inspection 2. Inspection content (1) Inspection content at the top of the coke tower (2) Inspection content at the bottom of the coke tower (3) Inspection content of the high-pressure water pump system (including P620, P683 and suction inlet pool, D683, settling tank) (4) Inspection content of the elevator Section 2 Purge and flushing of the decoking water system 1. Purpose of purging and flushing 2. Conditions that the system should have 3. Contents and steps of purging and flushing Section 3. Trial operation 1. Conditions that the system should have during trial operation Part 2. Trial operation of lubricating oil system 3. High-pressure water pump interlocking and self-protection debugging 4. Trial operation of high-pressure water pump 5. Trial operation of drilling rig winch 6. Trial operation of tower bottom cover loader 7. Trial operation of elevator Section 4. Joint load trial operation of decoking system 1. Purpose of trial operation 2. Trial Operation Steps Chapter 8 Heating Furnace Baking Plan 1. Purpose of the Furnace 2. Conditions the Oven Should Have 3. Preparations before the Oven 4. Oven Steps: Chapter 9 Device Pressure Test Airtightness and Replacement Plan Section 1 Device Pressure Test Airtightness Plan 1. Purpose, Requirements and Precautions for Pressure Test Airtightness (1) Purpose: (2) Requirements: (3) Methods and precautions: (4) Pressure test of towers, containers, cold exchange equipment and ancillary process pipelines (5) Pressure test process: Section 2 Wind and Water Plan 1, Purpose 2, Wind and Water Process 3 and Method Section 3 System Replacement 1, Purpose 2 and Steps Chapter 10 Diesel Cold and Hot Transportation Plan 1 and Purpose of Oil Transportation: 2. Conditions that should be met before diesel oil transportation 3. Preparation work before diesel oil transportation 4. Collection of gasoline, diesel and wax oil 5. Cold transportation of diesel oil 6. Cyclic heating and dehydration 7. Oil removal Chapter 11 wax oil-residual oil start-up plan 1. Purpose of wax oil diversion 2. Unit oil diversion conditions 3. Oil diversion preparation work 4. Unit diversion and establishment of wax oil circulation Chapter 12 Cold coke system trial operation plan 1. Steam penetration Purge 2, Water Flushing, Water Combined Transport 3, Cold Coke Water System Commissioning Plan Chapter 13 Start-up Process HSE Management 1, Start-up Preparation Stage 2, Device Inspection Stage 3, Utility Engineering Reference Stage 4, Through-Purge Stage 5, Single Machine Trial Operation Stage 6, Water Flush, Water Combined Transport Stage 7, Device Airtight Replacement Stage 8, Oil Diversion Stage (Diesel Cold and Hot Transport, Wax Oil-Residue Oil Transport) 9. Operation stage Chapter 14 Accident prediction plan during the start-up process 1. Accident handling principles 2. Emergency accident handling 3. Public engineering accident handling plan 5. Main process accident handling 4. Major mobile equipment accident handling 5. Fire and H2S poisoning accident handling (1) Furnace tube leakage and fire (2) Coke tower bottom (top) cover catches fire (3) Fractionation tower bottom circulation system catches fire (4) H2S poisoning accident handling Chapter 15 Boiler plan 1, Boiler purpose 2, Thermal system water and steam process description 3, Water flushing plan 4, Water pressure test 5, Water treatment plan 6, Boiler 7, Precautions during the boiler process