How to deal with a large-scale power outage in an oil refinery

In the event of a large-scale power outage in the refinery, the first thing to do is to ensure the smooth operation of the power system and ensure that there is enough purified air and steam to deal with the accident. The other devices can use steam first according to their importance to minimize losses caused by the shutdown.

This situation is called a large-scale power outage. Usually there are two power supply buses in a refinery, and when one line is interrupted, it will automatically jump to the other line. Of course, there will be fluctuations in the jumpers, which will sometimes cause some transformer cabinets to lose power, causing some electrical equipment to trip. This situation is more common and easier to deal with. What you mentioned is that the power supply cannot be restored, causing all water, electricity, steam and wind to stop. Even if emergency shutdown measures are taken, since the materials cannot be evacuated, the materials can only be controlled in a safe state according to the characteristics of the respective devices. Usually, the material input should be cut off, the pressure should be removed and the temperature should be lowered. The principle requirements are that there will be no overtemperature, no overpressure, no fire, no explosion, no personal accident, and no material leakage. 1. Be sure to cut off the path from the high-pressure medium to the low-pressure pipeline. For example, the electric desalination medium flows back from the water injection line, and the catalytic stabilization material flows back from the crude gasoline line into the fractionation. 2. Be sure to pay attention to the liquid level of each container to prevent the tank from overflowing and leaking oil. For example, in the process of introducing gas into the furnace by reducing the ceiling, the gas entering line must be cut off, otherwise once the tank is full of oil, it will enter the high-temperature furnace... 3. Once a secondary accident occurs, corresponding measures must be taken to prevent expansion. For example, if materials leak, area blockades must be organized to restrict the entry of vehicle personnel. If toxic materials are involved, evacuation must be organized. 4. Relevant firefighting and gas prevention units must be on standby and ready to leave at any time. 5. The most dangerous thing is that after the power supply is gradually restored, it is necessary to consider whether the process conditions allow the operation of the equipment and the entry of materials. For example, whether the catalytic recirculation system allows the loose air compressor station to use non-purified air to enter the system. ； The same goes for other devices that feed each other. Throwing bricks to attract good opinions, making people laugh, and generous words are full of meanings!

, the lecture was very in-depth and professional. I learned a lot. Thank you.~~~

On the fourth day of the Spring Festival in 2007, the whole factory had a power outage for more than 20 hours. At that time, there were five people on duty in my catalytic device, and there was also a female colleague. She was so tired that she almost vomited blood. The temperature was below zero, and there was heavy fog. I couldn't see my fingers. I heard all kinds of weird noises from the device.* * , the walkie-talkie lost its function, and there was no contact between the internal and external operations. It was terrible. Emergency training is very important. Only by knowing what happens can you not panic when something happens.

We also experienced a large-scale power outage across the entire factory and an emergency shutdown. In fact, each device has its own shutdown plan, which is coordinated by the dispatch center. Generally, there is no major problem. The main thing is to prevent leakage. Reduce the risk as much as possible! :handshake

Today's factories have two busbars. If one is out of power, it will jump to the other immediately. What is prevented is a power outage. For the refinery, a power outage means a waste of raw materials, equipment outage, and discontinuous production. I don't know how much everyone's hard-earned money will be lost!

Our company has two lines and a self-contained power plant. Although there has been a complete power outage, it has not happened as the poster said.

There have been two large-scale power outages in the entire plant. The longest one lasted more than 30 hours. At the beginning, the DCS still had power to see the parameters. All devices entered the cooling and pressure reduction stage. For example, the catalytic device reaction device cut off the two reactors, closed the valves at the root of the loose points and backflush points. The riser was purged with steam residual pressure and then closed the nozzle wall valves. The fractionation stopped oil slurry and discharged water from the external throw-off line cooler. Stably cut off the analysis tower, The heat source at the bottom of the stabilizing tower was closed. The hand valves of each outlet device were closed and the pressure gauges were maintained on site. Due to a long power outage, the oil slurry was thrown out and a generator was used with an oil pump to pump diesel to the oil for use at the start of the operation. After more than 2 hours, the DCS had no power and a black screen. At night, everything was dark and there was no movement at all. Don't worry about it. After the call came, the main fan regenerator still had more than 600 degrees, and the work started according to the start-up steps. In fact, the scary thing is not a complete power outage. It is basically safe if all of them are stopped and put into self-protection. I am afraid that the feed pump will not listen when the main fan is stopped, or the main fan will not stop after the feed pump is stopped. Oxygen-rich regeneration is better. Oxygen-poor regeneration is particularly prone to tail combustion. Once the tail combustion is not properly controlled, the dilute phase of the regenerator and the flue temperature can reach 700 or 800 degrees in an instant, which is called a * * Yeah, now is the time to test the reaction operator. He must be able to make timely judgments and adjustments, and he must not panic when something happens.

The poster is from Luoyang, right? In fact, Dahuang Electric refineries generally have at least two-way power supply. However, sometimes if the timing is lucky, there will be large-scale power outages. I remember that Qilu once had a three-way power supply and suffered a major blackout. Let me talk about my experience. I personally experienced Dahuang Electric as a power supply when I was working as a dispatcher. The main responsibility of the dispatcher is to ensure the safety of the public media of water, electricity, steam and wind, maintain the stability of the pipe network as much as possible, prevent media from crossing each other, prevent equipment from over-temperature and over-pressure, prevent oil and gas media from leaking, ensure the smooth flow and combustion state of high- and low-pressure acid gas flares, and protect key devices first if possible. Power outages are generally divided into local power outages and large-area power outages. The time and scope of the power outage are key to responding to power outages. They are very important and essential in accident planning. Local power outages are relatively simple.: Just deal with the local situation in time, and generally speaking, you can recover immediately. Widespread power outage: The difference between short-term and long-term is that: Short-term power outages are more difficult, because you have to consider the issue of resuming production immediately. Generally speaking, long-term power outages only require a smooth stop, because there is no point in rushing, and other things must wait until the arrival point. Generally speaking, the principles for handling large-area power outages are as follows:: In the event of a sudden power outage, the existing steam (estimated to last 15~30min), purified air, non-purified air (15min), and gas pipe network (15min) pressure and flow can be used. The UPS power supply of DCS can guarantee at least 30min. The SIS interlocking self-protection can be put into use as much as possible (automatic state will be put into use automatically, manual need to be manually adjusted) Accurately judge the situation and put it into use), make full use of the degree of automation, minimize manual labor, cut off various interconnected media (remember FO, FC valves), start from the key parts, discharge 1, 2, and 3 according to the critical importance, and proceed in order. Preventing various media from interconnecting and equipment over-temperature and over-pressure is the first priority, and ensure the smooth flow and burning state of the high and low-pressure sour gas torches. As long as it can be ensured that the device will stop as smoothly as possible without causing a major accident, as for parts prone to condensation such as heavy oil pipelines, it may not be estimated for the time being. If possible, handle the pipeline equipment first and then lightly after it stops smoothly. When possible, the public engineering system should take into account the possibility of transporting public media when work is started immediately during the shutdown process. After other devices are stopped, they should also be prepared for the next start of work. This post was last edited by longsky on 2008-5-5 10:18 ]

Remember the emergency plan and perform emergency shutdowns frequently* ! If there is a power outage, you won’t be afraid if you shake a little, only if you are technically proficient will you be confident!

Power outages can be encountered basically once a year. In fact, in accident handling, the best thing to deal with is a power outage. Our operators' favorite emergency is a large power outage of the equipment. There is no hesitation or complicated judgment. Just stop the work in an emergency and put the device down safely. ； For different devices, maintain pressure when maintaining pressure, release pressure when releasing pressure, cool down, cut off materials, check on-site processes, wait for calls, and start work according to the start-up procedures.

Electricity shocks are very common for us, two or three times a year. It starts and stops every time. Torture……

The company has an emergency rescue plan. If a power outage occurs, everyone must implement the plan. In the past, when the system's power grid was unstable, power outages were frequent. At its worst, there were six power outages a month. We were on duty every time. Everyone knew what they were supposed to do and handled these accidents with ease. The key is experience (learning* ) and the practicality of the plan.

During the Lantern Festival on February 21, Fushun Petrochemical Company suffered an unprecedented large-scale power outage due to a power grid failure in Fushun City. Company leaders stepped forward to direct the company, and cadres and employees initiated emergency shutdown plans. No accidents occurred, and production is currently recovering. 　　At 17:35 and 37:00 on February 21, the 66,000-volt high-voltage power supply network in the east of Fushun City Power Supply Company was interrupted after two consecutive power outages. Fushun Petrochemical Company's No. 2 Petroleum Plant, No. 2 Petrochemical Plant, Thermal Power Plant, Ethylene Plant, Washing Plant, and Acrylic Fiber Plant suffered a long-term and large-scale power outage unprecedented in history. This large-scale power outage caused an instant interruption of all public engineering systems such as industrial water, electricity, steam, instrument air, industrial air, and nitrogen, and the power outage lasted for nearly two hours. The 37 sets of production equipment, auxiliary equipment and power boiler generator sets that are operating at full capacity are facing an unprecedented emergency shutdown test. 　　At 19:34, a power outage occurred in the western power grid affiliated to Fushun City Power Supply Company, causing an emergency shutdown of more than 90% of the equipment in the washing and chemical plant. At this time, the Shili Refinery in the eastern region of Fushun Petrochemical was in darkness. High-temperature, high-pressure, flammable and explosive production equipment is like a“ * * ”, accidents may happen at any time. 　　After the danger occurred, the company leaders went to the production line to provide on-site command and put forward overall requirements for emergency shutdown. All production companies activate production emergency plans as soon as possible. The employees on duty relied on the excellent skills they had learned in daily life, and when the production area was dark and all public works were interrupted, they carried out emergency shutdowns of units, equipment, and towers with high temperature and high pressure, flammable, explosive, toxic and harmful units in accordance with operating procedures, and adopted scientific and effective methods to safely and smoothly shut down the units. 　　At 19:30, the main leaders of the company completed the on-site inspection of the eastern production enterprises and confirmed that all production enterprises had achieved safe and stable parking, and no safety and environmental accidents had occurred. The company leaders decided on the spot to immediately restore lighting and electricity in the production area to ensure the personal safety of employees and the safety of monitoring equipment. At the same time, we strive to restore public engineering systems such as water, electricity, steam, and wind in the shortest possible time. 　　Just after 18:00, the industrial water supply line of the Second Petrochemical Plant was restored to service. 　　At 19:55, the 40,000-volt backup power supply line was put into use, and lighting in various production plants was gradually restored. 　　At 24:00, all power supply systems in the eastern part of the country were restored and restrictions on production power consumption were lifted. ； Air compressor stations and air separation units resume operation ； The three boilers of the thermal power plant were ignited one after another to deliver urgently needed high and medium pressure steam for production. However, the low steam pressure has become a "bottleneck" restricting the resumption of production. 　　On the 22nd, Fushun Petrochemical, which suffered huge losses due to a sudden power outage in the external power grid, resumed production in an all-round and rapid manner. Two sets of alkylbenzene units, one set of sulfonation unit and power air separation unit of the washing and chemical plant have resumed production. The public engineering system of the eastern plant area has returned to normal. Each plant has confirmed the starting conditions in accordance with operating procedures. 　　As of the 23rd, all thermal power plants in the eastern region of Fushun Petrochemical have resumed normal production. ； The refinery's southern catalysis, northern distillation and gas separation units have started construction ； The chemical enterprise's ethylene plant feeding, acrylic fiber plant, ethoxylation plant, and BOPP plant have started operations, and the resumption of production of other plants is in full progress. No secondary accidents occurred during this period, the company's environmental protection equipment was operating normally, and industrial sewage was always discharged in compliance with standards. In the early morning of the 23rd, heating was resumed for residents in the eastern region. Note: This case seems to highlight the importance of "leadership", but the most important thing is to nip it in the bud and take precautions! Prevention is the first priority. Systemic power outage is a systematic project. Every factory should learn lessons from various accidents and failures, and learn from refineries that have successfully turned danger into safety! !

A power outage is not terrible. As long as each device can be handled according to the accident plan, it can basically be stopped safely. A power outage in the power grid causes a complete shutdown of the power system supply. This situation is too rare and too sudden. As for whether the coking and catalytic devices coke during the shutdown, it all depends on luck. At that time, the entire No. 2 Petroleum Plant first used electricity to supply fresh water, and then started the operation of the catalytic device as soon as possible, so that steam could be produced. and gas production, which is conducive to the resumption of production of other devices (because the captive power plant at that time could not resume normal steam supply), the distillation unit and coking unit production were restored in sequence, and the main process was quickly opened up. What was left was to use steam heating lines for each device and adjust operations. It took nearly 6 days for the entire plant to resume production. No production safety accidents occurred, and the handling was relatively good. The recovery of the oil system was also critical.

The key to dealing with electric shock is to detect it promptly. If found in time, the operation of the pump can be restored directly, with little impact on the device. Large-area power outages must be treated differently. If power systems such as purified air and circulating water are stopped, the focus of the device must be manual control of pressure venting, especially catalytic, gas separation, MTBE and other devices, to prevent accidents caused by overpressure or pressure imbalance. Secondly, large equipment must be cranked to prevent shaft jamming. If the power system is normal and the instrument indications are normal, it will be relatively easy to deal with the problem. Just follow the accident emergency plan. When resuming production, the dispatch system must make overall plans and reasonably determine the use of public systems by each device.

There was a power outage in our factory last year. It didn't last long, but the consequences were very bad. It is said that there was a power outage from the Northeast Power Grid. At that time, the backup line of our own power plant was switched, but it may be that all the devices were turned on at the same time, which brought down the own line. Needless to say, the instrument wind, circulating water, etc. were all gone. There were strange noises at the scene, and it was immediately stopped at Level 5. :lol

Last year, we had a 6,000-volt line trip. Because one circuit was supplying power at that time, the other line was undergoing maintenance, so the entire device was shut down in an emergency. The main thing is that all high-voltage motors are out of service. Nothing else will be affected, just be careful not to over-temperature or over-pressure. Fortunately, it was a total downgrade, affecting two sets of devices, but not the others.

Last year, we had a 6,000-volt line trip. Because one circuit was supplying power at that time, the other line was undergoing maintenance, so the entire device was shut down in an emergency. The main thing is that all high-voltage motors are out of service. Nothing else will be affected, just be careful not to over-temperature or over-pressure. Fortunately, it was a total downgrade, affecting two sets of devices, but not the others.

On February 21, 2001, our factory also suffered a large-scale power outage. (Heavy rainstorms caused high-voltage lines to short-circuit and trip.) Due to strict emergency plans, no major safety equipment accidents occurred. First of all, it should be ensured that medium channeling does not occur, and the pressure vessel must be relieved in time to avoid overtemperature. Those that can be self-pressurized back to the tank area will be sent to the tank area under their own pressure. It is necessary to ensure that other media are prohibited from entering the steam, purified air, non-purified air, and nitrogen systems.