Training Outline for Operational Positions

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Position of shift leader, internal operation position (becoming a system operator): 1. Understand the composition of the plant, master and draw the principle flow diagrams and automatic control flow diagrams of the plant; be proficient in the principles of automatic control and normal production operations, as well as the installation diagrams of key equipment. Improve the ability to review basic and detailed design of process packages, as well as have an understanding of the composition and properties of raw materials and products, their flow directions, auxiliary agents, product properties, and the conditions under which feed and products enter and leave the plant. 2. Understand and master the basic principles of processes such as hydroprocessing, hydroisomerization dewaxing, hydrorefining, and product distillation; be familiar with the process flows of systems for hydroprocessing, isomerization dewaxing, hydrorefining, and product distillation, with trainees required to be proficient in these aspects. 3. Understand the chemical reaction mechanisms of this device, such as hydrogenation desulfurization, hydrogenation denitration, hydrogenation deoxygenation, hydrocracking, alkane isomerization, and aromatic saturation. 4. Understand the design conditions of the following units: process parameters, and the composition and properties of different crude oils ； Specifications and properties of supplemental hydrogen and deoxygenated water ； Composition and dosage of catalysts and auxiliary agents such as vulcanizing agents, passivators, and corrosion inhibitors ； An overview of the properties of the main product and by-products of this device, as well as the conditions for the product to enter and leave the device. 5. Understand the utility requirements for this device, including steam, boiler feed water, cooling water, nitrogen, industrial air, fuel oil, fuel gas, power supply, and start-up oil; become familiar with the control procedures related to these utilities in this project, thereby enhancing the ability to carry out engineering acceptance checks. 6. Understand concepts such as the minimum pressure rise temperature (MPT) of HDT, IDW, and HDF reactors, as well as the temperature difference across the reactor surface; master the operations of increasing pressure, reducing pressure, raising temperature, and lowering temperature in these reactors. 7. Understand the comprehensive inspection process for containers (reactors, separators, towers, tanks, etc.), pipelines, and instrumentation systems, in order to prepare for future design and construction reviews, thereby improving the ability to conduct such reviews and to address issues. 8. Be familiar with the procedures and precautions related to pressure testing of the plant, purging and flushing of the plant, as well as individual unit tests; focus on mastering the commissioning procedures for plant drying tests, the new hydrogen compression system, the reactor system, and the feedstock and distillation systems. Understand the issues that need attention during the plant construction process, in order to prepare for the future commissioning of the white oil (isomerization, refining) plant. 9. Be familiar with the startup operation procedures and steps for the following devices: (Some of items 1, 2, 3, 4, 5, and 6 are not available in white oil, but familiarity with them is still required.) 1) Initial airtightness test of the reactor system (operations such as industrial gas airtightness testing, system nitrogen purging, and cold nitrogen airtightness testing). 2) Initial drying of the reaction system (without catalyst) and a gas-tightness test at operating pressure (establishing gas circulation – igniting the furnace – heating and drying the reactor). 3) Catalyst loading (understanding the conditions, mastering the steps, and noting the precautions). 4) Commissioning of the HDT reactor system equipped with fresh catalyst (system nitrogen purging and airtightness check – establishing a nitrogen circulation – heating the reactor – dehydrating the catalyst). 5) Sulfidation of the HDT catalyst (establishing a hydrogen partial pressure of 14–28 kg/cm2 – starting sulfidation at low temperatures – high-temperature sulfidation and homogenization treatment – final preparation of the HDT feed system). 6) Introduction of the wax oil feed into the HDT reactor. 7) Commissioning of the reactor system equipped with the new catalyst IDW/HDF – nitrogen purging and airtightness check – preparation for high-pressure operation of the reactor system. 8) Catalyst reduction (establishing gas circulation and conducting a gas-tightness test – heating the reactor). 9) Introduction of wax oil feed and deactivation of the IDW catalyst (IDW reactor feed – ammonia deactivation). 10) Obtaining qualified product and switching of plant feed. 10) Normal commissioning of the feeding and distillation systems (purging, pressure testing, trial operation, etc.). 10. Be familiar with the preparatory work and operational procedures for a normal shutdown of the plant: 1) Normal shutdown of the reaction system (without removing the catalyst): reducing the feed rate, cooling the reactor, performing thermal stripping of the reactor, cooling it to suitable conditions, and purging and isolating the reaction system with nitrogen. 2) Catalyst removal (understand the conditions, master the operational steps, and be aware of the precautions) 3) Proper shutdown of the feeding and distillation systems (Feeding system: remove oil, add water – pipeline purging) ； Fractionation system: system circulation, cooling, shutdown of side streams, oil removal, pipeline purging, etc.). 4) Understand the normal shutdown of the reaction system, as well as the normal shutdown of the feeding and distillation systems and the removal of catalyst. 11. Have thorough knowledge of the correct operation methods and procedures for the following equipment or units in HDT, IDW/HDF, as well as proficiency in operating the related process DCS systems: (gas-assisted automatic backwash filters, high-pressure feed pumps, feed/reactant heat exchangers, feed heaters, hydrogenation reactors – including understanding the causes and control methods for pressure, sulfur and nitrogen content, quench hydrogen, temperature distribution, and pressure drop; reasons for uneven reactor fluid distribution and ways to control it), HDT thermal high-pressure separators (temperature, liquid level, hold-up time, outlet temperature), causes and control methods for scaling and corrosion in the cooling of HDT reaction product gases, HDT cold high-pressure separators, HDT recycle gas compressors, thermal low-pressure separators, and stripping towers. 12. Past technical improvement measures: Review the past equipment improvement projects at Xue** Qing Refining & Chemical Plant, such as the installation of new heat exchangers for raw materials (purpose, reasons, technical solutions, process changes, operating methods, media used, process diagrams), the addition of new furnace tubes to the high-pressure furnace (purpose, reasons, technical solutions, process changes, operating methods), and the installation of variable-frequency motors for high-pressure pumps (purpose, operating methods), etc. Understand the reasons for implementing these technical improvements, their operational status, and the effects achieved