How to deal with voltage fluctuations in the reforming unit? Experts, please help!
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How to deal with voltage fluctuations in the reforming unit? Experts, please help! Thank you! In the event of a long power outage, such as for several hours, does the reforming reactor need to maintain its temperature and pressure?7.3.1.1 Symptoms of the incident
(1) All pumps and machines stop operating; flow indicators return to zero.
(2) All lights go out and do not turn back on immediately.
7.3.1.2 Cause of the incident
The power grid ceases to supply electricity.
7.3.1.3 Confirmation of the incident
On-site pumps and air-cooling fans have stopped operating.
7.3.1.4 Measures to handle the incident
(1) Immediate actions
① Extinguish all heating furnaces.
② Maintain pressure in the reforming reaction system and pre-hydrogenation reaction system.
③ Manually control all control valves to prevent overheating or overpressure.
(2) Operational objectives
① Extinguish heating furnaces to prevent overheating of the catalyst beds.
② Maintain system pressure to facilitate a smooth restart of operations.
③ Prevent high-pressure fluid from flowing into low-pressure sections, thereby avoiding secondary incidents.
(3) Potential problems
① Overheating of catalyst beds.
② High-pressure fluid flowing into low-pressure sections, leading to secondary incidents.
③ Excessive and rapid drop in system pressure.
(4) Operating procedures
**Level A operations**
1. Make contact with relevant personnel.
2. Immediately extinguish all heating furnaces.
3. Maintain pressure in both hydrogen-containing and non-hydrogen-containing systems.
4. Stabilize liquid levels in high- and low-pressure separators to prevent high-pressure fluid from entering low-pressure sections.
5. Handle reciprocating compressors and centrifugal pumps accordingly.
6. Manage the waste heat boiler properly.
7. Manage towers as required.
**Contingency state:** Pre-hydrogenation furnaces are extinguished and pressure is maintained; reforming furnaces are likewise extinguished and pressure is maintained.
**Level B operations**
1. Make contact with production dispatch to determine the extent of the power outage.
Report the situation to shift supervisors and members of the emergency response team.
Notify the diesel hydrotreating unit to prepare for prolonged interruption of hydrogen supply.
Notify the jet fuel desulfurization unit to prepare for prolonged interruption of hydrogen supply.
Notify the hydrogenated dewaxing (diesel hydrorefining) unit to prepare for prolonged interruption of hydrogen supply.
2. Immediately extinguish all heating furnaces.
(P) Verify that interlocks have caused F-102 and F-201–F-204 furnaces to shut down.
Close all burner valves and extinguish pilot lights.
Shut down main burners in reboilers at tower bottoms and extinguish their pilot lights.
3. Maintain pressure in both hydrogen-containing and non-hydrogen-containing systems.
Close pressure control valve D-201.
Close manual valve at hydrogen outlet point No. 25 on D-201.
Close pressure control valve D-102.
Close manual valve at hydrogen outlet point No. 25 on D-102.
Close pressure control valves D-101, D-103, and D-203.
(P) Verify that pressures in high-pressure separators and reflux drums remain within safe limits.
(P) Verify that reactor bed temperatures stay within acceptable ranges; if overheating occurs, open appropriate high-pressure separator pressure control valves to relieve pressure.
4. Stabilize liquid levels in high- and low-pressure separators to prevent high-pressure fluid from entering low-pressure sections.
Close level control valves for high-pressure separators.
Close level control valves for low-pressure separators.
(P) Verify that liquid levels in high-pressure separators remain above 40%.
If levels drop too rapidly, close upstream and downstream valves of the respective level control valves.
(P) Verify that liquid levels in low-pressure separators remain above 40%.
If levels drop too rapidly, close upstream and downstream valves of the respective level control valves.
On-site, close inlet and outlet valves of all pumps.
5. Handle reciprocating compressors and centrifugal pumps.
In the control room, press emergency stop buttons for all reciprocating compressors.
Close seal oil supply valves; monitor oil supply from the overhead oil tank of unit K-201 closely and keep track of coast-down time.
After compressors stop running, turn their shafts once every three minutes at 180° intervals.
Set load levers of reciprocating compressors to 0%; close inlet and outlet valves, open interconnecting valves, vent all gas from the compressor casing, then close vent valves.
6. Manage the waste heat boiler.
Vent steam from D-401 to the atmosphere.
7. Manage towers as required.
Try to maintain tower top pressure within the range specified in process specifications.
Ensure liquid levels in all towers and reflux drums remain within normal process limits.
Contingency state: Pre-hydrogenation furnaces are extinguished and pressure is maintained; reforming furnaces are likewise extinguished and pressure is maintained.
7.3.1.5 Resuming operations after power restoration
1. Conduct single-tower circulation for each tower.
(P) Verify that liquid levels at tower bottoms remain above 50%; if below 50%, use refined oil to raise levels to 70%.
Start circulation pumps at tower bottoms.
Ignite burner flames in reboilers at tower bottoms following normal startup procedures; adjust operating parameters to maintain single-tower circulation.
2. Verify that the waste heat boiler operates normally.
(P) Verify that P-401 continues circulating.
(P) Verify that liquid level in D-401 remains normal.
3. Start recycle hydrogen compressor K-201 and ignite the “four-in-one” furnace.
(P) Verify that pressure in D-201 remains no lower than 0.8 MPa(g).
Off-site personnel and compressor operators jointly start K-201 per standard startup procedures and bring it to full load.
Ignite burner flames in the “four-in-one” furnace following normal procedures.
Raise temperature in the fourth reforming reactor at a rate of 15–20°C until reaching 370°C, then hold steady.
4. Start recycle hydrogen compressor K-101 and ignite F-101.
(P) Verify that pressure in D-102 (PIIC2102) remains no lower than 2.0 MPa(g).
Off-site personnel and compressor operators jointly start K-101 per standard startup procedures and bring it to 100% load.
Ignite burner flames in F-102 following normal procedures.
Raise outlet temperature of F-101 at a rate of 15–20°C until reaching 200°C, then hold steady.
5. Feed oil into the reforming system.
Resume chlorine and water injection into the reaction system.
Reconfigure pipelines so that refined oil from the tank farm flows into the plant; prime pump P-105/2.
(P) Verify that outlet temperatures of F-201–F-204 reach 370°C.
Start P-105/2 to pump refined oil into C-102 as a cushion.
(P) Verify that bottom liquid level in C-102 (LIC-2106) exceeds 70%.
Start P-108 to feed oil into the reforming reaction system.
Once oil appears in high-pressure separator D-201, raise its temperature at a rate of 15–20°C/h northward toward the fourth reforming reactor.
When liquid level in D-201 exceeds 50%, feed oil into D-203.
When liquid level in D-203 exceeds 50%, feed oil into C-201.
When liquid level in C-201 (LIC-2206) exceeds 60%, transfer excess oil to the oil storage facility.
(P) Verify that the reforming reaction system generates hydrogen and that pressure in D-201 (PIC-2201) rises.
(P) Verify that pressure in D-201 (PIC-2201) reaches 1.20 MPa; switch PIC-2201 to automatic control mode with a setpoint of 1.20 MPa, and route waste hydrogen to the plant-wide gas network.
6. Feed oil into the pre-hydrogenation system.
(P) Verify that hydrogen purity in D-201 exceeds 75% (V).
Start K-202 per normal procedures and bring it to 100% load to supply hydrogen to the pre-hydrogenation system.
(P) Verify that pressure in D-102 (PIC-2102) reaches 4.0 MPa(g).
Switch PIC-2102 to automatic control mode with a setpoint of 4.0 MPa.
Start P-101 to pump reforming feedstock into C-101.
(I) Verify that liquid level in C-101 (LIC-2101) exceeds 70%.
Start P-105/1 to pump bottom oil from C-101 into the pre-hydrogenation reaction system.
(P) Verify that liquid level in D-102 (LIC-2103) exceeds 60%.
Open LIV-2103 to reduce oil flow into C-102 while maintaining D-102 liquid level between 40% and 50%.
Stop operation of P-105/2 while keeping C-102 liquid level between 45% and 55%.
7. After all systems are interconnected, adjust operating parameters accordingly.
(P) Verify that all systems are fully interconnected; increase reforming feed rate to normal levels.
Adjust all operating parameters per process specifications.
Notify and supply hydrogen to all hydrotreating units.
Resume corrosion inhibitor injection.
Verify that inlet and outlet valves of all idle pumps remain closed.
**Note:**
1. (1) When pressure in the reforming system exceeds 0.8 MPa and pressure in the pre-hydrogenation system exceeds 2.0 MPa, the pre-hydrogenation system may be started first. After producing qualified refined oil, this oil can be used to start up the reforming system. (2) When the pressure in the reforming system is below 0.8 MPa while the pressure in the pre-hydrogenation system is high, hydrogen can be introduced into the reforming system via pre-hydrogenation to ensure that its pressure remains above 0.8 MPa. In such cases, the refined oil from the tank area should be used to start the reforming system first, followed by starting the pre-hydrogenation system. (3) When it is not possible to ensure that the pressure in the reforming system is greater than 0.8 MPa, first introduce the refined oil from the tank area into the hydrogen production system; use the crude hydrogen produced to start up the reforming system, and then feed it into the pre-hydrogenation system. 2. The ignition of each heating furnace must be carried out in strict accordance with the \"Heating Furnace Operation Procedures\"