Record of Emergency Handling for Slurry Pump Leakage

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At around 15:20 on April 29, 2010, process personnel at a company’s catalytic unit discovered a leakage at the weld site where the pre-heating line led out from the P208/1 outlet. They immediately reported this to the shift supervisor, who in turn informed the workshop management and production scheduler. Since the leakage amount is small, it can be controlled. The workshop agreed to use emergency plugs to seal the leaks. Contact the processing department to make the clamps. During distillation operations, reduce the frequency of P208/1 appropriately; the shift leader should assign someone to monitor P208 and use steam for shielding. At 15:40, the leakage rate at that point suddenly increased rapidly; the personnel on duty immediately shut down P208/1 and simultaneously notified the fire department and production control team by phone. Significantly reduce the reaction unit’s output (to around 60%) and lower the main air flow, while maintaining normal operations for this unit ； Distillation is used to increase the circulation rates of the re-refined oil returning to the tower (with full closure of the re-refining system), the intermediate oil, and the top-loop oil, as well as the cooling flow rate at the tower top, in order to ensure stable operation and maintain the temperatures at various points. Contact the dispatch to have the unqualified tank changed in the diesel tank area. During the actual control process, proper supervision was provided in the workshop, the operators at their posts acted decisively, the reduction in processing volume was appropriate, the adjustments to the re-refined oil and intermediate top circulation were suitable, the dry point of the crude gasoline met the requirements. After the diesel was separated, the sample analysis showed normal temperatures, so it was transferred back to the qualified tank. Later, the liquid level at the bottom of the tower increased slightly, so the slurry discharge control valve was opened; due to the low viscosity of the slurry, it could be transported to the tank area under its own pressure. After stopping the slurry pump, there is no leakage at the leak point. The Machining Department carried out emergency welding to repair the leakage points. At 17:20, the patch welding was completed. Turn on P208/1; slowly increase the pump outlet pressure – no abnormalities were detected, and operations were gradually resumed. After the clamps were manufactured, the welded areas were reinforced with glue. Production operations have been fully resumed. Thanks to the timely discovery and proper handling of this incident, an accident involving massive leakage and spontaneous ignition was avoided, as well as an emergency shutdown of the facility.