How to handle the sudden shutdown of the catalytic boiler water pump?

Close the outlet and start the backup pump; there is no problem for a short period of time. Over a long period of time, it is necessary to reduce the flow rate first; if the standby pump cannot be started, this is due to a low level of heat transfer fluid, and in such cases the catalyst circulation for heat extraction should be stopped. In the second unit as well, the flow rate can be increased, and more heat can be extracted from the slurry in the first unit. If heat integration is possible, it can be utilized to extract additional heat.

In the control room, shut off the water supply to the fractional distillation drum; it’s fine for them to operate without water for a short time. Reduce the external heat transfer flow rate significantly, lower the volume accordingly, and close the pressure control valve for water supply. The second operator should start the backup pump, close the manual drain valve on site, and check the glass panels there.

Do you mean 40 refers to the gas production volume? Are there steam turbines?

Yes, there is about 40 units of steam consumed by the turbine; it’s a back-pressure type

It feels like too much heat is being drawn from the outside, which causes the pan to dry out instantly

The heat generation and gas release rate when using external heat is too high; it must be reduced instantly

This depends on the actual conditions of the installation; for example, we have internal and external heat extraction methods. External heat extraction generates around 30 tons of steam, and the steam drum contains at least ten tons of water, which is sufficient to sustain operation for some time. Moreover, the external heat can be removed, and water can be added gradually later before it is reintroduced. If it’s just a minor issue and the backup pump can be started, the fluctuation in flow rate becomes even greater. It needs to be handled based on the actual situation.

Even a short period of time won’t do; when water cannot flow in, the drum dries out very quickly – it basically becomes dry within about five minutes. Think about it: by that time, the feed pump for the drum will likely already be too slow to function properly. Therefore, the solution, in my opinion, is to reduce the amount of feed supplied, and minimize external heat extraction. If it’s still possible to keep the system running, close the water supply valve and use a bypass line to control the amount of steam entering the drum. It’s best to have two people handling this task: one person adjusts the opening of the bypass line, while the other monitors the liquid level gauge on site. Before that, it’s necessary to check whether there is water in the waste discharge stream; if not, there’s no need to make any adjustments. It’s very serious when water enters a dry steam drum, so be sure to pay close attention to this

In the event of a short-term shutdown due to a pump failure, the backup pump should be activated immediately on site. Generally, it is acceptable to maintain the level of liquid in the steam drum at around 50% for 20 minutes. If the supply of desalinated water is interrupted, resulting in a shortage of deoxygenated water, or if pipeline valves fail for an extended period causing problems with water supply, it is necessary to contact the dispatch team right away to ensure an adequate supply of medium-pressure steam to the compressors. The supply of desalinated water must be restored as soon as possible, while also reducing the amount of heat drawn from external sources until such heating is stopped, in order to prevent the boiler from drying out. The amount of coking generated during the reaction should be reduced, and the regeneration temperature must be kept within acceptable limits. The flue gas from the boiler should be directed through a bypass, and the oil slurry should also be routed via a bypass. The operation of the distillation tower needs to be adjusted to prevent overheating and overpressure, ensuring that the product quality remains satisfactory. The self-generated medium-pressure steam should be isolated from the main steam network, with some venting allowed. Once the cause of the deoxygenated water issue is identified and the problem is resolved so that supply can be restored, steam should be introduced promptly, the temperature and pressure raised, operations adjusted, and production resumed