【Learning from Others’ Experiences】Yangzi Petrochemical Addresses the Critical Issues Affecting Its Equipment Through Targeted Solutions

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Yangzi Petrochemical Takes on the Challenge to Solve the ‘Bottleneck’ Problems in Its Facilities 2019-02-18 Source: Sinopec News Network Print Article Petrochemical News “Who dares to take on the task of addressing the operational defects in the PLC system of the steam compressors in the olefin plant’s utility facilities?” ”As soon as the host finished speaking, “I’ll do it!” ”Wu Diji from the Olefin Instrumentation Workshop of the Instrumentation Center at Yangzi Petrochemical raised his hand to respond and walked over to the main console. On February 1, the Electrical and Instrumentation Center of Yangzi Petrochemical held a ceremony to launch the technical research projects for 2019. Through this innovative approach of publicly announcing these projects, an atmosphere of enthusiasm for learning new technologies was created among all employees. It encouraged grassroots technical staff who are willing to take on responsibilities and delve into research to actively engage in scientific research and technical development efforts, thereby breaking the monopoly of foreign manufacturers and overcoming technical barriers, and solving the problems that hinder the stable operation of the facilities. Faced with the rapid development of electrical and instrumentation technologies, the Electrical and Instrumentation Center of Yangzi Petrochemical has mobilized its employees’ enthusiasm to carry out intensive technical research and development efforts on its own, in light of the outdated equipment, backward technology, and increasing risks associated with operational hazards. In 2018, the center successfully resolved ten major challenges, including the \"black box\" issue related to the regeneration of catalyst No. 350 in Unit 1 of Yangzi Petrochemical’s aromatics plant, the risk of paralysis of the PLC system for the utility pipelines in Yangzi Petrochemical’s olefins plant, and operational faults in the C241/301 system of the recycle gas compressor in Unit 2PP of Yangzi Petrochemical’s plastics plant. Achieving significant results with minimal investment, the Electrical and Instrumentation Center of Yangzi Petrochemical has assembled a team of top experts to carry out pilot projects in four workshops dedicated to olefins, aromatics, refining, and plastics processing. These projects involve the independent development of technologies such as \"introducing current signals from Class A motors into the DCS system\" and \"implementing online monitoring and management of the operating status of Class A motors in certain units within the refining area.\" Through techniques such as adding current transducer circuits, laying signal cables between cabinets and substations, expanding DCS cards, and performing configuration programming, technical personnel analyze and process operational data in real time, using signals such as colors, sounds, and charts to alert process engineers to inspect and repair faulty equipment. At present, the current signals of 59 Class A motors in 5 units, including Unit 2 for ethylene, have been successfully integrated into the control system, reducing the operation risks and failures of critical equipment. The instrumentation and control technicians at Yangzi Petrochemical have also taken bold steps to innovate in the field of big data application technologies; they have initiated pilot projects to upload \"instrument control system fault alarm diagnosis information\" and \"SIS system alarm interlock signals\" to IP21 platforms and push them to mobile devices. Currently, the alarm information from the SIS and DCS systems of the PDEB unit in the aromatic compounds plant can be uploaded. The pilot project for delivering SIS alarm information via mobile phone has been completed; fault diagnosis of critical equipment is carried out promptly and clearly, thereby improving the accuracy of identifying abnormalities and the speed of response. The various departments of the Instrumentation and Control Center at Yangzi Petrochemical worked closely together; the technical staff overcame challenges such as complex processes and high technical difficulties. Last year, they completed 37 technical improvement projects, which helped to effectively control abnormal fluctuations in the plant’s operations and unplanned shutdowns. This year, the Electrical and Instrumentation Center will build on the positive momentum in technical innovation achieved in 2018. By focusing on services that enhance quality and outcomes, it will list the key and challenging projects that require resolution. There are no restrictions as to background – anyone with the skills can take on these tasks, allowing young professionals to grow rapidly through technical challenges. It aims to motivate those who are willing and capable to work hard together to address these issues, thereby providing strong technical support for the safe, environmentally sustainable, and efficient operation of the company’s production facilities over the long term. (Bao Jun)