Operation of the slurry system

I. Preventing equipment scaling 1. Anti-coking measures for lift pipes ⑴ Maintain an appropriate preheating temperature for the feed oil. The feed temperature of the crude oil (surface thermocouple TI280) should be 165–185. (2) The amount of atomizing steam for the crude oil must be controlled such that FI205 is not less than 6.5 t/h. ⑶The riser exit temperature TI214 should be ≮480°C, and the riser pressure drop PDI223 should be ≮60 KPa. 2. Anti-coking measures for the settler ⑴ Unobstructed flow of anti-coking steam (orifice plate limit: 600 Kg/h). ⑵Stirring steam (upper): FI207A ≮ 0.5 t/h; (lower): FI207B ≮ 2.5 t/h. ⑶The fluidized steam flow in the overflow hopper FI286 is ≮1.0 t/h. 3. Anti-coking measures at the bottom of the fractionation tower: (1) Keep the slurry stirring line unobstructed. ⑵The stirring steam line at the bottom of the tower must remain unobstructed. ⑶The bottom temperature of the tower ≯355°C. ⑷The slurry scale inhibitor is injected at a rate of 20 Kg per shift. ⑸The circulation rates of both streams in the oil slurry circulation system must be ≥380 t/h, thereby reducing the occurrence of flow imbalance. ⑹The solid content and density of the oil slurry are analyzed three times a week. Under normal circumstances, the amount of oil slurry discharged is maintained at 6%. However, when the solid content in the oil slurry exceeds 5 g/L or its density exceeds 1.05 kg/m³, the volume of oil slurry discharged should be increased. II. Special maintenance for major equipment and management of special valves: 1. Strengthen monitoring of dust concentration at the inlet of the flue gas turbine; dust concentration should be analyzed once a week. In special cases, contact the testing center to increase the frequency of analysis ； Equipment technicians conduct online monitoring of the vibration and shaft displacement of axis M101 at least once per week. 2. Control the oil seal differential pressure of compressor 504/2 to ensure it remains stable and exceeds 100 KPa. Analyze the quality of the lubricating oil once daily, and replace the oil based on the analysis results ； Replace air with nitrogen; the pressure in the nitrogen system must be ≥250 KPa, and the pressure entering the machine must be ≥200 KPa. During the operational process, it is necessary to constantly monitor changes in the amount and composition of the rich gas, and make adjustments in a timely manner to prevent the compressor from running out of pressure. 3. Special valve management. The operator checks the oil temperature, oil level, etc., during each inspection, while the equipment technician in charge checks them once a day and compares the valve positions indoors and outdoors. III. Daily Process Management 1. Prevent significant loss of catalyst: Maintain stability in the regeneration bed, strengthen monitoring of the dilute-phase density, and make adjustments promptly in case of any abnormalities. The regenerator inventory WI204 is maintained at 185–195 tons; after a decrease in the regenerator inventory, the feeding rate is appropriately increased. The dilute and dense phase levels of DI211 in the regenerator are generally between 5–7 Kg/m3. When DI211 exceeds 8 Kg/m3, it is necessary to analyze the cause. The catalyst’s sieving properties and activity should be checked once a week, and the catalyst should be replaced promptly in response to any changes. 2. For external heat extraction, operator ① is responsible for monitoring the analysis data of the boiler water; special care is given to the chemical dosing pumps, and any issues are addressed promptly. Proper drainage of boiler water from the drum is also ensured. Add chemicals regularly to ensure that the boiler water quality meets standards ； ②. When the Na+ content in the saturated steam from the external heat recovery drum is not within acceptable limits, the saturated steam is not fed into the waste heat boiler for superheating ； ③. The external heat extraction steam generation rate FIC901 should be maintained between 20 and 25 t/h. ④. The liquid level in the external heat extraction steam drum LIC901 should be kept between 35% and 50% ； 3. Strengthen the handover inspections: check the liquid levels and pressures of each drum, as well as whether the indications on the liquid level and pressure gauges of various towers and containers are accurate ； Are all pumps and machines operating normally? Improve the quality of scheduled inspections to ensure that all necessary inspections are carried out, so that any issues with the equipment can be detected promptly and addressed properly. 4. Operate strictly in accordance with the process cards; the process team should strengthen the inspection and evaluation of process parameters. For any parameters that deviate from those specified in the process cards, the team must analyze the reasons and devise corresponding measures. 5. The process team holds a catalytic production analysis meeting once a week to analyze problems that arise during production, formulate solutions, and establish unified principles for subsequent production adjustments. IV. Daily Equipment Management 1. Equipment operators shall conduct vibration and temperature measurements on all pumps at least once per week, and record the results ； At least twice a week for P301, P302, P304, P308, P309, P404. 2. All mechanical pumps in the catalytic pump area must be switched over once a month to ensure they are in good standby condition ； The switching of the slurry pumps and all variable-frequency pump sets should be scheduled during the day whenever possible, and process and equipment technicians must be present. 3. During inspections, operators must conduct a thorough check of the lubricant quality, oil level, operating condition of the pumps, as well as the status of the standby pumps. The equipment team will carry out random inspections from time to time, and those who identify problems will be held strictly accountable. 4. Any equipment issues that occur during shift must be reported and addressed promptly, ensuring that problems are resolved before the end of the shift; the \"three states\" of the equipment must be carefully recorded in the shift handover log. 5. Formulate specific monitoring measures for the 28 defective ball valves currently present in the catalytic unit. Strengthen the routine inspection of ball valves; operators should report any deformation or leakage of the casing promptly for handling. Equipment technicians measure the thickness of the jacket boxes weekly and keep records; any reduction in thickness is addressed promptly. V. Strengthen employee training 1. Technical personnel and operators should enhance their learning and familiarity with the new technologies and equipment introduced as a result of the upgrades (special valves, variable frequency operation methods), as well as the new processes. The operations department will organize technical lectures and on-site examinations. 2. Technical personnel monitor and record the important operational parameters in their respective areas on a daily basis, conduct analyses, propose solutions to problems, and carry out regular assessments.

1. Ensure that the temperature at the bottom of the fractionation tower does not exceed the limit, to prevent polymerization and coking, which could affect the operation of the slurry system； 2. The increase or decrease of the slurry circulation rate should be within certain limits; if the slurry circulation rate is too low, it will result in excessively low linear velocities on the slurry side of heat exchangers and drums, leading to local deposition and coking ； 3. Control the quality of the oil slurry product, maintain a certain amount of overflow, and keep the solid content at ≤6 g/l; it is not advisable to set this value too high to avoid local deposits that could block the flow area ； The slurry density parameter can also be referred to. 4. Ensure that the dosage and injection point of the slurry scale inhibitor are proper.

Control the oil seal differential pressure of compressor 504/2 to ensure that it remains stable and above 100 KPa. Analyze the quality of the lubricating oil on a daily basis, and replace it based on the analysis results. Isn’t it a bit too frequent to test the properties of the lubricating oil? Here we conduct such tests once a month