Device operation safety assurance plan
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The existing catalytic unit is over 10 years old and has been in operation continuously; all the equipment is original, with some pipelines having been replaced. However, now some of these pipelines are developing sand holes and leaks. What can be done to ensure safe operation? How do people manage their old devices?
The last edit to this post was made by Zhongyuanren on 2016-9-11 at 11:29. For leaks in sand eyes, one approach is to use stationary equipment for cleaning and repair； The other party is considering replacing them by carrying out technical upgrades and purchasing new pipelines
The issue with the machinery isn’t that serious, after all, there are interlocks in place. What worries me are the pipelines; no matter how carefully they are inspected, sand holes can still occur. If such sand holes appear in the insulation, it becomes even more dangerous.
There is no better way; the only solution is to increase the frequency of inspections in order to reduce the risks posed by sand holes in the catalyst pipelines!
Pressure pipelines need to be dealt with promptly.
While the device is in operation, major risks can only be avoided by strengthening inspections; often, leaks are not that dangerous – what’s important is to detect them promptly and handle them correctly. Later on, pressure pipeline inspections and technical upgrades/replacements will still be necessary.
The mechanical seal of the pump body in the stable P306 (deethanized gasoline pump) was damaged, resulting in a large amount of a mixture of gasoline and liquefied gas leaking from the site. Since this pump is an operating pump with a pressure of around 1.4 Mpa, the high-pressure fluid was ejected in a fan-shaped pattern in both directions; one of those directions led to an operating liquefied gas pump. Upon detecting the leak, the P306 power supply was turned off immediately, followed by the rapid closure of the inlet and outlet valves of the pump. The source of the leak was sealed at 13:01, after which the backup pump was started promptly in conjunction with the personnel who arrived on site. The main operator inside was informed, and the area was cleaned up. On September 12, the seal of the unit’s pump leaked
The pipelines he mentioned should not only include catalyst pipelines; there may also be leaks in the process pipelines. The only solution is to carry out more frequent inspections and address any issues that arise
Is this your old unit or the one with a 1.4 million DCC? Nowadays, light oil pumps are required to use double-end face seals, which helps reduce the risk of leaks
Let’s talk about my personal thoughts: 1. Conduct regular inspections of pressure pipelines; this task should be handled by the quality inspection team! They need to be thorough, and if not, help them do it! However, it seems that this aspect is merely a formality at best. 2. Continue and add thickness testing as well as leak detection for areas where leaks are suspected; this can be achieved by establishing proper procedural guidelines. Have you used thickness gauges and portable combustible gas detectors before? There is also VOC management, etc ； 3. The positive influence of performance evaluation: After all, work is about honors and money, that is, about merits and benefits! It is essential to maintain the right balance in order to ensure that inspections are carried out for a genuine reason rather than just as a formality ； 4. Review the relevant design documents, including the scrap cycle, pipe margin, and replacement records, to carry out targeted and thorough inspections ； 5. Adopt benchmarking management to accumulate average metrics for similar devices, thereby ensuring a more targeted approach! 5. Prepare emergency response plans to enable timely action in the event of such accidents…