Process Area Event – [I See Now-06] A Great Dam Is Destroyed by Ant Holes
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This post was last edited by B0SS on 2016-10-21 at 12:34. Those familiar with catalytic cracking units know that such units in petrochemical enterprises are characterized by their large scale, complex structure and control systems, as well as the large number of positions required for their operation. Although the once dominant companies have lost some of their prominence today, the importance of catalytic cracking units remains undeniable. Without further ado, let’s get to the point. Since operations began in 2015, the performance of the catalytic flue gas turbine has not been good; severe scaling on the turbine blades caused extremely high vibration levels, prompting six shutdowns to clean the blades. Of these six operation cycles, the longest one lasted 122 days, while the shortest one lasted only 37 days. Why, why? What’s going on here? What’s the matter? Several workshop managers discussed the issue several times and agreed that it was caused by an excessive level of catalyst dust in the smoke. But the recovery efficiency of the three-rotation and four-rotation processes is quite good, the catalyst consumption per unit is not high, and there’s also a way to dispose of the waste catalyst – which is quite strange. I have also reported the issue to the company’s equipment department on multiple occasions, but the problem persists and has not been resolved. It wasn’t until a few days ago, while conducting inspections near the smoke extractor and deep in thought, that I accidentally noticed the balance line on top of the small waste tank to be cold. Oh, I see! ! ! This pipeline is blocked, which makes it difficult for the catalyst recovered from the third and fourth spinners to reach the small waste tank; as a result, the recovery efficiency of the third spinner is greatly reduced. A lot of fine catalyst powder ends up going directly through the flue gas pipes into the flue gas burner, so it’s impossible for the burner to operate stably over a long period of time! ! ! I drew a sketch; it’s clear at a glance. Operating conditions after scale removal of the flue gas turbine on October 15
Oh, I forgot to mention @friends~ @Guan Gongyu @Fish in the Desert @altpage @liuquan1100 @I_am_kind @Learning_is_eternal166 @Black_toothpaste @*ezhongxu
Apart from regular cleaning and enhanced inspections, can this pipeline be optimized? Such as increasing the pipe diameter?
It’s not possible to optimize for now. This pipeline is a stainless steel pipe with dimensions of Φ114×7, and the makeshift solution is to make an opening under pressure. After identifying the location of the blockage, two holes with a diameter of Φ80 are drilled, two valves are installed, and a temporary pipeline with dimensions Φ114×7 is used. Wait until the device undergoes major maintenance, and then install a new pipe in accordance with the process requirements.
First, include it in the major repair plan, start procuring equipment materials, and prepare work instructions
Yes, usually we tally the issues that need to be addressed during major repairs. For example, leaks that cannot be fixed or pipelines that require optimization through technical upgrades – the pipelines I mentioned certainly need to be included in the major maintenance plan. :lol
It would be great if it could solve the problem; congratulations!
This event is great; hurry up and sign up for one~:lol
Based on the poster’s description, it seems to be a vapor pressure balance tube. I think adding pressure displays at both ends would allow such abnormalities to be detected promptly, enabling timely intervention~~
There are pressure gauges at this site, and three temperature points are displayed on the DCS; it’s just that no one paid attention to this small detail. Therefore, it caused very bad consequences for the smoke extractor. Everyone, from managers to operators, is involved in this to some extent. :handshake
Please accept my knees; I didn’t understand. :Q:L