The reforming unit was started successfully

The continuous reforming device is a key device for the company to reduce oil and increase quality and efficiency. From July 2018 to this overhaul, it has been running safely and smoothly for 5 years, setting a new record for the continuous long period of construction of the continuous reforming device. In the past five years, the continuous reforming unit has experienced more than 10 times of compressor shutdown, online replacement of regenerative water cooler leakage, non-replacement isolation of extraction air cooler and other unconventional operations; The production adjustment of monobenzene production scheme, aromatics decolorization scheme and triphenyl production scheme was completed. In the past five years, no matter what difficulties and frustrations encountered, all the staff of the reorganization workshop maintain a positive attitude, tackle difficulties, strive for excellence, and ensure the safe and smooth operation of the device. On May 27, 2023, the continuous reforming unit completed the first cycle production task and ushered in the first major overhaul.

Stop work and confirm every key point step by step.

In order to meet the requirements of green environmental protection shutdown and successfully pass the safety acceptance of the continuous reforming device at one time, the production Department has developed a scientific and rigorous shutdown purge program in advance and implemented the "step by step confirmation" layer by layer compaction responsibility. The shutdown process strictly follows the plan to grasp each key step, fully identify possible risks, and implement preventive measures one by one.

In the displacement purging, implement the displacement purging of pipelines and equipment one by one, resolutely eliminate omissions, optimize the displacement plan according to the actual situation, and ensure that the displacement purging of each dead Angle of the device is in place; At the same time, the blind plate plugging operation is implemented one by one in strict accordance with the established "blind plate list" to ensure that the blind plate on site is error-free and fully covered, and effectively prevent media from channeling each other. It is the implementation of strong measures, the fulfillment of the responsibilities of each participant, to help the high standard to successfully complete the load reduction, parking, replacement and other work of the device.

Maintenance, each quality pass to achieve strict protection

"The overhaul is the first comprehensive overhaul since the completion of the continuous reforming device, large scale, tight time, wide coverage, uncertainty and large workload, all the personnel involved in the overhaul must go all out to do a good job of the overhaul work, quality and quantity to complete each overhaul task." This is not only a directive issued to all maintenance personnel, but also a heavy responsibility on the shoulders of inspection personnel.

In order to make the overhaul work more clear, the workshop management staff issued a task sheet to the post staff every morning, and the work content, location and requirements were clearly defined on the task sheet. After work every day, the task sheet was retrieved for the record of the responsible person, and the maintenance plan was updated in the evening and the next day's work tasks and personnel arrangements were formulated. Complete each maintenance plan task item by item.

In order to control the quality and compaction responsibility in the whole process, each work is maintained and monitored by the designated personnel of each post from beginning to end, and no one is changed in the middle; Ensure no omissions in each sub-item, high quality and efficient.

The inlet and outlet pipelines of the forced circulation pump of the reformer drum have had 4 leakage points during the construction period. The inspection and repair was carried out one weld inspection one by one for the 30m high scaffolding set up for the forced circulation line, and the regional workshops that could not detect faults at night coordinated noon inspection. A total of 8 problematic welding joints were detected, and all repairs were completed to ensure the smooth operation of the device in the next cycle.

The blind end flange cover of the outlet manifold of the reforming heating furnace is a maintenance error, and most of the reforming devices did not carry out the blind end inspection of the manifold. After disassembling the blind end flange cover of the manifold, it was found that the second and third reverse flange covers were worn by nearly 15mm due to the gas eddy current caused by the design structure. We communicated with the design institute to weld the anti-eddy current baffle to prevent the generation of gas eddy current.

The inspection and overhaul of the internal parts of the reforming reactor is the key to the overhaul of the entire reforming unit. The workshop management personnel are the first to enter the reactor to check the changes of the internal parts after a long period of operation, and the last to leave the reactor to confirm the quality of the reactor overhaul and the internal remnants. There is serious coking in the middle of the three reverse and four reverse fan cylinder and the wall, and the three reverse fan cylinder appears obvious S-shape deformation. The workshop set up a "reactor raid group" to clear the coke through the soft ladder in the narrow space of the reactor more than ten meters high, and the operation is uninterrupted from 7 a.m. to 9 p.m., and the cleaning, installation and maintenance of the reactor interiors are successfully completed in 8 days.

The reforming catalyst adopts the domestic advanced physical screening technology, the dust, half particles and high carbon agent in the reforming catalyst are screened at different levels, and a total of 6.8 tons of dust and high carbon agent are screened, ensuring the performance and regeneration of the next cycle of reforming catalyst.

The reorganization workshop has completed 27 technical reform projects in this major overhaul, especially the technical reform projects such as cracking heavy stone direct supply reforming reaction, direct naphtha direct supply reforming, analytical gas direct supply reforming, and increasing the cutting valve of benzene tank, which can not only improve the processing capacity, but also reduce the labor amount of employees and improve work efficiency.

03

On-site, strictly implement the safety and environmental protection management requirements

In order to ensure maintenance safety and environmental protection control, the second production department strictly follows the maintenance safety and environmental protection management requirements, so as to achieve partition management and package to people. The guardianship personnel are responsible for the safety, environmental protection control and on-site cleaning around 20m of the guardianship area;

After the construction is completed every day, the workshop management personnel will carry out acceptance inspection on the site to ensure that the construction site is clean and tidy. Establish a maintenance safety and environmental protection inspection team with directors, safety officers and technicians as the backbone to achieve seamless management of "where there is work, where there is supervision". Through on-site risk control, we can effectively ensure that on-site operations are supervised, illegal operations are managed, and hidden dangers are stared at.

04

Start, control start node steady progress

Nitrogen replacement, 2.0Mpa test, hydrogen test, all working nodes in the maintenance after the completion of the steady progress. According to the material receiving process and temperature control in each area of the plant, the disassembly and start-up plan are carried out in accordance with multiple working nodes, such as pre-hydrogenation replacement test densification, pre-hydrogenation oil extraction start up, post-fractionation test densification pad oil heating up, reaction system test densification heating up, reaction system oil intake, extraction system replacement solvent circulation, regeneration black burning to white burning, etc., to ensure that materials in each area can be connected and process adjusted. At 14:00 on June 26, the pre-hydrogenation part of the oil started, and at 16:00 on June 28, the refined naphtha was qualified to be sent to the tank farm; At 17:00 on July 2, the reforming reaction feed was fed, the hydrogen was incorporated into the pipe network at 20:00, and the reforming product entered the finished tank farm at 8:00 on July 3. At 10 o 'clock on July 5, the black burning of the reforming catalyst turned to white burning, representing the complete completion of the reforming device, and officially entered the stage of smooth operation of the second cycle.

This summer, destined to be a passionate look. More than 200 people gathered up the great strength, they are not afraid of wind and rain, not afraid of heat waves, overcome difficulties, act as, with hard work, not afraid of difficulties, struggle attitude, braced together in the overhaul battlefield. Focusing on the key links, the maintenance work was completed on time with high standards and high quality, setting a benchmark for Yatong Petrochemical's high-standard maintenance.

The tide of thousands of sails competing, the evening is right. New starting point, new beginning, new journey; Always maintain the awe of safety and environmental protection, with a down-to-earth attitude of "initial heart like rock", with a hard temper to create a "pioneer image", brave to stand on the tide, brave to take on the burden, 踔厉 hard work, and do not idle, and strive to produce two reforming devices in the second week to create a new record of long-term safe and stable operation.