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2022-08-05
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Guangzhou Petrochemical: strictly control the "instrument" to ensure the safe operation of instruments and equipment

the "Four-level inspection" of Guangzhou Petrochemical Instrument control center ensures that there is no dead angle in hidden danger investigation, preventive maintenance ensures the long-term operation of instruments, and strictly control the "safety" of instruments in an all-round way to ensure the safe and reliable operation of instruments and equipment

recently, linxinghua, deputy director of Guangzhou Petrochemical I & C center, just entered the office. He immediately turned on the computer to check the production status reported by all units in the production group of the I & C center

"there were 20 items of production yesterday, and there were 4 items this morning." He could not help frowning, "the shaft vibration of No. 2 steam turbine in power station 2 fluctuated, and some parameters gave alarms." He kept his eyes on the problem and recorded it in his notebook

At the production coordination meeting at

9, linxinghua raised the existing problems, and the participants combed the problems and formulated solutions and rectification measures

since the beginning of this year, the instrument control center has taken such measures as "Four-level inspection" to ensure that there is no dead angle in hidden danger investigation, joint tackling of instrument problems, preventive maintenance and long-term operation of instruments, and strictly controlled the "safety" of instruments in an all-round way

"four level inspection" ensures that there is no dead angle in hidden danger troubleshooting

"the fast discharge valve of d-203 discharge line valve xcv-234a of No. 2 polypropylene unit does not operate smoothly." Recently, limanyi, a shift member of No. 2 polypropylene unit in the second workshop of the instrument control center, found problems in the special inspection of the regulating valve. After timely replacement of the discharge valve, the normal operation of the valve was ensured

the instrument control center regularly carries out "four level inspection" on instrument equipment - the center, workshop, team and shift personnel go deep into the existing line to check hidden dangers, focus on checking the integrity of instrument equipment at key parts and key posts, specially check the operation of valves, and thoroughly check the indication of temperature points at hidden parts

through "Four-level troubleshooting", in the first quarter, the center successively found 67 hidden dangers, such as air leakage in the instrument air pressure reducing valve of the feed valve of the 6 bin pump of the 2 boiler of the CFB boiler. In view of the major hidden dangers such as the fault alarm of DCS cabinet redundant controller of heavy catalyst unit and the unstable performance of flame detection probe of combustion furnace of sulfur unit, after making a full safety risk assessment, the instrument control center developed a detailed and rigorous construction scheme, which was handled in conjunction with relevant departments such as process department, so as to ensure the safe operation of instrument equipment

for the problems found in the troubleshooting, they classified and summarized the problems. For those that can be rectified immediately, and for those that cannot be rectified temporarily, they formulated rectification measures, defined the rectification personnel and completion time, and implemented closed-loop management

effective experimental space of the joint research and solution instrument: the problem of 650mm meter

some time ago, the d-1251 high-pressure steam outlet regulating valve of the steam drum of the 65000 standard vertical/hour hydrogen production unit was stuck when the valve position opening was greater than 35%, resulting in difficulty in load adjustment of the unit. The I & C center, together with technicians from the mechanical power department and the fourth oil refining department, jointly tackled key problems. The remote control is realized by adding pneumatic motor. When the opening is small, the positioner is used for control, and when the opening is large, the pneumatic motor control is switched to realize the accurate control of the opening of the regulating valve

people should pay more attention to some details when using "there are more methods than difficulties. As long as there are instrument problems, the instrument control center will always wait and concentrate on solving them." Linxinghua said

at the end of last year, two sets of sulfur unit tail gas systems were upgraded for environmental protection, among which a set of DCS system was added for tail gas treatment of 20000 t/a sulfur unit. Since the model of the new system controller is different from that of the original system, and there is a risk of unit shutdown due to the initialization of the lower system, the unit needs to be shut down for operation. However, during the shutdown period, the acid gas balance of the whole plant will be affected, and the sulfur dioxide in the tail gas is easy to exceed the standard, so there are safety and environmental protection risks

faced with the dilemma, the instrument personnel and process personnel carried out joint research. After a series of safety risk assessments, they decided to jointly choose to implement "" and "" when the load of the unit is low. With the close cooperation of all departments, the safety and reliability of the newly added DCS system was finally realized

through joint research, the I & C center has also successfully solved more than 20 instrument problems, such as frequent failure alarm of frequency card in DCS system, air valve failure of power 3 and 4 boilers, which constitute a cooperative device for promoting the development of new material industry, and ensured the safe and stable operation of the device

preventive maintenance ensures long-term operation of instruments

s zorb unit is completed and put into operation, there are many failures of the program control valve in the regeneration system, especially the internal leakage of the program control valve. On the basis of summarizing the repair and maintenance experience, the instrument control center has developed a series of preventive maintenance strategies, which have achieved remarkable results by strengthening the on-site routine maintenance, tackling key problems in the localization of instruments and equipment, optimizing production procedures, regularly adding fillers and other preventive maintenance measures. In the first quarter of this year, there was no internal leakage fault of the program control valve

the instrument control center has established a troubleshooting account to record in detail the failure and maintenance of the program control valves of s zorb, styrene, polyethylene, reforming and other units, analyze the causes of the valve failure, and formulate a targeted preventive maintenance plan to change the post maintenance into pre prevention, which improves the reliability of instrument and equipment operation

in view of the serious internal leakage of 86 programmed control valves in the hydrogen purification unit of No. 2 reforming unit, the instrument personnel took preventive maintenance measures such as changing the material of sealing components, replacing valve accessories and strengthening patrol inspection. The maintenance cycle was increased from once every 5 ~ 6 months to once every 12 months

since this year, the instrument control center has implemented a total of 517 instrument preventive maintenance projects, ensuring the safe and reliable operation of instrument equipment

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