In preparation for the Spring Festival, Anqing Petrochemical Refinery II carried out a critical maintenance task on the I-set hydrogen saturation reactor 001. Prior to the holiday, the team replaced the unloader and performed a catalyst changeout by removing the old catalyst and installing new material. This process was executed smoothly, ensuring a seamless transition in production and maintaining product quality throughout.
Previously, the increasing pressure difference in the 001 differential pressure of the I-saturated hydrogenation reactor had begun to affect the efficiency of the hydrogenation reaction. To ensure continuous and stable production, it was necessary to perform a crowning operation on the reverse 001. The use of the I-hydrogen saturation reactor helped protect the I-set hydrogenation reactor 101, preventing excessive differential pressure caused by coked catalysts and avoiding potential shutdowns that could disrupt operations. By cutting out the furnace filter directly, the maintenance was completed without halting production.
During the Spring Festival, the hydrogenation unit at the second refinery initiated pre-holiday equipment and HSE inspections. Comprehensive measures were taken to address challenges such as gas pipeline fluctuations, ensuring the safe and stable operation of the facility. Maintenance personnel conducted thorough checks on equipment and HSE conditions, confirming that all pumps were in optimal working condition and ready for service. Large-scale units and special equipment were properly managed, and both combustible gas alarms and fire alarm systems were confirmed to be fully functional. Any identified risks were promptly addressed, and safety protocols were strictly followed to prevent any operational issues.
To prepare for the colder weather during the holiday, anti-freezing, anti-coagulation, and anti-slip measures were implemented on-site. Careful comparisons were made between on-site liquid levels, boundaries, and DCS readings to avoid instrument errors. Key equipment such as the III hydrogenation cycle machine K-302 and raw material pumps were closely monitored, with attention paid to temperature, steam seal, and liquid levels. Technicians were required to keep their phones available 24/7 to report any issues immediately.
Due to a shutdown in one of the coking units, the gas supply decreased, and factors like increased liquid content and pressure fluctuations affected the temperature control of the I-set hydrogenation unit. To prevent impacts on product quality and equipment integrity, operators closely monitored the DCS interface, manually adjusting key parameters and combining on-site and indoor adjustments to maintain stable inlet temperatures and ensure smooth production.
Recently, a new television monitoring system was installed in the two hydrogenation operation rooms, featuring 13 electronic cameras placed across the site. This system provides full-process surveillance of the entire hydrogenation plant, including towers and pumps, enabling quick detection and response to any unexpected or abnormal situations. This enhanced monitoring capability acts as a strong protective layer for on-site safety, ensuring a secure and stable production environment during the holiday period.
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