PSA Operation Manual

Operation Instruction of
PSA Unit
Zinder Refinery Co., Ltd.

October, 2010
Operation Instruction of PSA Unit
Zinder Refinery Co., Ltd.

October, 2010
Preparation and approval table
Item Signatures Date
Liu Lan
Prepared by: Li Wenxin September 2010
Yan Peiren
HSE department
Machine and power

Zhang Jianming September 2010
department
Reviewed by
Technical department Fan Chunjiang September 2010
Production department Yuan Xuanmin September 2010
Approved by: Ma Lifei September 2010

Table of Contents
Chapter 1 Process technology regulation ......................................................................................................... 1

Section 1 Unit overview............................................................................................................................... 1
Section 2 Process flow of the unit and corresponding descriptions ............................................................. 2
Section 3 Production principle and major operation factor analysis ............................................................ 5
Section 4 Schedule and main parameters of unit and equipments (safety valve)....................................... 13
Chapter 2 Post Operation Method ................................................................................................................. 22
Section 1 Unit startup regulation................................................................................................................ 22
Section 2 Suspension regulation of the unit ............................................................................................... 30
Section 3 Post operation method ................................................................................................................ 33
Section 4 Accident treatment plan.............................................................................................................. 45
Chapter 3 Safety and Environment Protection Regulation.......................................................................... 54
Section 1 Safety and environment protection responsibility ...................................................................... 54
Section 2 Safety and environment protection system................................................................................. 56
Section 3 Hot work regulation of the unit .................................................................................................. 66
Section 4 Safety and environment protection accident response plan........................................................ 66
Section 5 DCS system operation management regulation.......................................................................... 69
Section 6 The identification of key environment factors of the unit and risk mitigation measures ........... 71
Appendix 1: Summary table of physical and chemical properties of raw and auxiliary materials and three
agents of the unit................................................................................................................................................. 74
Appendix 2: Interlock logic of the unit............................................................................................................. 76
Appendix 3: Poisonous and combustible gas distribution point drawing ..................................................... 78
Chapter 1 Process technology regulation
Section 1 Unit overview
1.1 Unit introduction

The hydrogen purification unit of Zinder Refinery Co., Ltd. adopts the pressure swing adsorption technology of
Sichuan Tianyi Science Technology Co., Ltd. (Southwest Research & Design Institute of Chemical Industry, and
the process package and design are provided by Sichuan Tianyi Science Technology Co., Ltd. The construction
was started from October 2009, and it will be put into production in December 2012, and the designed capacity
of the unit is 3051Nm3/h hydrogen (purity>99.9%). The unit comprises PSA system, vacuum system,
compression system, deoxidization and drying system, and DCS system is adopted for control.
1.2 Technical features:
The pressure swing adsorption gas separation technology adopted for the unit has such advantages as simple
process, convenient for operation, high product purity, high automation, low energy consumption and low cost,
etc.
1. Self-adaptive optimal control system and multi-tower switching system are adopted, which realizes the full
automatic operation of the unit and reducing the influences of anthropic factors on the unit operation.
2. The pressure and composition of gas mixture are relatively stable, which largely simplifies the relational
expression between adsorption time and gas mixture load. When the gas mixture load has a change, the
adsorption time will change automatically, which guarantees the product gas quality.
3. Pressure control is adopted for final pressurization regulation. After the gas mixture load has a change, the
change in adsorption time will automatically change the set value of the final pressurization regulating valve,
making the final pressurization regulating valve reach the design condition through automatic adjustment under
the new gas mixture load. This can guarantee that the unit is able to run optimally and stably when load change.
4. The reverse flowing process can automatically adjust with the load change of raw materials, guaranteeing
the stable desorption gas system.
5. Program control valve inspection and pressure signal are adopted to judge the fault of the program control
valve, and the fault condition of the program control valve can be accurately judged (such as the fault of
instrument element, internal leaking of program control valve and fault of actuating mechanism, etc.), reducing
the mis-operation.
6. Two-stage buffer system (desorption gas buffer tank and desorption gas mixing tank) is set for the
desorption gas system, making the pressure, flow rate and calorific value of the desorption gas more stable.
7. As for the key equipment-PSA program control valve, the fifth-generation flat program control valve and
the third-generation triple eccentric program control butterfly valve researched and manufactured by Sichuan
Tianyi Science Technology Co., Ltd. are combined at the positions with high pressure and large gas flow impact.
There is fast open-close speed, good two-way flowability, good sealing property (ANSI grade VI) and long
service life (＞ 1 million times); the valve location display is reliable and the repair and maintenance are
convenient, which can guarantee the long-term stable operation of the unit.
8. The program control system is driven by compressed air; the ambient temperature has a small influence on
the medium viscosity; the physical properties driving the medium in the four seasons are basically unchangeable,
which can guarantee the consistent action time of the program control valve in the four seasons. The control
system, which is simple, is featured by smooth operation, safe and reliable action and no environmental
pollution.
9. As for the running program of the unit, besides the main program 8-2-3/V, auxiliary program7-2-3/V,
6-2-2/V are also compiled, which can guarantee the running under different working conditions. Even if there is
a fault, the unit may be switched over to tower 7 or tower 6 for running, guaranteeing the safe, smooth and
continuous running of the unit.
1
Section 2 Process flow of the unit and corresponding descriptions
2.1 Process flow description

Under normal working conditions, the feed gas is the gas mixture of reformed gas and sweet dry gas. The
reformed gas enters the unit under the pressure of 1.1MPa and the temperature of ≤40℃; first, the pressure is
reduced to 0.7MPa through the regulating valve (PV-1001). The pressure and temperature of the sweet dry gas
are respectively 0.7MPa and ~45℃; first, it enters the feed gas cooler (E-101) to make the temperature reduced
to ≤40℃, and then enters the knockout separator (D-101) to remove the containing suspended water; next, after
passing through the feed gas buffer tank (D-102) and measurement by the flowmeter (FIQ-1001), it enters the
PSA-H2 system comprising 8 adsorbers (C-101A~H) and a series of program control valve for hydrogen
purification. The operation process of 8-tower operation, 2-tower feed, 3-time pressure equalizing and reverse
flowing vacuation step-down desorption (8-2-3/V process) is adopted for the PSA system.
The feed gas enters the 2 adsorbers that are under adsorption status from up to down; the internal adsorbent
performs selective adsorption; the impurities are adsorbed; the hydrogen not adsorbed flows out from the
adsorber top under the adsorption pressure, and the product hydrogen is obtained. Through pressure reduction,
the adsorbed impurities desorb from the adsorbent, and the desorption gas is obtained, and the adsorber is
regenerated. The remaining 6 adsorbers performe the operation of other steps, and the 8 adsorbers are operated
alternately and circularly in time, so as to reach the purpose that the feed gas is input continuously and the
product hydrogen is output continuously. The various steps of the pressure swing adsorption process are
completed through computer control.
The regulating valve (HV-1001, H V-1002) controls the instantaneous gas flow of the final pressurization step;
the regulating valve (PV-1007) controls the feed gas over pressure or the emergency stop and venting of the unit;
the regulating valve (PV-1003) controls the adsorption pressure.
Through the product gas buffer tank (D-103) and the hydrogen compressor (K-102AB, one is for use and one is
for standby), the product hydrogen coming from the adsorber top is compressed to 2.4MPa, and it is
continuously and stably sent to the deoxidization and drying system. The unqualified or over pressure product
hydrogen may enter the venting main pipe through the regulating valve (PV-1004A); the regulating valve
(PV-1004B) controls the low pressure reverse flow at the inlet of hydrogen compressor.
The desorption gas of the PSA hydrogen production system is from the reverse flowing and vacuation stage of
the adsorber. After the pressure equalizing step is completed, the adsorber starts the reverse flowing step. At the
initial stage of reverse flowing, the desorption gas with high pressure enters the desorption gas buffer tank
(D-104) for buffer, and then enters the desorption gas mixing tank (D-105) after the pressure regulation by the
regulating valve (PV-1002A). At the later stage of reverse flowing, the desorption gas with low pressure enters
directly enters the desorption gas mixing tank after the pressure regulation by the regulating valve (HV-1003,
HV-1004). After the reverse flowing step is completed, the adsorber starts the vacuation step; four large
complete sets of water ring vacuum pump (P-101A~D) are used for further step-down desorption of the
adsorber, making the impurities that are not desorbed completely in the reverse flowing step desorbed
completely. Then, it enters the desorption gas mixing tank via pipe; the mixed desorption gas enters the
desorption compressor (K-101AB, one is for use and one is for standby) through the regulating valve
(PV-1005A) and is sent to outside after being compressed to be ≥0.45MPa. The regulating valve (PV-1002B)
controls the over pressure venting at the inlet of the desorption compressor, and the regulating valve (PV-1005B)
controls the low pressure reverse flow at the inlet of the desorption compressor.
After the compressed, the product hydrogen enters the deoxidization and drying system. First, it is heated to
50~100℃ by the heater (E-102) and enters the deaerator (R-101); its reacts with O2 and H2 in the deaerator to
generate water; make the O2 content ≤20ppm; after deoxidization, its temperature is reduced to 40℃ through the
cooler (E-103); after the suspended water is removed by the deoxidization separator (D-106), it enters the dryer
(C-102AB) for constant pressure drying, and then make the qualified product hydrogen sent out the unit. The
H2O content of the dried product hydrogen shall be no larger than 5ppm.
The regeneration gas used for regeneration drying is taken after the deaerator and before the flow regulating
valve (FV-1101); it enters the predryer (C-103) for drying after the measurement by the flowmeter (FIC-1101);
next, it is heated to ~150℃ by the heater (E-104), and then enters the dryer that is in heating desorption stage;
after regeneration, the regeneration gas containing moisture, after being cooled by cooler (E-105) and drained
by drying separator (D-107), returns to the mainstream product hydrogen to be dried.
2
The deoxidized and dried product hydrogen is sent to outside after the measurement by the flowmeter
(FIQ-1102).
The regulating valve FV-1101 is used to control the flow rate of the regenerated hydrogen, and PV-1101 is used
to control the pressure of the deoxidized and dried product hydrogen.
When startup, the feed gas is catalytic sweet dry gas that has enters the PSA unit under the pressure of 0.7MPa
and the temperature of ~45℃. First, it enters the feed gas cooler (E-101) to make the temperature reduced to
≤40℃, and then enters the knockout separator (D-101) to remove the containing suspended water; next, after
passing through the feed gas buffer tank (D-102) and measurement by the flowmeter (FIQ-1001), it enters the
PSA-H2 system comprising 8 adsorbers (C-101A~H) and a series of program control valve for hydrogen
purification. The operation process of 8-tower operation, 2-tower feed, 3-time pressure equalizing and reverse
flowing vacuation step-down desorption (8-2-3/V process) is adopted for the PSA system. Other processes are
the same with that of normal startup.
3
2.2 Process principle flow diagram
Process principle flow diagram
R-101
E-105
K-102AB
E-102
D-103
E-101 C-101A~H C-102A C-102B C-103
E-104
E-103
D-106 D-107
D-101
D-104
D-105
K-101AB
D-102
P-101ABCD
4
Section 3 Production principle and major operation factor analysis
3.1 Production principle

The unit adopts PSA gas separation technology for hydrogen purification.
The basic principle of pressure swing adsorption: the adsorption selectivity of adsorbent to gas is made use of.
That is to say, the separation of gas mixture and regeneration of adsorbent are realized by making use of the
characteristics that different gases (adsorbates) have different adsorbances on the adsorbent and the adsorbance
of a specific gas on the adsorbent varies with pressure.
These characteristics are utilized in the PSA hydrogen purification technology. Under the condition of selective
adsorption of adsorbent, the impurities in feed gas are subject to pressurizing adsorption, and the components
that are not liable to be adsorbed (such as hydrogen) are vented from the adsorber top through the adsorption
bed, realizing the separation of gas mixture. The adsorbed impurities are desorbed by reducing the pressure of
the adsorption bed, making the adsorbent regenerated.
The adsorption of the adsorbent in the adsorber to different components is quantitative. After the adsorption of
the adsorbent to the impurities reaches certain amount, the impurities could be effectively desorbed from the
adsorbent. The adsorption separation process is only meaningful when the adsorbent can be reused. Therefore,
each adsorber must experience the adsorption and regeneration stage during the actual process. For each
adsorber, the adsorption process is intermittent, so multiple adsorbers must be adopted for circular operation, so
as to realize the continuous production of product gas.
The meaning of multi-bed pressure swing adsorption: There is the same quantity of adsorbers that are under
adsorption status at any time, making the product hydrogen continuously and stably output; guarantee proper
pressure equalizing times, making the product hydrogen have high recovery rate. Under normal working
conditions, the unit adopts 8-2-3/V operation mode; i.e. 8 adsorbers are set; 2 of them are always under different
adsorption stages; realize 3 times’ pressure equalizing process; vacuation desorption is performed to reduce the
partial pressure of impurities as possible, effectively making the adsorption bed realize the regeneration to the
maximum degree.
The 8 adsorbers execute the adsorption and regeneration operation in order to make the feed bas continuously
input and the product hydrogen continuously output, and the whole operation process is carried out under
ambient temperature. Each adsorber is subject to such steps as adsorption (A), depressurization equilibrium 1
(E1D), depressurization equilibrium 2 (E2D), depressurization equilibrium 3 (E3D), reverse flowing (D),
vacuation (V), pressurization equilibrium 3 (E3R), pressurization equilibrium 2 (E2R), pressurization
equilibrium 1 (E1R) and final pressurization (FR), completing one adsorption cycle.
After the pressure equalizing step is completed, the main components in the adsorber is hydrogen, methane and
high-carbon hydrocarbon; the gas vented by reverse flowing and vacuation through the desorption to the
adsorption bed by reverse flowing and vacuation is called desorption gas.
3.2 The specific work process of PSA system (describe the process by taking one adsorption tower as an
example)
The main program and various auxiliary programs are stored in the computer system; when it is necessary to run
a program, just press the corresponding function key according to the working conditions or the actual
conditions, and the computer system will automatically switch over in the corresponding step. Among the
programs, the main program 8-2-3/V are most frequently used. Now, the adsorber C-101A will be taken as an
example to describe the processes in various technical steps when running under 8-2-3/V mode and within one
cycle period, as well as the actions of the tower-related program control valves (all the open-close actions of the
program control valves are completed through computer control).
1. Adsorption (A)
Open the program control valve KV-1001A and KV-1002A (close other valves connected with adsorber C-101A,
the same below).
The feed gas enters the adsorption tower C-101A from the program control valve KV-1001A under 0.7MPa
pressure; N2, CH4 and other impurities are adsorbed; the product hydrogen comes out from the adsorber top and
is input to the back part through the program control valve KV-1002A. When the adsorption frontier (the
maximum concentration required for the impurities in product gas) of the adsorbed impurities moves to the
certain position of the adsorber, close KV-1001A and KV-1002A, and stop the input of feed gas and the output
5
of product gas of the tower.
Process pressure: 0.7MPa
Adsorption time: 160S
The pressure during the adsorption process is controlled by the regulating valve PV-1003: when the adsorption
pressure is on the high side, the valve will gradually open wide, or it will close a little bit. Alarm for low
pressure is set.
2. First-stage pressure equalizing drop (E1D)
Open the program control valve KV-1005A and KV-1005D.
After the adsorption step of the adsorber C-101A is completed, connect with the adsorber C-101D by outlet end
for the first-stage pressure equalizing. When the pressure of the two adsorbers is basically the same, close the
program control valve KV-1005A, and the first-stage pressure equalizing drop is completed (go on to open the
program control valve KV-1005D for the final pressurization of C-101D in the next step).
Process pressure: Reduce to 0.51MPa from 0.7MPa.
The implementation time of the step: ~40S
3. Second-stage pressure equalizing drop (E2D)
Open the program control valve KV-1004A, and the program control valve KV-1004E keeps the open status of
the previous step.
The adsorber C-101A and C-101E perform the second-stage pressure equalizing. When the pressure of the two
adsorbers is basically the same, close the program control valve KV-1004E, and the second-stage pressure
equalizing drop is completed.
4. Third-stage pressure equalizing drop (E3D)
Open the program control valve KV-1004F, and the program control valve KV-1004A keeps the open status of
the previous step.
The adsorber C-101A and C-101F perform the third-stage pressure equalizing. When the pressure of the two
adsorbers is basically the same, close the program control valve KV-1004A, and the third-stage pressure
equalizing drop is completed.
5. Reverse pressure discharge I (D1)
After the third-stage forward pressure reduction of the adsorber C-101A is completed, open the program control
valve KV-1003A and KV-1008A. The gas in the tower flows into the desorption gas buffer tank D-104 through
the program control valve KV-1003A and KV-1008A along the reverse direction of adsorption; i.e. reverse
flowing prophase; partial impurities in the adsorbent are desorbed. When the tower pressure reduces to about
0.06MPa (this pressure may be properly adjusted according to the pressure of the sent desorption gas), close the
program control valve KV-1008A, and the reverse pressure discharge I is completed (go on to open KV-1003A
for the reverse pressure discharge II of C-101A in the next step).
The implementation time of the step: ~15s
The regulating valve HV-1003 and PV-1002A may have a fixed adjustable opening during the process, so as to
make the output desorption gas more stable.
6. Reverse pressure discharge II (D2)
By this step, the regulating valve HV-1003 automatically acts in accordance with the program design.
The gas containing a large number of impurities in adsorber C-101A enters the desorption gas mixing tank
6
D-105 through the regulating valve HV-1003 along the reverse direction of adsorption; i.e. reverse flowing later
stage; partial impurities in the adsorbent are desorbed. When the tower pressure reduces to about 0.02MPa,
close the program control valve KV-1003A and regulating valve HV-1003, and the reverse pressure discharge II
is completed.
7. Vacuation 2 (V2)
Open the program control valve KV-1006A, KV-1007A, KV-1007B. 1 vacuum pump is used to vacuate the
adsorption tower, making the impurities adsorbed in the adsorbent further desorbed. Close KV-1007A,
KV-1008B after the vacuation 2 is completed.
Process pressure: Reduce to -0.04MPa from 0.02.
8. Vacuation 1 (V1)
Open the program control valve KV-1006A, KV-1007A, KV-10007B. 2 vacuum pumps are used to vacuate the
adsorption tower, making the most impurities adsorbed in the adsorbent desorbed. Close KV-1006A, KV-1007C,
KV-1007D after the vacuation 1 is completed.
Process pressure: Reduce to -0.08MPa from - 0.04
9. Third-stage pressure equalizing rise (E3R)
Open the program control valve KV-1004A, and the program control valve KV-1004D keeps the open status of
the previous step.
The adsorber C-101A is connected with the adsorber C-101D (E2D is just completed for it) by outlet end for the
third-stage pressure equalizing. When the pressure of the two adsorbers is basically the same, close the program
control valve KV-1004D, and the third-stage pressure equalizing rise is completed (go on to open KV-1004A for
the second-stage pressure equalizing rise of C-101A in the next step).
Process pressure: Increase to 0.12MPa from -0.08MPa.
10. Second-stage pressure equalizing rise (E2R)
Open the program control valve KV-1004E, and the program control valve KV-1004A keeps the open status of
the previous step.
The adsorber C-101A and the adsorber C-101E (E1D is just completed for it) perform the second-stage pressure
equalizing. When the pressure of the two adsorbers is basically the same, close the program control valve
KV-1004A, and the second-stage pressure equalizing rise is completed (go on to open KV-1004E for the
third-stage pressure equalizing drop of C-101E in the next step).
Process pressure: Increase to 0.31MPa from 0.12MPa.
11. First-stage pressure equalizing rise (E1R)
Open the program control valve KV-1005A and KV-1005F, and the regulating valve HV-1001A has a fixed
adjustable opening in this step.
The adsorber C-101A is connected with the adsorber C-101F (A is just completed for it) by outlet end for the
first-stage pressure equalizing. When the pressure of the two adsorbers is basically the same, close the program
control valve KV-1005F, and the first-stage pressure equalizing rise is completed (go on to open KV-1005A for
the final pressurization of C-101A in the next step).
7
12. Final pressurization (FR)
The regulating valve HV-1001 automatically calculates for PID regulation in accordance with the program
design.
After the first time of pressure equalizing rise, the adsorber C-101A uses product gas for flow limiting
pressurization through the regulating valve HV-1001, making it gradually reach the adsorption pressure. When
the pressure approaches or is equal to the adsorption pressure, close the program control valve KV-1005A and
regulating valve HV-1001, and the final pressurization is completed.
During this process, the opening of the final pressurization flow regulating valve HV-1001 is controlled by PID
mode according to the pressure rise speed of the adsorber needing pressurization, or controlled by slope
coefficient mode according to the whole final pressurization time. Manual operation may be carried out under
special circumstances.
By this time, the adsorption and regeneration process of the adsorber C-101A are totally completed, and next
cycle follows on. The valve action of other adsorbers is the same with that of the adsorber C-101A, but the
corresponding program control valve and regulating valve shall change correspondingly.
Note: The step execution time and process pressure in the process description are illustrative, and the time and
pressure may be adjusted at any time according to the change in flow rate, composition and pressure of feed gas.
The steps and execution time of other operation modes are similar to the steps of the main program 8-2-3/V, and
the inspection and operation can be performed in accordance with the corresponding steps and methods. The
detailed description will not be given here.
3.3 Analysis of the major operational factors
1. Process indicators
S.N. Names Item Unit Indicator
Feed gas mixture buffer tank

1 Pressure MPa 0.45~0.60
(D-102)
2 Vacuum pump P-101A Working fluid tank level % 10~40
3 Vacuum pump P-101B Working fluid tank level % 10~40
4 Vacuum pump P-101C Working fluid tank level % 10~40
5 Vacuum pump P-101D Working fluid tank level % 10~40
6 Vacuum pump P-101A Inlet pressure MPa -0.08~-0.02
7 Vacuum pump P-101B Inlet pressure MPa -0.08~-0.02
8 Vacuum pump P-101C Inlet pressure MPa -0.08~-0.02
9 Vacuum pump P-101D Inlet pressure MPa -0.08~-0.02

10 Hydrogen compressor (K-102A) Outlet pressure MPa 1.2~1.4
11 Hydrogen compressor (K-102B) Outlet pressure MPa 1.2~1.4
Desorption gas compressor
12 Outlet pressure MPa 0.5~0.54
(K-101/A)
13 Outlet pressure MPa 0.5~0.54
(K-101/B)
8
S.N. Names Item Unit Indicator
The pressure of the main

14 Hydrogen compressor (C-901) pipe of the lubricant MPa ＞0.15
supply
Main bearing
15 Hydrogen compressor (K-102AB) ℃ ＜60
temperature
Main motor stator
16 Hydrogen compressor (K-102AB) ℃ ＜125
temperature
The pressure of the main
17 pipe of the lubricant MPa ＞0.15
(K-101/AB)
supply
Desorption gas compressor Main bearing
18 ℃ ＜60
(K-101/AB) temperature
Desorption gas compressor Main motor stator
19 ℃ ＜125
(K-101/AB) temperature
1) PSA system
(1) Normal working condition (catalytic sweet dry gas and reformed gas)
a. Adsorption pressure: 0.7MPa
b. Adsorption temperature: ≤40℃
c. Gas capability: 7188Nm3/h
d. Table for PSA (8-2-3/V process) time sequence
Steps Pressure (MPa) Temperature (℃) Time (s)

Adsorption A 0.7 ≤40℃ 160
Depressurization equilibrium 1 0.7→0.5 ≤40℃ 40
E1D
The pressure drop balance 2 0.5→0.3 ≤40℃ 40
E2D
The pressure drop balance 2 0.3→0.1 ≤40℃ 40
E2D
Reverse flowing (D) 0.1→0.01 ≤40℃ 40
Vacuation (V) 0.01→-0.08 ≤40℃ 160
Pressurization equilibrium 3 -0.08→0.1 ≤40℃ 40
E3D
Pressurization equilibrium 2 0.1→0.3 ≤40℃ 40
E2D
Pressurization equilibrium 1 0.3→0.5 ≤40℃ 40
E1D
Final pressurization (FR) 0.5→0.65 ≤40℃ 40
Total (cycle period) ≤40℃ 640
(2) Startup working condition (catalytic sweet dry gas)

a. Adsorption pressure: 0.7MPa
b. Adsorption temperature: ≤40℃
c. Gas capability: 4835Nm3/h
9
d. The operation steps, pressure and time sequence of adsorber are the same with that of normal startup
(3) Product hydrogen
a. Components: ≥99.9%（V%)
b. Pressure: 2.3MPa
c. Temperature: ≤40℃
d. Flow: 3051Nm3/h (Normal working condition)
1545Nm3/h (Startup working condition)
e. Hydrogen recovery rate: ≥85% (Normal working condition)
≥80% (Startup working condition)
f. Requirements for other impurities: CO+CO2≤20ppm, O2≤20ppm, H2O≤5ppm
(4) Desorption gas
a. Pressure: 2.3MPa
b. Temperature: ≤40℃
c. Flow: 4127Nm3/h (Normal working condition)
3274Nm3/h (Startup working condition)
2) Deoxidization and drying system
(1) Main parameters for drying
Pressure for drying 2.35MPa

Temperature for drying 40℃
Pressure for regeneration 2.35MPa
Regeneration temperature 150℃
Cycle 16h
(2) Table for constant pressure drying time sequence
C-102A A H C
C-102B H C A
C-103 A H A H
Time h 4 4 4 4
2. Quality indicators
(1) Intermediate control (condensate outlet) indicator
Sample Quality Analysis frequency

S.N. Analysis items Test method Remarks
names indicators (Times/hours)
Components: %
(Volume fraction)
H2
O2
1 Feed gas N2 Q/SYLS0203 1/24
CO
CO2
Hydrocarbon
C1-C6
10
Components: %
(Volume fraction) 99.906
H2≥ 20ppm
O2≤
2 Hydrogen N2 20ppm Q/SYLS0203 1/24
CO≤
CO2≤
Hydrocarbon
C1-C6
(2) Consumption for public works
Hourly
Use consumption
S.N. Names Specifications Unit Remarks
condition
Normal Maximum
220V 50HZ Interruption Kwh 8.5 Instrument and
lighting
1 Electricity 380V 50HZ 376.2 Vacuum pump and
Continuous crane
6000V 50HZ 612 Compressor
3
2 Instrument air 0.7±0.2MPa Continuous Nm 100 Regulating valve and
program control valve
3 Low pressure 0.7±0.2MPa Interruption Nm3 2000 Displacement
nitrogen
4 Low-pressure 1.0±0.1MPa Continuous kg 210 Heater
steam
5 Circulating 0.2-0.45MPa Continuous t 241 Cooler, vacuum
water pump, compressor
6 Fresh water 0.4MPa Interruption t 17 Vacuum pump,
compressor
2. Analysis of the major operational factors

1) Adsorption time: Execute according to the debugging guidance of on-site designers.
2) Hydrogen recovery rate
(1) Under the condition that the flow rate of feed gas and product gas is accurate, the recovery rate can be
calculated according to the flow rate and composition of feed gas, flow rate of product gas and the hydrogen
purity, and the formula is as follows:
Flow rate of product gas* hydrogen purity (V%)
Hydrogen recovery rate = *100%
Flow rate of feed gas * hydrogen content in feed gas (V%)
(2) In case that the measurement of feed gas and product gas is inaccurate, the recovery rate can be calculated
according to the hydrogen content in feed gas, product hydrogen purity and hydrogen content in desorption gas
by the following formula:
HB* (HA-HC)
Hydrogen recovery rate = *100%
HA*(HB-HC)
In the formula: HA is the hydrogen content in feed gas (V%); HB is the product hydrogen purity (V%), and HC is
the hydrogen content in desorption gas (V%).
The higher the hydrogen recovery rate, the more complete the regeneration of adsorbent. However, if the
11
hydrogen recovery rate is too high, the product purity will be affected – the product purity will decrease.
Therefore, the hydrogen recovery rate shall be improved as possible under the condition that the product purity
is qualified. The guarantee value of hydrogen recovery rate of the unit is ≥87.0%, and the expected value is 89%
(V).
12
Section 4 Schedule and main parameters of unit and equipments (safety valve)
4.1 Equipment summary table
Names Quantity (set)

Reactor 12
Heat exchanger 5
Vessel 7
Pump 4
Compressor 4
Safety valve 20
Small equipments 4
Summary 44
4.2 Reactor
Operation Temperature ℃ Pressure MPa Specifications and internal

Body Manufacturing
S.N. No. Names Quantity structure (equipment
medium Design Operation Design Operation material factory
model)
Adsorption Dry gas, H2 The 7th
1 C-101/A-H 8 60 40 0.88 -0.78 φ2200×11285×16 Q345R
device and H2S company
The 7th
2 R-101 Deaerator 1 H2 170 150~40 2.64 2.4 Φ600×3795×10 Q345R
company
The 7th
3 C-102AB Dryer 2 H2 170 150~40 2.64 2.4 Φ800×3820×12 Q345R
company
The 7th
4 C-103 Pre-dyer 1 H2 170 150~40 2.64 2.4 Φ600×3385×10 Q345R
company
13
4.3 Heat exchanger
Operation
Temperature (℃) Pressure [MPa(G)]
medium
Quantity Specifications Body Manufacturing
S.N. No. Names
(set) Tube side Shell side Tube side Shell side and models material factory
Tube Shell
side side
Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet
Dry
gas, B=300
Feed gas Cooling Jiangsu
1 E-101 1 H2 32 42/62 50/70 40 0.63 0.63 0.88 0.88 F=47.6m2 Q345
cooler water Lanjiang
and φ500*3761*8
H2S
B=240
Heater for Jiangsu
2 E-102 1 Steam Steam 40 100/120 270/290 183 2.4/2.64 2.4 1.1/1.28 0.9 F=9.36m2 20/Q345R
deoxidization Lanjiang
φ273×3520×8
B=300
Deoxidization Cooling Jiangsu
3 E-103 1 H2 32 40/60 120/140 40 0.4/0.58 2.4/2.64 F=24.8m2 Q345R/Q345B
aftercooler water Lanjiang
φ400×3630×8
B=300
Heater for Jiangsu
4 E-104 1 Steam Steam 40 150/170 270/290 183 2.4/2.64 2.4 1.1/1.28 0.9 F=7.45m2 20/Q345R
drying Lanjiang
φ273×2700×8
B=300
Cooler for Cooling Jiangsu
5 E-105 1 H2 32 40/60 150/170 40 0.4/0.58 2.4/2.64 F=14.3m2 20/Q345R
drying water Lanjiang
φ325×3630×8
4.4 Vessel
Operation Temperature ℃ Pressure MPa Specifications and

Body Manufacturing
S.N. No. Names Quantity internal structure
(equipment model)
Knockout
separator of Dry gas, H2 φ1000×4060×8 The 7th construction
1 D-101 1 60 40 0.88 0.7 Q345R
raw oil buffer and H2S V=2.5m3 company
tank
Feed gas buffer Dry gas, H2 φ2200×9325×12 The 7th construction
2 D-102 1 60 40 0.88 0.7 Q345R
tank and H2S V=30m3 company
3 D-103 Product gas 1 H2 60 40 0.88 0.7 φ2400×10365×12 Q345R The 7th construction
14
Operation Temperature ℃ Pressure MPa Specifications and
Body Manufacturing
S.N. No. Names Quantity internal structure
(equipment model)
buffer tank V=40m3 company
Desorption gas φ3200×16800×14/20 The 7th construction
4 D-104 1 Dry gas 60 40 0.4 0.02~0.1 Q345R
buffer tank V=120m3 company
Desorption gas φ3600×19540×16/28 The 7th construction
5 D-105 1 Dry gas 60 40 0.21 0.03~0.1 Q345R
mixing tank V=180m3 company
Deoxidization φ600×2900×10 The 7th construction
6 D-106 1 H2 60 40 2.4 2.6 Q345R
separator V=0.6m3 company
Drying φ400×2280×8 The 7th construction
7 D-107 1 H2 60 40 2.4 2.6 Q345R
separator V=0.2m2 company
4.5 Compressor
Operation condition Design conditions
Temperature Pressure Temperature Pressure Operation Requirements
Flow Flow
Quantity (℃) [MPa(G)] (℃) [MPa(G)] Specification / Manufacturing
S.N. No. Names
(set) Inlet Inlet Power model factory
(Nm / 3 Inlet Outlet Inlet Outlet (Nm / 3 Inlet Outlet Inlet Outlet Medium
(kW)
h) h)
K- Wuxi
Product gas DW-8.83/(6.5-24)-
1 101 2 3400 40 40 1 2.4 3400 40 112 0.65 1.36 Hydrogen 187.6 Compressor
compressor X
AB Factory
The
40 135 1.36 2.4
secondary
K- Desorption Wuxi
Desorption DW-90.8/(0.1-5)-
2 102 gas 2 4800 40 105 0 0.5 4800 40 105 0.01 0.154 407 Compressor
gas X
AB compressor Factory
The
4800 40 105 0.15 0.5
secondary
15
4.6 Water ring vacuum pump
Operation condition Design conditions Optional pump Auxiliary motor
Temperature
Temperature
Manufacturing
Manufacturing
Quantity Operation Pressure Pressure Shaft Shaft
factory
factory
No. Names Flow Flow
(set) medium [MPa(G)] [MPa(G)] Code power Code power
(m3/h) (℃) Inlet Outlet (m3/h) (℃) Inlet Outlet (kW) (kW)
P- Vacuum Gas -0.08~ 0.02~ Hubei Hubei
4 ≥3750 ≤40 0.02 ≥3750 2BE1-353-0E 103 YA400S-12 132
101A-D pump mixture 0.02 0.08 Tongfang Tongfang
4.7 Safety valve

Operation parameters Design parameter Specifications
Set Back Discharge QuantityOperation/ Valve
S.N. No. Installation position Medium Pressure Temperature Manufacturing factory
pressure pressure quantity Code standby bodyMaterial
(MPa g) (℃ )
(MPa g) (MPa g) (kg/h)
In front of D-101 Sweet dry China Aerospace
1 PSV1001AB 0.7 45 0.82 0.06 3336.8 HTO-01CB 2 WCB
knockout separator gas Petrochemical
In front of D-102 Feed gas China Aerospace
2 PSV1002AB 0.7 40 0.82 0.06 4560.6 HTO-01CB 2 WCB
feedstock surge drum mixture Petrochemical
Product China Aerospace
3 PSV1003A-H Adsorption device 0.7 40 0.82 0.06 273.2 HTO-01CB 8 WCB
gas Petrochemical
At back of D-104
Desorption China Aerospace
4 PSV1004AB desorption gas buffer 0.1 40 0.35 0.06 3088.4 HTO-01CB 2 WCB
gas Petrochemical
tank
At back of D-105
Desorption China Aerospace
5 PSV1005AB desorption gas 0.03 40 0.16 0.06 4627.4 HTO-01CB 2 WCB
gas Petrochemical
mixing tank
At back of D-103
Product China Aerospace
6 PSV1006AB product gas buffer 0.7 40 0.82 0.06 273.2 HTO-01CB 2 WCB
gas Petrochemical
tank
In front of R-101 Product China Aerospace
7 PSV1007AB 2.4 40 2.58 0.06 273.2 HTO-03aCB 2 WCB
deaerator tank gas Petrochemical
16
4.8 Small equipments
Specifications and internal structure Body

S.N. Names Quantity (set) Manufacturing factory
(equipment model) material
Qidong Tianyu Petrochemical
1 Silencer 1 TY-SP-300-10.0
metallurgy equipment Co., Ltd.
Qidong Tianyu Petrochemical
2 Flame arrester 1 TY-SFW-I-250-2.0
metallurgy equipment Co., Ltd.
Explosion-proof electric double girder
3 1 20/5T explosion-proof electric bridge crane Q235-B Yinchuan Crane Factory
bridge crane
Explosion-proof electric single girder 5T explosion-proof electric single girder
4 1 Q235-B Yinchuan Crane Factory
bridge crane suspension crane
4.9 Temperature and control points
Remote drive Operation conditions

Position No. Scale range ℃ Function
position number Process medium Pressure MPa (G) Temperature ℃
TG-1011 TE-1001 Feed gas 0.7 40 0~100 Indicate the temperature of feed gas mixture
Indicate the temperature of semi-product gas
TG-1012 TE-1002 Half-finished product H2 0.65 40 0~100
before compression
Indicate the temperature of semi-product gas
TG-1013 TE-1003 Half-finished product H2 2.4 40 0~100
after compression
Indicate the temperature of desorption gas after
TG-1014 TE-1004 Desorption gas 0.5 40 0~100
compression
TG-1015 Reformed gas 1.1 40 0~100 Indicate the temperature of reformed gas
TG-1016 Catalytic dry gas 0.7 45 0~100 Indicate the temperature of catalytic dry gas
Indicate the temperature of catalytic dry gas
TG-1017 Catalytic dry gas 0.7 40 0~100
after cooling
Indicate the temperature of replacement
TG-0011 Nitrogen displacement 0.7 40 0~100
nitrogen
TG-0012 Cooling water supply 0.4-0.45 32 0~100 Indicate the temperature of cooling water
17
Remote drive Operation conditions
Position No. Scale range ℃ Function
position number Process medium Pressure MPa (G) Temperature ℃
TG-0013 Low-pressure steam 1.0 250 0~400 Indicate the temperature of low pressure steam
TG-0014 Fresh water 0.4 32 0~100 Indicate the temperature of fresh water
Indicate the temperature of product after
TG-1111 TE-1101 Deaerated product H2 2.4 40 0~100
deoxidization and drying
Temperature of product gas after deoxidization
TG-1112 TE-1102 Deaerated product H2 2.4 40 0~100
and cooling
TG-1113 TE-1103 Deaerated product H2 2.4 40 0~100 Indicate the temperature after cooling
Indicate the temperature of regeneration gas
TG-1114 TT-1104 Deaerated product H2 2.4 150 0~200
after heating
Indicate the temperature of regeneration gas
TG-1115 TT-1105 Deaerated product H2 2.4 150 0~200
before heating
Indicate the deaerator middle (back)
TG-1116 TE-1106 (middle) Deaerated product H2 2.4 120 0~200
temperature
Indicate the temperature after the heater for
TG-1117 H2 2.4 100 0~200
deoxidization
Temperature of regeneration gas entering the
TG-1118 Regenerated H2 2.4 40~150 0~200
predryer
Temperature of regeneration gas exiting from
TG-1119 Regenerated H2 2.4 40~150 0~200
the predryer
4.10 Pressure and control points
Operation conditions
Remote drive
Position No. Temperature Scale range ℃ Function
position number Process medium Pressure MPa(G)
℃
Pressure of reformed gas before
PG-1011 Reformed gas 1.1 40 0~1.6
regulation
PT-1001 Reformed gas 0.7 40 0~1.6 Pressure of reformed gas after
18
Remote drive
℃
regulation
Pressure of desorption gas after
PG-1012 PT-1002 Desorption gas 0.03-0.01 40 0~0.06
mixing
PG-1013 PT-1003 Hydrogen 0.65 40 0~1.6 Indicate the adsorption pressure
Pressure of semi-product hydrogen
PG-1014 PT-1004 Hydrogen 0.65 40 0~1.6
before compression
Indicate the pressure of catalytic dry
PG-1015 Catalytic dry gas 0.7 45 0~1.6
gas
Pressure of semi-product hydrogen
PG-1016 PT-1006 Hydrogen 2.4 40 0~4.0
after compression
Indicate the pressure of feed gas
PG-1017 PT-1007 Feed gas 0.7 40 0~1.6
mixture
Indicate the pressure of desorption
PG-1019 PT-1009 Desorption gas 0.02-0.1 40 0~0.1
gas buffer tank
Indicate the pressure of catalytic dry
PG-1020 Feed gas 0.7 40 0~1.6
gas
Pressure of desorption gas before
PT-1005 Desorption gas 0.03-0.01 40 0~0.06
compression
Pressure of desorption gas after
PG-1021 PT-1010 Desorption gas 0.5 40 0~1.0
compression
Indicate the pressure of instrument
PG-0011 Instrument air 0.6 40 0~1.0
air
PG-0012 Nitrogen displacement 0.7 40 0~1.6 Indicate the pressure of nitrogen
PG-0013 Water 0.4-0.45 32 0~1.0 Indicate the pressure of cooling water
PG-0014 Fresh water 0.4 40 0~1.0 Indicate the pressure of fresh water
Indicate the pressure of low pressure
PG-0015 Low-pressure steam 1.0 250 0~1.6
steam
19
Remote drive
℃
Deoxidized product Indicate the pressure of qualified
PG-1111 PT-1101 2.4 40 0~4.0
hydrogen product hydrogen
PG-1112A/B PT-1102A/B Hydrogen 2.4 40-150 0~4.0 Indicate the pressure of dryer A/B
Indicate the pressure after the heater
PG-1113 Hydrogen 2.4 100 0~4.0
for deoxidization
Indicate the pressure after
PG-1114 Hydrogen 2.4 120 0~4.0
deoxidization
Indicate the pressure of adsorption
PG-1018A-H Feed gas -0.08~0.7 40 0~1.6
tower
4.11 Regulating valve and functions
Position when
Position No. Function Remarks
instrument air fault
PV-1001 Close (gas is supplied) Pressure reduction regulation of reformed gas
PV-1002A Close (gas is supplied) D105 pressure regulation
PV-1002B Open (gas switch) Over pressure venting of desorption gas
PV-1003 Close (gas is supplied) PSA adsorption pressure regulation
PV-1004A Open (gas switch) Over pressure venting of semi-product hydrogen
PV-1004B Open (gas switch) Low pressure backflow regulation of semi-product hydrogen compressor
PV-1005A Close (gas is supplied) Pressure regulation at the inlet of desorption gas compressor
PV-1005B Open (gas switch) Low pressure backflow regulation at the inlet of desorption gas compressor
PV-1007 Open (gas switch) Over pressure venting pressure regulation of feed gas
HV-1001/1002 Close (gas is supplied) Final pressurization flow regulation by manual operation
20
Position when
Position No. Function Remarks
instrument air fault
HV-1003/1004 Close (gas is supplied) PSA reverse flowing regulation by manual operation
PV-1101 Close (gas is supplied) Pressure regulation of deoxidized product hydrogen
FV-1101 Close (gas is supplied) Regeneration gas flow regulation
21
Chapter 2 Post Operation Method
Section 1 Unit startup regulation
1.1 Critical path drawing of startup

Serial Date Day 1 Day 2 Day 3
Steps
No. Hour 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Preparation
3.2.1 Commencement of for
1 8h commencem
work
ent of work
3.2.2 Introduction of Introduction

2 4h
utilities of utilities
3.2.3 System airtightness
3 10h System airtightness test
test
3.2.4 System nitrogen
4 24 System nitrogen displacement
displacement
3.2.5 Introduction of raw
5 material for 1h Introduction of raw material for commencement of work
commencement of work
22
1.2 Inspect the process flow
1. Confirm that the adsorbent of the eight adsorption towers, the oxidant of one oxidizer and the drier of three
dryers have been filled.
2. Confirm that the process line of the unit has been connected.
3. Confirm that the valves and flanges are in good conditions.
1.3 Inspect the tower, vessel and cooling exchange equipment
1. Inspect the safety accessories of tower and vessel
2. Inspect the cooling exchange equipment
3. Inspect the vacuum pump
1.4 Inspect the instrument and DCS system
1. Confirm that the elements for measuring pressure, temperature, liquid level and flow rate are in good
conditions
2. Confirm that the action of regulating valve is accurate and sensitive
3. Confirm that the action of the program control valve of adsorption tower is accurate and sensitive
4. Confirm that the DCS system is in normal condition, and the interlocking debugging has been completed
1.5 Inspect the safety and environmental protection facilities
1. Confirm that the drainage ditch and sewage well are unblocked
2. Confirm that fire fighting facilities and utensils as well as protective tools are ready.
3. Confirm that the flammable gas detector is put into use after being tested to be qualified
4. Confirm that the hydrogen sulfide alarm apparatus is put into use after being tested to be qualified
5. Confirm that the air breathing apparatus is at standby status
1.6 Pressure test for air tightness of unit system
1. Pressure test for air tightness of adsorption tower
1) Close the condensate drain valve at the bottom of C-101A-H and the vent valve at the top
2) Close the condensate drain valve at the bottom of D-101, D-102, D-103, D-104 and D-105
3) Close the condensate drain valve at the bottom of P-101/ABCD
4) Fully open C-101A-H inlet and outlet valve
5) Fully open E-101 inlet and outlet valve and D-101 outlet valve
6) Fully open the battery limit nitrogen purge line valve for entering into C-101A-H
7) Open the KV-1002A-H remote controlled valve completely;
8) Regulate the inlet pressure regulating valve PV-1003 of D-103, OP=100%
9) Confirm the balance between D-103 pressure and nitrogen pressure
10) Confirm the balance between C-101A-H pressure and nitrogen pressure
11) Close KV-1002A-H program control valve
12) Regulate the inlet pressure regulating valve PV-1003 of D-103, OP=0%
13) Fully open KV-1003A-H program control valve
14) Regulate the manual regulating valve HV-1003 and HV1004, OP=20%; confirm that the pressure of D-104
is 0.15MPa
15) Meanwhile, open PV-1002A, OP=100%; confirm that the pressure of D-105 is 0.04MPa
16) Close KV-1003A-H program control valve
23
17) Regulate the manual regulating valve HV-1003 and HV1004, OP=0%
18) Fully open KV-1006A-H program control valve
19) Open the P-101/ABCD inlet valve a little bit
20) Confirm that the pressure of P-101/ABCD is 0.04MPa
21) Confirm that the pressure of D-105 is 0.04MPa
22) Close P-101/ABCD inlet and outlet valve
23) Inspect and handle the leaking point
24) Confirm that the manhole and flange of C-101A-H have no leakage
25) Confirm that the manhole and flange of D-103, D-104 and D-105 have no leakage
26) Open the vent valve at the top of C-101A-H a little bit
27) Open the condensate drain valve at the bottom of D-103, D-104 and D-105 a little bit
28) Open the condensate drain valve at the bottom of C-101A-H a little bit
29) Open the condensate drain valve at the bottom of P-101/ABCD a little bit
2. Pressure test for air tightness of compressor system
1) Close the vent valve at the top of K-101AB, K-102AB and the condensate drain valve at the bottom
2) Close K-101AB and K-102AB inlet and outlet valve
3) Fully open the first-stage cooler tube side and shell side inlet and outlet valve of K-101AB; close the vent
valve
4) Fully open the second-stage cooler tube side and shell side inlet and outlet valve of K-101AB; close the
vent valve
5) Fully open the first-stage cooler tube side and shell side inlet and outlet valve of K-102AB; close the vent
valve
6) Fully open the second-stage cooler tube side and shell side inlet and outlet valve of K-102AB; close the
vent valve
7) Open the nitrogen purge line valve of K-101AB, 102AB a little bit
8) Confirm that the pressure of K-101AB, K-102AB reaches 0.7MPa
9) Close the nitrogen purge line valve of K-101AB, K-102AB
10) Confirm that the flange of K-101AB, K-102AB has no leakage
11) Open the vent valve at the top of K-101AB, K-102AB and the condensate drain valve at the bottom for 2
turns
3. Pressure test for air tightness of deoxidization and drying system
1) Close bottom condensate discharge valve of R-101, D-106, D-107, C-102AB and C-103.
2) Slowly open the nitrogen purge line valve, and constantly repressurize the deoxidization and drying system
to make its pressure reach the pressure of nitrogen system
3) Confirm that the flanges of the vessels and pipelines have no leakage
4) Open the condensate drain valve at the bottom of R-101, D-106, D-107, C-102AB, C-103 for pressure
release until micro-positive pressure
1.7 Nitrogen replacement of the system
1. Confirm that the nitrogen purge valves in the unit have been closed
1) Close the condensate drain valve at the bottom of D-101, D-102, D-103, D-104 and D-105
2) Close the condensate drain valve at the bottom of C-101A-H and the vent valve at the top
24
3) Close the condensate drain valve at the bottom of P-101/ABCD
4) Close the condensate drain valve at the bottom of K-101AB, K-102AB and the vent valve at the top
5) Close bottom condensate discharge valve of R-101, D-106, D-107, C-102AB and C-103.
2. Nitrogen displacement
1) Slowly and fully open the battery limit nitrogen purge line valve
2) Open the condensate drain valve at the bottom of D-102 a little bit and nitrogen is seen
3) Fully open the vent valve at the top of C-101A-H and nitrogen is seen
4) Open the condensate drain valve at the bottom of C-101A-H a little bit and nitrogen is seen
5) Open the KV-1002A-H remote controlled valve completely;
6) Fully open KV-1003A-H program control valve; open HV1003/HV1004 a little bit; the pressure of D-104
shall be controlled to be no larger than 0.15MPa
7) Fully open KV-1006A-H program control valve; open P-101A-D inlet valve a little bit; the pressure of
D-105 shall be controlled to be no larger than 0.04MPa
8) Open the condensate drain valve at the bottom of P-101/ABCD a little bit and nitrogen is seen
9) Open the condensate drain valve at the bottom of D-103, D-104, D-105 a little bit and nitrogen is seen
10) Slowly and fully open the nitrogen purge line valve at the inlet of K-101AB and K-102AB
11) Open the condensate drain valve at the bottom of K-101AB, K-102AB and the vent valve at the top and
nitrogen is seen
12) Slowly and fully open the nitrogen purge line valve of deoxidization and drying system
13) Open the condensate drain valve at the bottom of R-101, D-106, D-107, C-102AB, C-103 and nitrogen is
seen
14) Open the vent valve at the pressure control valve position at the battery limit of unit for outlet of hydrogen
product, and close all the vent points in front
15) Confirm the oxygen content (it is qualified if ≤0.5%)
16) Close the inlet nitrogen purge line valves
17) Close the condensate drain valve and vent valve of the vessels, and confirm that the system pressure is
0.01MPa
1.8 Introduce raw materials for startup
1. Preparation for startup
1) Release the pressure of the adsorber by making use of the pressure relief valve at the bottom of the
adsorber; and close the pressure relief valve after the pressure of the adsorbers is released to normal pressure.
2) Confirm the parameter setting of the regulating valves, the alarm parameter and interlocking parameter
setting;
3) Confirm that the interlocking program has been canceled;
4) Contact the dispatch center to confirm whether the working procedure for feed gas supply and hydrogen
use is smooth; know about the composition and pressure parameters of feed gas;
5) Confirm the route of unqualified product gas, and confirm the route of desorption gas at the initial stage of
startup;
6) The compressor and vacuum pump have been debugged and they can be started at any time;
7) Reconfirm whether the manual valves on all pipelines of PSA unit that shall be opened or closed are in
proper condition;
(1) Valves that shall be closed
a) The bypass valve of all regulating valves;
25
b) The vent valve and blow off valve of all adsorbers and vessels;
c) The bypass valve of all safety valves;
d) The blow off valve of all process pipes and instruments;
e) Feed gas battery limit valve, desorption gas battery limit valve and product gas battery limit valve.
(2) Valves that shall be opened
a) Flare vent battery limit valve;
b) The front and back valve of all regulating valves;
c) The front and back valve of all safety valves;
d) The foreline valve of all pressure gauges;
e) The gas source valve of all program control valves and regulating valves;
f) Instrument air valve;
g) The foreline valve of all pressure transmitters;
h) The inlet and outlet hand valve of adsorbers;
i) The hand separating valve among the groups of adsorbers;
j) The sampling valve of analyzer;
k) The flow-limiting valve for reverse flowing gas;
8) PSA time setting
It shall be set by the on-site technicians of Sichuan Tianyi Science Technology Co., Ltd. according to the actual
conditions, and the records shall be given.
2. Feed for operation
1) As for putting into use of the cooling water of cooler, the valve shall be opened properly, and then regulate
it according to temperature after the feeding for operation;
2) Pressurization of adsorber
Open the No. 1 valve of the adsorption tower under manual status; open the feed gas battery limit valve; and
slowly introduce the feed gas to pressurize the adsorption tower. The pressure is dependent on the pressure
status displayed by the adsorption towers. If the status is adsorption, then pressurize to the adsorption pressure;
if the status is reverse flowing, then pressurize to the normal pressure.
(1) Open XV-1001A, and the adsorption pressure of C-101A shall be 0.7MPa
(2) Open XV-1001B, and the adsorption pressure of C-101B shall be 0.7MPa
(3) Open XV-1001C, and the adsorption pressure of C-101C shall be 0.3~0.5MPa
(4) Open XV-1001D, and the final pressurization pressure of C-101D shall be between normal pressure
~0.1MPa
(5) Open XV-1001E, and the replacement pressure of C-101E shall be normal pressure
(6) Open XV-1001F, and the reverse flowing pressure of C-101F shall be normal pressure
(7) Open XV-1001G, and the vacuation pressure of C-101G shall be 0.1~0.3MPa
(8) Open XV-1001H, and the pressure equalizing pressure of C-101H shall be 0.5~0.7MPa
3) Start the vacuum pump;
(1) Fully open the outlet valve of P-101 vacuum pump
(2) Open the inlet and outlet communication valve of P-101 vacuum pump
(3) The vacuum pump starts to operate (no load operation)
4) Start the compressor
26
(1) Confirm that the tank safety valve and pressure gauge between stage I and stage II of K-102AB have been
put into use
(2) Confirm that the tank level meter between stage I and stage II of K-102AB has been put into use and the
condensate drain valve has been closed
(3) Confirm that the safety valve and pressure gauge of tank between stage I and stage II of K-101AB have
been put into use
(4) Confirm that the tank level meter between stage I and stage II of K-101AB has been put into use and the
condensate drain valve has been closed
(5) Fully open K-101 inlet and outlet valve
(6) Fully open K-102 inlet and outlet valve
(7) Start K-101 for no load operation
(8) Start K-102 for no load operation
First, open the battery limit valve of product hydrogen and desorption gas leading to outside; at the initial stage
of startup, the unqualified product gas may be vented through PV-1004A and the desorption gas may be vented
through PV-1002B. After a time, when the concentration of semi-product hydrogen reaches above 98% (it is
dependent on on-site conditions), the semi-product hydrogen compressor can be started, and the desorption gas
compressor also can be started. At this time, gradually close PV-1004A and PV-1002B, or put into automatic
operation.
5) Open the feed gas battery limit valve (halfload); start 8-2-3/V automatic operation mode
(1) The DCS operating system is set at “AUTO operation” status
(2) Make the pressure control valve PIC-1002A of D-105 adjusted to automatic status; SP=20kPa; the pressure
of D-105 shall be controlled at 15-25kPa
(3) Make the pressure regulating valve PIC1007 of D-102 adjusted to automatic status, SP=0.7 MPa
(4) Make the pressure regulating valve HV-1003 of D-104 adjusted to manual status, OP=50%; the pressure of
D-104 shall be controlled at 0.020-0.10MPa
(5) Make the inlet pressure regulating valve PV-1003 of D-103 adjusted to manual status; the pressure of
D-103 shall be controlled at 0.65MPa
(6) Make the inlet pressure regulating valve PV-1004A of K-102 adjusted to manual status; the pressure shall
be controlled between 0.60-0.65MPa
(7) Make the inlet pressure regulating valve PV-1002B of K-101 adjusted to manual status; the pressure shall
be controlled between 0.008-0.020MPa
(8) Confirm that when the pressure of D-103 increases to 0.65MPa, the load control button on the regulation
panel of compressor K-102 on site is used to make the load increase to 100% for operation, and confirm that the
K-102 runs stably under full load. PV1004AB is switched over to automatic mode, SP=0.65MPa.
(9) Make PV1005A set at manual status, OP=100%. Confirm that the pressure of PT1005 increases to 20 KPa,
the load control button on the regulation panel of compressor K-101 on site is used to make the load increase to
100% for operation, and confirm that the K-101 runs stably under full load. PV1005AB is switched over to
automatic mode, SP=20KPa.
(10) Confirm that the vacuation pressure of P-101 increases to 20KPa
(11) The by-pass valve of P-101 is closed
(12) Confirm that the PSA operating system is normally put into use
(13) The unqualified hydrogen shall be switched into the fuel gas system according to the dispatching.
6) Putting into use of analytical instrument
20min after the feed gas is introduced into the unit, sampling analysis may be carried out for the product
hydrogen. If the hydrogen purity in the product reaches 98%, the hydrogen analyzer can be put into use.
7) Putting into use of deaerator
27
After the semi-product compressor is started, start the low pressure steam and make the heater for deoxidization
put into use; the temperature at the initial stage shall be about 80℃.
8) Putting into use of constant pressure drying
The constant pressure drying procedure may be started when the compressor is started, and make the heater for
drying E-104 put into use.
9) Operation adjustment
At the beginning, the flow rate of feed gas is smaller than the design value, so the adsorption cycle period may
be prolonged properly (only 2~5s can be increased each time), and half an hour later, adjustment shall be carried
out according to the product quality change. Or the feed gas amount may be gradually increased when the feed
gas amount is enough. In the meantime, adjust the relevant parameters of the self-adaptive system in accordance
with the correspondence condition of adsorption time and flow rate. Accurate adjustment shall be further carried
out for the initial opening, PID parameter and slope coefficient parameter of regulating valves (such as final
pressurization regulating valve HV-1001, etc.).
10) 12h after feeding for operation (it may be dependent on on-site conditions), if all the conditions are normal,
then the load can be gradually increased until it reaches 70-85% load, and full load operation shall be performed
after it runs for 24h. While the load is increased, the operating parameters (such as adsorption time, etc.) shall be
adjusted.
11) Quality analysis
1) Contact the laboratory for analysis
2) Confirm that the product hydrogen purity of two continuous points is ≥95% (volume fraction)
3) Contact the dispatch center for switching into hydrogen pipe network
3. Startup descriptions
1) Preparation before feeding and the notes
(1) Full inspection shall be carried out from head to tail and from inside to outside of the unit according to the
flow, and each position shall be inspected.
(2) Inspect the raw material feed unit and product outlet unit, and whether the blind plates used for equipment
pressure test and other constructions and operations have been completely removed.
(3) Inspect whether the blind plates applied between equipment in the system have been properly installed and
meet the requirements.
(4) Inspect whether the process line inside and outside the unit is unblocked, and whether the valves, flanges,
gaskets and bolts meet the requirements.
(5) Inspect whether the dewatering valve between systems, equipment and on pipeline, the pressure relief
valve of flare removal line, barometric vent valve, low point condensate drain valve, liquid level drain valve and
sampling valve have been closed.
(6) Make the safety valve, level meter and pressure gauge valve of the equipment fully opened and make them
at standby status.
(7) Inspect whether the main valve of lead-out device of the flare system is opened, and perform test, and the
operation only can be started after it is confirmed to be unblocked.
(8) Inspect whether the vacuum pump, compressor cooling water and the lubricating oil system are normal.
(9) Inspect whether the instrument (including primary instrument, secondary instrument, regulating valve and
program control valve) are flexible to use and in operation status.
(10) Inspect the safety facilities of the unit; the steam hose for fire extinguishing and freeze protection shall be
connected for the designated places; the fire-fighting apparatus and fire extinguishers shall be complete and in
good conditions.
(11) The unit site shall be clean, and the main passageways shall be unblocked.
2) Notes for startup
28
(1) Before raw materials are introduced for startup, the pressure of the adsorption towers shall pressurized to
the corresponding pressure, so as to prevent the overlarge feed amount when startup affecting the pressure of the
system net pipeline.
(2) Pay attention to the dehydration of D-101, D-102, D-104, D-105 and K-101AB, K-102AB after feed.
(3) During the pressure rise process, carefully inspect whether the equipment, pipeline and valves have leaking
phenomenon.
At the initial stage of startup, each shift shall carefully inspect the hydrogen leakage status of the equipment,
pipeline and valves during the night.
29
Section 2 Suspension regulation of the unit
2.1 Critical path drawing of suspension

Serial Date Day 1 Day 2 Day 3
Steps
No. Hour 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1. Preparatory Preparatory work for

1 work for 4h shutdown
2. System System
2 shutdown 1h shutdown
3. System System
3 depressurization 5h depressurizatio
4. System System
4 purging 32h purging
5. Inspection and Inspection and
5 confirmation 18h confirmation
30
2.2 Preparation for shutdown
1. The steam for fire extinguishing shall be in good conditions
2. The fire-fighting apparatus shall be in good conditions for standby
3. The flammable gas detector shall be in good conditions
4. The hydrogen sulfide alarm apparatus shall be in good conditions
5. Confirm that the valve key has been prepared
6. Confirm that the sewage system has no sludge and is unblocked
7. Contact the dispatch center to perform well in arrangement of dry feed gas after shutdown
8. Contact the dispatch center to perform well in nitrogen purge supply for shutdown
9. Notify the instrument and metering department for performing well in preparation for metering instrument
for shutdown
2.3 System shutdown
1. Shutdown of adsorption system
1) Confirm that the catalytic tail gas of the unit is led to the high pressure gas pipe network
2) Regulate the feed pressure regulating valve PIC-1007 of the unit, OP=0%
3) Confirm that the adsorption tower feed FI-1001 of the unit displays 0Nm3/h
4) The status of DCS operating system is set as “PSA pause” and “PSA initialization”
5) Stop the operation of P-101 (see 3.3 in Chapter 2 Shutdown of Water Ring Vacuum Pump for details)
6) Confirm that the PSA operating system is stopped normally
2. Shutdown of compressor system
1) After the DCS operating system stops running, confirm that the pressure of D-103 decreases to 0.1MPa
2) K-102 runs under 0 load condition (see 3.2 in Chapter 2 Shutdown of Hydrogen Compressor for details)
3) After the DCS operating system stops running, confirm that the pressure of D-105 increases to 0.01MPa
4) K-101 runs under 0 load condition (see 3.2 in Chapter 2 Shutdown of Desorption Gas Compressor for
details)
5) Stop the operation of P-102 (see 3.2 in Chapter 2 Shutdown of Hydrogen Compressor for details)
6) Stop the operation of K-101 (see 3.2 in Chapter 2 Shutdown of Desorption Gas Compressor for details)
7) Close K-102 inlet and outlet valve
8) Close K-101 inlet and outlet valve
9) Close the main valve of desorption gas outlet unit
10) Close the main valve of hydrogen outlet unit
2.4 System pressure release
1. Release pressure to flare system
1) Confirm that the boundary valve of the flare unit is opened
2) Slightly open the safety valve by-pass of D-102 for 3 turns for slow pressure release
6) Slightly open the safety valve by-pass of K-102 for 3 turns for slow pressure release
7) Slightly open the safety valve by-pass of K-101 for 3 turns for slow pressure release
31
8) Fully (manually) open XV-1003A-H program control valve of the 8 adsorption towers one by one
9) Regulate the pressure of D-104, and release pressure to flare through PIC-1002B, OP=100%
10) C-101A-H slowly releases the pressure through the safety valve by-pass of D-104
11) P-101/ABCD slowly releases the pressure through the safety valve by-pass of D-105
12) Confirm the balance between system pressure and the flare pipe network pressure, and the pressure
indicated by on-site pressure gauge shall be 0.05MPa
13) Contact the electrician of power plant for cutting the power of rotating equipment
14) Confirm that power is cut off for all the motors in the electric apparatus
15) Close the safety valve by-pass of D-102
19) Close the safety valve by-pass of K-102AB
20) Close the safety valve by-pass of K-101AB
21) Close the XV-1003A-H program control valve of the 8 adsorption towers
2.5 Suspension descriptions
1. Notes for shutdown and pressure release
1) The operators and the relevant units shall enhance contact during the shutdown process, so as to ensure
safe shutdown.
2) After shutdown, both the raw material feed valve and product outlet valve shall be completely closed, so as
to prevent the dry gas returning to the unit.
3) When pressure release, all the overpass, by-pass and communication valves on equipment process line
shall be opened, and cut off the contact with outside.
4) The pressure release speed shall be slow, so as to avoid too large pressure fluctuation of the gas system,
which may affect the normal production of other units.
5) It is forbidden to discharge gas in large amounts to the sewer in the unit, so as to ensure safe shutdown.
32
Section 3 Post operation method
3.1 Production operation method

After the unit runs normally, the relevant parameters shall be adjusted when the composition, pressure or flow
rate of the feed gas have a change, making the product gas quality reach the normal state as soon as possible.
1. Adjustment of final pressurization step
Under the circumstance that the final pressurization is too short or the adsorption pressure fluctuation is frequent,
the pressure in the adsorber may fail to reach the adsorption pressure when the final pressurization is completed,
and this is called incomplete final pressurization. The incomplete final pressurization will affect the fluctuation
in pressure and flow rate of feed gas, which will further affect the fluctuation in adsorption pressure and product
gas flow rate, making the product gas quality reduce rapidly. In the meantime, if the final pressurization speed is
too fast, a large amount of product gas will flow into the adsorber within a short time, and the adsorption
pressure also will fluctuate, which will affect the flow rate and quality of the product gas. Therefore, the
debugging of the final pressurization regulating valve HV-1001 is very important.
The debugging method of the final pressurization regulating valve HV-1001 is as follows: I. Setting of PID
parameter. The larger the P value, the smaller the I value, and the faster the tracking set value of the regulating
valve; and vise versa. However, when P value is too large and I value is too small, the regulating valve will
suffer from oscillation, and the regulating effect will become poor. Therefore, PID parameter shall be properly
adjusted; when the adjustment is performed each time, the following adjustment shall be performed according to
the effect of the previous adjustment. Repeat the process until the best effect is reached. II. Setting of opening
for the first-stage pressure equalizing rise. The setting shall be used when incomplete final pressurization. When
the pressurized adsorber performs the first-stage pressure equalizing rise, the final pressurization regulating
valve HV-1001 has certain opening, making the pressurized adsorber perform final pressurization in advance.
However, during such process, the opening of the final pressurization regulating valve HV-1001 shall not be too
large (generally, it shall be no larger than 15%), or the pressure drop in the adsorber subject to the first-stage
pressure equalizing drop will be very small, and the pressure drop purpose will not be reached. Therefore, if the
final pressurization time is enough, the opening for the first-stage pressure equalizing rise may be set as zero.
2. Adjustment of reverse flowing step
Although the reverse flowing process is short, it is hoped that the gas emission during actual operation process
is stable. If the reverse flowing speed is too fast, the desorption gas mixing tank D-104 will have too large
pressure fluctuation, and adsorbent abrasion will be caused. If the speed is too slow, the pressure in the adsorber
will not reach 0.02MPa, which will affect the regeneration effect of the adsorbent.
The reverse flowing process is carried out in two steps. Step one: open the program control valve KV-1008A/B
to make the reverse flowing gas with high pressure discharged into the desorption gas mixing tank D-104,
reducing the impact on the sent desorption gas. Furthermore, it can be supplemented from the desorption gas
mixing tank D-104 when the sent desorption gas pressure is low. During this process, the reverse flowing gas
regulating valve HV-1003 has a fixed adjustable opening, and the purpose is to make the desorption gas have
stable pressure. This opening shall not be too large or small (generally, it shall be no larger than 25%). Step two:
Close the program control valve KV-1008A/B, and make the residual gas in the adsorber discharged into the
desorption gas mixing tank D-105 through the reverse flowing gas regulating valve KV-1008A/B. PID or slope
coefficient of the regulating valve HV-1003 shall be adjusted during this process. If the reverse flowing gas is
discharged too fast, then reduce the slope coefficient, or increase the slope coefficient.
3. Control over product gas quality
An adsorber has fixed loading capacity for impurities, so if the adsorption time is too long, the concentration of
impurities in the product gas will increase due to the too much introduced feed gas. If the adsorption time is too
short, the product will have a low impurity concentration, but the unit will have low efficiency due to the
insufficient utilization of the bed. Therefore, during the normal production process, the purpose of controlling
product quality is reached by two main means – adjust the adsorption time or change the feed gas amount.
4. Adjustment of adsorption time
After the adsorption pressure and product purity are determined, the factors affecting the cycle time change are
processing quantity and change in components, and processing quantity is the main factor. When the processing
quantity increases, the adsorption time shall be reduced, or it shall be increased. The principle of guaranteeing
33
product gas quality shall be always followed at all events. The change in product gas quality only can be
reflected after a period of time (about two cycles), so any adjustment shall be prudently carried out; observe the
change trend of the product gas quality in about half an hour after the adjustment, and then perform further
adjustment.
1) Adjustment of product quality
(1) Principle for adjustment of product quality:
H2 purity will reduce if the adsorption time is prolonged and the operation coefficient is increased; and H2 purity
will increase if the adsorption time is shortened and the operation coefficient is reduced;
(2) Adjustment principle of influences of feed gas flow rate on H2 purity:
H2 purity will reduce if the feed gas flow rate increases (large feeding rate), and reduce the adsorption time; H2
purity will increase if the feed gas flow rate decreases (feeding rate reduces), and properly increase the
adsorption time
2) High product hydrogen purity
Impact factors Adjustment method.

Short adsorption time Extend the adsorption time
High adsorption tower pressure Adjust the feed pressure of the adsorption tower
Feeding rate increases Extend the adsorption time
Feed component change According to the analysis, adjust the adsorption time.
3) Low product purity
Impact factors Adjustment method.

Long adsorption time Reduced adsorption time
Low adsorption tower pressure Make the pressure of the adsorption tower controlled within the
index
Feeding rate reduces Reduced adsorption time
Feed component change According to the analysis, adjust the adsorption time.
5. Adjustment for recovery of unqualified product

The decrease of product purity shows that the whole bed has been contaminated, and purities have broken
through the frontier of adsorbent. The reason causing this may be the change in composition and flow rate of
feed gas, or improper operation, or the fault of the automatic control system of the unit. First, reduce the feeding
rate or reduce the adsorption time, and then find out the reasons. It shall recover to the normal conditions as
soon as possible after the proper handling. Effective adjustment method: I. Run a period of time under low load
(small processing quantity); II. Shorten the adsorption time. The effect will be better of the two are combined,
and the product purity will recover soon. However, it shall be noted that shortening the adsorption time shall be
implemented under the precondition of guaranteeing the minimum time necessary for reverse flowing and final
pressurization process.
3.2 Reciprocating compressor
1. Startup operation
1) Inspection and confirmation before the startup
(1) Nitrogen displacement
Close the vent valve and condensate discharge valve of compressor pipelines; confirm that load regulator of
compressor is in the zero-load state; open nitrogen valve and charge the unit; during the nitrogen introduction,
do not exceed working pressure of the compressor inlet; if the unit repair is completed, carry out airtight sealing
for the unit and relevant equipments until the sealing is qualified. Then the nitrogen introduction can be started;
confirm that the utilization condition of inlet and outlet pipeline condensate discharge valve, separation valve of
hydrogen separation tank and level gauge; open outlet pipeline slowly for vent valve relief; Repeat charging
nitrogen. Carry out pressure relief until the nitrogen displacement is qualified (oxygen content is less than 0.5%);
34
confirm that outlet pipeline vent valve is closed; confirm that nitrogen valve is closed.
(2) Preparation for the startup
a. Use cooling water system. Confirm that temperature and pressure of the cooling water is in accordance
with process requirements. Put through the cooling water flow. Start cooling water pump. Confirm that cooling
water pump is in normal operation. Confirm that air drag in various working points is removed. Confirm that
various cooling water lines are smooth. Adjust cooling water tank level to about 85% height.
b. Use lubricant system. Establish lubricant system operation flow. Start the lubricant preheating system. Start
the auxiliary pump of the compressor. Add oil in the lubricant system and discharge air. Confirm that oil
temperature is qualified (≧20℃). Confirm that low oil pressure alarming is released (≧0.17MPa). Adjust the
lubricant pressure between 0.25MPa and 0.3MPa. Under the temperature between 27℃ and 32℃, confirm that
filter differential pressure is no more than 0.1MPa. The lubricant interlocking test result is normal.
c. Use nitrogen charging protection system
d. Rotate the shaft of the unit. Confirm that the pressure in the unit is released completely. And the shaft
rotation is completed. The shaft rotation is even and flexible. Confirm that various valves are not in the upper
and lower dead center. Shaft rotation tools should be removed (for the PSA unit K-101/AB, shaft rotation device
should be removed and locked).
e. Process medium is introduced into the compressor. Open the condensate discharge valve of outlet and inlet
pipeline and the dehydration valves of hydrogen knockout tank to deplete the air. Close the condensate
discharge valve of outlet and inlet pipeline and the dehydration valves of hydrogen knockout tank. And the
valve action should be slow.
f. Use the self-protection interlock system.
g. Check whether the motor meets with the startup conditions.Contact the power and electrical personnel to
supply power to the motor;
2) Start the compressor without load.
(1) Start the motor.
Slowly open the inlet and outlet valve of compressor; make the load adjusted to zero load by using the load
controller; confirm that the unit meets the startup conditions; report to the production dispatch center and the
electric apparatus; start the motor.
Stop the unit immediately under the following cases:
a. Abnormal vibration
b. Abnormal noise
c. Temperature exceeds the allowable values.
d. The current is over limit continuously.
e. Flame
f. Smoke
(2) Inspection and confirmation after startup
a. Lubricant temperature system:
After the confirmation that shaft head pump outlet pressure is normal, manually stop the auxiliary lubricant
pump. Switch the auxiliary lubricant pump to automatic mode (remote mode). Confirm that the lubricant system
is normal.
b. Cooling water system:
Confirm that cooling water system operation is normal.
c. Mechanical system:
Confirm that mechanical system has no abnormal vibration or noise (collision and fracturing sound). Confirm
that temperature at various points is normal. Confirm that the oil temperature and oil level of the unit is normal.
35
d. Motor:
Motor inspection and confirmation
e. Instrument and electrical systems:
Confirm that instrument and electrical systems are normal.
3) The compressor is in the operation with increased load.
(1) Load increase of compressor
Confirm that inlet and outlet valves are coned completely. Increase the load to 0-50% firstly. Then check the
unit. If the inspection is qualified, increase the load to 100% (according to the sequence of 0-50%-100%).
Carry out emergency shutdown under the following cases:
a. Abnormal leakage
b. Abnormal vibration
c. Abnormal sound (collision and fracturing sound)
d. Temperature exceeds the allowable values.
e. The current is over limit continuously.
f. Flame
g. Smoke
(2) Confirmation and adjustment after load increase of compressor
a. Lubricant temperature system
Confirm that temperature and pressure of lubricant is within the indicator range. Confirm that differential
pressure of lubricant is within the indicator range. Confirm that all the alarming signals are removed.
b. Cooling water system
Adjust cooling water system to normal state (sleeve, oil cooler, motor and piston rod stuffing box)
c. Motor
Confirm that the motor operation is normal.
d. Mechanical state
Confirm that vibration is normal, sealing leakage is in accordance with relevant standards and that temperature
at various points is normal.
e. Instrument and electrical systems
Confirm that self-protection and interlock system is put into use.
f. The unit process system
Adjust temperature, pressure and flow of the process medium according to the process indicators. Confirm that
there is no abnormal leakage and vibration. Confirm that inlet separator level is within the indicator range. Close
all the vent valves and condensate discharge valves.
4) Final state confirmation:
Outlet valve is opened completely. Sub-line valve is closed completely. Inlet valve is opened completely. And
instrument and electrical systems are put into use (pressure gauge, differential pressure switch, thermometer,
alarm and automatic protection interlock, etc.) Safety valve is put into use; nitrogen line valve is closed; the
inlet and outlet buffer tank and pipeline vent valve and condensate drain valve are closed; the flare valve is
closed; ther shall be no abnormal leakage and the unit shall work normally.
5) Notes
(1) Before lubricant pump outlet pressure is normal, auxiliary lubricant pump can not be stopped.
(2) Observe whether the current and voltage are stable, and it shall not be beyond range and there shall be no
36
large fluctuation;
(3) The unit shall be started under no load condition, and the load shall be increases gradually without great
change.
(4) Before the startup, it must be reported to the production dispatch center of refinery.
2. Shutdown operation
1) Compressor shutdown
Gradually reduce the unit load to the empty load. Press the stop button of the motor. Close the compressor outlet
valve. Relieve the pressure inside completely. Suspension for a long time requires nitrogen displacement; note
that the auxiliary oil pump should be started automatically. If it is not started automatically, it is necessary to
manually open the auxiliary pump.
2) Deliver compressor for repair.
Scavenge the unit as well as sealing condensate discharge line of the inlet and outlet and between buffer drums
with N2. Confirm that the toxic, harmful and combustible gas analysis is qualified. N2 line valve is closed. Open
the condensate discharge valves and vent valves of the inlet, outlet and between buffer drums. Close inlet and
outlet valves of compressor. Close nitrogen charging line valve and the unit. Close condensate discharge valves
and vent valves of the inlet and outlet and between buffer drums. Close safety valve sub-line valve, vent valve
and the unit. Open the condensate discharge valves and vent valves of the inlet, outlet and between buffer drums.
Cut off the power supply of all the electrical equipments. According to corresponding regulation carry out
instrument repair. Confirm that power supply is cut off. According to the safety regulation of repair operation
permit. Transfer the unit for repair.
3. Normal switch
1) Switching operation
a. Confirm the state of the standby unit.
Confirm that the cooling water system is normally used; the lubricating oil system is normally used and the unit
jigger is normal; process medium has been introduced into the unit; self-protection interlock system is put into
use and the motor meets the startup conditions; before switchover, report to the production dispatch center and
the relevant electric apparatus.
b. Start standby motor (without load).
See specific operations in the starting operation in this chapter.
c. Switching
Contact relevant posts to prepare for the switching. Open outlet and inlet valves of the standby motor completely.
Start the standby motor and open outlet and inlet valves of the standby motor completely. Increase the load of
standby motor to 100% (according to the sequence of 0-50%-100%). At the same time, release the load of the
main motor to zero (according to the sequence of 100%-50%-0). After the inspection that the two sets of units
are operating normally, the two sets of units are operating for 10 minutes and the load is released to zero
(according to the sequence of 100%-50%-0). Gradually adjust the outlet and inlet pressure of the standby motor
and main motor to the normal value. The main motor is stopped. In the switching course, pay attention to close
and unified cooperation and decrease the flow fluctuation as possible. If there is any abnormal in the switching
course, stop the switching immediately.
4. Auxiliary descriptions
Notes:
A Before lubricant pump outlet pressure is normal, auxiliary lubricant pump can not be stopped.
B Observe whether current and voltage is stable. It can not exceed the range or vary violently. The unit can
not produce unusual sound;
C During starting the unit, it should bear no load firstly. And the load may be increased gradually. The rise
should not be too large.
D Lubricant pressure should be no less than 0.15MPa; ensure lubricant level and quality;
37
E Bearing temperature ≤ 80℃, the motor stator temperature ≤ 130℃,
F Hydrogen can not carry more oil. And serious hydrogen leakage should be omitted.
G Temperature and pressure of discharged air can not exceeds the rated value;
H Carry out the maintenance for the standby unit, such as shaft rotation and ensure the normal standby state
of the unit.
I Before the switching operation, report refinery production progress to relevant personnel.
5. Operation guide
1) Daily inspection and maintenance
(1) Auxiliary system
a. Check whether temperature, pressure and level of lubricant is in the required indicator range or the quality
is good. Check whether the lubricant level in crankshaft is in the required level (1/2~2/3) or lubricant pipeline is
smooth. The oil pressure after the filter should be between 0.25MPa and 0.35MPa. Check oil level and quality
of motor bearing.
b. Check whether differential pressure of lubricant is in the required indicator range. And the differential
pressure of oil filter is less than 0.1MPa.
c. Check whether nitrogen sealing operation is normal.
d. Check whether temperature and pressure of cooling water system (cylinder sleeve, oil cooler, vapor lock
and piston rod stuffing box) is normal. In general, reflux water temperature of the cooling water system should
be less than 40℃ and circulation water pressure should be more than 0.25 MPa and less than 0.4 MPa.
e. Check whether the sealing and isolation system is normal.
(2) Compressor
a. Check whether the vibration is abnormal.
b. Check whether the sealing and leakage is in accordance with relevant standards.
c. Check whether temperature and pressure at various points are normal.
d. Check whether the internal sound of the machine is normal or fasteners and connection components are
fixed firmly.
(3) Inspect whether the motor runs normally
(4) Process system
a. Check whether the temperature, pressure and flow of process medium meet with the process indicators.
b. Check whether inlet and outlet pipelines, valves, safety valves, etc. are leaked.
c. Check whether there is abnormal vibration.
d. Check whether the level of inlet, outlet and inter-grade separation tank is in the required indicator range.
Remove the oil in time.
(5) Others
Rotate the shaft of the standby unit as required.
6. Common problem troubleshooting
Failure
S.N. Failure causes Treatment method
phenomena
1) Filter or cooler is plugged. 1) Switch and clean the filter or cooler.
2) Pipelines are plugged or leaked. 2) Clean or repair the pipelines.
Lubricant
1 3) Gear pump fails 3) Stop the unit for gear pump inspection.
pressure is low.
4) Oil in tank is not enough. 4) Add lubricant.
5) Cooling water is insufficient. 5) Adjust the cooling water quantity.
38
Failure
phenomena
6) Oil gauge fails. 6) Change oil gauge.
7) Lubricant is deteriorated, 7) Change lubricant.
containing water or other impurities. 8) Stop the unit for repair.
8) The lubricant position clearance
is too large.
1) Water supply pressure is low
1) Contact the production dispatching room
and water is not enough.
for increasing water supply.
2) Water pipeline is plugged or
Cooling water 2) Handle with plugged or leaked water
leaked.
temperature is pipelines.
2 3) Cooler fouling or plugging
high and 3) Wash the cooler.
cylinder is hot. 4) Intake water temperature is too
4) Contact the production dispatching room
high.
to decrease water temperature.
5) Suction and venting valves are
5) Stop the machine for repair.
leaked.
1) Suction or exhaust valve in the 1) Stop the unit for repair.
cylinder fails. 2) Stop the unit for repair.
2) Serious abrasion of piston ring 3) Stop the unit for repair.
3) Inlet and outlet pipelines or 4) Stop the unit for repair.
Air displacement valves fail 5) Stop the unit for repair.
3
is not enough 4) Air intake filter is plugged. 6) Increase inlet pressure.
5) Push valve action is in failure
and intake valve can not be closed
easily.
6) Inlet pressure is low.
1) Crosshead, piston rod and piston 1) Stop the unit for repair.
are not fastened firmly. The nuts are 2) Stop the unit for repair.
loose. 3) Stop the unit for repair.
2) Connection rod shaft lining 4) Stop the unit for repair.
clearance is too large and the
connection rod bolt is loose. 5) Stop the unit for repair.
3) The clearance between 6) In the cases of removed fluid, current
crosshead and guide is large. Thus and voltage exceeding the required values as
percussion is produced. well as mechanical risks, carry out
4 Abnormal sound emergency shutdown.
4) Sundries drops into the cylinder
or venting buffer. 7) Stop the unit for repair.
5) Pneumatic valve is looser.
Startup spring is fractured. Or valve
sheet is warped.
6) The cylinder carries liquid.
7) Piston clearance is not proper.
And cylinder clearance is too small.
1) Sealing ring and locking ring are 1) Stop the unit for repair.
installed in the wrong positions or 2) Stop the unit for repair.
wave spring fails. 3) Stop the unit for repair.
Stuffing is 2) The surfaces of various sealing 4) Stop the unit for repair.
5 rings, locking rings and components
leaked seriously. 5) Intensify draining the fluids. And
are not leveled or there are solid
particles on the surface. contact relevant posts to decrease the carried
fluid.
3) Sealing ring and locking ring is
abrasive seriously. Piston rod is
39
Failure
phenomena
abrasive and out of circularity with
vertical drag mark.
4) The clearance between sealing
ring and piston rod is too small. Thus
they are blocked due to thermal
expansion in the operation.
5) Condensate damages lubricant
membrane.
1) Cylinder part: Loose supporting, 1) Stop the unit for repair.
exceeding-limit load or improper 2) Stop the unit for repair.
piping load to too large pulsation 3) Stop the unit for repair.
2) The unit frame: The clearance
between bearing and slipway is too
Abnormal large. The fastening bolts are loose.
6
vibration Piston ring is loose. Poor installation
and cylinder vibration.
3) Pipeline part: Pipeline is not
fixed firmly. Pipe stack strength is
not enough or air flow is abnormal.
Thus pipe is vibrating.
7. Control system interlock logic

1) Interlock logic description of K101/A, B control system
(1) Commissioning condition:
The compressor lubricating oil pressure shall be ≥0.17MPa; the lubricating oil temperature shall be ≥20℃; the
compressor may be started when the barring mechanism is cut off.
(2) Alarming items:
Alarm will be given when the pressure of the stage I gas inlet main pipe of compressor is ≤0.095MPa; alarm
will be given when the main pipe lubricating oil pressure of compressor is ≤0.15MPa or≥0.30MPa; alarm will
be give when the demineralized water pressure is ≤0.25MPa or MPa≥0.35MPa; alarm will be given when the
differential pressure of lubricating oil filter is ≥0.1MPa; Hi-alarm will be given when the stage I and stage II
exhaust temperature is ≥115℃; alarm will be given when the temperature of oil supply main pipe is ≥45℃;
alarm will be given when the soft water temperature is ≤42℃; Hi-alarm will be given when the temperature of
the main bearing of compressor is ≥60℃ and Hihi-alarm when it is ≥65℃; Hi-alarm will be given when the
temperature of stator of the main motor is ≥135℃; Hi-alarm will be given when the temperature of the bearing
of the main motor is ≥80℃ and Hihi-alarm when it is ≥85℃; intermediate separator liquid level Hi-alarm; alarm
will be given when the water tank liquid level is ≤1/3 installation position and the displacement of piston rod is
≥1.2mm.
(3) Interlock items
When the compressor lubricant pressure is no more than 0.12MPa, compressor is in interlocking shutdown
(Select 2 items from 3 items); when the main motor stator temperature is no less than 140℃, compressor is in
interlocking shutdown; when the compressor lubricant pressure is no more than 0.15MPa, the auxiliary oil
pressure is started automatically; when the compressor lubricant pressure is no less than 0.3MPa, the auxiliary
oil pressure is stopped manually; press the emergency shutdown button in the main control center.
2) Interlock logic description of -K102/A, B control system
(1) Commissioning condition:
The compressor lubricating oil pressure shall be ≥0.17MPa; the lubricating oil temperature shall be ≥20℃; the
compressor may be started when the cooling water pressure is ≥0.3MPa.
(2) Alarming items:
40
Alarm will be given when the pressure of the stage I gas inlet main pipe of compressor is ≤0.6MPa; alarm will
be given when the pressure of the stage I exhaust main pipe of compressor is ≥1.31MPa; alarm will be given
when the pressure of the stage II exhaust main pipe of compressor is ≥2.4MPa; alarm will be given when the
main pipe lubricating oil pressure of compressor is ≤0.15MPa; alarm will be give when the soft water pressure
is ≤0.25MPa; alarm will be given when the differential pressure of lubricating oil filter is ≥0.1MPa; Hi-alarm
will be given when the stage I and stage II exhaust temperature is ≥115℃ (and ≥125℃); alarm will be given
when the temperature of oil supply main pipe is ≥45℃; Hi-alarm will be given when the temperature of the
main bearing of compressor is ≥60℃ and Hihi-alarm when it is ≥65℃; Hi-alarm will be given when the
temperature of stator of the main motor is ≥130℃; Hi-alarm will be given when the temperature of the bearing
of the main motor is ≥80℃ and Hihi-alarm when it is ≥85℃; alarm will be given when the water tank liquid
level is ≤1/3 installation position.
(3) Interlock items
When the compressor lubricant pressure is no more than 0.12MPa, compressor is in interlocking shutdown
(Select 2 items from 3 items); when the main motor stator temperature is no less than 140℃, compressor is in
interlocking shutdown; when the compressor lubricant pressure is no more than 0.15MPa, the auxiliary oil
pressure is started automatically; when the compressor lubricant pressure is no less than 0.3MPa, the auxiliary
oil pressure is stopped manually; press the emergency shutdown button in the main control center.
3.3 Operation of water ring vacuum pump
1. Operation specification for starting water ring vacuum pump
1) The initial state confirmation
When the test run of single pump unit is completed, the pump is under no-process medium status; confirm that
the coupling has been installed and the safety case has been installed; the mechanical, electrical and instrument
of the pump has been confirmed; the pump rotation shall be uniform and flexible; the inlet filter of pump shall
be cleaned and installed; confirm that the cooling water has been led to the pump; confirm that the grease is
qualified; confirm that the bearing case grease has been filled; confirm that the inlet and outlet valve of the
pump has been closed; confirm that the pump motor switch is in off or stop status; confirm that the power of
pump motor is cut off.
2) Preparation for starting water ring vacuum pump
(1) Close the manual condensate drain ball valve of the pump; confirm that the vacuum gauge on the pump
inlet line, the pressure gauge on the outlet steam-water separator and the pressure gauge on the pump water feed
line have been installed; make the vacuum and pressure gauge put into use; make the pneumatic automatic water
feed and drainage valve and level meter on the steam-water separator put into use; close the vent valve at the
bottom of steam-water separator tank; contact the electrician and mechanical fitter to confirm that the rotating
direction of motor and pump is consistent, the used tools (spanner, stethoscope, rag, oil kettle) are complete;
confirm that the electrostatic grounding of the pump is proper and the foundation bolt of the pump has no loose
phenomenon; make the circulating cooling water of cooler put into use and confirm that the water return is
smooth.
Slowly open the pump inlet and outlet valve for 1/3 valve position; rotate and inspect whether the flange has
leaking phenomenon.
(2) Water injection of unit
The pump belongs to the closed circulating system. As for the makeup water of the system, the water of the
steam-water separator is reinjected into the pump after cooling; before the pump is started, open the by-pass ball
valve of the automatic water injection valve of the steam-water separator to make water injected into the pump.
When the automatic drainage valve at the pump bottom has water, close the by-pass ball valve of the automatic
water injection valve of the steam-water separator; close the valve on the water injection line of the pump; close
the sealing liquid valve; stop injecting water into the pump; the water in pump and the automatic drainage valve
at the pump bottom shall just have water drops.
3) Start the water ring vacuum pump:
(1) Confirm that the pump motor has been powered on and the startup conditions have been met; contact the
relevant operators to confirm that the pump inlet and outlet valve has been opened for 1/3 valve position;
confirm that the pump does not rotate; the rotation is uniform and flexible; start the motor; the valve on the
water injection line of the pump and the sealing liquid valve shall be opened immediately after the motor is
41
started; make the water in the pump and the steam-water separator reach balance status.
In the following cases, stop the pump immediately:
Abnormal leakage, vibration, sound and odor, fire, flue gas and continuous current.
(2) Regulate the pump inlet and outlet valve; confirm that the pump outlet pressure and flow rate and the
motor current are within the normal range; adjust the pump flow rate; contact the relevant operators to confirm
that the pump inlet and outlet pressure is stable.
Note:
Idle running of water ring vacuum pump under no-liquid condition is forbidden, so as to prevent damage of
parts. After the water ring vacuum pump is started, long-time running is unallowable under the condition that
the outlet valve is not opened.
(3) Confirmation and adjustment after startup:
Confirm that the flow rate and pressure of the pump are normal and stable; confirm that the pump vibration is
normal; confirm that the external temperature of the bearing case is no larger than 70℃; confirm that there is no
leakage; confirm that the temperature and pressure of cooling water are normal; confirm that the motor current
is normal and the motor vibration sound is normal.
2. Operation specification for stopping water ring vacuum pump
1) Stop the pump.
Notify the relevant operators and shift leader to close the valve on the water injection line of the pump; close the
sealing liquid valve; stop the motor; close the pump inlet and outlet valve; confirm that the pump inlet and outlet
valve is fully closed.
2) Isolation and ventilation
Close the pump inlet valve; close the pump outlet valve; close the water feed valve of the steam-water separator;
confirm that the pump inlet and outlet valve has been closed. Open the vent valve of the steam-water separator;
open the pump vent valve; confirm that the medium in the pump has been completely vented.
3) Delivery for repair
Confirm that pump inlet valve is closed. Confirm that the pump is completely separated from the system.
Confirm that pump is depleted completely, condensate discharge valve is open and vent valve is open. Confirm
that the power supply of motor is off. The following facilities are provided around the pump: Fire steam band
and fire extinguishers.
3. Operation specification for switching water ring vacuum pump
Notify the relevant operators and shift leader to start the standby pump according to the operation specification
for starting water ring vacuum pump. Properly close the inlet valve of the running pump; keep contact with the
relevant operators; ensure that the flow rate and pressure have no large fluctuation. Stop the running pump
according to the operation specification for stopping water ring vacuum pump after the pump inlet valve is
closed and the flow rate is stable.
4. Routine inspection and maintenance of water ring vacuum pump
1) Pump and auxiliary system
(1) Inspect whether the pump has abnormal vibration and sound
(2) Inspect whether the bearing temperature is normal
(3) Inspect whether the lubricating oil level is normal
(4) Inspect whether the lubricating oil quality is qualified
(5) Inspect whether the mechanical seal leakage meets the requirements
(6) Inspect whether the cooling water is normal
(7) Inspect whether the static seal points have leaking phenomenon
2) Process system
42
(1) Check whether outlet pressure is normal and stable.
(2) Inspect whether the pipeline has serous vibration phenomenon
3) Others
(1) Rotate the shaft of the standby pump as required.
(2) The lubricating oil level and quality of the standby pump shall be periodically inspected
(3) In winter, pay attention to anti-freezing inspection.
5. Failure analysis and treatment method
S.N. Phenomena Causes Treatment method

1) The cooling water is 1) Increase the cooling water
insufficient or cut off, or the or contact the dispatch center to
temperature of the supplied cooling reduce the temperature of the
water is too high circulating water
The measured 2) The lubricating oil is 2) Fill lubricating oil or make
temperature of insufficient or excessive the lubricating oil level adjusted
bearing box is to 1/2~1/3
high. 3) The bearing is damaged or the
bearing clearance does not meet the 3) Contact mechanical fitter for
standards repair
1. Handling for 4) The oil slinger is out of 4) Replace the oil slinger
bearing temperature function
rise of water ring
vacuum pump 1) The bearing case has water 1) Replace the lubricating oil
inflow; the lubricating oil suffers in the bearing cavity
from emulsification or 2) Wash the bearing case for
deterioration multiple times
Lubricant 2) There is impurity in the
temperature is 3) Make the load properly
bearing case reduced according to technical
high.
3) Too large pump load index
4) The balance disk clearance 4) Adjust the balance disk
of multistage pump is too large clearance of multistage pump to
reduce leakage
1) Pump cavitation (see 1. 1) Eliminate the cavitation
Phenomena for pump cavitation) factors (see 1. Handling for pump
2) The pump diaphragm is cavitation)
broken or damaged 2) Replace the diaphragm
3) Rotor imbalance 3) Make the rotor balanced
4) The bearing is damaged or the 4) Change bearing.
bearing clearance is large 5) Realign the pump and motor
2. Cause of 5) Pump and motor is not 6) Realign the rotor part
vibration of water concentric. 7) Inspect the impeller
ring vacuum pump Vibration 6) Collision or friction between 8) Remove sundries.
and the handling rotor and stator
9) Find out the cause and
method 7) The impeller is loose eliminate the foundation
8) There is impurity in the pump resonance
9) Pump foundation resonance 10) Screw down the foundation
10) The foundation bolt of pump bolt of pump
is loose 11) Replace the pump impeller
11) The pump impeller has 12) Replace the shaft
serious erosion
12) The shaft is bent
3. Cause of Seize 1) The oil tank has insufficient 1) Please contact the
43
S.N. Phenomena Causes Treatment method
seizure of water oil or has no oil mechanical fitter in time for
ring vacuum pump 2) The lubricating oil quality is handling if the following
and the handling unqualified, and it contains phenomena are found at the
impurity or water or suffers from initial stage: the bearing case has
suffers from emulsification high temperature, or the
3) The bearing has poor quality lubricating oil contains metal
or suffers from fatigue & aging fragments
caused by long-time running 2) If the following phenomena
4) Great vibration are found, switch to the standby
pump in time, stop the running
5) The bearing has large pump, and then notify the
installation deviation, or the used operation room: the pump has
bearing, shaft sleeve or shaft is abnormal noise, severe vibration,
improper current increase and even trip of
motor. Then contact the
mechanical fitter in time for
handling
1) Sealing stuffing is improperly 1) Select sealing filler and
selected or installed. install it properly according to the
4. Cause of seal 2) Filler, shaft sleeve abrasion or regulation.
leakage and the Seal is leaked. loose gland 2) Contact the mechanical fitter
handling 3) The shaft has severe vibration for replacement of filler, gland or
compressing the gland
3) Disassemble for inspection
1) Friction between rotor and 1) Contact mechanical fitters
stator for treatment.
2) Components of the pump is 2) Contact mechanical fitters
damaged or blocked. for treatment.
3) Shaft is seriously bent. 3) Contact the mechanical fitter
5. The cause of 4) The filler in filling pump is for replacement of bearing
failure in water ring Motor shaft compacted too tight 4) Contact the mechanical fitter
vacuum pump can not be 5) Seize for loosening the filler gland or
rotation and the rotated. 6) There is foreign matter in the enhancing rotation
handling method pump, which causes jamming 5) Contact mechanical fitters
7) The bearing gets rusty or is for treatment.
damaged 6) Contact mechanical fitters
for treatment.
7) Contact mechanical fitters
for treatment.
1) The outlet pipeline is blocked 1) Handle the outlet pipeline
2) The outlet valve handle falls 2) Inspect and replace it
(or the opening is too small) 3) Replace the pressure gauge
3) The pressure gauge has a fault 4) Find out the causes and
6. Cause of pump Outlet
outlet pressure pressure 4) The pump inlet pressure is too make the inlet pressure reduce
exceeding index exceeds the high 5) Enhance water absorption
and the handling standard. 5) The oil contains too much 6) Select proper impeller or cut
water (density increases) the original impeller
6) The selected impeller is
improper and the diameter is too
large
44
Section 4 Accident treatment plan
4.1 Accident treatment principle

Accident treatment principle is to control the accident in the sequence of mitigation, prevention, attenuation,
isolation and warning.In the cases of risk and hazard accidents, stick to the principle of rescuing the personnel
before materials, key parts before common parts and the control measures before the removal measures for
flexible and resolute treatment to prevent enlarged accidents.
4.2 Emergency suspension method
1. Conditions for emergency shutdown of unit
1) The equipment has serious faults and the normal production cannot be maintained
2) The supply of water, power and instrument air is cut off and it cannot be recovered quickly
3) The unit suffers from serious fire
4) There are other serious accidents and the production cannot be continued
2. Method for emergency shutdown of unit
1) Notify the front and rear working sections the emergency shutdown of the unit;
2) Notify the storage & transportation system for prepration for releasing pressure to the flare system;
3) Close the main valve of general catalytic dry gas feeding unit.
4) Close the main valve of reformed gas inlet device;
5) When all the adsorption towers (C-101/A~H) are in the positive pressure, click the “Run/Suspend” button
on the DCS with the mouse to stop the PSA operation program;
6) Click the “initialize” button on DCS with the mouse
7) Stop the product gas compressor K-102 (see 3.2 Shutdown of Hydrogen Compressor for the operation
steps);
8) Manually open PV-1004A, PV-1007B, OP=100, product gas flare;
9) Stop the desorption gas compressor K-101 (see 3.2 Shutdown of Desorption Gas Compressor for the
operation steps);
10) Manually open PV-1002B, OP=100, open desorption gas to the flare;
11) Open the inlet and outlet bypass valve of the vacuum pump, and stop the vacuum pump one by one (see 3.3
Startup, Stop and Switching Operation of Water Ring Vacuum Pump for the operation steps);
12) Close the inlet and outlet valves of vacuum pump.
13) Close the feeding main valve of adsorption tower.
14) Open balance valves KV-1002A~H on DCS for the basically identical pressure in various towers.
15) Close all the valvs at unit battery limit (if the planned shutdown time is long, blind plate shall be used);
16) Full inspection shall be performed for the unit process line and equipment.
Notes
The inlet valve shall be closed in time when the vacuum pump is stopped, so as to prevent the soft water
flowing back into the adsorption tower. In addition, dehydration shall be performed on the vacuation line
immediately after the shutdown, so as to guarantee that the adsorption tower is dry.
4.3 Accident treatment plan

1. Fire caused by liquid drainage of gas tank
1) Accident phenomenal: The liquid drainage position of gas tank catches fire
2) Accident cause: The dewatering flow speed is fast, and fire is caused by static electricity or open fire.
45
3) Accident confirmation: There is open fire by visual inspection.
4) Accident treatment:
1. Report it to and contact relevant departments.
(1) The person who find the fire shall report to the shift leader immediately, describing the fire position and
fire behavior;
(2) Dial the fire reporting telephone; describe the unit name, fire position, the medium catching fire and
arrange the personnel to wait for the coming fire trucks;
(3) Notify the dispatch center for coordinating with waste water treatment plant, and take the necessary
emergency measures.
2. Emergency shutdown of unit
(1) Emergency shutdown of unit (see 2.2 Method for emergency shutdown of unit for the operation steps)
3. Emergency disposal measures
(1) Arrange those who are familiar with the route to lead the irrelevant personnel to evacuate in order.
Evacuation route and the notes:

Evacuation route:
Notes:
1. When the fire site is surrounded by dense smoke and there is a low visibility, walk in low posture or crawl
forward to pass through the dense smoke.
2. Cover the mouth and nose with wet towel, so as to smoothly evacuate from the smoke area.
(2) Confirm that the following emergency facilities and materials are in good conditions: self-contained
positive pressure air breathing apparatus, long-hose respirator, wool felt, shovel, sand bag, fixed type gas alarm,
fixed type hydrogen alarm, fixed type hydrogen sulfide alarm apparatus, portable hydrogen sulfide alarm
apparatus, etc.
(3) Arrange special personnel to cut off the relevant road sections, so as to prevent the passing or entry of
vehicles and irrelevant personnel and guarantee the unblocked road for fire trucks.
(4) Close the process valves in front and at the back of the gas tank and make the gas tank isolate (see 10.7.2.1
Control over Leakage Source for the isolation method).
(5) Move away the combustible materials near the fire point.
(6) The initial fire shall be extinguished with dry powder extinguisher and steam hose.
(7) The equipment pipeline around shall be cooled with fire fighting water cannon.
(8) The waste oil water well of the system shall be sealed immediately, so as to prevent fire wastewater
flowing into the industrial wastewater system.
(9) Dike with soil bag or sand bag for cut-off, so as to make the pollutants retained on the unit for recovery,
prevent the pollutants flowing into the rainwater drainage system and expansion of pollution area.
(10) Spray water to the toxic and harmful gas with steam and fire fighting water cannon, so as to accelerate the
diffusion of toxic and harmful gas to atmosphere.
(11) Use fixed type and portable toxic and harmful gas detector to continuously monitor the concentration of the
toxic and harmful gas on site.
(12) Make the on-site pollutants collected, recovered, covered and removed; the pollutants shall be disposed of
in a reliably way, preventing the occurrence of secondary accident.
46
(13) The pollutants produced during on-site cleaning and facilities recovery must be disposed of in time in
accordance with the environmental protection regulations; the hazardous waste shall be dumped and buried in
the designated place, so as to prevent environmental pollution.
Notes for disposal process

1. If the concentration of on-site toxic and harmful gas exceeds the standard, self-contained positive pressure
air breathing apparatus must be worn before entering the site;
2. One-person operation is forbidden, and special personnel shall be arranged for supervision for all
operations; and the supervisor also shall wear the self-contained positive pressure air breathing apparatus;
3. In case of personal injury, the injured shall be saved firstly, and then perform accident handling;
4. The site only can be opened after the concentration of on-site toxic and harmful gas meets the standard
requirements.
Withdrawn state:
Complete shutdown of unit
2. Serious leakage of hydrogen compressor

1) 3.2.1 Accident phenomenon: The hydrogen alarm installed at K-102AB position gives an alarm.
2) Accident cause: Some position of the hydrogen compressor has serious hydrogen leakage.
3) Accident confirmation: The outside operator and shift leader shall come to site for detection and
confirmation by using the portable flammable gas detector.
(1) Make the leakage condition immediately reported to the shift supervisor of the unit and dispatch center of
the refinery.
(2) Notify the storage and transport system that the unit is prepared to relieve pressure to flare system.
(3) Ask the dispatch center of the refinery to coordinate the fire trucks for monitoring, and arrange the
personnel to wait for the coming fire trucks.
2. Emergency treatment measures
(1) All the operations nearby that may ignite the leaking medium shall be inhibited immediately.
(2) Use steam to isolate and cut off the relevant roads.
(3) Find out the leaking points by making use of the portable flammable gas detector.
(4) Close the connecting valve in front and at the back of the leaking points, and isolate the leaking point (see
10.7.2.1 Control over Leakage Source for the isolation method).
(5) Emergency shutdown of unit (see 7.2.2 Method for Emergency Shutdown of Unit for the operation steps).
(6) Close the hydrogen compressor inlet and outlet valve.
(7) Open the flare valve of the hydrogen compressor to release pressure to the flare system.
(8) After the balance between the pressure of the hydrogen compressor and the flare system, close the flare
valve.
(9) Open the nitrogen gas valve of the hydrogen compressor to input nitrogen for replacement and protection.
(10) Handle the leaking point by yourself or contact the relevant unit for blocking the leaking (it is dependent
on the actual leakage conditions).
47
Notes
1. Explosion-proof tools must be used during the operation process;
2. The emergency personnel must wear anti-static work clothes; the
non-explosion-proof communication tools (such as cell phone) shall be
powered off and the battery shall be taken down.
Withdrawn state:
The leakage source is isolated and controlled.
3. Power failure of the unit

1) Accident phenomenal: Sudden stop of compressor and vacuum pump.
2) Accident cause: The power grid stops power supply or there is power failure.
3) Accident confirmation: All the compressors and vacuums stops running simultaneously.
4) Accident treatment: After high-voltage power supply of the unit is cut off, the compressor and vacuum
pump will stop running; handle it as emergency shutdown.
(1) Report to the production dispatch center and find out the reason causing the power failure and know about
the power restoration time.
(2) Report it to the shift supervisor of the shift and members of accident emergency group.
(3) Notify the front and rear working sections the emergency shutdown of the unit;
(1) Immediately close the vacuum pump inlet valve;

(2) When all the adsorption towers (C-101/A~H) are in the positive pressure, click the “Run/Suspend” button
(3) Click the “initialize” button on DCS with the mouse
(4) Manually open PV-1004A, OP=100, open product gas to the flare;
(5) Manually open PV-1002B, OP=100, open desorption gas to the flare;
(6) Close the main valve of general catalytic dry gas feeding unit.
(7) Close the feeding main valve of adsorption tower.
(8) Open balance valves KV-1002A~H on DCS for the basically identical pressure in various towers.
Withdrawn state: Unit suspension
4. Instrument air of unit is cut off

1) Accident phenomenal: All the control valves and program control valves are out of function, and the
pressure of low pressure instrument air returns to zero.
2) Accident cause: The system net pipeline stops supplying the low pressure instrument air or stops air supply
due to a fault.
3) Accident confirmation: There is no air release after the low pressure instrument air vent valve is opened.
48
4) Accident treatment: All the control valves and program control valves are out of function due to the air
supply stop, and handle it as normal shutdown.
(1) Report to the production dispatch center and find out the reason causing the low pressure instrument air
supply stop and know about the supply restoration time.
(3) Notify the relevant work sections for emergency shutdown of the unit.
(4) Notify the storage & transportation system for prepration for releasing pressure to the flare system;
(1) Stop the product gas compressor K-102AB (see 3.2 Shutdown of Hydrogen Compressor for the operation
steps);
(2) Open the by-pass valve of PV-1004A; product gas flare;
(3) Stop desorption gas compressor K-101/A, B (see operation procedure in 5.2.2 desorption gas compressor
shutdown);
(4) Open the by-pass valve of PV-1002B; desorption gas flare;
(5) Open inlet and outlet by-pass valves of the vacuum pump. Stop vacuum pump one by one (see operation
procedure in 6.8.1 Opening, stopping and switching operation of water circular vacuum pump).
(6) Close the inlet and outlet valves of vacuum pump.
(9) Click “run/pause” button on DCS with mouse to stop the PSA running program;
5. Circulating water supply suspension of the unit

1) Accident phenomenal: The circulating water system has no water supply, and the circulating water pressure
returns to zero.
2) Accident cause: System pipeline network stops water supply or water supply is stopped due to failures.
3) Accident confirmation: There is no water drainage after the circulating water vent valve is opened.
4) Accident treatment: After the circulating water supply of the unit is stopped, therer is no cooling medium,
so the compressor must be stopped immediately to guarantee its safety.
(1) Report the production dispatch and water supply and drainage unit and know the water supply failure
reason. Restore supply time.
49
(3) Stop product gas compressor K-102 (see operation procedure in 5.1.2 hydrogen compressor shutdown);
(5) Stop desorption gas compressor K-101/A, B (see operation procedure in 5.2.2 desorption gas compressor
shutdown);
6. Fresh water supply of unit is stopped

1) Accident phenomenal: The soft water system has no water supply, and the soft water pressure returns to
zero.
2) Accident cause: System pipeline network stops water supply or water supply is stopped due to failures.
3) Accident confirmation: There is no water drainage after the soft water vent valve is opened.
4) Accident treatment: After the soft water supply of unit is stopped, contact the dispatch center and water
supply and drainage unit in time. If the water supply can be restored within a short time, the unit could perform
production with quantity reduced; if the water supply stop will last for a long time, the unit shall be subject to
temporary shutdown, and the disposal steps are as follows.
(1) Report the production dispatch and water supply and drainage unit and know the water supply failure
reason. Restore supply time.
(3) Stop product gas compressor K-102 (see operation procedure in 5.1.2 hydrogen compressor shutdown);
(5) Stop desorption gas compressor K-101 (see operation procedure in 5.2.2 desorption gas compressor
shutdown);
50
7. The quantity of raw materials reduces suddenly or returns to zero

1) Accident phenomenal: The quantity of raw materials reduces suddenly or returns to zero.
2) Accident cause: The upstream unit has a problem.
3) Accident confirmation: Contact the instrument technician for inspection; if it is confirmed that it is not
instrument fault, then contact the dispatch center and the upstream unit for inquiry and confirmation.
4) Accident treatment: If the quantity of raw materials reduces, inside operator shall perform adjustment and
the compressor operator shall make the load reduced on site (see Chapter 5 Operation Instruction of Special
Equipment for the operation steps). If the quantity of raw materials returns to zero, then execute the following
steps:
(1) Report to the production dispatch center of the refinery; if the raw materials supply cannot be restored
within a short time, then the unit shall be shut down.
(3) Stop the product gas compressor K-102AB (see 5.1.2 Shutdown of Hydrogen Compressor for the operation
steps);
shutdown);
8. Sudden stop of product gas compressor

1) Accident phenomenal: Sudden stop of the product gas compressor
51
2) Accident cause: The product gas compressor has a fault.
3) Accident confirmation: Contact the electrician and mechanical fitter for confirming that the product gas
compressor cannot work normally due to a fault.
(1) Report the situation to the production dispatcher.

shutdown);
9. Fault of vacuum pump

1) Accident phenomenal: The vacuum pump inlet pressure cannot reach -0.08KPa, and the product hydrogen
purity is affected (it is hard to be qualified).
2) Accident cause: The vacuum pump inlet and outlet bypass valve has leaking phenomenon.
3) Accident confirmation: The vacuum pump inlet and outlet bypass valve is inspected to be untight and have
internal leaking, and the vacuum pump inlet pressure cannot reach -0.08KPa.
4) Accident treatment: Switch to other vacuum pumps for operation; and repair the inlet and outlet bypass
valve. In case that there is no standby vacuum pump, then emergency shutdown shall be performed.
(1) Report the situation to the production dispatcher.

52
(3) Stop the product gas compressor K-102AB (see 5.1.2 Shutdown of Hydrogen Compressor for the operation
steps);
shutdown);
53
Chapter 3 Safety and Environment Protection Regulation
Section 1 Safety and environment protection responsibility
1.1 Safety and environmental protection responsibilities of responsible personnel of the unit
1. Under the leadership of safety and environment protection department, take charge of the safety production
of the unit (system and station) and ensure the orderly safety and environment protection work of the unit
(system and station).
2. Organize and develop the safety and environmental systems of the unit (system and station) and safety and
environmental responsibilities of each post. Realize one duty for one post. According to the requirements and
plans of the company, organize the preparation, decomposition, implementation and summary of the production
goal of the unit (system and station). Ensure the completion of the production task.
3. Organize the whole personnel of the unit (system and station) for safety training education. Carry out one
time of safety activity for the personnel of the whole station; carry out secondary safety education for the new
staff (including the intern and training-on-contract personnel).
4. Carry out one time of comprehensive inspection of the unit (system and station) every week. The
inspection focus includes the implementation of safety environment operation technology regulation and labor
protection facilities. Ensure production equipments, safety equipments, fire facilities, labor protection utensils,
etc. are in the intact state.Report the safety production of the unit (system and station) to the department leader
in briefing.
5. Manage the accident strictly. Report and analyze the accidents of the unit (system and station) in time.
According to the rule of “Four NON-Passed Items”, take part in the investigation and treatment; if the accident
is caused by yourself, you may accept the investigation and treatment by the department leader practically.
6. Take charge of the first hot work application, approval of secondary hot work and implementation of safety
measures of hot work of the unit (system and station). Implement fire protection measures and safety system at
hot work site and ensure hot work safety.
7. Establish the safety management network of the unit (system and station). Make full use of all the staffs.
Cooperated with safety and environment protection department, organize fire rehearsal and training and
intensify fire fighting work.
1.2 Safety and environmental protection responsibilities of unit engineer
1. Under the leadership of the responsible personnel of the unit, carry out the safety and environment
protection work of the unit (system and station) and ensure the smooth safety and environment protection work
of the unit (system and station).
2. Take charge of preparation of production technology regulation, startup and suspension plans, etc. of the
unit (system and station) according to the requirements of safety and environment protection. Supervise the
implementation situation.
3 Take charge of training the staff about various safety and environment protection and organize technical
exercise and examination for safety and environment protection.
4 Take charge of inspection of on-site safety and environment protection and review for the operation actions of
the staff according to relevant regulations and rules.For the personnel who do not work according the persuasion,
relevant personnel has the right to stop his work.
5. Take charge of the preparation of technical programs of hot work, minor repair, repair, etc. of the unit
(system and station) according to the requirements of safety and environment protection. Monitor the
implementation of relevant programs.
6. Take charge of on-site confirmation of hot work items.
7. Take part in investigation, analysis, treatment and preventive measures preparation of various accidents and
prevent another similar accident.
1.3 Safety and environment protection responsibilities of posts of shift supervisor and internal operator
1. Under the leadership of the management engineer (of the unit (system and station)), study all the
54
regulations and rules of the company and obey them strictly. Take charge of the shift task.Shift supervisor
should be directly responsible for the safety and environment protection in the production.
2. According to the production task of the current shift, make a reasonable production plan, lead the field
operators to complete the operation and communication of various posts and ensure the normal production of
the refinery.
3. Adjust the system operation parameters. Ensure that the operating equipment does not exceed the required
temperature, pressure, speed or load; strictly monitor the operation situation of DCS. Deal with alarming,
shutdown and other accidents. And report it to the company dispatcher and the supervisor and responsible
personnel of the unit (system and station).
4. Internal operator makes operation record every hour, urge field operator to inspect the unit every half hour
and waste water drainage every hour to ensure the normal operation of the unit.
5. Strictly implement fire protection system. It is prohibited to pile combustible materials around the
high-temperature equipments. Especially during draining the fluid, relevant personnel should be on the site.
Open flame or kindling is prohibited in the site.
6. Working clothing of the post is required according to responding regulation. Preserve well and use various
protective utensils and fire fighting tools properly.
7. Organize (take part in) various safety activities, post technology exercise, fire fighting training and accident
plan rehearsal for good fire fighting work.
8. To have the right to reject the violation orders and the right to persuade and stop other violation actions.
9. Based on the safe production of the shift, implement relevant spirit and systems of the company as well as
the specific requirements of the unit (system and station). According to the review and evaluation rules of
economical responsibilities, cooperate with management engineer and internal post personnel in the reward and
punishment work. Intensify the safety and environment protection of the unit (system and station) for the
smooth production of the refinery.
1.4 Safety production responsibility of field operation post
1. Under the leadership of the shift supervisor and internal post personnel, study all the regulations and rules
of the company and obey them strictly. Take charge of the shift task and the security of all the production
activities within the post responsibility.
2. According to the production task of the current shift, make a reasonable production plan, lead the field
operators to complete the operation and communication of various posts and ensure the normal production of
the refinery.
3. Strictly implement the field operator patrol inspection system to ensure that the operating equipment does
not exceed the required temperature, pressure, speed or load; according to internal operation orders, adjust the
operation parameters, deal with alarming, shutdown and other accidental conditions and report it to the shift
supervisor and internal operators timely.
4. Cooperate with internal operator for one time of operation record every hour, one time of unit inspection
every half hour and one time of waste water drainage every hour to ensure the normal operation of the unit.
5. Strictly implement fire protection system. It is prohibited to pile combustible materials around the
high-temperature equipments. Especially during draining the fluid, relevant personnel should be on the site.
Open flame or kindling is prohibited in the site.
6. Working clothing of the post is required according to responding regulation. Preserve well and use various
protective utensils and fire fighting tools properly.
7. Organize (take part in) various safety and environment protection activities, post technology exercise, fire
fighting training and accident plan rehearsal for good fire fighting work.
8. To have the right to reject the violation orders and the right to persuade and stop other violation actions.
9. Implement relevant spirit and systems of the company as well as the specific requirements of the unit
(system and station). According to the review and evaluation rules of economical responsibilities, cooperate
with management engineer and internal post personnel in the reward and punishment work. Intensify the safety
and environment protection of the unit (system and station) for the smooth production of the refinery.
55
Section 2 Safety and environment protection system
2.1 Safety production regulation of the unit

1. You must observe national regulations and various safety management regulations of the company strictly.
2. Mobile phones are prohibited in the combustible and explosive sites;
3. Anti-static working clothing is required in the combustible and explosive sites to prevent static electricity
flame;
4. It is forbidden to enter the unit by carrying kindling materials and other flammable and explosive materials,
and smoking is forbidden at any position of the unit;
5. It is prohibited to wipe clothing, tools, equipment, floor, etc. with gasoline. Special oil requires safety proof
or relevant permits in advance.It is prohibited that the company staff or any external personnel give the oil
product to others for use.
6. It is prohibited to wear spiked shoes in the unit or knock the unit with black metal and other objects which
can produces flame during the knocking.Wear explosion-proof tool when dismantling and installing combustible
and explosive materials and equipments.
7. Anti-static working clothing is required in the combustible and explosive sites to prevent static electricity
flame. Mobile phones are prohibited in the production area.
8. Various vehicles entering the unit should have the permit. If it is necessary to use fire in the equipment
repair, apply the fire permit according to the fire category. And implement the fire utilization management
system strictly.
9. Do not bake foods and various combustible materials on high-temperature pipelines.
10. It is prohibited to dismantle pipeline and flange arbitrarily. It is prohibited to arrange oil products, materials,
etc. arbitrarily.
11. It is prohibited to wash motors, cables, electric switches and other electric equipments with water and
steam.
12. During the operation, the following indicators of the unit can not be exceeded: temperature, pressure, speed
and load.
13. Operation permit is required for the equipment repair. Power supply should be cut off for the mechanical
repair. Manual operation mode of the equipment is required for the instrument repair.
14. Fire hydrant, shots, fire extinguishers and fire protective items should not be appropriated or damaged.
Flexible and good utilization should be ensured. Carry out regular inspection. Keep the fire passage smooth.
15. Slipping away from the post, visiting various posts site, reading newspapers and reading books is
prohibited. Non-production-related work is prohibited.
2.2 “30-second” confirmation system before single-personnel operation
1. Confirm that personal protection working utensils are safe, for example, the cuff is fixed well, the clothing
has no placket and the longhair is coiled in the helmet, etc.
2. Confirm that the operation action of the item is in accordance with the operation instruction and production
rules.
3. Confirm that the equipment No. and movement state of the operation item is correct.
4. Confirm whether the current ambient condition is safe.
5. Confirm that necessary safety protection measures are ready.
6. Confirm whether the standing position is safe
2.3 Notes of high-temperature sampling port
1. Pay close attention to high-temperature scald.
2. Before the sampling, confirm that the sampling device is intact.
56
3. Cooling equipment should be intact and operating.
4. Sampling operator stands in the one side of the sampler for sampling.
5. During the sampling, sway it gently and take the sample slowly. It is prohibited to open the valve widely.
Prevent scald due to splashed medium.
6. When steam is used to heat the pipeline condensate, close the valve firstly. After the pre-heating, open the
valve for sampling. Prevent hot oil blowout and natural combustion.
2.4 Daily production safety regulation
1. All the employees of the unit must strictly execute the company’s rules, regulations and systems and the
health and safety management-related regulations and requirements.
2. All the staffs entering the unit must experience the training for safety knowledge and skills. Before startup
work of the posts, Post Certificate and Safety Operation Certificate after the qualified exams of safety and post
skills are required.
3. Operators and management personnel must be familiar with the production safety inspection contents
within their own responsibility scope, and shall perform inspection actively; the found problems shall be
handled immediately; if the problems need to be handled by professional maintenance unit, then contact the
relevant unit in time; report to the unit and make the records.
4. The following items should be inspected at any time: lightning protection, flood protection, sunstroke
protection, fire protection, explosion protection, static electricity protection, poisoning prevention, slipping
protection, falling protection, etc. And the found problems should not be postponed to the next day for treatment.
And the events required to be reported should not be concealed.
5. The post operator should implement the shift transfer system and safety patrol inspection system strictly.
6. All the post operators must grasp post operation skills and accident emergency treatment plans.In
production process control, failure treatment and other operations, post responsibility system, unit management
system, operation instruction, process card and accident treatment plan should be implemented strictly. The
working rule of “4 Systems and 1 Card” should be obeyed strictly.
7. The personnel entering the operation site should wear safety helmet, anti-static working clothing and flattie
without iron nails.In order to prevent turning injuries, female workers should coil their long hair in the safety
helmet.
8. The post operators must be able to use safety protection facilities and fire fighting facilities.
9. In daily work, implement Dangerous Chemical Safety Management Regulation strictly. If it is necessary to
carry out the dehydration on the site, supervisor is required on the site. And hydrogen sulfide preventive safety
measures should be provided before the dehydration.
10. Wear dust-proof mask during the dechlorinating agent change in the site.
11. In daily work, strictly implement relevant management regulations of environment and occupation disease
factor protection of the company.
12. During the dehydration, portable hydrogen sulfide and combustible gas detection and alarming device.
13. If hydrotreating system, compressor and heater self-protection system fail, contact relevant units for
treatment. And the unresolved problems should not be postponed to the next day for reporting to subordinate
leaders.
14. Carry out the closed lamp inspection of hydrotreating system.
15. Starting, suspension and suspension for scavenging should be implemented strictly according to starting
and suspension programs.
16. Regularly inspect fire fighting facilities and gas protection utensils to ensure that protection facilities are
ready and complete.
17. In case of emergency power failure, air supply stop, water supply stop or steam supply stop, control and
operate according to the handling mthod in the operation instruction; in case of leakage, fire and explosion,
handle according to the emergency response scheme for unit accidents.
57
18. All the overhead vent valves on the equipments should be added with blind plates.
19. In the defect testing with radioactive sources, construction party must implement the special environment
protection regulation “Management of Radioactive Isotopes and Radiation Devices”; for defect testing,
workshop and construction party jointly develop special security and environmental control measures.
Implement the measures strictly during the defect testing.Within 20 minutes before the defect detection, the
operation units must notify all the surrounding operation rooms. And the notification should be confirmed by the
shift supervisor through signatures; during the radioactive resource defect detection, in order to prevent personal
hurt, the operations of patrol inspection, dehydration, regulation, etc. should be adjusted for personnel safety.
20. For the violated command, operation and behaviors, rectify it with Suspension Operation Card.
2.5 Safety production regulations on temporary work
1. Dismantle or change valve and gasket without pressure. Deal with plugged pipelines or carry out
ventilation without pressure.
2. During the inspection, maintenance and cleaning of rotating equipment, strictly implement the “30-second”
confirmation system.
3. Regularly inspect the rotating equipments. Change the damaged pressure gauges and thermometers. If
lubricant has the indicators of water-carrying, emulsification and deterioration, change the lubricant
immediately.
4. Before instrument workers deal with instrument failures and mechanical fitters deal with rotating
equipments, contact the operators firstly and apply the operation permit. After the operators take corresponding
measures, instrument workers and mechanical fitters may start their work.When ESD system fails, automatic
and instrument workers should develop proper programs before the treatment.
5. For the temporary repair and hot work in normal production process, risk evaluation and safety preventive
measures are required. And special personnel should be assigned to inspect the measure implementation.
6. Before starting the combustible material unit, fire steam belt should be provide at the pump with steam.
And the preventive measures for fire and leakage should be prepared.
2.6 Equipment safety and technical regulations
1. Carry out regular suspension of the unit for the special inspection of the inner and outer parts of the
equipment. Carry out equipment renewal, transformation, repair and cleaning. Especially for the problems
which can not be treated in the production process, carry out the overhaul to eliminate potential safety problems
for the intrinsic safety.
2. Regularly carry out physical and chemical detection and pressure (sealing) test according to Supervision
Regulation of Safety Technology of Pressure Vessel to ensure the strength of equipment and pipeline; especially
for the equipment and pipeline with sour water and abrasion (catalyst abrasion) to be repaired, physical and
chemical detection should be carried out to ensure inner and outer surfaces of the equipment are not damaged;
all the inner and outer surfaces of the equipment should have no corrosion, convex, concave or other defects and
the equipment body should have no fracture. And the static sealing position should be free of leakage or other
defects. For the defective equipment which may not be changed in the operation period, carry out the defect
evaluation according to relevant standards. According to the evaluation report, carry out the defective equipment
management. For the equipment which can not be repaired according to the required period, apply the
inspection delaying report and develop operation safety risk control measures.
3. In the equipment operation, temperature and pressure should not exceed the required values. And the
instruments for pressure, temperature, liquid level and flow are precise. Regularly calibrate the indication values
of the pressure gauge on DCS with 0.25-level standard pressure gauge. Calibrate the indication values of the
level meter on DCS with actual glass plate (tube) level gauge.
4. Rotating equipments
1) Safety protective shied of moving parts can not be loose or missing. If the shields are loose or missing,
contact relevant personnel for treatment in time. If some shields are not long or high enough, increase the length
or width of the shield. If some parts have no shields, add protective shields;
2) Rotating equipments must be always in good lubrication state;
3) The temperature of rotating equipment motor is in accordance with relevant regulations. Temperature and
58
vibration of bearing (pad) is in accordance with relevant regulations. The overall vibration of rotating equipment
is in accordance with relevant regulations;
4) Rotating equipments do not exceed the required speed;
5) Normal soundIf pump has abnormal noise, switch it immediately; if the large unit has abnormal noise,
report it to relevant personnel and contact relevant personnel for treatment. If the situation is very serious, treat
it according to the case of emergency shutdown.
6) Carry out rotating equipment cooling.
7) Dynamic seal of rotating equipment is not leaked.
8) Rotating equipment lubrication:
(1) “Three-stage filtering” regulations must be strictly followed for the lubricating oil filling; under normal
conditions, the lubricating oil of pump bearing case shall be replaced for 1 time/6 months; and the lubricating oil
shall be replaced at any time in case of emulsification, deterioration or impurities.
(2) The lubricating oil of large unit shall be subject to 1 time of sampling analysis per month; in case that the
mechanical impurities and water content are unqualified, then remove them with kidney shaped oil filter; in case
that the flash point, acidity or kinematic viscosity is unqualified, then add new oil for replacement, so as to
guarantee the lubricating oil quality of the unit.
(3) The apparatus for adding lubricating oil shall be special and shall be cleaned by each shift;
(4) The oil-using equipment shall be consistent with the stipulated lubricating oil grade;
(5) The oil level of the filling points shall be 1/2~2/3 of the oil gauge.
5. The heat preservation and surface anticorrosive coating of the equipment and pipeline shall be complete,
and report to the unit in time for handling in case of any damage.
6. The fire-proof layer of framework pillar, pipe strap pillar and tower skirt base of the equipment is intact.
7. Carry out the overheating point inspection of the reformer to grasp the internal operation situation of the
high-temperature equipment with lining.
8. For the prehydrogen system, equipment and pipeline which are corrosive and abrasive, regularly carry out
physical and chemical detection. Find and deal with relevant problems as soon as possible.
9. Test ESD system one time before each startup. If any problem is found, deal with in time. Ensure the
self-protection and interlock system is usable.
10. The equipment commissioning should be in accordance with relevant regulation.Firstly carry out the
comprehensive inspection on the equipment. Confirm that whether equipment repair is completed, sealing
component is fixed firmly, various accessories (such as pressure gauge, plug, and protective shield) are installed
completely, all the vent valves are closed and the ambient condition is clean.Whether the air displacement is
qualified? The material introduction sequence may be in accordance with the principle of cool material
introduction before the hot materials.
11. Safety accessories
1) Safety valve
(1) The safety valve No. shall be indicated on the nameplate of the safety valve;
(2) There is pressure setting plate on the safety valve, and the safety valve No., pressure setting vale and
pressure setting date are indicated on the plate;
(3) Lead sealing shall be applied for the combind safety valve hood, valve body and pressure setting needle (or
manual startup handle)
(4) During the normal running process, the opening of the inlet and outlet valve must be large, and the inlet
and outlet valve has lead sealing;
(5) The safety valve shall have no external or internal leaking;
(6) The safety valve must be maintained, cleaned, inspected and calibrated according to the stipulated period,
and it shall not work with the pressure setting period exceeded. If the use of pressure setting cannot be stopped
59
due to production-related reasons, the inspection delay report shall be given;
(7) The safety valve tripped during normal production shall be repaired in time. For the equipment with only
one safety valve, after the safety valve tripping, production control measures and the emergency failure
treatment programs in the process should be provided for the case without safety valve. Repair the safety valve
in time.
2) Pressure gauge
(1) The pressure gauge installed on the equipment must meet the equipment use conditions; for example,
shock absorption pressure gauge shall be installed for the equipment with serious vibration, and the pressure
gauge with radiator shall be installed on high-temperature equipment. Engineering measurement range on the
pressure gauge panel should be 1.5~2.0 times of maximum working pressure of the equipment. The normal
operation pressure of the equipment should be 1/2~2/3 of the panel scale.
(2) The pressure gauge must have grade mark, and there must be the mark indicating the upper limit value of
equipment working pressure (red line) on the disk.
(3) If the pointer fails to return to zero after the pressure gauge is not used, the dial plate cannot be cleaned, the
dial plate glass is broken, the gauge has internal leaking, the pressure pointer has deformation or there is no
calibration lead sealing, then the pressure gauge must be replaced;
(4) The pressure gauge shall be calibrated or replaced according to the stipulated period.
3) Glass tube level gauge
(1) The use & operation conditions must be indicated on the nameplate of the glass tube level gauge; the limit
operation condition of the installed equipment shall not exceed the upper limit value of the use & operation
conditions indicated on the nameplate of the glass tube level gauge;
(2) During the normal running process, the opening of the upstream and downstream valves must be large; the
valve and draft tube shall be unblocked; and there shall be no false liquid level;
(3) The glass tube that has breakage or leaking shall be replaced in time; and the glass tube with indiscernible
display shall be cleaned or replaced in time.
4) The equipment grounding wire for lightning and static electricity
(1) The use conditions of the lightning rod at the stack top shall be checked every time when overhaul, and the
found problems shall be handled in time; the lightning rod ground wire shall be inspected periodically; the
problems in poor connection and poor contact shall be handled in time;
(2) The static equipment, pipe rack directly grounded and the equipment frame ground wire shall be inspected
periodically; the problems in poor connection and poor contact shall be handled in time;
(3) The grounding of motor body, motor junction box and switch pillar shall be inspected periodically; the
problems in poor connection and poor contact shall be handled in time;
(4) The indirect resistance of the static ground wire shall be periodically tested; and handling shall be
performed if the resistance value is larger than 100Ω;
(5) DCS, ESD, instrument and electrical maintenance unit is required to perform electrostatic grounding
inspection periodically;
(6) Blind plate shall be applied for the tower top and settler top evacuation every time when overhaul is
completed.
12. Others
1) The equipment operator can not enter the working post until he gets qualified examination and obtains the
discipline operation qualification certificate after the technical and safety training by professional departments.
2) In order to prevent twisting injury, rotating equipment operators wear working clothing and fasten buttons
of cuffs and skirts.Female should coil their long hair in the safety helmet and fix it firmly; do not contact the
rotating parts with hands. Do not do the cleaning work or carry out other operations in the rotating parts.
3) Patrol inspection shall be carried out in accordance with the company’s patrol inspection regulations and
systems; in case that any problem is found, contact the maintenance unit in time for handling; report toe the unit;
the problem shall be solved as soon as possible, and records shall be given;
60
4) When there is pressure in the equipment, repair or fixation is not permitted.For the special production
process, in the commissioning temperature rise (drop) process, the equipment with bolts which need to be
fastened (hot bolting) with high temperature and pressure requires valid operation requirements and protection
measures developed according to relevant requirements. And relevant measures should be approved by relevant
responsible personnel of technology;
5) In the following cases of the equipments, operators should take emergency measures immediately and
report it to the relevant departments of the plant in time according to required reporting procedure.
(1) The equipment working pressure, medium temperature or wall temperature exceed the allowable value, and
it still cannot be effectively controlled even if measures are taken;
(2) The main pressure parts of the equipment have the defects that endanger safety, such as cracks, bulge,
deformation, leaking, etc.
(3) The equipment accessories are out of function;
(4) The connecting pipe and fastener are damaged, and safe operation cannot be guaranteed;
(5) Fire accident occurs, which directly threatens the safe operation of the pressure vessels;
(6) The vessel liquid level is out of control, and it still cannot be effectively controlled even if measures are
taken;
(7) The equipment or pipe has serious vibration or abnormal sound, which threatens the safe operation.
13. If fire work and personnel entry are necessary for the faulted equipment during the normal production
process, isolation with blind plate, purging and replacement handing shall be performed; all the required work
permits shall be handled, or the construction shall not be carried out.
14. It is prohibited to wash motors, cables, electric switches and other electric equipments with water and
steam.
2.7 Safety regulation for dehydration and fluid removal
1. Personal safety and protection preparation before dehydration and water removal.
1) Before dewatering and liquid drainage, the outside operator shall notify the inside operator; and the
dewatering and liquid drainage operation shall be carried out under the condition that the inside operator know it;
For the posts of internal operators and field operators, shift supervisor should be notified the dehydration and
fluid removal operations.
2) If there is supervisor, contact the supervisor: 1 person performs dewatering and 1 person supervises it. If
safety monitoring camera is provided, adjust the position of the monitoring camera.
3) The person who performs dewatering and liquid drainage shall take along the walkie-talkie, portable
hydrogen sulfide and flammable gas detector, explosion-proof valve plate, gloves. At the dehydration port with
splashing and spraying phenomena, the operators must wear corresponding protective mask.
4) Unit arrangement shall be made for the special dewatering port that has no dewatering in normal times, and
the dewatering scheme shall be established.
2. Check the water removal and dehydration ports.
1) Dehydration port has no leakage. Nearby equipments are not leaked. Lighting in the night is good. There is
no collision or other obstructions. And the ground has no water, oil, ice and other sliding factors.
2) The first valve of the dehydration port is in the opened state without abnormal phenomena.
3) Fire steam hose is provided at the dehydration port. And open the hose properly. Fire extinguisher is
available near the dehydration port.
4) Distinguish the direction; confirm and remember the escape route.
5) If there is repair of pump and other equipments, hot work or other dangerous operations nearby, notify
them to stop and temporarily leave the safe area.
6) Any external construction personnel surrounding the dehydration site should be notified with the
dehydration operation and leaving the site.
61
3. Dehydration and water removal
1) Confirm the wind direction. Stand in the upwind position. And the guardian should stand in the upwind
position. The contacting mode should be determined.
2) The monitoring personnel open portable alarming devices for hydrogen sulfide and combustible gases. If
the concentration of hydrogen sulfide in the operation area is near to 8~10mg/kg, stop the dehydration
operation.Dehydration personnel wear positive pressure air respirator before the operation. Otherwise the
operation is prohibited.
3) Dehydration personnel open the valve for the operation slowly according to the Operation Card for
Dehydration and Water Removal. Observe the water flow state. If water flow contains combustible materials,
adjust the opening degree of the valve. Observe, distinguish and confirm water, oil, combustible gas, etc.
4) Close the valve after the dehydration.
5) Confirm that dehydration point has no problem. And relevant personnel can not leave the site until the
dehydration is completed.
4. Requirements
1) Before the dewatering valve is closed, the dewatering operator shall not leave the dewatering point.
2) If the dehydration personnel are not in the operation fro a long time and the walkie-talkie has no response,
the shift supervisor should organize relevant personnel to investigate the dehydration site and confirm the
situation.
3) If the dewatering valve cannot be closed, isolate with steam hose; immediately report to the shift leader;
start the corresponding emergency response scheme and report to unit.
4) If certain utensil is used when dehydration port valve can not be easily opened, explosion-proof tools are
required.
5) The second dehydration valve is leaked internally and should be replaced in time.
6) In order to protection the first dehydration valve, the first dehydration valve should be normally opened.
7) For the personnel who should be responsible for the accidents, treat it according to the regulations of
subordinate sectors.
2.8 Starting safety regulation of the unit
1. Before the startup, organize the staff to study the startup program and safety risk evaluation program
seriously. Discuss the doubts and unreasonable problems in the program seriously. Then develop safe and
reliable startup program with amendment.The operator should grasp the startup program.
2. During the startup, strictly implement startup program, risk evaluation program, operation instruction and
process card. According to operation confirmation card, carry out confirmation and operation. Ensure that the
equipment is not damaged and that the temperature and pressure should not be exceeded.
3. Prepare the pressure test and air sealing table for the equipments and relevant pipelines in the startup
program. Carry out scavenging and pressure test according to the program. Ensure that the equipments and
relevant pipelines are smooth without leakage.Carry out scavenging and pressure test, especially on the
modified equipments and process pipelines. Ensure equipment pressure does not exceed the required range and
safety valve dose not trip. Without qualified pressure test, combustible material introduction is prohibited.In the
steam introduction and pressure test, prevent equipment damage or personnel hurt due to spraying steam.
4. Develop detailed table of adding and dismantling blind plate during startup to prevent omitted adding and
dismantling. In the adding and dismantling, implement the Operation Permit of Unit Repair and Adding and
Dismantling Blind Plate of the company.
5. Add isolation blind plates between various media, such as nitrogen, air, water, steam and fuel gas. Ensure
that there is no oil blow-by and gas (steam) blow-by.
6. Before the startup, carry out the comprehensive acceptance of equipment and process. The integral transfer
sheet is required. Startup is not permitted during the construction. If the construction or hot work is not ceased,
combustible materials can not be introduced. During the startup, stop all the operations with fire resource.
7. Before the introduction of combustible materials, all the electricity utilization equipment should be
62
supplied with power. Electrical workers carry out inspection and confirmation: electrical equipment is intact
without creepage or discharge. Otherwise, the introduction of combustible materials is not permitted.
8. To prevent maintenance and renovation omission and error, after the maintenance is completed, the unit
shall organize the equipment and process technicians, together with the relevant maintenance personnel, to
perform inspection and acceptance for the maintained, renovated and new projects according to the drawings
and maintenance plan, and handle the acceptance certificate; special description shall be given in the startup
scheme for the renovation and new projects, and the scheme for putting into use of single unit shall be provided.
9. If some equipments have large modifications, special descriptions should be provided in the starting
programs for the modified equipment, flow and instrument. If the equipment is basically isolated from other
equipments, special startup program is required. And the equipment should be the focus in the starting.
10. Nitrogen replacement shall be performed for the hydrogen system and fuel system according to regulations,
and the oxygen content in the system shall be ≤0.3%.
11. Before the pressure test of the equipment, safety valve is qualified in the calibration and installed well for
use.
12. Upper and lower guide tubes of glass level gauge of the tower and vessel re smooth. Glass plate is clear
and usable.
13. Spring tube pressure gauge induction pipe is smooth and put into use.The measurement range of the gauge
is 1.5 to 2 times of the maximum working pressure of the unit.
14. After the instrument repair and qualified calibration, if the combined commissioning and combined
commissioning of the reaction system, unit system, hot work self-protection system are qualified, start the
system. If they are unqualified, startup may be stopped.
15. Add blind plates for top and bottom of various tower, reflux tank top and bottom vent of reflux tank.
16. For the sake of good operation environment, less material loss and environment protection, add blind plates
for proper vent valves of pipelines as possible and add plugs at relevant positions as possible.
17. In the day of receiving oil or introducing fuel gas, set up warning line at the crossing in the road. Vehicles
are prohibited in the day; before the fuel gas introduction, material feeding unit confirmation permit is required.
18. Before receiving the combustible materials, ensure that all the gas protection, fire protection,
communication and lighting facilities are ready for use. Floor drainage seal is taken off. And that fire steam belt
can reach the pump, heat exchanger and flow orifice plate. Obstructions, waste oil, wastes, luggage, scaffold,
temporary power supply and temporary lighting on the equipment, roof and ground should be cleaned or
dismantled to ensure that inspection and fire passage is smooth.
19. Do not discharge anything arbitrarily and make the clean startup.If the discharged is not avoided, the
arrangement from the unit engineer and above is required. And the safe and environment measures are also
provided.
20. During the startup, various post personnel should intensify close cooperation with each other. And they
should also intensify the correspondence with relevant unit. Ensure safe startup without risky conditions.
21. Treatment principle of combustible material leaked from relevant storage equipment in the startup.
1) Start corresponding accident emergency treatment program of the unit, such as power failure and accidents
of steam, air and water as well as single equipment accident.
2) During receiving oil, if the equipment is leaked, stop the operation immediately. Cover the leakage position
with fire steam. And special personnel are required for the monitoring until the leakage is removed.
3) Contact construction unit to fix the unit and carry out pressurized leakage plugging in time;
4) If the leakage is too large for the treatment, stop partial unit or the whole unit, relieve the pressure and
withdraw the materials.
5) In tightening bolts or other operations, construction units should adopts explosion-proof utensils.
6) Gas and low-temperature equipment can be sprayed with fire water. High-temperature equipment can be
sprayed with fire water;
7) Mobile phones are prohibited in the unit area.
63
8) The equipment risk treatment should be in accordance with the Supplementary Management Regulation of
Suspension for Overhaul of the Unit of the Company.
2.9 Suspension and repair safety regulation of the unit
1. Before the suspension, organize the staff to study the suspension and scavenging programs and safety risk
evaluation program seriously. Discuss the doubts in the program seriously. Then develop reasonable programs to
ensure that there is no oil blow-by, exceeding the required temperature and pressure, equipment damage or
accidents during the suspension and scavenging.
2. Suspension and scavenging should be in accordance with relevant programs and relevant risk evaluation
programs.
3. During the suspension and scavenging, stop all the operations with fire resource.Check the safety and fire
fighting facilities of the unit. Ensure all the facilities are available and usable.Before the suspension, check
whether the floor drainage and underground well are smooth. Before the repaired unit transfer, seal the floor
drainage and underground well.
4. During the suspension and scavenging, various posts should intensify close cooperation with each other.
And they should also intensify the contacting with relevant units for safe suspension.
5. During the shutdown and purging period, security line shall be set at the crossings to prevent the passing of
all motor vehicles; isolation belt shall be hung at the crossings leading to the unit to prevent irrelevant personnel
entering the unit (or accident may be caused), and special personnel shall be arranged for patrol inspection.
6. During the oil withdrawal from the unit to tank farm, control temperature and quantity. Do not carry light
component.Intensify the contacting and cooperation with tank farm. Confirm it before the steam supply for
scavenging system.
7. The requirements of retreating oil.In order to prevent fire and environment pollution, oil withdrawal
routing should be reasonable. And the withdrawal should be complete as possible.
8. Scavenging requirements
1) Scavenge the unit according to the scavenging sequence and routine to ensure the scavenging quality. Do
not remain blind zone and corner. Do not omit lines and equipments.
2) Scavenge all the equipments and pipelines according to the scavenging time required in scavenging
program. Scavenging quality should be ensured by enough scavenging time;
3) During the scavenging, pay attention to environment protection and safety protection. Arbitrary discharge
is improper.
4) Arrange reasonable discharging positions of system scavenging line.
9. Confirmation permit is required in the process of opening the first manhole of various equipments.
10. In order to prevent spontaneous combustion of ferrous sulfide in the stripper and pre-fractionator, flush the
unit with water.
11. When increasing the blind plate size,
1) Construction unit fills in the risk evaluation table and implement the blind board ticket system.
2) Deplete the stored oil and ensure that ventilated steam has low oil gas;
12. Before inspection and hot work
1) Except for steam and instrument air pipelines, other pipelines related to combustibles should be provided
with isolation blind plate. Carry out inspection, confirmation, board posting and three-party confirmation sheet:
(1) Battery limit isolating blind plate for entering/exiting the unit;
(2) The isolating blind plate of untreated equipment;
(3) The isolating blind plate of the running equipment or device;
(4) The isolating blind plate between different mediums, such as steam, nitrogen, instrument air, water.
(5) The isolating blind plate of the pipeline that has connection with the medium introduced in advance when
the maintenance is not completed.
64
2) Seal and close the underground well and floor drain cover. Before hot work in the morning and hot work in
the afternoon, carry out two times of inspection. If any problems are found, rectify them immediately.If the fire
preventive measures have problems in hot work, stop hot work immediately. Restore hot work after the
rectification.
3) Implement the patrol inspection system seriously. And the special maintenance personnel for the computer
in the production should carry out the patrol inspection according to the following contents.
4) Arrange special fire supervisor for equipment maintenance. Fire supervisor have to know the device well.
And provide fire monitoring training for them.
5) The employees of the unit who participate in the maintenance shall receive safety training.
6) Carry out safety education for the outsourcing construction personnel participated in the repair.
7) Check the permits of relevant operations of the implementation company. Without relevant operation
permits, no construction can be started.
2.10 Alarming treatment regulation of alarming devices of poisonous, harmful and combustible gases.
1. Give response to any alarm. Investigate the site, find the alarming causes and carry out targeted treatment.
It is not permitted to neglect any alarm.
2. For instrument failure, contact instrument workers for repair.
3. In order to prevent poisoning accident during the safety detection alarming instrument repair by the
instrument workers, internal operator and the field operator in the area with the failed instrument should be
cooperated well for the safeguard.
4. If the equipment has leaking (no matter it is toxic gas or flammable gas), the operators of the leaking
equipment must isolate and control the leakage source by strictly following the corresponding equipment
leaking response scheme, and report to the unit in time for handling.
5. In the shift transfer inspection of internal operator, alarming device drawing on DCS should be inspected.
If any problem is found, contact relevant personnel for treatment.
6. In the shift transfer inspection of field operation, on-site fixed alarming instruments for combustible gas
and hydrogen sulfide. If any problem is found, contact relevant personnel for timely treatment.
7. If no action is taken when an alarm is observed or timely contact is not performed for eliminating the fault
of the safety test alarm instrument, examination will be carried out according to the unit examination system.
2.11 Regulation for environment protection and clean production
1. Strictly implement the environment protection and clean production management systems of the company.
2. Strictly implement pollutant discharge indicators. Intensify the pollution resource control for the qualified
discharge.
3. Only rain, deminerized water, soft water and condensed water can be discharged into rain drainage system.
The waste water polluted by oil can not be discharged into rain drainage system.
4. After repairing, cleaning or washing process equipment and pump, the used oil should be recovered for
treatment. It is prohibited to discharge it into underground well or the floor.
5. In the production process, the waste gas and water discharge should be in the certain sequence. Waste
molecule sieve and waste dechlorinating agent is sent to the dreg field of the company.
6. In the suspension and repair period of the unit, carry out the restricted discharge of waste water and waste
gas according to repair environmental plan. Register waste solid in categories at safety and environmental sector
for the leaving-factory procedure of waste solid. Transport it to the designated sites. The depleted waste water
and solid from tower, tank and reactor should be sent the designated sites according to the strict approval system
of the company. It is prohibited to discharge oil and mud mixture directly into the rain drainage system or oily
water system.
7. Contractors for repair, construction, etc. should provide the environment protection program in the
construction program; if relevant operation produces waste water, report to the environment department and
discharge (oily or chemical) waste water in the designated site; if waste dregs or waste materials are produced,
carry out relevant treatment according to relevant systems or arrangement; underground water discharge should
65
be in accordance with the approval system of the company strictly.
8. In the defect testing with radioactive sources, construction party must implement the special environment
protection regulation “Management of Radioactive Isotopes and Radiation Devices”; for defect testing,
workshop and construction party jointly develop special security and environmental control measures.
Implement the measures strictly during the defect testing. Within 20 minutes before the defect detection, the
operation units must notify all the surrounding operation rooms. And the notification should be confirmed by the
shift supervisor through signatures; during the radioactive resource defect detection, in order to prevent personal
hurt, the operations of patrol inspection, dehydration, regulation, etc. should be adjusted for personnel safety.
9. When flare discharge, the relevant operators shall make the actual operation condition reported to the unit
and dispatch center, and record the discharge time.
10. Regardless of any failure or accident on the unit (fire vehicle is required or you extinguish the fire by
yourself), you must truthfully report the situation to the dispatcher.The oily fire water can only be discharged
into oily water system. And the fire water without oil pollution can discharged into rain drainage system.
Section 3 Hot work regulation of the unit
1. The medium in the pipelines and equipments connected with hot work sites (systems) should be depleted.
2. The pipelines and equipments connected with hot work sites should be added with blind plates. Add
flexible pad on the side near to the hot work site for the convenience of steam discharge during the scavenging.
And add fixed pad on the other side.
3. During equipment overhaul, the inlet and outlet medium pipelines must be added with blind plates.
4. Continuous scavenging period should be no less than 48 hours.
5. Various detection and analysis before the hot work should be qualified and in accordance with relevant
regulations.
6. Before hot work, qualified hot work permit must be issued. And corresponding fire preventive measures
must meet relevant requirements.
7. According to the hot work grade and risk grade, the dispatched fire protection personnel should be familiar
with the environment, know the production process and have practice experiences and highly responsible
attitude. At the same time, he must have the fire protection permit.
8. Implement hot work system strictly, “Three-No-Hot-Work”: Do not start hot work until the valid hot work
permit arrives. Do not start hot work until all the fire preventive measures are intensified. Do not start hot work
until special personnel is assigned to watch the hot work.
9. Fire protection personnel should stick to his post to master the hot work situation in the construction site. If
any abnormal phenomenon is found, take timely measures to prevent relevant accidents.
10. If the fire protection personnel are not on site, hot work is prohibited.
11. According to the hot work situation, the following fire fighting utensils should be prepared.Steam hose, dry
powder fire extinguisher, shovel, felt, etc.
12. In the case of combustible gas leakage from process pipelines, vessels, etc., stop hot work and find the
reasons. Another hot work is not available until the rectification analysis is qualified.
Section 4 Safety and environment protection accident response plan
4.1 Environment accident treatment principle

1. If the pipelines breaks or container is damaged, the unit will cause a large number of oil leakage. It will not
only cause the fire, but also environmental pollution. In the case of leakage, environmental pollution must be
minimized.
2. When environment protection conflicts with safety, ensure the safety. And the leaked materials may be
discharged into refined oily water system.Report it to dispatcher of the branch plant immediately and ask him to
notify refinery waste water treatment department of waste water treatment plant to take emergency measures. Or
report to dispatching room of the company. And the company starts the secondary environment protection
66
measures.
4.2 Emergency treatment measures
1. Contact and arrange the outside operator to find out the leakage source, and report to the unit and
production dispatch center.
2. Confirm the on-site inspection and find out the leakage source; make the sewage well (ditch) immediately
blocked with sand bag; set the security area; prevent personal poisoning and unit fire. The remaining oil on
ground shall be cleaned away (adsorb with waste catalyst). If the oil enters the sewage well, immediately notify
the dispatch center and the dispatch center shall notify the wastewater treatment unit of the power plant. If the
leaking oil has a large amount, soil bags shall be set at the unit boundary as cofferdam; the soil bags shall be
used around the power distribution room as cofferdam to collect the oil, and contact the oil collection team for
recovery.
Isolate the leaked port from the unit. If the pipeline is leaked, close valves at both ends. If the tower or vessel is
leaked, cut it off.Stop the operation of the post which can not be isolated partially from the unit or stop the unit;
carry out leakage plugging with pressure as possible firstly. After the leakage control, carry out complete
treatment. If the leakage plugging is not available, carry out partial suspension and relief for scavenging
treatment. Dispel the leaked air with steam. If liquid is leaked, build the weir with sand firstly. And then recover
it with large barrel. For the leaked oil, actively organize the recovery as soon as possible to prevent it from
entering underground well and infiltration into the soil. Report it to the production department to contact
relevant departments for waste oil recovery.
3. The leakage resource control
If welding port, flange and valve are leaked and pressure gauge of spring tube, double-metal thermometer and
other accessories are leaked at the port, according to the feature of unique transport pipeline of the refinery unit
process, close valves at the two ends of the pipeline to cut off leakage resource.If heat exchanger and cooler are
leaked, change materials to sub-line to control leakage resource. The heat exchanger without sub-line can be
stopped directly, indirectly or together with partial part (the tower). Especially stop the unit for partial
isolation.If the vessel is leaked, close all the inlet valves, deplete all the materials outside and release the
pressure in the flare line.If it can not be isolated through closing the valves, stop partial post operation (related
tower, heat exchanger and vessel) and even the whole unit for partial isolation.If the tower is leakage, close all
the inlet and outlet valves. Deplete all the materials. Relieve the pressure of flare line. If the tower and vessel are
leaked, stop the unit immediately. Line up the pipeline to the front tower. Carry out partial isolation for leakage
position.Through shutdown cutting and switching, power equipment leakage resource can be controlled.
For serious leakage of the unit, carry out local shutdown or comprehensive emergency shutdown to control
leakage resource; oil in the leaked equipment can be transferred to the bucket through the belt; for various
equipments have different operating pressure, if the pressure is not relieved completely, steam can not be
introduced. Otherwise oil or gas may enter the steam pipeline. And gas meeting with the steam may freeze. Thus
steam can not be introduced until the pressure is relieved completely.
4. Leakage
1) Seal and close the underground well and floor drain cover. Do not discharge anything underground.
2) Control the oil through the weir under the ground equipment. Transfer the oil to the underground tank with
the pneumatic pump and plastic dustpan and prevent it from flowing around.
3) Add sand on the damaged weir. If there is no weir, prepare the weir with sand.
4) For the oil which can not be collected, absorb it with sand and send it to the waste solid field.
5) If the quantity is too large for recovery in time, in order to prevent accidental fire, it is required to be
introduced to the underground well. Report the situation to the dispatcher immediately. And the dispatching
room reports it to the waste water treatment department and the security department of the company.
6) When a large amount of wastewater is discharged and it cannot be completely accepted by the equipment
lower cofferdam and temporary cofferdam, immediately report to the dispatch center, and in the meantime, start
the company’s emergency response scheme for environmental accident. Personnel shall be immediately
arranged to make woven bag filled with sand and soil used at the unit boundary as cofferdam for cutting off,
preventing the wastewater flowing out from the unit. The leaking hole shall be isolated with steam.
7) During receiving oil, in order to prevent fire due to flame, stop all the operations with fire resource. Do not
67
open or close lighting or other switches on the site. Do not use non-explosion-proof tools. Do not use mobile
phones or non-explosion-proof walkie-talkie. Fully open the fire steam to increase the vapor content in the air;
8) If the fuel gas, other combustible gases or flue gases are leaked, set the warning area immediately, report it
to the gas protection personnel for detection and monitoring and disperse the combustible gases with fire
fighting steam.According to the leaked position, leakage quantity and control state, determine local isolation or
shutdown for leakage resource control. Notify repair unit to organize the emergency repair.
4.3 Leaked port treatment
After the leakage is controlled, according the specific conditions, carry out pad change, welding, enforcement,
replacement, repair and other plugging measures. For the leakages which can be plugged with pressure, the
plugging measures with pressures may be used to stop and mitigate the leakage to ensure temporary safety.
Obtain certain time to stop and deal with leaked equipment. Then carry out welding, replacement and other
complete measures. The equipment experiencing leakage plugging measures with pressure may not be used for
a long time.
4.4 The leaked material treatment
After the leakage is controlled, cover, dilute, recover, clean and treat the leaked materials on the site in time.
Ensure that the leaked materials are reliably treated and prevent secondary accidents.
1. When large quantity of oil is leaked, build weir with sand, waste catalyst and flood protection sandbag to
block the oil. Pump the oil with pneumatic pump and collect oil with large barrel.If the oil leaked on the ground
can not be collected, absorb it with sand (waste catalyst) and send it to the waste solid field.
2. In the case of leakage, spray atomized water toward the leaked gas with steam and fire water and dispel the
air. Accelerate the gas diffusion;
3. When hydrogen sulfide is leaked, wear positive pressure air breathing apparatus. Dissipate hydrogen
sulfide with steam.
4. During the leakage treatment, block the open rain drainage ditch or wells with sand bags to prevent the
leaked materials from flowing along the open ditch and extend the polluted area. Prevent fire and secondary
accidents
5. Oil product is leaked down. Collect it through the weir under the equipment. Then recover it through the
large barrel.
6. When environment protection conflicts with safety, ensure the safety. And the leaked materials may be
discharged into refined oily water system.Report it to dispatcher immediately and ask him to notify waste water
treatment department to take emergency measures. The leaked materials should be treated by the waste water
treatment department.
4.5 Emergency material supply
Whether it
S.N. Material name Storage position Function meets the
requirements
Crossings of various Plugging and flood
1 Sand bag Yes
units protection
2 Woven bag Storehouse Loading sand Yes
3 Shovel Storehouse Concaved earth Yes
4 Raincoat Storehouse Rain protection Yes
5 Flashlight Main operation room Temporary lighting Yes
6 Emergency lamp Main operation room Temporary lighting Yes
7 Air respirator Various operation room Air protection Yes
8 Portable alarm Field operation room Inspection Yes
9 Explosive-proof walkie-talkie Various operation room Personal contacting Yes
10 Fixed emergency lamp Operation room Emergency use Yes
68
Section 5 DCS system operation management regulation
5.1 Computers used in production include Distributed Control System (DCS), Emergency Shutdown (ESD),
Unit Control System (ITCC), Data Acquisition System (DAS), Programmable Logic Controller (PLC),
microcomputer, minicomputer, network equipment and industrial process control computer.
5.2 According to the regulation of the system, various units should combine their own current computers of
production process to develop specific management rules and carry out strict review.
5.3 Instrument and automatic equipment maintenance unit should develop the working contents of regular
inspection and maintenance according to the features of computers of production process.In general, the
contents should include:
1. Regularly clean and change the air filter screens of cabinets and other devices on the operation station
and control station.
2. Regularly clean disc drive.
3. Regularly clean printer and lubricate mechanical driving parts.
4. Regularly change the battery in the system.
5. Regularly clean various equipments, remove dust and rubbish in the operation station and cabinets and
around the equipment. And take efficient measures to prevent dust.
6. Implement the measures for hazards from rats and other small animals.
5.4 Operation management of computers of the production process
1. In order to ensure normal operation of the computer in the production, it is necessary to assign special
personnel for the maintenance. The relevant personnel should experience technical training and pass the
examination by the instrument maintenance unit before entering the post.
2. The operators of production process computer shall receive training and work after passing the production
unit examination. The operators shall well apply the various functions, monitor and control the production of the
whole unit.
3. Implement the patrol inspection system seriously. And the special maintenance personnel for the computer
in the production should carry out the patrol inspection according to the following contents.
1) Through the adjustment of air-conditioning shift, the ambient condition can be adjusted to the required
technical scope.
2) Check the operation state through the system state interface and system alarming interface. If anomaly is
found, deal with it in time.
3) Check the LED indication states of the inserted cards of various computers of the production process.
4) Check whether the cooling fans in the cabinets are in the normal operation. If the fan is damaged or is in
abnormal rotation, take necessary measure and change it timely.
5) Check the working condition of printer and hard copy machines including the color band and printing
paper.
4. When the production process computer is inspected and handled and the computer parameters are adjusted,
the work permit for instrument inspection and maintenance shall be handled in advance, and the relevant work
shall be carried out upon the approval of production unit and the corresponding measures have been taken.
5. If computers of the production process are in abnormal condition or failure, the maintenance personnel of
automatic instrument should handle with it and report it to relevant leaders timely.During the maintenance
operation, it is necessary to prevent card damage due to the static electricity. Antistatic wristband and other
antistatic measures are required before the maintenance.
6. Establish running log of the computer in the production. The maintenance personnel should prepare the
detailed records including results of patrol inspection of every day, the operation condition of various devices
and systems, the found problems and corresponding treatment process and results.
7. The key of the keyboard lock should be stored by special personnel. And carry out the operation within the
required scope.
69
8. In order to prevent computer virus, do not use the soft disks of the set of the computer in the production. It
is prohibited to play electronic games on operation station and engineer station.
5.5 The management of software of computers of the production process
1. Two sets of system software, application software and drive programs should be provided for the
computers of the production process. One set or several sets are standby and one set is for operation.Software of
computers of the production process should be copied regularly. In principle, copy software one time every one
year; if the condition is not proper, software copy is required in every overhaul. In any case, the software backup
period should be no longer than 3 years.
2. Software of computers of the production process should be stored in fixed sites. And software should be
managed by the special personnel of the maintenance unit. In the storage site, corresponding management
method, management account and proper storage conditions should be provided to ensure the storage quality.
And the software should have clear mark for available utilization at any time.
3. In the annual overhaul, the computer software in the production should be inspected comprehensively or
randomly to ensure the safe and reliable functions of the computer software and the proper configuration
parameters.
4. Establish the statistic table for the software of computers of production process.
5. If it is necessary to modify relevant application software or certain configuration data, the modification
application unit proposes the modification plan. And the modification can not be implemented until it is
approved by operation department and mechanical power department of the secondary unit.Instrument and
automatic equipment maintenance unit should develop specific operation steps and complete the configuration
data sheet. After the instrument repair operation permit is issued, assign dedicated personnel to carry out the
operation. And the production workshop should provide active cooperation.
6. The changed application software shall be subject to analog debugging to confirm that its functions
completely meet the technical requirements, and it only can be put into operation after the co-confirmation by
the production unit, Production Department and Maneuvering Department.
7. After the successful operation of the modified application software, relevant technical data should be
timely archived timely. And copy the files in time. The backup software should be the latest version.
8. Establish the modification recording book of application software.After the application software
modification, complete the software modification record carefully.
5.6 The management of control center of computers of the production process.
1. Computer control centers in the production include main operation room, cabinet room and engineer
station room.
2. Control center of computers of the production process should be provided with separated air-conditioning
system to ensure the indoor temperature is between 20℃ and 28℃.The production unit department is
responsible for the maintenance and management of central air-conditioning.
3. It is prohibited to eat anything and pile sundries in the control center. Do not drink water or beverage or put
water cup before engineer station and operation station.Clean the main operation room one time every shift.
Clean engineer station room one time every day. Clean the cabinet room cleaning one time every week. Ensure
that central control room is clean and tidy.
4. Fire-fighting apparatus shall be provided in the production process computer central control room
according to regulations, and the production unit shall be periodically inspected, so as to confirm that it is
reliable and in good conditions.
5. Implement the measures for hazards from rats and other small animals in the inlet of indoor cable passage
of control center of computers of the production process to prevent accidents.
6. The floor in control center of computers of the production process should be made with anti-static
materials. And various carpets are prohibited.
5.7 The management of spare parts of computers of the production process.
1. The management of spare parts of computers of the production process should be in accordance with
management systems of spare parts of the company.
70
2. The maintenance unit of instrument and automatic equipment should develop the statistical table of spare
parts of computers of the production process.
3. Various electronic insertion cards, special utensils, special cables and special fuse protector, etc. should
have proper amount of spare parts to ensure the normal operation of computers of the production process.
4. The spare insertion cards may be damaged due to long-time unused state. Thus the quality can not be
determined.Thus, the alternative use or test plan is required for the standby electronic insertion cards.
5. The machine and power department of the company carries out reasonable arrangement and coordination
of the spare parts and components of computers of production process.
5.8 Maintenance of production process computer (periodical point inspection)
1. In order to ensure the reliable operation of computers of the production process in the operation, regular
overhaul (regular random inspection) is required.
2. During the regular unit repair and suspension for overhaul, the computers of the production process should
be scanned, inspected, tested and adjusted comprehensively. And the system grounding should be tested and
inspected.
3. According to the special conditions, overhaul plans and programs should be developed in advance. At the
same time, various utensils, materials and spare parts should be prepared.According to the time of power supply
suspension and water supply suspension, develop practical repair time table.
4. Before the overhaul of computers of the production process, system software and application software
should be copied for backup.
5. In the repair of computers of the production process, make the repair record and complete the inspection,
testing, adjustment and repair reports.
6. Repair acceptance of computers of the production process is organized and completed by the machine and
power department.
7. The repair outsourcing of computers of the production process should be in accordance with relevant
regulations of the company. Review the qualification of the repair unit strictly. And the unqualified repair unit
can not enter the repair work. Thus the repair quality of computers of the production process can be ensured.
Section 6 The identification of key environment factors of the unit and risk mitigation
measures
6.1 Environmental factor identification table and control measures of the unit
Environment Environment
S.N. Post Activit & product service Control measures
factor impact
The dewatering
The whole Waste water Pollute the
1 Equipment dewatering operation card shall be
unit drainage body
strictly executed.
Contact the waste oil
The whole Oil filling & replacement of Waste oil Pollute the recovery unit to recover
2
unit pump drainage body all the replaced waste
oil
The whole Noise Intensify labor
3 The pump operation Produced noise
unit pollution protection.
Noise Intensify labor
4 Compressor Compressor running Produced noise
pollution protection.
Equipment Discharge into the flare
The whole Pollute the
5 Equipment maintenance medium system to the maximum
unit atmosphere
discharge degree
The whole Leaking caused by Leaking of oil Pollute the Intensify monitoring
6
unit corrosion of pipeline, valve and atmosphere, and replace it in time.
71
body and flange hydrocarbon soil and water
body
Stack in designated
place, and make it
The whole Adsorbent Solid waste
7 Adsorbent replacement transported to the
unit discharge pollution
company’s slag yard for
landfill
The whole Gas pressurization and Noise Intensify labor
8 Produced noise
unit pressure release pollution protection.
Make the sampling
The whole Venting of Pollute the valve tightly closed
9 Sampling and venting
unit petroleum gas atmosphere immediately after the
sampling is completed
6.2 Risk mitigation measures

1. All the repair items are completed and the problem treatment is also completed.Before the startup, carryout
pressure test acceptance for repair items.Startup is not permitted until the acceptance is qualified.
2. Process pipelines must be scavenged and tested with pressure as required.Before the steam introduction
and scavenging, deplete the residual water in the equipment and pipelines. Remove water in the steam. Prevent
water impact and shocking equipments and process pipelines.
3. Demobilize the temporary wire support. Transport construction machines outside. Clear sundries on aerial
platform to prevent hurt due to dropped objects.
4. Do the industrial hygiene work of the whole unit and ensure that there is no sundry and luggage.Oil, rags
and other combustible materials should not exist around the high-temperature pipelines and equipments.
5. Clear the mud in the underground well and ensure smooth passage. Cover the open ditch with covering
plate and the underground well.
6. The insulation damaged during the repair should be restored.
7. Indoor and outdoor lighting equipment and ventilation should be complete and available. And they should
be in accordance with explosion-proof requirements.
8. Rotating equipment should be installed with security shield. Lubricating and cooling work is
required.Check whether all the pump components are complete.
9. Ladder, platform, railing and other protective facilities are complete.
10. Intensify the management and inspection of fire protection utensils and gas mask. Ensure that fire
extinguisher, air respirator, fire fighting steam, etc. is flexible and usable.
11. Safety valve and hand valve should be in the complete opening position and sealed with lead.
12. The unit shall organize all employees of the teams to come to site for learning and knowing about the
process line. Startup Scheme shall be established, letting all employees know about the startup steps.
13. In the startup, unified command and action are required. During the startup, carry out the operation strictly
according to the requirements in Startup Program and process card.
14. Change startup process according to technical requirements. Full-time personnel should be responsible for
the startup process. Confirm that the process is proper. Ensure that there is no material blow-by, steam blow-by
or pressure accumulation during startup.
15. Before oil is input into the unit, strict inspection shall be carried out and the blind plate sheet shall be
prepared, and the records shall be given. The operator, shift leader and unit shall confirm the blind plate
according to the three-level management requirements.
16. External contact shall be well performed before feeding; enhance the dewatering of the feed tank, so as to
guarantee that the water content of the raw material entering the unit belows the stipulated index.
17. During the operation adjustment phrase, pay attention to more inspection, more regulation, more
observation, detailed analysis and minimal change in the operation. Implement process card strictly for optimal
72
and stable operation. Increase the daily crude oil processing quantity step by step to meet the production for the
normal operation state of the unit.
18. During the dehydration of storage tank and reflux tank, the post personnel should be on the site to avoid
discharging oil into water.Compare the instrument readings and the actual values in time and find the instrument
problems.
19. The operation shall be stable to prevent pressure building; the waste oil produced during pump repair
process shall be recovered in time, and it shall not be dumped into the sewage system.
6.3 Failure and leakage control and treatment principle of the equipment
1. The leakage resource control
1) The leaking of toxic and harmful substances (hydrogen sulfide, dry gas, liquefied petroleum gas) and
flammable and explosive substances (hydrogen, ethane, ethylene, etc.) may be controlled through the following
methods:
2) Process pipelines: As for the leaking of welded junction, flange and valve of process line, the leaking of
interface of such accessories as spring elastic pressure gauge and bimetallic thermometer, according to the
characteristic of uniqueness of oil refining unit process line, close the valves at the two ends of the process line
to control the leakage source. If there is no valve on the two ends of the pipelines, stop the pipelines with the
equipment. Thus the leakage resource of the equipment is isolated.
3) Leaking of heat exchanger and cooler: Make the material go through the by-pass to control the leakage
source; for the heat exchanger without by-pass, close the outlet valve of the upstream equipment supplying
material to the leaking heat exchanger, close the inlet valve of the downstream equipment of the leaking heat
exchanger, and make the leaking heat exchanger isolated;
4) Leaking of tower and vessel: The unit shall be subject to emergency shutdown; close all of its inlet and
outlet valves to cut off the material source, and isolate the leaking point;
5) As for dynamic equipment, shut down to cut off or switch to control the leakage source;
6) The leaking point shall be isolated with steam belt firstly, and safety protection comes first.
7) As for serious leakage, local shutdown or complete emergency shutdown of unit could be adopted to
control the leakage source;
8) The equipment has different operating pressures, and the pressure will increase sharply if the gas meets
with high-temperature steam (gas expansion), so steam shall not be input into the equipment before the pressure
is released completely.
2. Leaked port treatment
1) After the leakage is controlled, gasket replacement, welding, reinforcement, replacement and inspection
and maintenance for blocking the leaking shall be carried out according to the specific conditions of the leaking
point.
2) Carry out the under-pressure sealing measures to stop or mitigate the leakage and ensure temporary safety.
Thus certain time is obtained to stop the leaked equipment for welding, change or other treatment measures.
3. The leaked material treatment
Spray water to the toxic and harmful gas or flammable and explosive gas with steam, fire fighting water cannon
or fire hose, so as to prevent its diffusion to atmosphere. Dike with soil bag or sand bag for cut-off, so as to
make the pollutants retained on the unit for recovery, prevent the pollutants flowing into the 7# rainwater
drainage system and expansion of pollution area. Security area must be set when the leaking material is
disposed of; prevent fire and poisoning. In case of serious leakage, immediately report to the dispatch center of
the refinery, and the dispatch center shall notify the waste water treatment plant for taking emergency measures,
and ask the dispatch center to coordinate with the fire department and gas protection station for supervision.
73
Appendix 1: Summary table of physical and chemical properties of raw and
auxiliary materials and three agents of the unit
1. Index of raw and auxiliary materials
1) Composition of catalytic sweet dry gas:
Components H2 C1 C2 C2= C3 C3= H2O nC4 H2S
Content V% 39.85 23.56 13.25 14.72 0.1 0.54 1 0.02 25mg/Nm3
Components iC4 C4= nC5 iC5/ C5= O2 N2 CO2 CO Σ
Content V% 0.08 0.24 0.06 0.02/0,02 0.22 5.61 0.68 0.01 100
2) Reformed gas composition:
Components H2 C1 C2 C3 C6
Content V% 69.18 9.94 8.78 6.32 1.02
Components nC4 iC4 nC5 iC5 Σ
Content V% 2.09 1.7 0.53 0.44 100
3) Product gas composition:
Components H2 N2 C1 CO CO2 O2 Σ
Content V% 99.906 0.0098 0.08 0.0016 0.0006 0.002 100
4) Desorption gas composition:
Components H2 C1 C2 C2= C3 C3= H2O nC4 O2 H2S

Content V% 13.035 33.12 20.25 17.25 3.48 0.63 0.97 1.14 0.26 0.002
= =
Components iC4 C4 nC5 iC5 C5 C6 N2 CO2 CO Σ
Content V% 1 0.29 0.35 0.26 0,02 0.542 6.59 0.8 0.011 100
2. Filling and quantity of adsorbent

1) Table for technical specification of adsorbent:
S.N. Names Color Granularity mm Bulk density t/m3

1 Adsorbent SNA-421 Spheral, white Ф3~5 0.76
2 Adsorbent SNA-211 0.64
4 Adsorbent SNA-314 Columnar, black Ф3~5X10~15 0.79
74
2) Filling amount of adsorbent
Filling Filling amount of

Adsorbent name Total filling amount Remarks
equipment single tower
SNA-229 2.12 16.69
SNA-421 1.52 12.16
Adsorption
SNA-314 2.37 18.96
device
SNA-211 4.48 35.84
SNA-193 12.0 96
SNA-561 0.52 0.52
Deaerator
SNA-421 0.038 0.038
SNA-314 0.79 1.58
Dryer
SNA-421 0.15 0.3
SNA-314 0.395 0.395
Pre-dyer
SNA-421 0.076 0.076
75
Appendix 2: Interlock logic of the unit
76
77
Appendix 3: Poisonous and combustible gas distribution point drawing
Plane EL±0.000 m
Plane EL±5.000 m
Notes:
1. The preceding 212- is used for all the instruments, valve tag numbers
and junction box numbers in the drawing.
2. In the drawing, the outdoor finished ground level is EL0.100, the
finished ground level in vacuum pump room is EL0.200, the finished
ground level in compressor building is EL0.300, and the combustible
gas transmitter installation height is 2 meters above the ground.
3. In the drawing, the sign ○ × is used to stand for the combustible gas
transmitters of 8 in total.
Drawings associated with this drawing:

1. Position of instrument and field wiring diagram 0901-50-12
combustible gas detection alarm

plane layout
78

PSA Operation Manual

Uploaded by

Copyright:

Available Formats

PSA Operation Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PSA Operation Manual

Uploaded by

Copyright:

Available Formats

Operation Instruction of

Zinder Refinery Co., Ltd.

Zinder Refinery Co., Ltd.

Item Signatures Date

Machine and power

Production department Yuan Xuanmin September 2010

Approved by: Ma Lifei September 2010

Chapter 1 Process technology regulation ......................................................................................................... 1

1.1 Unit introduction

2.1 Process flow description

3.1 Production principle

S.N. Names Item Unit Indicator

Feed gas mixture buffer tank

5 Vacuum pump P-101D Working fluid tank level % 10~40

6 Vacuum pump P-101A Inlet pressure MPa -0.08~-0.02

7 Vacuum pump P-101B Inlet pressure MPa -0.08~-0.02

8 Vacuum pump P-101C Inlet pressure MPa -0.08~-0.02

9 Vacuum pump P-101D Inlet pressure MPa -0.08~-0.02

The pressure of the main

Steps Pressure (MPa) Temperature (℃) Time (s)

(2) Startup working condition (catalytic sweet dry gas)

Pressure for drying 2.35MPa

(2) Table for constant pressure drying time sequence

Sample Quality Analysis frequency

(2) Consumption for public works

2. Analysis of the major operational factors

4.1 Equipment summary table

Names Quantity (set)

Operation Temperature ℃ Pressure MPa Specifications and internal

Operation Temperature ℃ Pressure MPa Specifications and

4.7 Safety valve

Specifications and internal structure Body

4.9 Temperature and control points

Remote drive Operation conditions

4.10 Pressure and control points

4.11 Regulating valve and functions

1.1 Critical path drawing of startup

3.2.2 Introduction of Introduction

2.1 Critical path drawing of suspension

1. Preparatory Preparatory work for

3.1 Production operation method

Impact factors Adjustment method.

3) Low product purity

Impact factors Adjustment method.

5. Adjustment for recovery of unqualified product

7. Control system interlock logic

S.N. Phenomena Causes Treatment method

4.1 Accident treatment principle

4.3 Accident treatment plan

1. Report it to and contact relevant departments.

2. Emergency shutdown of unit

3. Emergency disposal measures

Evacuation route and the notes:

Notes for disposal process

2. Serious leakage of hydrogen compressor

1. Report it to and contact relevant departments.

2. Emergency treatment measures

3. Power failure of the unit