Automation in Petro-Chemical Industry

Risk analysis of LPG transportation process based on Bow-tie model

2025, 61(2): 0-0.

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In recent years, there have been frequent incidents of hazardous chemical transportation leaks, and the safety risks throughout the entire process of hazardous chemical transportation have become increasingly concerned. In order to effectively reduce the occurrence of hazardous chemical transportation accidents, a statistical analysis was conducted on the hazardous chemical transportation accidents that have occurred in China in recent years. The common liquefied petroleum gas (LPG) transportation accident was selected as the research object, and the Bow tie (BT) analysis method was used to analyze the hazard factors and accident consequences of LPG loading, unloading, and transportation. A Bow tie analysis model for the entire LPG transportation process was constructed, and preventive measures and accident consequence mitigation measures were proposed for key risk factors. The results indicate that the Bow tie analysis method, based on intuitive safety structure charts, can clearly express the causes, consequences, and corresponding prevention and control measures of accidents throughout the entire LPG transportation process, which is conducive to improving the level of LPG transportation safety management.

Development and application of on-line settlement monitoring device for atmospheric tank

2025, 61(2): 0-0.

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The foundation settlement, tank deformation and stress concentration of atmospheric pressure tank will endanger the normal use of the tank. On-line settlement monitoring is one of the important means to ensure the safe operation of the storage tank in service. In this paper, an on-line settlement monitoring device is developed and applied in an oil depot in order to solve the safety hazards of tank foundation settlement, deformation and stress concentration. The on-line monitoring method can reflect tank settlement and stress status in real time, provide data support for tank risk management, and help to improve the safe operation management level of storage tanks.

Application discussion of optical fiber safety warning system in pipeline

2025, 61(2): 0-0.

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The optical fiber safety warning system applies optical fiber scattering sensing technology,which can achieve temperature monitoring based on Raman scattering, temperature and strain monitoring based on Brillouin scattering, and vibration monitoring based on Rayleigh scattering. By monitoring the temperature, strain,and vibration of optical fiber cables, real-time monitoring of pipeline leaks, soil deformation around pipelines, and third-party intrusions can be achieved. This article introduces the basic principles and technical applications of distributed optical fiber safety warning system, and analyzes and discusses the application scheme, system architecture, and engineering difficulties of distributed optical fiber safety warning system in gas pipeline engineering based on experimental engineering.The application of experimental engineering has proven that the distributed fiber optic safety warning system is suitable for gas pipelines and can achieve good pipeline protection effects.

Application of slide valve in high-pressure differential venting conditions

Jie WANG

2025, 61(2): 0-0.

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In the gasification process technology，the Coal Dust Lock，as a pressure alternating equipment, requires continuous pressure rise and drop. The vent valve, as its pressure drop equipment, is applied to high pressure difference and solid particle-containing conditions. Under the action of high pressure difference, solid particles will flow at high speed, causing severe wear to the valve, shortening the service life of the valve and leading to device shutdown. Therefore, this process has high requirements for the adaptability to high pressure difference and wear resistance of the valve. Explain the adaptability of the slide valve from its internal structure, flow analysis, sealing, wear resistance etc.

Application and practice of on-line vibration monitoring system in ORV static equipment of LNG receiving station

Shafer气液联动阀执行机构运行故障现象解析冯招招

2025, 61(2): 0-0.

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In order to improve the safety and work efficiency of ORV (open-shelf seawater carburetor) operation in LNG receiving station, real-time monitoring of ORV equipment vibration data is realized by the operator of central control operation without changing the ORV operation mode and equipment structure, so as to avoid the operation risks of equipment and detect early signs of equipment failure in time. The on-line vibration monitoring system, which is used to monitor the vibration of dynamic equipment, is applied to the ORV static equipment of CNOOC Fujian LNG Receiving station for the first time, which greatly reduces the failure rate of ORV equipment, effectively improves the operation efficiency and production efficiency, reduces the production cost and loss, and helps the stability and reliability of equipment operation. In addition, it also lays a foundation for the popularization of online vibration monitoring system in the future application research of electric motor and rotary pump in LNG receiving station.

Discussion on the use of thermometers in storage tanks

2025, 61(2): 0-0.

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Based on the characteristics of liquid ethylene, LNG, LPG, liquid ammonia, and other storage tanks, taking LNG storage tank as an example, the selection and scheme of thermometer used in the storage tank are described. Thermometers are surface multipoint thermometers measuring inner tank surface, inner tank bottom, surface multipoint thermometers measuring inner tank outer wall, annular space, and average temperature of inner tank liquid level. It is pointed out that the temperature at distinct positions reflects the operation of the inner tank and the outer tank of the storage tank. The thermometers on the inner and outer walls of the storage tank and the bottom of the inner tank are not only used for temperature detection, but also used for real-time monitoring of the temperature during the pre-cooling process of LNG storage tank, to control the whole pre-cooling process. Surface thermometers on the outer wall of the inner tank and in the annular space also detect LNG leakage through temperature changes. The scheme and purpose of temperature monitoring in storage tank are put forward.

A method and practice for safety integrity level analysis of aromatic hydrocarbon adsorption separation unit

2025, 61(2): 0-0.

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SIL assessment is a crucial step in ensuring chemical production safety. Safety Integrity Level (SIL) is a widely used performance indicator for evaluating Safety Instrumented Functions (SIF). The correction risk map method is a semi qualitative risk analysis method in SIL grade, which comprehensively evaluates various aspects such as process flow, personnel injury, environmental impact, property damage, and probability of occurrence, and finally obtains the SIL grade. The article introduces the practical engineering application of the risk map correction method based on the SIL determining process of a typical SIF circuit in aromatic hydrocarbon adsorption separation units, and proposes qualitative measures for achieving SIL levels.

Gas mapping application in safety monitoring system of Petrochemical Process

2025, 61(2): 0-0.

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The necessity of detector coverage performance evaluation and optimization in safety monitoring system are discussed. The concept of safety monitoring effectiveness evaluation is introduced. Gas mapping and optimization apply quantitative approach to evaluate the coverage effectiveness of combustible gas and tox gas detection. The detector layout design is verified and optimized to improve the efficiency of the detector coverage. Improving the overall effectiveness of safety monitoring is the effective technical way to mitigate risk and dangerous incident consequence severity.

Several Issues of SRS for a Large Integrated Petrochemical Project under Construction in Zhanjiang, Guangdong Province

2025, 61(2): 0-0.

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Abstraction: The Safety Requirements Specification (SRS) is an important document in the safety lifecycle of safety instrumented systems. With the increasing attention of relevant departments, related specifications and documents have been issued one after another, requiring the preparation of the initial version of SRS in the preliminary design stage. This article lists relevant specifications and explains the necessity of meeting these requirements from two aspects: SIL pre validation and SIS system cost estimation. Then, taking the preparation of SRS for an integrated petrochemical project in Zhanjiang as an example, this article lists many practical cases of the four key data in SRS: measurement system accuracy, interlock value, SIF loop response time, and inspection and testing interval. The paper analyzes in detail the setting principles of these data and their significant impacts on process design, instrument & control valve selection, SIS system design configuration, and process operation and maintenance. Finally, this article provides conclusions and some suggestions.

Analytical Parameter Stability Domain based Active Disturbance Rejection Control Method for Sour Gas Pressure of Natural Gas Purification

2025, 61(2): 0-0.

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Sour gas control is an important part of the sulfur recovery process in natural gas purification plant. Due to the fluctuation of acid gas pressure, it is difficult to meet the requirement of reaction temperature when entering the main combustion boiler, which affects the quality of natural gas purification. In this paper, the pressure of acid gas is controlled by the active disturbance rejection control, and the search space of multi-objective optimization algorithm is constructed by the parameter stability domain, so that the parameters of the controller can be optimized and adjusted automatically. Compared with the PID control effect adjusted by the critical proportion method, this control method can decrease the acid gas pressure fluctuation and the dynamic response overshoot and therefore ensure the purification quality.

Research and simulation of precision pressure control system for ground testing based on Simscape

2025, 61(2): 0-0.

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In this paper, aiming at the problems existing in the surface test operation of high-temperature and high-pressure oil and gas wells, the precise pressure control system for surface testing based on Simscape is studied. Firstly, the limitations of the existing technical solutions are analyzed, the risks of manual control of the pressure of the test pipeline are pointed out, and the importance of automated and intelligent equipment is emphasized. Then, the pressure reduction principle of the throttle valve was introduced, and the physical model of the throttle pressure reduction was built by Simscape, and the flow characteristics and pressure regulation process of the throttle valve were simulated. Then, the principle and structure of the PID controller are discussed, and two PID parameter tuning algorithms are proposed to solve the problem that PID parameters are difficult to adjust: recursive least squares (RLS) and gradient descent algorithm. Finally, through the joint simulation of Simulink and Simscape, the adjustment effect of the two algorithms in the throttling and step-down model is compared, and the RLS algorithm is more suitable for the control parameter adjustment of the throttling and step-down model with overshoot, regulation time and stability as the evaluation indexes.

Application of digital twin technology based on intelligent storage and transportation tank farm industrial Internet platform

2025, 61(2): 0-0.

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This paper introduces the application of digital twin technology in a storage and transportation tank farm, which realizes the overall management of daily process management, production management and business plan management through the industrial Internet platform, so as to establish the intelligent tank farm.The author introduces the system architecture and functions of the platform, and the successful application of the digital twin system.

The Safety and Environmental Impact of UPS in Petrochemical Enterprises

2025, 61(2): 0-0.

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UPS, as an uninterruptible power supply device, plays a crucial role in ensuring the safe operation of petrochemical enterprises. However, UPS power failures have occurred frequently in recent years, causing unnecessary losses and impacts for many enterprises. This paper starts from the important perspectives of safety and the environment, and summarizes and discusses the problems existing in the real-world uninterruptible power supply systems consisting of UPS. It also puts forward requirements and prospects for the future new uninterruptible power supply technologies.

Analysis and optimization of abnormal sudden change in rotation speed of steam turbine

2025, 61(2): 0-0.

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The compressor unit is the core equipment of the PTA plant. In response to the abnormal sudden change in the speed of the steam turbine in this compressor unit, factors causing the sudden change in the turbine speed were analyzed from various perspectives, including the quality of steam and lubricating oil, the connection of the speed probe signal line, the card of the overspeed protection system, and the interference of the surrounding environment on the speed probe. The working principle of the speed sensor is introduced, and different faults are experimentally analyzed. By implementing corresponding measures such as replacing the card and grounding brush, the stable operation of the compressor unit and the production plant was ultimately ensured.

Successful Application of Masoneilan Control Valves in Fluidized Bed Residue Hydrogenation Unit

2025, 61(2): 0-0.

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In a petrochemical enterprise, the top pressure control valve of the fractionating tank in the fluidized bed residue hydrogenation interstage experienced operational difficulties after one year of use under high temperature and pressure, containing catalyst powder and corrosive media. The MasoneilanTM 41 series cage-guided valve was adopted, but it led to difficulties in operation, causing the differential pressure of the fractionating tank to be uncontrollable automatically, which affected the separation efficiency of the reactor and the stability of the liquid level. After disassembling the valve, it was found that the accumulation of catalyst powder and coking substances in the gap between the valve core and cage increased the resistance of the valve movement, resulting in valve sticking. MasoneilanTM technicians collaborated with the user to analyze the deviation of the working conditions and the problem of impurity accumulation, and decided to replace the 41 series with the 21 series single-seat valve, which solved the sticking issue. The MasoneilanTM 74 series erosion-resistant high-pressure angle valve plays a crucial role in the fluidized bed residue hydrogenation process, including level regulation, pressure reduction regulation, and preventing high-pressure media from entering the low-pressure area. The angle valve adopts flow path separation pressure reduction technology and double guide structure, which improves the stability and erosion resistance of the valve. Through technical optimization and process control flow improvement, the angle valve achieves long-term stable operation, meeting the needs of continuous and stable operation of the unit.

Discussion on active maintenance strategy of program-controlled valve in hydrogen production plant

2025, 61(2): 0-0.

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In response to the problem of high-frequency operation of PSA program control valves in hydrogen production plants, as well as high failure rates of valve bodies, actuators, and accessories, this article proposes a targeted proactive maintenance strategy, including maintenance cycle, content, standards, etc. Based on the service life, it proposes the principle of spare parts reserve and provides suggestions for the maintenance cycle of program control valves according to their importance and working conditions, in order to achieve the goal of economic and reasonable maintenance and ensure their safe, reliable, and long-term operation.

Study on the Temperature Changes of Ethanol and Automotive Gasoline Blended Component Oil Mixing

2025, 61(2): 0-0.

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Abstract: The volume of a liquid changes with temperature, so when measuring the volume and flow rate of a liquid, it refers to the volume and flow rate measured at a specific temperature. The mixing of ethanol with gasoline blending components for automotive use leads to a temperature drop, which can amplify the volumetric measurement error during the loading process. Laboratory tests analyzed the precise temperature drop values when ethanol and gasoline blending components were mixed isothermally at different temperatures. These results were applied in oil depot production to confirm the reliability of the laboratory data. This provides reliable foundational data to address the accuracy of ethanol gasoline outflow measurement.

Application of Split Zirconia Oxygen Analyzer in Steam Boilers

2025, 61(2): 0-0.

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Abstract：This article briefly describes the role and importance of oxygen analyzer in air/fuel ratio control of steam boilers, and elaborates on the detection principle of zirconia oxygen analyzer. In response to the problem of using an integrated zirconia analyzer in a steam boiler of a natural gas purification plant due to high working environment temperature, it is proposed to adopt Yokogawa Electric's split zirconia oxygen analyzer. A detailed introduction was given on the installation, debugging, and application of the split zirconia oxygen analyzer, which has achieved good results after one year of use and ensured the stable operation of the steam boiler.

Exploring the post service and post evaluation of digital handover in the construction of Intelligent Plant

2025, 61(2): 0-0.

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This paper explores the positioning and significance of digital handover in the construction of Intelligent Plant. For projects implementing digital handover, it analyzes the application of post services in the enterprise engineering domain, production domain, security domain, and equipment domain, and discusses the evaluation of digital handover projects' technology progressiveness, data quality and availability, system utilization, return on investment, new value creation, and user satisfaction. At present, in industry practice, the maturity of digital handover applications still needs to be improved. Among them, the expansion of post service can significantly enhance the maturity of applications, further maximizing the value of delivery results and investment returns. Meanwhile, providing a comprehensive and accurate post evaluation of the implementation of digital delivery projects will drive the value driven, healthy, and sustainable development of the digital delivery market.

Research and Application of Engineering Laboratory Metrology Management Platform

2025, 61(2): 0-0.

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The engineering laboratory is the core of innovation and quality assurance system for petrochemical products. Metrology is the window for enhancing internal fine management in the laboratory. Integrating information technology with the petrochemical engineering specialty, a metrology management platform for the engineering laboratory is established to solve the problems of low efficiency in resource utilization, lack of overall planning, and untimely safety hazard inspection in the old mode of operation of the laboratory, providing reference for the informatization construction of the laboratory.

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