制氢联合操作规程

海星化工制氢装置操作规程HX-JQ002山东东营海星化工有限公司30000Nm3/h干气制氢及10000Nm3/h甲醇裂解制氢装置操作规程山东东营海星化工有限公司2014年5月范围本规程是在东营市海星化工30000NM3/h天然气转化制氢和10000NM3/h甲醇裂解制氢装置的初步设计、主要设备供应商提供的相关资料、装置开工指导书的基础上编写而成。主要规定了东营市海星化工30000NM3/h天然气转化制氢和10000NM3/h甲醇裂解制氢装置的工艺原理、流程、开停工操作法、岗位操作法、设备操作法及事故处理方案等内容。本规程适用于东营市海星化工30000NM3/h天然气转化制氢和10000NM3/h甲醇裂解制氢装置的生产操作。引用标准下列标准所包含的条文，通过在本规程中引用而构成本规程的条文。本规程出版时，所示版本均为有效。所有标准都会被修订，使用本规程的各方应探讨使用下列标准最新版本的可能性。编制本规程起草单位：加氢改质车间本规程于2014年5月开始编制本规程负责编制人员：毛志伟、张国辉车间复审：宋永明公司审核：王刚公司批准：目录第一部分30000Nm3/h天然气转化制氢装置操作规程第一章装置概况 一装置概述····················································1二生产流程简述···············································4三原料及产品的主要技术规格····································9四物料平衡···················································11五装置消耗指标及能耗········································12六生产控制分析·············································16七环境保护及安全措施·········································29八装置对外协作关系··········································23第二章制氢工艺原理 一原料预加氢··········································24二原料脱硫与净化······································25三转化················································25四中温变换············································26五变压吸附············································27第三章装置正常操作一装置主要动设备操作法································28二脱硫精制系统操作法··································48三转化中变系统操作法··································56四锅炉系统操作法·······································73五PSA系统操作法·······································82第四章装置正常开工一开工前准备工作·······································109二气密···························110三脱硫系统升温开工····················113四转化中变催化剂还原···················116第五章装置正常停工与紧急停工一停工前准备工作·······································121二注意事项·············································121三停工步骤·············································121四装置紧急停工·········································122第六章事故处理一事故处理原则···········································125二重大事故处理方法·······································125三一般事故处理方法·······································125第七章安全技术一概述···················································128二氢气基本特性···········································128三系统的安全设施·········································128四消防···················································129五安全生产注意事项·······································129附录一：30000Nm3/h天然气制氢流程图···························130附录二：30000Nm3/h天然气制氢装置设备表························130附录三：30000Nm3/h天然气制氢装置安全阀明细表····················130第二部分10000Nm3/h甲醇裂解制氢装置操作规程第一节装置概况············································11.1前言···················································1311.2装置规模及技术路线·····································1311.3原料···················································1311.4主要产品规格···········································1321.5物料平衡·············································1331.6化学反应原理···········································1331.7分析化验··············································133第二节装置的吹扫及冲洗····································1352.1吹扫及冲洗的目的····································1352.3吹扫及冲洗的原则和注意事项···························136第三节机泵试车·············································139第四节催化剂的性能及装填··································1404.1甲醇裂解催化剂性能简介·································1404.2催化剂的装填···········································1414.3吸附剂的装填···········································142第五节装置负荷试运··········································1445.1装置负荷试运·········································1445.2二次粉尘吹扫、装置气密与氮气置换·······················1445.3甲醇裂解催化剂还原····································1445.4裂解部分工艺流程简述··································1475.5PSA工序开工······································1485.6调整操作参数向用户供氢································1495.7工艺过程主要控制指标·································149第六节装置的操作···········································1516.1装置的开车········································1516.2甲醇裂解部分的开车····································1516.3PSA部分的开车···································1526.4正常操作···········································1536.5紧急停车操作···········································1546.6临时停车···········································1556.7正常停车后的再启动··································1556.8VPSA部分紧急停车······································157第七节常见故障及处理方法····································1597.1外界供给条件失常······································1597.2操作失调···········································1597.3PLC故障···········································1607.4操作注意事项···········································1607.5VPSA部分维修与故障处理·······························161第八节离心泵操作法···································163一、设备结构及工作原理····································163二、离心泵主要部件的结构与作用·····························163三、开机前的准备工作······································164四．启动程序···········································165五．停车···········································165六、立式高速泵操作法····································165七、离心泵常见故障及处理方法······························169第九节水环真空泵操作规程···································174一、概述············································174二、水环真空泵工作原理·································174三、水环真空泵的操作规程··································175第十节 导热油系统操作规程·····························178一、导热油系统的组成··································178二、导热油的选用···········································180三、导热油在使用中的要点···································181四、导热油循环流程·····································181五、导热油系统的调试···································182六、导热油系统的运行操作··································186七、导热油系统报警及安全保护······························188八、常见故障的诊断与排除··································189九、异常现象的处理····································190第十一节导热油炉的操作·····································191一、导热油炉特点···········································191二、使用条件···········································191三、燃油炉主要由以下设备组成·······························191四、燃油燃烧器···········································191五、燃料油···········································194六、燃油炉的正常操作······································194七、日常保养···········································197八、周期检修···········································198第十二节VPSA脱碳部分的操作·························201一、VPSA部分介绍···········································201二、工艺过程说明···········································202三、工艺条件与装置处理能力的关系··························205四、氢气回收率影响因素···································205五、产品氢纯度的影响因素···································207六、工业吸附分离流程的主要工序·····························207七、工艺流程说明···········································208八、控制功能说明···········································213第十三节 安全规程···········································2257.1车间情况介绍···········································2257.2安全技术·························