Abstract: The full use of the digital booster skid can effectively shorten the construction time of the company’s booster station, simplify the production process, and realize automated production, which greatly saves labor and improves work efficiency. Large-scale use of digital booster skids in modern production can free manpower from harsh environments. However, in the process of using digital booster skids, many problems have been encountered. In addition to the impact of harsh environments, there are more The key is the reason for the existence of the product itself. Analyze the use of the digital booster skid, and promptly discuss and solve the problems encountered. Introduction With the continuous development of society, industrial enterprises gradually began to use automated machinery and equipment, which greatly improved work efficiency and liberated the labor force. New digital booster skids are widely used in the petrochemical industry, and with the gradual popularization of product lifecycle management and ERP systems, new requirements are put forward for the R&D capabilities and cost control of enterprises. The increasingly fierce market environment has promoted the improvement of the manufacturing level, and all walks of life have gradually realized the importance of product quality and service. Therefore, the working principle of the digital booster skid is systematically explained, and the problems encountered during the use of the digital booster skid are systematically analyzed, so as to propose targeted measures and plans.
1 Introduction to the control principle and working principle of digital booster skid The digital booster skid is composed of heating zone and buffer zone, valves, instruments, mixed transport pumps, variable frequency controllers, pipelines, programmable controllers and other components. The digital booster skid installs different parts of the system and equipment on the module. The digital booster skid equipment occupies a small area and is easy to install, disassemble and operate; when the digital booster skid is installed on-site, it requires less manpower and material resources, and the workload is small. Only the import and export pipelines and electrical parts are required. Just connect, it is easy to operate, safe, and can be operated remotely during equipment maintenance, without the need to arrange personnel to be on-site. The separated gas can be used for secondary use and can be supplied to the burner for use. The digital booster skid used in various fields has certain pressure protection equipment. The digital booster skid installs the air-heated booster, safety devices, and cryogenic valves on the booster skid. In order to ensure that the digital booster skid can be used in a low temperature environment, it is necessary to install a cryogenic liquid phase safety valve, a safety relief valve and a gas phase safety valve, etc.; in order to effectively avoid the phenomenon of electrostatic breakdown of electronic components in automatic equipment, it is necessary Install electrostatic grounding in the digital booster skid protection equipment, and the wiring of the instrument must be installed in the explosion-proof junction box to ensure safety; connect various signals such as pressure, temperature, current and monitoring equipment to ensure the safety of workstation personnel ; The explosion-proof level needs to be set according to the requirements. The explosion-proof grade of the digital booster skid of petrochemical enterprises generally chooses Exd Ⅱ BT4.
2 Problems in the field application of digital booster skid
2. 1 In the low temperature working environment, the burners of the digital booster skid have many failures. The burner used in the heating zone of the digital booster skid is exactly the same as the traditional booster skid, which belongs to the burner of traditional industrial production. The burners used in industrialization are also called burners. There are many types and specifications. They can be divided into oil burners, gas burners, and coal burners. Industrialized burners can be applied to many types of projects, and burners are required in industrial production that requires fuel heating or reaction. The combustor is also called an integrated combustor, which mainly uses oil and gas. The industrialized combustor can fully realize the function of the combustor after adding corresponding equipment. However, the existing integrated combustor cannot meet the requirements of industrial production for heating or heating fuel. The need to react. When the digital booster skid is designed, the main fuel is natural gas, but natural gas cannot be provided in the actual production and construction process. Therefore, the fuel needs to be replaced with the gas separated by the digital booster skid. In the actual use of the digital booster skid, under cold winter conditions, the line of the burner gas pipeline will be blocked due to the condensation of a large amount of oil, or the condensed oil will enter the burner along with the pipeline, making the gas The nozzle is blocked, causing the burner to malfunction, and the crude oil cannot work normally, which makes the digital booster skid unable to work in cold winter conditions. As shown in Figure 1, SIU-240 /32-Ⅲ digital booster skid, gas purification process: the associated gas generated by the digital booster skid will enter the gas pipeline with the mist trap at the top of the buffer zone, with the help of design After the purification treatment, the associated gas will enter the combustion pipe for combustion. When the associated gas was separated on site, it was found that there was a large amount of condensate oil. Only the liquid separator was used to purify the associated gas. High-quality associated gas could not be obtained, which easily caused the burner to malfunction and the crude oil could not be kept warm. Processing, the digital booster skid is difficult to work in the cold winter environment.
2. 2 The digital buffer float level gauge is easy to jam and freeze, causing liquid level distortion. The digital booster skid level acquisition device can be divided into two categories: on-site acquisition by magnetic flap level gauge and remote acquisition by liquid level sensor. The magnetic flap level gauge is developed with the help of the principle of buoyancy and magnetism. When the position of the liquid in the container to be detected changes, the magnetic float in the level gauge tube will also change with the change of the liquid level. The permanent magnet in the float enters the indicator of the magnetic turning column level gauge by means of magnetic coupling, causing the red turning column and the white turning column to flip 180°. When the liquid level rises, the white in the turning column gradually changes to red; when the liquid level drops downward, the red in the turning column turns to white. The red and white boundary of the magnetic turning column indicator is the true height of the liquid inside the container, so that the position of the liquid can be clearly displayed. Liquid level sensor: By sensing the position of the magnetic float in the tube of the magnetic flap level gauge, the height of the buffer liquid can be judged. The liquid level sensor can remotely transmit the collected liquid level information with different current signals and transmit it to the PLC control cabinet. The PLC control cabinet can control the export pump of the booster skid according to the height of the liquid position, so as to effectively control the export of crude oil.
3 Improvement measures
3. 1 A new large-scale gas-liquid separator is added to purify the associated gas and reduce the failure of the burner. The associated gas generated by the digital booster skid enters the gas pipeline through the mist trap at the top of the buffer zone. Purification treatment, the associated gas after purification treatment will enter the combustion pipe for combustion. When the associated gas was separated on site, it was found that there was a large amount of condensate oil. Only the liquid separator was used to purify the associated gas. High-quality associated gas could not be obtained, which easily caused the burner to malfunction and the crude oil could not be kept warm. Processing, the digital booster skid is difficult to work in the cold winter environment. Therefore, it is necessary to actively find a solution to the problem of digital booster skid combustor. In this regard, the designer optimized and improved the gas flow of the digital booster skid, and used X800 large gas-liquid separators and equipment to purify the associated gas. After the digital booster skid transforms the gas purification process, the purification effect of the associated gas is significantly improved, and the probability of burner failure is also greatly reduced. The digital booster skid can also be used normally in cold winter conditions to ensure the equipment Security and stability.
3. 2 Solutions for the blocking and freezing of the buffer level gauge
1) Strengthen the cleaning of the level gauge in the buffer zone, pay attention to heat preservation, and minimize the jamming and freezing of the level gauge. The main reason for the jam of the magnetic flap level gauge is that the filter is not cleaned in time and effectively, which makes the filtering effect of the filter unable to be implemented normally. Therefore, in order to effectively avoid the jam of the level gauge, it is necessary to strengthen the cleaning of the filter, increase the cleaning frequency of the filter, and shorten the cleaning cycle of the filter. The filter in the digital booster skid must be cleaned after about 7 days, and it needs to be inspected and cleaned according to the pressure of the digital booster skid to ensure the cleanliness of the filter. In the insulation work of the level gauge, in order to effectively avoid and prevent the occurrence of freezing and blockage, it is necessary to use cattle felt to wrap the level gauge, and then use galvanized iron to fix the cattle felt externally, so as to carry out the external fixation of the level gauge. Thermal insulation, enhance thermal insulation performance.
2) Use level gauges in accordance with regulations and requirements. Scientific and reasonable use can observe the height of the solution in different types of containers. The magnetic flap level gauge is suitable for the indication of the liquid level in the industrialized fields such as the petroleum and chemical industries. The liquid level structure of the magnetic flap is relatively simple, which is convenient for observing the position of the liquid, can obtain data information intuitively, will not cause blockage or leakage, and is simple to install and disassemble, and is convenient for maintenance. When the glass plate level gauge is installed, the upper and lower end installation valves need to be connected to the container to form a communicating device. With the help of the glass plate, the height of the liquid in the container can be visually observed. Safety steel balls are installed at the upper and lower valves. When the glass plate is impacted by external force and breaks, the steel balls will automatically seal under the pressure in the container to organize the flow of liquid and ensure the safety of the staff.
3) Upgrade and transform the pressurization control system of the digital pressurization skid, and establish and improve the jamming and freezing alarm system of the level gauge. The buffer level of the digital booster skid requires the establishment of a monitoring system, an alarm system and an emergency system to solve the jam and freezing of the liquid level in a timely and effective manner. First of all, the software needs to be upgraded and replaced to effectively monitor the curve of the buffer level. Analyze the monitoring curve of the digital booster skid level to ensure that the production of the level gauge and the booster skid remain normal, then the buffer level curve presents a regular and continuous wave line. And this is regarded as the cycle of whether there is a change in the level of the digital booster skid level monitoring curve. If within the cycle, the change of the liquid level is zero, the alarm system starts to work, and a fault language is issued to give an alarm. Secondly, a new set of non-contact level gauges is added, which is suitable for emergencies. The digital booster skid buffer area needs to be installed with a level gauge, and the numbers can be directly transmitted to the digital booster skid monitoring system. When the monitoring system generates an alarm, the level gauge can check the magnetic flap liquid in the original buffer zone. The position gauge can be replaced, and the digital booster skid can be effectively controlled to ensure that the digital booster skid can work normally. 4 Conclusion With the continuous development of society and the continuous progress of science and technology, the degree of informatization of industrialized enterprises in equipment production, research and development, raw materials, product sales and other links has gradually increased. The quality management department needs to conduct strict inspections on the quality of products. To track the sales of products, use the most advanced quality information system and other departments for timely information exchange and delivery. The key to the realization of quality engineering lies in the effective implementation of the digital management system. The improvement and improvement of the traditional digital booster skid can ensure the normal use of the digital booster skid and improve work efficiency and economic benefits.
Post time: 09-12-21