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1目录一，工艺流程简介························································································11，装置的生产过程···············································································································12，装置流程说明···················································································································1二，设备列表······························································································3三，仪表列表······························································································4四，现场阀列表·························································································10五，工艺卡片····························································································12六，物料平衡····························································································13七，复杂控制说明······················································································14八，重点设备的操作···················································································14九，操作规程····························································································171，正常开工·························································································································172，正常停车·························································································································253，压缩机K101/K102事故停机························································································274，停1.0MPA蒸汽··············································································································285，反应器R101飞温··········································································································286，原料油中断·····················································································································297，新氢中断·························································································································298，高分串压至低分·············································································································309，F101炉管破裂···············································································································3010，燃料气中断···················································································································3111，过滤器压差超高···········································································································3112，项目列表·······················································································································32十，流程图画面·························································································35十一，加氢精制仿真PI&D图·······································································37十二，加氢精制装置DCS流程图···································································49十三，加氢精制装置现场操作画面·································································62加氢精制装置操作工技能竞赛系统用户手册1一，工艺流程简介1，装置的生产过程原料油经泵抽入装置后，依次经过自动反冲洗过滤器滤去固体杂质后，进入原料油罐，再经原料油泵升压；新氢进入新氢压缩机升压后，先与来自循环氢压缩机的循环氢混合，再和升压后的原料油混合，换热后进入反应加热炉升温，再进加氢精制反应器。在反应器中进行加氢脱硫、脱氮、脱氧、烯烃饱和芳烃开环饱和等反应。反应产物换热后，在高压分离器中经过气、油、水三相分离后，气相经脱硫后再由循环氢压缩机升压后，返回反应系统。生成油先与产品换热，再与反应产物换热后，经H2S汽提塔后进产品分馏塔。分馏塔顶油气经冷凝冷却后，进分馏塔顶回流罐进行气、油、水三相分离。气相即分馏塔顶低压含硫气体送至装置外的火炬系统焚烧处理；水相至含硫污水汽提装置处理；油相即粗汽油由粗汽油泵抽出，将其大部分为回流，少部分作为产品送出装置。塔底出来的精制柴油经换热后作为产品出装置。2，装置流程说明（1）反应部分工艺流程混合进料由原料罐区进装置，经原料油升压泵（P-101/A.B）升压后，进入原料油过滤器（SR-101/A.B）进行过滤。过滤后的原料油经液位控制阀LV3101后进入滤后原料油缓冲罐（D-101）。反应进料泵（P-102/A.B）将D-101内的原料油抽出并加压到约9.5MPa，经反应进料流量控制阀（FV3105）后与来自压缩机（K-101/102）的混氢混合。混合后的混氢油进入反应产物与混氢油换热器（E-103/A.B、E-101）换热至一定温度，然后经反应进料加热炉(F-101)加热，经加热后约350℃的反应进料进入柴油加氢反应器（R-101）进行加氢反应。在加氢反应器中，原料油和氢气在催化剂作用下，进行加氢脱硫、脱氮、烯烃饱和以及芳烃饱和等加氢反应。自压缩机（K-102）来的急冷氢经温度控制阀由加氢反应器（R-101）中部打入，以控制整个加氢反应过程的温升。反应产物（370℃）先后经反应产物与混氢油换热器（E-101）、反应产物与低分油换热器（E-102）、反应产物与混氢油（E-103/A.B）换热到约120℃进入反应产物空冷器（A-101/A-D）进行冷却，冷却至50℃左右进入高压加氢精制装置操作工技能竞赛系统用户手册2分离器（D-103）进行气液分离。反应产物在高压分离器内分离为循环氢、高分油、酸性水。高压分离器（D-103）顶气体至C203脱硫后至循环氢分液罐（D-105）分液后，再经循环氢压缩机（K-102）升压，与来自新氢压缩机的新氢混合，返回到反应系统，作为循环氢。另外循环氢分液罐（D-105）顶气体也可经流量控制阀（FV3114）排放。为保证压缩机（K-102）的入口流量，在反应空冷器前设有反飞动线。为防止产生氨盐结晶堵塞反应空冷器管束，在反应空冷器前注入适量软化水。从高压分离器（D-103）中部出来的高分油经液位控阀（LV3109）送入低压分离器（D-104）进行油、水、汽三相分离。自低压分离器分离出来的低分油去分馏部分。低压分离器顶气体与循环氢分液罐顶气体合在一起送出装置，从高压分离器及低压分离器底部出来的含硫含氨污水分别经界位控制阀（LV3108、LV3114）减压后，送出装置。（2）分馏部分工艺流程低分油经液位控制阀（LV3113）后，经柴油产品与低分油换热器（E-201）及反应产物与低分油换热器（E-102）换热后，进入H2S汽提塔（C-201），脱除油中的H2S。塔顶油气经H2S汽提塔顶空冷器（A-201/AB）、H2S汽提塔顶冷却器（E202）冷凝冷却到40℃，进入塔顶回流罐（D201）。其中液体由塔顶回流泵（P-201）加压后一部分经流量控制阀（FV3202）作为塔顶回流，其余部分返回塔进料口，当塔底产品不合格时可作为轻烃经液位控制阀（LV3202）送出装置。含硫气体经压控阀（PV3201）出装置。含硫污水经界控阀（LV3202）后与高压分离器及低压分离器底部出来的含硫含氨污水一起送出装置。塔底汽提油经流量控制阀（FV3200）后进入分馏进料加热炉（F-201），加热到约250℃后，进入分馏塔（C-202），进行石脑油和柴油的分离。塔顶油气经分馏塔顶空冷器（A-202/A-D）、分馏塔顶冷却器（E-203）冷凝冷却到40℃左右，进入塔顶回流罐（D-202），回流罐压力由罐顶压控阀（PV3205/A.B）或引入燃料气或放入放空总管分程控制。凝缩油由回流泵（P-203/A.B）加压后部分经流量控制阀（FV3209）作为塔顶回流，另一部分经液控阀（LV3205）作为粗石脑油送出装置。酸性污水经界控阀（LV3206）送到软化水灌（D-107）作为反应注水。从分馏塔底出来的精制柴油产品，由泵（P-202）抽出加压经柴油产品与低分油换热器（E-201A-D）换热，再经柴油产品空冷器（A-203）冷却到50℃，最后经液位控制阀（LV3204）送出装置。（3