大型炼油厂PSA氢提纯单元运行经验与故障处理

Operating experience and fault handling of PSA hydrogen purification unit in large refineries

通过分析某大型炼油厂制氢装置PSA(变压吸附)单元实际生产情况,发现PSA单元运行中出现的问题主要集中在吸附剂粉碎和程控阀故障两方面。经分析认为:吸附剂粉碎主要原因为均压过程压差和气体流速太大、吸附塔顶吸附剂压网和压板的影响、原料气带水;程控阀故障则主要包括阀检报警、电磁阀故障、阀芯密封面损坏、填料压盖泄漏以及阀板轴套开裂和阀销折断等。根据长期实践经验,总结列出判断故障的依据,分析造成各类故障的原因,制定出细化设备安装检查、加强日常维护保养、优化操作参数设置、升级相关配件材质等有效措施,可以消除PSA单元的常见故障,确保其长周期稳定运行。

Through the actual production situation of the PSA unit in a large refinery’s hydrogen production unit,it was found that the problems that occurred during the operation of the PSA unit were mainly concentrated in two aspects:Adsorbent crushing and program control valve failure.After analysis,it is believed that the main reasons for the crushing of adsorbent are the pressure difference and gas flow rate during the pressure equalization process,the influence of the adsorbent pressure network and pressure plate on the top of the adsorption tower,the presence of water in the feedstock gas,and the failure of the programmable valve,which mainly includes valve inspection alarm,electromagnetic valve failure,damage to the valve core sealing surface,leakage of the packing gland,cracking of the valve plate shaft sleeve,and breakage of the valve pin breakage,etc.Based on long-term practical experience,summarize and list the basis for judging faults,analyze the causes of various faults,and develop effective measures such as refining equipment installation inspections,strengthening daily maintenance,optimizing operating parameter settings,and upgrading relevant accessory materials.This can eliminate common faults in the PSA unit and ensure its long-term stable operation.