工艺装置区操作规程

工艺装置区操作规程编写：审核：审定：批准：张家口国储液化天然气有限公司生产部二○一三年七月新能能源公司低温甲醇洗操作规程1目录第一章工艺概述·················································31、岗位任务·····················································32、管辖区域·····················································33、生产工艺特点、原理及流程·····································4第二章设备及主要工艺参数·······································91、设备参数·····················································92、工艺参数····················································19第三章岗位操作规程·············································341、开车·························································342、停车·························································393、转动设备开停车操作··········································414、正常操作管理·················································445、设备维护保养要点·············································48第四章事故处理················································481、离心泵打不出液或打液不足·····································482、溶液受阻或短时中断···········································483、C3001循环气压缩机············································494、原料气中断···················································495、电源的故障···················································496、低压蒸汽故障·················································497、气提氮故障···················································50新能能源公司低温甲醇洗操作规程28、冷却水故障···················································509、仪表空气故障·················································5010、制冷装置故障·················································50第五章注意事项·················································501、开车前应仔细检查·············································502、运行期间对装置就定期检查·····································513、安全设备的测试···············································514、停车注意事项·················································515、安全注意事项·················································51新能能源公司低温甲醇洗操作规程3第一章工艺概述1．岗位任务1.1产品净化天然气组成：CO2≤50PPmH2O≤1PPmHg≤0.01ug/m3温度：30℃压力：5.0MPa（G）最终产品：LNG温度：-164℃2．管辖区域2.1塔类T0201，T0202，T0501A/B,A0301A/B,A04012.2换热器E0101,E0201，E0202A/B,E0203,E0204,E0205,E0301,E0302,E0501A/B,E0504A/B,E0502A/B,E0503A/B,E0701,EH0701,E0702,EH0702,E1001A/B,E1101A/B,E10022.3罐及分离器V0101,V0102,V0103,V0104,V0201,V0202,V0203,V0204,V0205,V0301,V0501A/B,V0502A/B,V0503A/B,V0504A/B,V0505A/B,V0506,V0507,V0508A/B,V0701,V0702,V0703,V0704,V0705,V0901A/B2.4泵P0201A/B,PO2O2A/B,PO203,P0501AA,AB/BA,BB,P0701,P0702,P1001A/B/C2.5压缩机C0101A/B/C,C0301A/B,C0801A/B,C0802A/B2.6过滤器F0201,F0202,F0203,F0204,F0205,F0301,F0401,新能能源公司低温甲醇洗操作规程4上述设备和设备的附属管线，阀门及就地指示仪表等。3．生产工艺原理及流程3.1生产工艺原理本装置采用两级分离三级节流的单一混合冷剂流程。尽可能减少混合冷剂组成数量，组分为氮气、甲烷、乙烯、丙烷、异戊烷，其中甲烷采用经净化后的原料天然气补充，氮气通过液氮汽化或变压吸附制取，仅乙烯、丙烷和异戊烷需要外购，降低了运行管理难度。采用MDEA吸收法脱除二氧化碳等酸性气体，脱除彻底，且无再生气消耗。脱水系统采用两塔吸附，操作简单。再生气经压缩后返回脱水系统入口循环使用。采用时序控制自动切换阀门的脱水系统。脱苯采用低温洗涤的方法，利用低温下原料气中冷凝出的重烃吸收原料气中的芳香烃，该法无再生气消耗，降低了运行成本。LNG采用常压储存，占地小，投资省。BOG经BOG压缩机增压后部分作为燃料气供厂区锅炉及导热油炉使用，其余进入城市管网。本装置主要包括以下系统1．预处理系统--原料气压缩系统--脱碳系统--脱水系统--脱汞系统2．液化系统3.循环压缩机系统4.冷剂储存及补充系统5.BOG回收系统6.LNG储存系统7.LNG装车系统8．辅助系统-火炬系统--导热油系统--制氮及仪表空气系统3.3工艺流程简介4.1原料气压缩系统（1）进系统条件压力：2.5-3.5MPa（调压后按2.5MPa进压缩机）新能能源公司低温甲醇洗操作规程5温度：0~30℃处理量：105.78×104Nm3/d（2）出系统条件压力：5.0MPa温度：36℃处理量：105.56×104Nm3/d（3）工艺流程简述原料气管路上设置计量、调压、紧急切断装置。同时考虑冬季时气温较低，为防止管道冻堵，在天然气进气管段上设置原料气加热器E-0101，可在冬季时控制原料天然气进气温度。原料气经进口分离器V-0101粗分杂质后。进入原料气压缩机C-0101A/B/C压缩至5.0MPa，冷却至≤36℃，然后经分离器分离后将天然气导入脱碳系统。4.2脱碳系统（1）原料气进系统条件压力：5.0MPa温度：36℃处理量：105.56×104Nm3/d（2）原料气出系统条件a）进脱水系统净化天然气压力：4.91MPa温度：36℃气量：104.1×104Nm3/d杂质含量：CO2≤50PPmvb）放空酸气压力：0.035MPa温度：40℃气量：~1.46×104Nm3/d（3）工艺流程简述为满足低温工作状态下的要求，经脱碳系统净化后的天然气中二氧化碳CO2含量应低于50PPmv。来自脱水系统的天然气经原料气过滤器F-0201脱除机械杂质和少量油分后，进入吸收塔T-0201底部，与塔顶来的MDEA溶液逆流接触，CO2气体被MDEA溶液吸收，净化气体在吸收塔上部经洗涤冷却经塔顶高效除沫器后，进入净化气冷却器E-0201降温至36℃，再经净化气分离器V-0201和净化气过滤器F-0205分离水份及杂质后送出界区。吸收CO2后的MDEA溶液称为富液，富液由吸收塔底减压至0.5MPa进入胺液闪蒸罐V-0202后，液相进入贫富液换热器E-0202A/B，气相主要成分为甲烷，送入燃料气缓冲罐。富液经贫富液换热器E-0202A/B加热后温度上升至～85℃，再进入再生塔T-0202顶部喷淋入塔。在再生塔T-0202内，溶液中的R2CH3NH+·HCO3-受热分解释放出CO2，CO2随同大量的水蒸汽及少量的MDEA蒸汽经洗涤由塔顶流出，进入酸水冷凝器E-0205，经冷却水降温至～43℃，然后去酸气分离器V-0203，在酸气分离器V-0203内，新能能源公司低温甲醇洗操作规程6气体夹带的水份被分离，气相为CO2气体就地放空，液相经酸水回流泵P-0202A/B提升回流至再生塔T-0202顶部。由再生塔T-0202底部引出的贫液经贫富换热器E-0202A/B与富液换热后被冷却至～82.5℃，进入胺液循环泵P-0201A/B加压至5.0MPa后经贫液后冷却器降温至常温后，再进入机械过滤器F-0202过滤固态杂质后，进入活性碳过滤器F-0203吸附烃类和胺液变质分解产生的杂质，再进入机械过滤器F-0202过滤固态杂质后后进入吸收塔上部喷淋入塔。系统内设有胺液储罐V-0205用于储存新鲜胺液，胺液补充泵P-0204安装于地下槽V-0204内，用于启动时添加胺液和正常运行补充日常损耗。地下槽V-0204安装位置位于系统最低处，在装置停运时可将系统内胺液全部排放至地下槽V-0204内进行回收。再生塔底设胺液再沸器E-0204，其加热的热源由来自导热油系统提供的中温导热油。4.3脱水系统（1）进系统条件a)原料气进(来自脱碳系统)压力：4.91MPa温度：36℃处理量：104.1×104Nm3/db)再生气进（经再生气压缩机后）压力：4.93MPa温度：43.2℃处理量：12×104Nm3/d（2）原料气出系统条件进脱汞系统净化天然气压力：4.85MPa温度：36℃气量：115.94×104Nm3/d杂质含量：H2O≤1PPmv（3）工艺流程简述为满足低温工作状态的要求，经脱水系统净化后的天然气中水含量低于1PPm。脱水系统由两台分子筛干燥器A-0301A/B、一台再生气加热器E-0302、一台再生气冷却器E-0301、一台再生气分离器V-0301、一台粉尘过滤器F-0301、两台再生气压缩机C-0301A/B等组成、。分子筛干燥器为两台切换使用，一台吸附，一台加热再生及冷吹。从脱碳系统来的净化天然气进入干燥器A-0301A/B通过4A-LNG分子筛吸附脱除其中的H2O至小于1PPm，进入粉尘过滤器F-0301，去除粉尘后进入脱汞系统。干燥器用再生气取自脱汞系统后的净化天然气。再生气进入再生气加热器加热到~280℃后，作为再生气进入干燥器，解吸其中的H2O；出干燥器后经再生气冷却器冷却到常温，并经再生气分离器分离水后，经再生气压缩机增压后返回脱水系统干燥器入口，冷吹时，再生气旁通再生气加热器。新能能源公司低温甲醇洗操作规程74.4脱汞系统（1）进系统条件进系统原料气压力：4.85MPa温度：36℃处理量：115.94×104Nm3/d（2）原料气出系统条件a)进液化系统净化天然气压力：4.66MPa温度