After the solvent recovery device is put into operation, the deviation of the operating parameters from the design is quite common: the inlet concentration is different from the design value, the production load changes year by year, the operating habits are inconsistent with the design assumptions, and the actual operating point of the device has long left the design point. What the process diagnosis service does is to find out the actual state of the device, find out the gap that deviates from the design, and then use operation optimization or minor changes to pull back the capacity.
This service is different from debugging training: whether the debugging solution can be opened or not, and whether the diagnostic solution is opened or not. The stage when the device has no obvious failure but the recovery rate is declining year by year and the energy consumption is quietly rising is the window for diagnostic services to play a role.
Diagnosis is based on data plus two lines on site: data line-recovery rate, energy consumption, emission concentration and operation ledger are compared annually to find out trend deterioration items and sudden change points; Field line-material balance calculation field check, key instrument check, operation process and design comparison to find out the deviation that cannot be seen in the book. The conclusions of the two lines are cross-validated so that the diagnostic report can match the cause with the phenomenon.
Common diagnostic findings include several types of high-frequency items: instrument drift distorts the operation basis, slight fouling of the heat exchanger causes the temperature level to go up, habitual bypass and load reduction causes the system to deviate from the design range, and changes in batch production rhythm cause the device to be in a low-load and low-efficiency area for a long time. Most of the findings do not require a large investment, adjustment and clean-up can cash in the benefits.
Optimization is graded by input: zero input level-operation parameter regression design interval, matching adjustment between batch production period and device load, instrument calibration reset; Small input level-heat exchanger cleaning, local insulation repair, control logic fine-tuning; CIC level-local equipment replacement and process adjustment, with payback period calculation for decision-making. The effect of each level has a verification method. Before optimization, the assessment caliber should be agreed and the reconciliation should be made according to the caliber.
The results of optimization should be solidified into a system: the new operating parameters should be written into the operating procedures, the new inspection focus should be written into the inspection table, and the optimization can be maintained for a long time without human attention. The diagnosis report and optimization records shall be archived and become the technical files of the device, which shall be directly called in the next modification or overhaul.
The object of diagnosis and optimization is not limited to the main engine: the operating status of utilities-chilled water, steam and compressed air-also affects the efficiency of the recovery device. The problem of many devices is not in the host but in the matching, which can be seen in the data comparison.
| Service Item | Content | Deliverables |
|---|---|---|
| Data diagnosis | Annual comparison of operating data | List of Deterioration Items |
| On-site diagnosis | Balance check and operation comparison | List of deviation items |
| Parameter optimization | Return to the design operating range | New operating procedures |
| Minor improvements and reforms | Cleaning repair and logic trimming | Effect Reconciliation Record |
| Medium input | Partial replacement with measurement | Decision Basis Document |
| Quarterly return visit | Operational Data Reconciliation | Follow-up visit recommendation |
It is valuable. No failure does not mean running in the optimal range, most of the device recovery rate and energy consumption from the design level of more than 10% of the gap, diagnosis to quantify the gap, the optimization of the benefits itself is the return.
Data line does not affect production; Most on-site checks are completed under operating conditions. Individual instrument checks are arranged in the planned shutdown window. The overall proportion of production is measured in hours.
Two mechanisms: the optimization results are solidified into procedures and inspection tables, and the operation is based on; Quarterly return visits to check the operation data, and the effect attenuation is found early. Most of the rebound is that the parameters are changed back, and the return visit is to focus on this matter.
This article by LuoyangWohong PetrochemicalEquipment Co., Ltd. arranges that the company provides design, manufacturing and operation and maintenance services for condensation recovery, membrane separation recovery and complete solvent recovery devices for chemical and pharmaceutical enterprises. If you need process evaluation or scheme configuration, please contact and exchange.
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