As the core link in establishing the anti-corrosion systems and managing corrosion risks for refining and chemical units, design material selection directly determines the operational safety, stability and maintenance economy throughout the entire lifecycle of the units. Drawing on over a decade of practical experience in material selection design, anti-corrosion optimization and risk mitigation for large-scale refining and chemical projects of a certain company, this paper highlights the application of Material Selection Diagrams (MSD) and intelligent material selection systems in engineering design. Furthermore, the paper explores in depth the synergistic application of Risk-Based Inspection (RBI) technology and systematic online corrosion monitoring and detection systems. The resulting design material selection methodologies and corrosion control experiences can provide standardized and replicable engineering reference for material selection and anti-corrosion design in large-scale units, thereby facilitating their safe, stable and long-cycle operation.

This paper utilized Dynsim software to conduct dynamic process simulation of the ethylene oxide (EO) reaction system under runaway conditions, enabling real-time tracking of critical system parameters such as fluid temperature and reactor wall temperature. Additionally, Fluent software was employed to simulate the maximum attainable temperature of the reactor wall during runaway scenarios. This approach provides robust theoretical support for ensuring the safety, economy and rationality of EO reactor design. Based on the simulation results, the EO reactor design temperature at runaway conditions was reduced from 584 ℃ to 380 ℃ and the reactor wall thickness was decreased to 62 mm from 261 mm. This has effectively reduced manufacturing costs, shortened the production cycle and resolved engineering challenges in reactor design and manufacturing.

As the key chemical equipment in the production of polyolefin materials, the installation quality of loop reactor affects the production efficiency and product quality directly. The traditional single-pipe and segmented hoisting method suffers from issues such as excessive high-altitude work and lengthy construction cycles during reactor installation and maintenance. To address such issues, the paper innovatively introduces the "character-shaped" integrated modular hoisting technology for loop reactors. By strengthening the structure of the equipment, designing the special hoisting beam and supporting tools, and combining with the ANSYS analysis and verification, the modular hoisting construction was successfully implemented in a project, which verified the feasibility and effectiveness of the modular construction technology. This technology not only significantly improves the installation quality and hoisting efficiency of the loop reactor, but also effectively controls the safety risks and provides an innovative solution for the hoisting operation of similar equipment.

This paper focuses on the development and application of an AI-powered assistant for reviewing static equipment drawings. A review rule database was established encompassing conditional information, calculation sheet data, key technical requirements and node diagram details. Functionalities including basic data comparison, simple logic verification, review of key technical specifications and examination of typical node diagrams were developed. Testing in real-world projects demonstrated that the AI-powered assistant can effectively replace part of the manual workload, confirming its technical feasibility and application value. Building on this, development plans are formulated for intelligent matching technologies involving structured parsing of national/industry standards and decomposition of complex graphics, aiming to deliver replicable "human-AI collaborative" engineering review solutions for the industry.

Hydrocracking plays a pivotal role in resolving the acute contradiction between the increasingly heavier and inferior quality of crude oil and the lighter product slate. Leakage in hydrocracking high-pressure air coolers is one of the major challenges to the long-cycle operation, quality improvement and efficiency enhancement of hydrocracking units, and ranks among the top five issues constraining the "five-year turnaround" long-cycle operation. Traditional leak detection methods are slow to respond, making it difficult to promptly detect minor initial leaks. They cannot visually locate leakage points and fail to provide early warning. This paper presents the development of an online monitoring system for acoustic imaging of high-pressure air cooler leakage based on acoustic imaging technology. The system employs a microphone array to capture abnormal sound source signals, and achieves acoustic imaging localization of leakage points and visualized tiered alarming through diagonal loading beamforming algorithm, acousto-optic fusion technology and leakage risk classification algorithm. Experimental bench tests and field tests have validated that the system is capable of leak localization, visual display and tiered alarming in complex noise environments, achieving an alarm and location accuracy of no less than 90% and exhibiting favorable real-time responsiveness, robustness, and engineering applicability.

As an important secondary processing unit, the safe and stable operation of catalytic cracking is directly related to the full utilization of heavy oil and the improvement of enterprise economic efficiency. This paper systematically analyzes the main corrosion damage mechanisms and corresponding countermeasures for various systems in the catalytic cracking unit during operation, and proposes corrosion control strategies cove-ring material selection for high-temperature areas, corrosion control circuitry for low-temperature areas, equipment design and pipeline layout. By implementing these corrosion control strategies industrially, the corrosion issues in the catalytic cracking unit have been effectively improved, and the service life of equipment and pipelines have been significantly extended. This study can provide a basis and reference for anti-corrosion work in catalytic cracking units, which can help enterprises improve the operating cycle of the units.

This paper employs Computational Fluid Dynamics (CFD) methods to numerically simulate the dispersion behavior of chemical agents injected into a water pipeline through the discharge orifices of a circular-flow chemical dosing skid. It investigates the impact of the geometric shape, area and inclination angle of these orifices on the dispersion effectiveness of the agents. The results indicate that the geometric shape of the orifices has a relatively minor impact on the dispersion range of the chemical agent, while significantly influencing the intensity of its concentration distribution; circular orifices without sharp edges thereby facilitate more effective dispersion of the agent at relatively high volume fractions within the water pipelines. When the shape of the orifices is the same, increasing the single orifice area to enhance the total outflow area of the chemical agent in the multi-orifice ring pipe can improve the volume fraction of the chemical agent at a specific point. However, this approach is not conducive to improving the axial dispersion of the chemical agent in the pipelines. Conversely, reducing the orifice area diminishes the propensity for radial dispersion of the chemical agent while enhancing its axial dispersion along the pipelines. Increasing the orifice count to expand the total discharge area enhances the axial dispersion propensity of the chemical agent while diminishing its radial dispersion propensity. Larger orifice inclination angles intensify the radial dispersion propensity of the chemical agent along the pipelines while correspondingly weakening axial dispersion, whereas smaller angles preferentially enhance axial dispersion. To maximize the protective effect of the agent against marine biofouling on pipeline walls, it is essential to suppress undesirable radial dispersion while sustaining desirable axial dispersion; therefore, circular orifices with small diameters should be adopted for the annular dosing pipe, arranged with small inclination angles in a multi-point uniform distribution configuration.

With increasingly stringent environmental regulations, the treatment of VOCs exhaust gas in refining and petrochemical enterprises has drawn significant attention. Combined with the characteristics of exhaust gas and the actual situation of construction projects, the research and development of efficient, rational and cost-effective treatment technologies has become a critical imperative for refining and chemical enterprises. Taking the treatment of VOCs exhaust gas from a polyolefin plant as an example, this paper addresses the challenges of large gas volume, low VOCs concentration, dust presence, high-temperature melting tendency of dust and intermittent emissions. By comprehensively evaluating various treatment methods according to project-specific characteristics, it identifies the optimal combination of treatment solutions. Meanwhile, research and optimization are conducted on the process flow and major equipment for this solution. Accordingly, the procedures and principles for selecting VOCs exhaust gas treatment methods are summarized.

In the petrochemical industry, the flue gas turbine is the core energy recovery equipment for catalytic cracking units. However, the complex composition of flue gas exposes its rotor system to harsh operating conditions such as high temperature, high pressure and erosion for a long time, leading to frequent rotor imbalance faults, which seriously affect the safe and stable operation of catalytic units. Aiming at the issue of complex operating conditions of flue gas turbines and difficulty in obtaining effective monitoring data, this paper took the flue gas turbine rotor system as the research object. It constructed a multi-parameter coupling diagnosis model based on fault traceability and realized the multi-physics simulation of the operating conditions of flue gas turbines and clarified the dynamic response characteristics of the rotor system. To address the persistent industry challenges of "difficult fault traceability and quantification in imbalance diagnosis," this study developed a novel methodology for rotor imbalance identification based on fault traceability and a non-stop quantitative analysis technology. By establishing a fault signature database through integration of simulation models and on-site measured data, and leveraging Pearson correlation analysis to extract on-site signal features and compute similarity index, the proposed framework enables precise root-cause localization and quantitative assessment of faults.

Natural gas compressors are the core equipment of natural gas processing plants. The operation of the compressor units is related to whether qualified natural gas can be supplied normally to the downstream. Air coolers are heat dissipation devices serving the compressor units. During summer when ambient temperatures rise, the temperature difference between the hot and cold media in a compressor air cooler of certain company decreases due to increased air temperature. After being used for a certain period of time, the comprehensive heat transfer coefficient of the air cooler decreases. This causes the heat transfer load of the air cooler to decrease, and the outlet temperature of the cooling medium to be high, resulting in repeated shutdown failures and affecting the normal operation of the compressor unit. This paper introduces an evaporative pre-cooling system centered on an evaporative pre-cooling module. This system uses water evaporation for cooling to pre-cool the air entering the air cooler, thereby enhancing the average temperature difference for heat transfer ΔT in the air cooler. Theoretical calculations and practical operations have proved that this system can enhance the heat transfer load of air coolers, completely resolving compressor over-temperature alarm shutdowns caused by high summer temperatures, and consequently improving the ambient temperature conditions for equipment operation.

Corrosion control in refining and chemical units constitutes a comprehensive strategic issue concerning enterprise safety, economic efficiency, environmental protection and social responsibility. Its primary objective extends beyond merely technological breakthroughs to establishing a systematic protection and management framework spanning the entire life cycle of facilities. This approach aims to achieve a fundamental shift from passive response to proactive prevention. Drawing on the concepts of lifecycle management, integrity, PDCA cycle management and continuous improvement from equipment integrity management systems, and utilizing advanced technologies such as Risk-Based Inspection (RBI), Integrity Operating Windows (IOW), Corrosion Control Documents (CCD), and an internet-based corrosion monitoring and early warning platform, this paper established a corrosion control integrity management strategy and system covering risk management, operational management, monitoring and inspection, preventive maintenance and other aspects. This system is designed to provide technical support and decision-making reference for enhancing the inherent safety of equipment and pipelines in refining and chemical enterprises, thereby ensuring their long-term stable operation.

In the new phase where informationization transformation converges with quality enhancement and efficiency improvement in oil and gas fields, equipment lifecycle management faces challenges of "numerous objects, extended chains, fragmented scenarios and diverse standards." To address this, the paper proposes a "data-driven lean equipment management" concept and constructs an integrated digital management system, advancing equipment management toward digital and intelligent transformation. This system employs a four-tier architecture: Perception—Processing—Intelligence—Governance. At the perception layer, cross-device multi-protocol online monitoring technology is developed to achieve real-time data aggregation and status perception. At the processing layer, an innovative equipment integrity integrated control technology is proposed, utilizing QR codes to realize full-process tracking of collection, repair and inspection, connecting the inspection-diagnosis-maintenance chain, and enhancing transparency and execution efficiency. At the intelligence layer, a KPI indicator system and health index model are formed, and support vector regression is introduced to carry out compressor energy consumption prediction and condition early warning, strengthening predictive maintenance. In addition, considering the characteristics of natural gas processing units, intelligent inspection and maintenance control is promoted to enhance the intrinsic safety level of operational processes. Practical applications demonstrate that this framework effectively resolves current challenges in oil and gas field equipment management. It significantly enhances the granularity and intelligence level of equipment management, reduces operational and maintenance costs, ensures safe and stable equipment operations and provides robust support for oil and gas enterprises in achieving quality-efficiency dual improvement and high-quality development.