In the daily maintenance work of distillation towers, operational errors are the main cause of equipment failures, which are mainly reflected in six core scenarios. These errors not only disrupt the normal process balance inside the tower, but also may cause serious problems such as damage to the tower body and internal components, and even lead to safety accidents. The specific details are as follows:

1. Sudden changes in feed and load: Fluctuations in feed flow rate, temperature, and composition in a short period of time, or long-term operation beyond the designed processing capacity of the equipment, can quickly break the gas-liquid equilibrium state inside the tower, leading to leakage of sealing parts such as tower flanges and manholes, damage to internal components such as trays and downcomers, and may also cause process abnormalities such as flooding and leakage.

2. Violation of temperature and pressure regulation: The heating medium of the reboiler and the cooling medium of the condenser are put into use/shut down too quickly, or the flow rate of the cooling medium is suddenly reduced or interrupted, and the process parameters are not adjusted synchronously in a timely manner; In addition, frequent and significant manual adjustment of the pressure valve opening can cause severe fluctuations in temperature and pressure inside the tower, leading to thermal expansion and contraction stress cracks in the tower body, and may also produce a "water hammer" effect that impacts internal components and pipelines.

3. Improper reflux system: Sudden changes in reflux temperature and reflux ratio, or illegal start and stop of reflux pump causing reflux interruption, resulting in balance collapse and loss of control of liquid overflow in the tower.

4. Liquid level control deviation: If the liquid level in the tower kettle is too high, it will flood the heat exchange tubes, or if it is too low, it will dry burn the reboiler, or if it relies on false liquid level data for operation, it will cause safety risks.

5. Irregular driving and parking: Failure to follow procedures, failure to replace/test pressure, rapid temperature and pressure rise, or failure to drain residual liquid, resulting in explosion risk and equipment stress damage.

6. Negligence in auxiliary maintenance: After maintenance, the installation of internal components is misplaced and not firmly fixed, and full load production is carried out without no-load trial operation, which can easily lead to the detachment and damage of internal components; Safety accessories such as safety valves and pressure gauges have not been regularly calibrated and have failed, making it difficult to provide timely warning and protection; Neglecting the anti-corrosion maintenance of the tower body will accelerate the thinning and perforation of the equipment wall thickness, and escalate minor faults into major accidents.