Académique Documents
Professionnel Documents
Culture Documents
DATE: 21/03/08
TRAINING MODULE
0
21/03/08
A
29/11/07
REV
DATE
TRAINING DURATION
Benoit Rabaud
Paul Walsh
Benoit Rabaud
Paul Walsh
PREPARED BY
CHECKED BY
VENUE
JB Guillemin
JB Guillemin
APPROVED BY
ATTENDANCE
ATTENDEES REQUIREMENTS
MODULE OBJECTIVES
INSTRUCTORS NAME/POSITION
SUMMARY/AGENDA
Page 2 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
IMPORTANT
THIS TRAINING MODULE HAS BEEN PREPARED BY ARAMIS FOR THE DUNG QUAT
REFINERY.
THIS MODULE MUST BE RECOGNIZED AS A TOOL AND GUIDE ONLY. IT WOULD BE
IMPOSSIBLE TO ANTICIPATE AND PRESENT ALL POTENTIAL VARIABLES AND
PROCESS CONDITIONS THAT OPERATIONAL PERSONNEL MIGHT BE EXPOSED TO.
IT IS IMPERATIVE THAT THE READER ALWAYS AS CERTAIN THAT REFERENCE
MATERIALS UTILIZED, WHILE PERFORMING OPERATIONAL DUTIES, CONFORM AT A
MINIMUM TO THE LATEST ISSUE OF STANDARD OPERATING PROCEDURES, SAFETY
CODES, ENGINEERING STANDARDS, AND GOVERNMENT REGULATIONS.
SOME DESIGN FIGURES MIGHT NOT BE IN LINE DURING THE START-UP OF THE
REFINERY.
Page 3 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TABLE OF CONTENT
SECTION 1 : GENERAL description ......................................................................................... 10
1.1.
1.2.
1.3.
2.2.
2.3.
2.4.
2.5.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
3.1.
DATE: 21/03/08
3.2.
3.3.
4.2.
4.3.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
5.1.
5.2.
6.2.
8.2.
8.3.
Page 6 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
9.2.
9.3.
9.4.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
10.11.
10.12.
10.13.
10.14.
10.15.
Page 8 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
Course Content:
Section 1 - General Description
Page 9 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Page 10 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Purpose
Incinerator Section
Sulphur Apron
The sulphur apron is where is collected the solid sulphur from the
degassing pit.
Page 13 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
SRU
TRAINING MODULE
REV: 0
DATE: 21/03/08
The Incinerator Unit has been designed to directly treat the following acid gases:
The Sulphur Degassing Section has been designed to treat the total sulphur
produced by the Claus Unit at design capacity.
The SRU is designed for a production capacity of 5 ton/day of produced degassed
liquid sulphur with a Sulphur Recovery Efficiency (SRE) of 95% minimum of the
sulphur entering the SRU.
The SRU can operate in steady conditions in the range of 50% to 100% of the
design conditions.
1.2.2.1. Feed Composition & Capacity for production of degassed liquid sulphur
1.2.2.1.1. ARU Off Gas FeedStock Specifications
Max. Distillate Case
Composition kg/hr
kg-mol/hr
Mol%
kg/hr
kg-mol/hr
Mol%
H2S
102.6
3.01
18.97
119.6
3.51
20.66
NH3
0.0
0.00
0.00
0.0
0.00
0.00
H2O
16.5
0.92
5.77
19.0
1.05
6.21
Cyanide
0.0
0.00
0.00
0.0
0.00
0.00
CO2
511.4
11.62
73.24
531.4
12.08
71.11
N2
1.0
0.04
0.23
1.0
0.04
0.21
Page 15 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Composition kg/hr
kg-mol/hr
Mol%
kg/hr
kg-mol/hr
Mol%
CO
0.1
0.004
0.02
0.1
0.00
0.02
H2
0.3
0.15
0.94
0.3
0.15
0.87
C1
1.4
0.09
0.55
1.6
0.10
0.59
C2
1.1
0.04
0.23
1.1
0.04
0.22
C3
0.4
0.01
0.06
0.8
0.02
0.11
Total
634.8
15.87
100.00
674.9
16.98
100.00
Composition kg/hr
kg-mol/hr
Mol%
kg/hr
kg-mol/hr
Mol%
H2S
82.0
2.41
88.94
50.3
1.48
88.09
NH3
0.0
0.00
0.00
0.0
0.00
0.00
H2O
4.8
0.27
9.96
3.1
0.17
10.12
Cyanide
0.7
0.03
1.10
0.7
0.03
1.79
CO2
0.0
0.00
0.00
0.0
0.00
0.00
N2
0.0
0.00
0.00
0.0
0.00
0.00
CO
0.0
0.00
0.00
0.0
0.00
0.00
H2
0.0
0.00
0.00
0.0
0.00
0.00
C1
0.0
0.00
0.00
0.0
0.00
0.00
C2
0.0
0.00
0.00
0.0
0.00
0.00
C3
0.0
0.00
0.00
0.0
0.00
0.00
Total
87.5
2.71
100.00
54.1
1.68
100.00
Composition kg/hr
kg-mol/hr
Mol%
kg/hr
kg-mol/hr
Mol%
H2S
14.7
0.43
3.24
8.9
0.26
2.76
NH3
157.6
9.27
69.75
112.3
6.61
70.25
Page 16 of 161
TRAINING MODULE
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Composition kg/hr
kg-mol/hr
Mol%
kg/hr
kg-mol/hr
Mol%
H2O
64.7
3.59
27.01
45.7
2.54
26.99
Cyanide
0.0
0.00
0.00
0.0
0.00
0.00
CO2
0.0
0.00
0.00
0.0
0.00
0.00
N2
0.0
0.00
0.00
0.0
0.00
0.00
CO
0.0
0.00
0.00
0.0
0.00
0.00
H2
0.0
0.00
0.00
0.0
0.00
0.00
C1
0.0
0.00
0.00
0.0
0.00
0.00
C2
0.0
0.00
0.00
0.0
0.00
0.00
C3
0.0
0.00
0.00
0.0
0.00
0.00
Total
237.0
13.29
100.00
166.9
9.41
100.00
Naphtenic /
Sulfidic Sweet
(Bach Ho Crude)
Phenolic Sour
(Mixed Crude)
Phenolic Sweet
(Bach Ho Crude)
29.3
Min
Min
H2O wt%
H2S wt%
53
28
RSH wt%
40
60
93
93
In normal condition, NH3 rich off gas (from SWS, unit 18) and
CNU Off gas (from unit 20) are used as support fuel to achieve
750C inside the incinerator combustion chamber.
Page 17 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Composition kg/hr
kg-mol/hr
Mol%
kg/hr
kg-mol/hr
Mol%
H2S
129.6
3.802
18.97
164.2
4.818
20.66
NH3
0.0
0.00
0.00
0.0
0.00
0.00
H2O
20.8
1.157
5.77
26.1
1.448
6.21
Cyanide
0.0
0.00
0.00
0.0
0.00
0.00
CO2
645.9
14.676
73.24
729.6
16.578
71.11
N2
1.3
0,045
0.23
1.4
0.049
0.21
CO
0.1
0.005
0.02
0.1
0.005
0.02
H2
0.4
0.188
0.94
0.4
0.202
0.87
C1
1.8
0.110
0.55
2.2
0.137
0.59
C2
1.1
0.04
0.23
1.1
0.04
0.22
C3
1.4
0.046
0.23
1.5
0.050
0.22
Total
801
20.040
100.00
926.6
23.312
100.00
Composition kg/hr
kg-mol/hr
Mol%
kg/hr
kg-mol/hr
Mol%
H2S
103.6
3.039
88.94
69.0
2.026
88.09
NH3
0.0
0.00
0.00
0.0
0.00
0.00
H2O
6.1
0.340
9.96
4.2
0.235
10.21
Cyanide
1.0
0.038
1.10
1.1
0.039
1.70
CO2
0.0
0.00
0.00
0.0
0.00
0.00
N2
0.0
0.00
0.00
0.0
0.00
0.00
CO
0.0
0.00
0.00
0.0
0.00
0.00
H2
0.0
0.00
0.00
0.0
0.00
0.00
C1
0.0
0.00
0.00
0.0
0.00
0.00
C2
0.0
0.00
0.00
0.0
0.00
0.00
C3
0.0
0.00
0.00
0.0
0.00
0.00
Total
110.7
3.416
100.00
74.3
2.300
100.00
Page 18 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
Specification
Organics (wt %)
Ashes (wt %)
Water (wt %)
0.10
10
Colour
Bright Yellow
Limit
SO2 (mg/m )
H2S (mg/m )
3
NOX (mg/m )
CO (mg/m3)
Ammonia (mg/m )
The above specifications are only applicable in normal operation and not
in bypass condition).
Note:
In the following subsections EXCEPT ELECTRICAL POWER:
Page 19 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
( ): Intermittent Producer/Consumer
+: Indicates Quantity Produced
-: Indicates Quantity Consumed
Service
Duty
Usage Factor
BM-2203A
200.0
148.00
155.60
BM-2203B
200.0
148.00
155.60
A-2201-BM01A
22.00
17.00
18.10
A-2201-BM01AA
0.75
0.60
0.60
A-2201-BM01B
22.00
17.00
18.10
A-2201-BM01BA
0.75
0.60
0.60
A-2201-BM02A
30.00
18.20
19.40
A-2201-BM02B
30.00
18.20
19.40
A-2201-BM02A
45.00
32.00
34.00
A-2201-BM02B
45.00
32.00
34.00
A-2201-PM01A
1.50
1.40
1.50
A-2201-PM01B
1.50
1.40
1.50
A-2201-PM02A
1.50
1.40
1.50
0.1
A-2201-PM02B
1.50
1.40
1.50
A-2201-PM03A
1.50
1.40
1.50
0.1
Description
Rated
Power
Mech.
Consumed
Absorbed
Normal
Normal
Active
Power
Power
Page 20 of 161
TRAINING MODULE
Item No.
Description
Usage Factor
DATE: 21/03/08
Duty
REV: 0
Service
A-2201-PM03B
1.50
1.40
1.50
A-2201-PM04A
3.00
3.00
3.20
0.1
A-2201-PM04B
3.00
3.00
3.20
A-2201-PM05A
5.50
5.50
5.90
0.1
A-2201-PM05B
5.50
5.50
5.90
WS-2201
63.00
63.00
37.10
Mech.
Consumed
Absorbed
Normal
Normal
Active
Power
Power
Description
A-2201
HP
STM
MP
STM
LP
STM
HP
cond
MP
cond
LP
cond
BFW
(T/h) Losses
(T/h)
LP
BFW
-0.3
-0.1
0.4
0.3
0.1
0.25
-0.8
(-0.4)
(-0.1)
(-0.4)
(0.4)
(0.1)
(0.25)
Steam (T/h)
Item No.
SRU Package
Condensate (T/h)
0.15
st
A-2201
1 start-up &
prior to shutdown
(0.15)
Description
A-2201
SRU Package
-3.2
-0.2
A-2201
(-3.7)
-(2.0)
Page 21 of 161
TRAINING MODULE
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DATE: 21/03/08
Item No.
Description
Instrument
Air (Nm3/h)
A-2201
SRU Package
-103.4
A-2201
(-161.6)
Note:
[1]: Instrument air consumption is in the extreme case where all
control valves and on/off valves act together.
1.2.4.1.5. Nitrogen
Item No.
Description
A-2201
SRU Package
A-2201
Nitrogen Nm3/h
Continuous
Intermittent
-26.0
-138.0
Item No.
Description
A-2201
SRU Package
A-2201
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
Sulphate Poisoning
DATE: 21/03/08
In present case Euro Support has been chosen as preferred supplier. The
trade names are S-2001 for Alumina-based Catalyst, S-7001 for Titanium
Oxide Catalyst and 1/2" Ceramic Balls as active catalyst support.
Catalyst
Item
Description
A-2201-R-02
1st reactor
nd
Catalyst
Alumina-based catalyst
0.94
0.94
A-2201-R-03
reactor
Alumina-based catalyst
1.32
A-2201-R-04
3rd reactor
Alumina-based catalyst
1.88
Description
A-2201-R-02
1st reactor
0.28
A-2201-R-03
2nd reactor
0.20
A-2201-R-04
3rd reactor
0.28
When the SRU is processing a feed with the design feed quality, the
Claus catalyst life shall be minimum 2 years.
Page 23 of 161
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OTHERS
ACE
ADP
AER
AI
Analyser Indicator
AIT
MCC
MCR
MCS
MOV
Control
System
MDF
AMS
MIS
ANSI
MMS
APC
MMT
API
ARU
ASC
MOC
MOM
MOV
Minimum Maintained
Temperature
Madrid Operating Center
Minutes of Meeting
Motor Operated Valve
MP
Medium Pressure
MPT
Minimum Pressurization
Temperature
MR
Material Requisition
MRR
MSD
MSDS
MTBF
MTTR
ADAS
ASME
ASP
ASTM
ATM
BCS
BEDD
BFD
BFW
MC
Marshalling Cabinet
MCB
Page 24 of 161
TRAINING MODULE
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DATE: 21/03/08
BL
BOM
Battery Unit
Bill of Materials
MTO
MTPA
BPC
MVIP
BPCD
NACE
BPSD
BRC
NCR
NDE
CAD
NFPA
CALM
CBT
NHT
NIR
NPSH
CCC
CCR
CCTV
CD
Material Take-Off
Metric Tonnes per Annum
Multi Vendor Interface
Program (Honeywell)
National Association of
Corrosion Engineers
Non Conformance Report
Non Destructive Examination
National Fire Protection
Association
Naphtha Hydrotreater (Unit)
Near Infrared Spectroscopy
NPV
NTU
OAS
OJT
CDU
OM&S
OSBL
OTS
CCAR
CENELEC
CFC
CFR
C&I
CMMS
CNU
OMSA
OOS
OPSS
PABX
CPI
PAGA
CSI
DAF
DAU
DCS
PCB
PFD
PFM
PDB
DEA
Diethanolamine
PGC
PHD
DMDS
DMS
PI
PIB
DNV
PID
Plant Air
Process Interface Building
Piping and Instrument
Diagram
Project Implementation
Manual
Process Knowledge System
(Honeywell DCS)
Pipeline End Manifold
Planning
Project Management
DEIA
DPTD
DQMIS
DQRP
DVM
DWT
PIM
PKS
PLEM
PLG
PMC
Page 25 of 161
TRAINING MODULE
EL
EOR
ERP
ES
ESD
ETP
ETS
EWS
FDC
FAP
Equipment List
End of Run
Electronic Document
Management System
Electromagnetic Compatibility
Engineering Procurement,
Construction and
Commissioning
Enterprise Resource Planning
Ethernet Switch
Emergency Shut Down
Effluent Treatment Plant
Effluent Treatment System
Engineering Work Station
Feed Development Contract
Fire Alarm Panel
FAT
FEL
F&G
FIU
FIC
FM
FOTC
EDMS
EMC
EPC
FTE
GC
GFT
HAZAN
HAZOP
HDT
Hydrotreater
HEI
HHP
HGO
HIC
HP
HSE
FSC
HVAC
IA
ICAO
ICE
REV: 0
DATE: 21/03/08
PMI
PMT
Consultant
Positive Material Identification
Project Management Team
PO
Purchase Order
POC
PP
Project Procedure
PPB
PPM
PRU
PWHT
QA
QC
RA
R&D
Sequence of Events
SOR
Start of Run
SOW
Scope of Work
SP
Specification
Page 26 of 161
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ICS
SPIR
IIP
I/O
IP
SPM
SR
SRU
STC
Construction Standard
IRP
IRR
STD
STEL
IS
Intrinsically Safe
SVAC
ISA
ISE
ISBL
ISOM
SWS
TAS
TBT
ITB
Invitation to Bid
TCF
ITP
TCM
JB
Junction Box
TEMA
JCC
TGIF
JCR
JSD
JSS
TLCR
TLCS
TN
JVD
TPS
KLOC
KTU
LAN
LCO
LCOHDT
TQM
TS
TWA
UFD
U/G
LDE
UL
Design Standard
Short Term Exposure Limit
Shelter Ventilation and Air
Conditioning
System (Analyser houses)
Sour Water Stripping (Unit)
Terminal Automation System
Technical Bid Tabulation
Temporary Construction
Facilities
Task Control Module
Tubular Exchanger
Manufacturers' Association
Temperature Gauge Indication
Facilities (Tankage)
Truck Loading Control Room
Truck Loading Control System
Transmittal Note
Total Plant Solution
(Honeywell)
Total Quality Management
Terminal Server
Time Weighted Average
Utility Flow diagram
Underground
Underwriter Laboratories
(Approval body)
IPS
LEL
LGO
LIMS
UPS
VDU
VPU
LIS
WABT
LLU
LP
LPG
LTU LPG
WBS
WHB
YOC
1.3.2. Glossary
Refer to separate glossary.
Page 27 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Page 28 of 161
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DATE: 21/03/08
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DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Page 31 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
In the 1st zone all combustion air, all H2S Rich Off gas and a fraction of
ARU Off Gas are burnt.
Combustion air flow rate present in flame area is relatively higher than the
required for Claus reactions, due to the by-pass of the part of ARU Off Gas
flow rate to the second zone. The resulting flame temperature is higher than
expected (regarding standard Claus reactions only) and in this way is
guaranteed flame stability and complete hydrocarbon and impurities
combustion.
In the 2nd zone the hot flue gas from the first zone and the remaining ARU
Off Gas are mixed. As the remaining ARU Off Gas is injected, temperature
is lowered and modifications in flue gas composition take place in order to
satisfy the overall heat and material balances.
Optimum temperature is achieved by-passing about 50% of ARU Off Gas to the
second zone at design flowrate.
The flue gas leaving then leaves the reactor and enters into the Claus Waste Heat
Boiler and Sulphur Condensers A-2201-SG-01.
The temperature inside the first zone is approx. 1240C and the temperature of
flue gas leaving the reactor is approx. 900C.
The expected overall conversion of H2S to sulphur in the Thermal Reactor (A2201-R-01) is approx. 16.4% at design conditions (Max. Gasoline Case).
Page 32 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
LP steam is generated shell side and delivered to the LP steam header. Produced
steam is controlled at 4.1 kg/cm2G by pressure controller PIC-555.
Boiler feed water is fed to the A-2201-SG-01 under level control of A-2201-SG-01
by LIC-514.
A-2201-SG-01 is equipped with the Claus Blow Down Cooler (A-2201-D-06), on
which service water is used in open circuit to cool the water blown down from A2201-SG-01. The water blown down is then discharged into oily surface water
sewer at a maximum temperature of 50C.
The combustion products leaving the Thermal Reactor A-2201-R-01 are sent into
the tubes and are cooled down to about 240C in pas ses I & II of the Claus Waste
Heat Boiler.
The process gas leaving the Claus Waste Heat Boiler is further cooled down to
about 162C in the 1 st Sulphur Condenser (A-2201-SG-01 pass III). The sulphur
produced in the A-2201-R-01 is condensed in the tube side of A-2201-SG-01 pass
III and discharged by gravity to the sulphur pit (A-2201-TK-02) through its
dedicated sulphur seal leg (A-2201-D-05 A).
Page 33 of 161
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DATE: 21/03/08
2.1.6. 2nd Condenser, 2nd Process Gas Reheater & 2nd Catalytic Reactor
The process gas leaving the 1st Catalytic Reactor (A-2201-R-02) is fed to the 2nd
Sulphur Condenser (A-2201-SG-01 pass IV). The sulphur produced in the A-2201R-02 is condensed in the tube side of A-2201-SG-01 pass IV and discharged by
gravity to the Sulphur Pit (A-2201-TK-02) through its dedicated sulphur seal leg
(A-2201-D-05B).
A mist eliminator device is provided on the outlet channel of the A-2201-SG-01
pass IV to remove the sulphur entrained as mist in the process gas.
The process gas leaving 2nd Sulphur Condenser (A-2201-SG-01 pass IV) at 170C
is fed to the 2nd Process Gas Reheater (A-2201-E-04) to be heated up to 205C by
means of superheated HP steam fed under temperature control by TIC-539 of the
process gas leaving the reheater. The process gas then enters the 2nd Catalytic
Reactor (A-2201-R-03) where the Claus reaction between H2S and SO2
continues until equilibrium is reached at these conditions, producing elemental
Sulphur.
Equilibrium temperature is approximately 223C at d esign conditions (Max.
Gasoline Case).
2.1.7. 3rd Condenser, 3rd Process Gas Reheater & 3rd Catalytic Reactor
The process gas leaving the 2nd Catalytic Reactor (A-2201-R-03) is fed to the 3rd
Sulphur Condenser (A-2201-SG-01 pass V). The sulphur produced in the A-2201R-03 is condensed in the tube side of A-2201-SG-01 pass V and discharged by
gravity to the Sulphur Pit (A-2201-TK-02) through its dedicated sulphur seal leg
(A-2201-D-05C).
A mist eliminator device is provided on the outlet channel of the A-2201-SG-01
pass V to remove the sulphur entrained as mist in the process gas.
The process gas leaving the 3rd Sulphur Condenser (A-2201-SG-01 pass V) at
162C is fed to the 3 rd Process Gas Reheater (A-2201-E-05) to be heated up to
190C by means of superheated HP steam fed under te mperature control by TIC540 of the process gas leaving the reheater. Heated process gas then enters the
3rd Catalytic Reactor (A-2201-R-04) where the Claus reaction between H2S and
SO2 continues until equilibrium is reached under these conditions, producing
Sulphur.
Equilibrium temperature is approximately 193C at d esign conditions (Max.
Gasoline Case).
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The non-degassed sulphur storage section, sized for about one day of production
of Claus section, is equipped with 2 fully steam jacketed sulphur pumps (A-2201P-04 A/B).
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A-2201-P-04 A/B transfer continuously the produced sulphur to the Liquid Sulphur
Degassing Pit (A-2201-TK-01).
The degassed sulphur storage section is sized for about one day of production of
Claus section and is equipped with two fully steam jacketed sulphur pumps (A2201-P-05 A/B) that transfer the degassed sulphur to the Sulphur Apron.
Sulphur pit operates under approx. -50 mmH2O (G). Air intake is sucked from A-2201TK-01 by the Pit ejector (A-2201-J-01 A/B) which is fully steam jacketed. Air is then
discharged to the Incinerator (A-2201-H-01).
The following DCS printout shows the sulphur storage pit and degassing section:
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TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Page 43 of 161
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022-FV-530 controlling the ARU gas flow to the thermal reactor A-2201-R01. In that case, PIC-529 is in cascade with FIC-530
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022-PV-530 controlling the H2S rich off gas flow to the incinerator A-2201H-01
022-FV-515 controlling the H2S rich off gas flow to the thermal reactor A2201-R-01. In that case, PIC-530 is in cascade with FIC-515
In case of a pressure increase the controller will first open FV-515 while PV-530
will remain close. Then PIC-530 will open PV-530, while FV-530 remains open.
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This cause a pressure decrease and PIC-530 controller output acts by closing
gradually PV-530 up to complete closure.
This way, gradual acid gas cut-in to the thermal reactor and acid gas cut-off the
incinerator are ensured.
The following DCS printout shows the ARU off gas KO drum and the H2S rich
SWS off gas KO drum:
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The following DCS printout shows the NH3 rich SWS off gas KO drum:
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H2S Rich Off Gas flowrate to the thermal reactor 1st zone is
measured by FIC-515 and the signal enters the compensation
block FY-548. Then the compensated H2S Rich Off Gas flowrate
value from FY-548 is multiplied by a proper Air/ H2S Rich Off Gas
ratio in the FY-549 block. Air/ H2S Rich Off Gas ratio is assigned
by a manual setting station HIC-509. The output of the ratio block
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ARU Off Gas flowrate to the thermal reactor 1st zone is measured
by FIC-530 and the signal enters the compensation flow block FY551. ARU Off Gas flowrate to thermal reactor 2nd zone is measured
by FIC-524 and the signal enters the compensation block FY-522.
The 2 compensated ARU Off Gas flowrates values are summed up
in FY-558 block, generating as output the total ARU off gas
flowrate. This value is then multiplied by a proper Air/ARU off gas
ratio in the FY-550 block. Air/ARU gas ratio is assigned by a
manual setting station 022-HIC-510. The ratio function output
represents the air quantity needed in order to burn with a
predetermined ratio the ARU Off Gas.
The output from FY-553 block is assumed as setpoint for FIC-527 which
regulates the main combustion air flowrate to the thermal reactor with FV527 accordingly.
In addition, FIC-527 receives a signal from FY-556 compensation block in
order to compensate the flowrate according to the actual conditions.
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3.1.5. Trim Air Flow to Thermal Reactor Control by Tail Gas Analysis
The purpose of the controller is to control the efficient acid gas conversion within
the thermal reactor by monitoring the residual levels of H2S and SO2 in the tail
gas from the Claus Section.
The trim air flowrate permits to achieve he optimum H2S/SO2 ratio of 2:1 in tail gas
leaving the Tail Gas Coalescer A-2201-D-04.
The controller acts in feed-back control mode on the trim air control valve FV-022
and takes into account small deviations of acid gases composition with respect to
the predetermined one.
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Air demand signal is measured by 022-AT-501 and provides set point for
combustion trim air controller FIC-522. The later adjust the trim air flowrate with
FV-522 on the trim air line to the thermal reactor.
When the output value of the controller AIC-501 is less than zero, the setpoint of
FIC-522 is increased thereby opening the control valve. When the output value of
the controller AIC-501 is greater than zero, the setpoint of FIC-522 is decreased,
thereby closing the control valve.
022-AY-501 calculates the air demand of the Claus section expressed in terms of
the stoichiometric air required by the process, that is 2 x [SO2] [H2S]. When the
optimum H2S/SO2 content ratio of 2:1 in tail gas is achieved, then the air demand
calculated is zero and no control action is required. When the calculated air
demand is greater than zero (SO2 content 0.5 H2S content in the tail gas) it
means that there is an excess of air and the controller shall close the control
valve. Conversely, when the air demand is less than zero, there is deficient air and
the controller shall open the control valve.
The output of trim air controller 022-AIC-501, representing the desired air/gas
ratio, is a very important signal. Normally it varies between very narrow limits,
following the specific air demand of the feed gases. In order to avoid heavy
upsets, e.g. as a consequence of H2S analyser malfunctioning, this signal should
be limited slightly outside the normal operating range. Outside the expected range,
the controller 022-AIC-501 is switched automatically to manual mode and the
air/gas ratio control is operated in automatic mode, using the manual output signal
as the ratio set points. If required, these set points should be changed very slowly
and carefully.
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CNU Off Gas flowrate is measured by FI-538 and the value is multiplied by
a proper Air/CNU Off Gas ratio in the FFY-538 block. Air/CNU Off Gas ratio
is assigned by a manual setting station HIC-506. The manipulated variable
represents the air quantity needed in order to burn with a predetermined
excess air the CNU Off Gas.
NH3 Rich SWS Off Gas flowrate is measured by FI-518 and the value is
multiplied by a proper Air/ NH3 Rich SWS Off Gas ratio in the FFY-518
block. Air/ NH3 Rich SWS Off Gas ratio is assigned by a manual setting
station HIC-505. The manipulated variable represents the air quantity
needed in order to burn with a predetermined excess air the NH3 Rich
SWS Off Gas.
The output from FFY-539B block is then compare to the thermal reactor
temperature (with the output from TY-560B) in the high signal selector FFY-539A,
which selects the greatest signal to reset the setpoint of FIC-539. FIC-539 controls
the air flowrate from the combustion air preheater to the thermal reactor with FV539.
FIC-539 is reverse acting: The valve FV-539 opening will be decreased when the
process variable of FIC-539 increases.
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TV-560 controlling the fuel gas flow to the incinerator (In the low
range (0-50%) signal output from TIC-560)
FV-539 controlling the air flow to the incinerator (In the high range
(50-110%) signal output from TIC-560). In this case, TIC-560 is in
cascade with FIC-539.
When the temperature increases, the controller output first closes TV-560
by means of TY-560A while TY-560B output remains zero. In this
condition the controller action is ignored on FIC-539 set point and FV-539
valve remains in its position determined only by the setpoint based on
combustible gases air requirement, as described previously.
If the temperature rise continues until TV-560 is fully closed, then TY560B output is increased and the controller action enters the FFY-539A,
thus contributing to the setpoint of FIC-539.
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In the 1st zone all combustion air, all H2S Rich Off gas and a fraction of
ARU Off Gas are burnt.
In the 2nd zone the hot flue gas from the first zone and the remaining ARU
Off Gas (about 50% of the total ARU off gas) are mixed.
The temperature inside the first zone is approx. 1240C and the temperature of
flue gas leaving the reactor is approx. 900C.
The Thermal Reactor Burner is combined burner type with two lances, one for
Fuel Gas combustion during plant heating up, turndown case, or during refractory
dry-out and the other one for acid gas combustion during normal operation.
The Reactor Burner has a lot of ancillaries to assure smooth and safe operation,
such as 2 flame scanners, ignitor, etc. A permanent low pressure steam line
(Quench) has been foreseen to moderate the flame temperature in the fuel gas
run. The steam requirement shall be approximately 6 kg/kg of fuel gas. The
quench steam flowrate shall be set by the operator to limit the adiabatic flame
temperature to 1400C max.
Reaction chamber is internally refractory lined to protect the vessel from high
temperature and it is equipped with one optical pyrometer and special
thermocouples to detect continuously the temperature in both reaction zones.
The expected overall conversion of H2S to sulphur in the Thermal Reactor (A2201-R-01) is approx. 16.4% at design conditions (Max. Gasoline Case).
Page 63 of 161
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5.2
0.49
343
250
Material:
Acid Gas Lance / Tip
Burner Construction
Installation
Yes
Flame control
2 flame
amplifier
85 dB at 1 m distance
detectors,
each
complete
with
2700
1290
Position
Horizontal
1450
Zone I: 1250/900
Refractory
Bricks Group
Grade 28
Classification Temperature
1540C
0.34W/mC
CaO content
1% typ.
Fe2O3 content
1.5% max.
Alkalies content
2% max.
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For all the 5 passes, there is one pass per shell or per unit. They are all oriented
horizontally.
The tubes of each pass are plain tubes, made of killed carbon steel.
A-2201-SG-01 is provided with 2 mist eliminators at Pass IV and V outlets to
minimize the entrainment of condensed elemental sulphur with the process gas at
the outlet of the pass.
7.5
Operating Conditions at Design Flowrate
Service
Shell Side
Tube Side
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
Inlet
Outlet
1533.8
1533.8
455
Liquid (kg/hr)
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(C)
112
152
897
4.1
0.44
Press. (kg/cm2g)
Duty (kW)
245
2
66.1
Clean: 68.1
Shell Side: 1
No. of tubes:
Tube Side: 1
Page 66 of 161
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7.62
Length (mm)
4500
Pitch
125 (SQUARE)
Surface/unit (m )
11.9
Operating Conditions at Design Flowrate
Service
Shell Side
Tube Side
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
Inlet
Outlet
1533.8
1533.8
240
Liquid (kg/hr)
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(C)
112
152
455
4.1
0.420
Press. (kg/cm2g)
Duty (kW)
107
2
51.6
Clean: 53.0
Shell Side: 1
Tube Side: 1
No. of tubes:
14
5.54
Length (mm)
4500
Pitch
85 mm (TRIANGULAR)
15.7
Operating Conditions at Design Flowrate
Shell Side
Tube Side
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BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
Inlet
Outlet
1533.8
1504.4
Liquid (kg/hr)
29.4
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(C)
112
152
240
4.1
0.40
Press. (kg/cm2g)
Duty (kW)
37
65.7
162
Clean: 67.9
Construction of 1 shell
No. Passes per Shell
Shell Side: 1
Tube Side: 1
No. of tubes:
35
2.77
Length (mm)
4500
Pitch
46 mm (TRIANGULAR)
Surface/unit (m )
16.2
Operating Conditions at Design Flowrate
Service
Shell Side
Tube Side
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
Inlet
Outlet
1504.4
1356.6
Liquid (kg/hr)
147.8
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(C)
112
152
321
4.1
0.28
Press. (kg/cm2g)
Duty (kW)
171
84
2
75.8
Clean: 78.9
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Shell Side: 1
Tube Side: 1
No. of tubes:
36
2.77
Length (mm)
4500
Pitch
46 mm (TRIANGULAR)
Surface/unit (m )
14.4
Operating Conditions at Design Flowrate
Service
Shell Side
Tube Side
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
Inlet
Outlet
1356.6
1329.5
Liquid (kg/hr)
27.1
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(C)
112
152
223
4.1
0.173
Press. (kg/cm2g)
Duty (kW)
28
62.7
162
Clean: 64.8
Construction of 1 shell
No. Passes per Shell
Shell Side: 1
Tube Side: 1
No. of tubes:
32
2.77
Length (mm)
4500
Pitch
46 mm (TRIANGULAR)
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A-2201-R-03
A-2201-R-04
Service
Alumina-based: 0.94
Alumina-based: 1.32
Alumina-based: 1.88
1900
1900
1900
Length (mm)
1375
1300
1375
Material:
Shell
Heads
Flanges
Coils
Beam
1504.4
1356.6
1321.5
IN Press. (kg/cm2g)
0.33
0.21
0.09
0.173
0.05
IN Temp. (C)
240
205
190
321
223
193
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3.3.4. Liquid Sulphur Storage Pit A-2201-TK-01 & Degassing Tank A-2201-TK-02
The purpose of A-2201-TK-01 is to collect the liquid elemental sulphur at the outlet
of the 1st, 2nd, 3rd and final sulphur condensers via sulphur seal legs (A-2201-D05A/B/C/D).
Each sulphur seal leg has been provided with dedicated filter (perforated plate
type) to avoid plugging by catalyst and refractory dust. Sulphur seal legs are fully
steam jacketed and sized to avoid blow up of process gas in all operating
conditions, also in case of heavy upset.
Note that each sulphur seal leg has a dedicated manual, steam jacketed valve, to
isolate the items in case of scheduled maintenance and during the dry out
operations. In no other conditions the valve should be closed.
Sulphur pit is divided in two different sections, a non-degassed sulphur pit and a
degassed sulphur storage pit, each sized for one day of production and equipped
with 2 steam jacketed transfer pumps.
Sulphur pit operates under approx. -50 mmH2O (G).
The purpose of the sulphur degassing tank A-2201-TK-02 is to reduce the H2S
entrained with liquid elemental sulphur to a safe level.
Both pits are made of concrete.
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Fuel Gas
The Claus Section Tail Gas and the Vent Gas from Degassing Section are
injected just downstream of the flame via dedicated nozzles.
The fuel gas is fed into the center of the burner with a single tip.
If SRU is shut-down, the Incinerator is capable to receive the ARU OFF GAS and
the H2S RICH SWS OFF GAS. In this case these acid gases will be received into
the Incinerator Summer to ensure efficient mixing into the flame zone and
combustion of sulphur and its compound to sulphur dioxide.
During start-up operation firing will be supported by Fuel Gas. Sufficient excess air
must be used to limit effluent gas temperature.
The turndown capacity of the incinerator is 50% of Design capacity (2.5 T/D) for
tail gas from Claus Section and 50% of given capacity for NH3 rich SWS off gas
and for CNU off gas.
The incinerator is cylindrical and horizontally installed. The internal diameter of the
incinerator chamber is 1450 mm. The incinerator is connected to the stack A2201-SK-01 via a refractory lined duct
The incinerator burner is of the forced draft type. It is horizontally installed and
flanged to the incinerator. The air box is incorporated in the burner.
Incinerator Burner is equipped with several ancillaries in order to achieve smooth
and fully controlled run. It has a flame detection system with 2 flame detectors
having the pilot flame in view, able to originate plant shut down in case of flame
failure, pilot burner, cut off valves activated by emergency shut down system etc.
Burner management has been designed in order to accept only local light off
operation.
A forced draft pilot burner is provided for the main burner light off. The pilot is
continuously operated and releases approx. 70 kW of heat.
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DATE: 21/03/08
1217
661
609
130
130
130
Vent Gas
(kg/h)
321
321
160
160
321
321
Vent Gas
(C)
145
145
145
145
145
145
926.6
801.7
50
50
74.3
110.7
90
90
Fuel Gas
(kg/h)
Fuel Gas
(C) [1]
45
43
Fuel Gas
M.W.
15.39
23
14
15.39
15.39
15.39
15.39
15.39
15.39
167
237
84
118.5
167
237
90
90
90
90
90
90
19
19
19
19
65
65
65
65
65
65
Combustion
air (kg/h)
2141
3229
2120
1820
7006
8082
90
750
Max. Distillate
SRU Bypass
Max. Gasoline
SRU Bypass
Start-Up / Hot
Standby
Operation
Max Distillate
Turndown
Operation
Max Gasoline
Turndown
Operation
Design operation
Max. Distillate
Design operation
Max. Gasoline
The following table displays the operating conditions of the incinerator according
to the operating case:
Page 79 of 161
Combustion
air (kg/h) [2]
2500
3594
Combustion
air (C)
36
36
36
36
Flue Gas
(kg/h)
3977
5032
3057
Flue Gas
M.W.
27.78
27.44
Flue Gas
(C)
750
750
7377
8420
36
36
36
2727
764
8521
9582
27.83
27.48
27.92
28.78
28.47
750
750
750
750
750
Max. Distillate
SRU Bypass
Max. Gasoline
DATE: 21/03/08
SRU Bypass
REV: 0
Start-Up / Hot
Standby
Operation
Turndown
Operation
Max Gasoline
Turndown
Operation
Design operation
Max. Distillate
Design operation
Max. Gasoline
Max Distillate
TRAINING MODULE
Notes:
[1]: If CNU and NH3 rich SWS off gas not available
[2]: If vent air from sulphur pit is not fed to the incinerator
Incinerator Operating Data
Firing Zone
Residence Zone
0.1
0.1
ATM
ATM
343
343
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3.3.6. Blowers
There are 6 blowers in the SRU:
The Combustion Air Blowers A-2201-B-01 A/B provides the combustion air
necessary for the combustion reactions in the thermal reactor R-01
The Dilution Air Blowers A-2201-B-03 A/B ensure the emission limits are
satisfied at the stack outlet by diluting the flue gas at the incinerator outlet
with air.
Combustion Air Blowers A-2201-B-01 A/B
Number Required
2 (1 operating + 1 standby)
Blower Type
Rotary Compressor
22
2930
Drive System
Direct Coupled
Accessories:
TRAINING MODULE
REV: 0
DATE: 21/03/08
MIN.
MAX.
RATED
79
549
604
ATM
ATM
ATM
0.6
0.6
0.6
36
36
36
Outlet Temperature
115
115
115
Speed (RPM)
2784
15.7
16.9
2 (1 operating + 1 standby)
Not available
Blower Type
Centrifugal Fan
Not available
Not available
Drive System
Direct Coupled
Accessories:
Operating Conditions
NORMAL
MAX.
RATED
2429
6077
6332
ATM
ATM
ATM
0.11
0.11
0.11
36
36 (MIN.:14)
36
36.1
37.5
Page 82 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
2 (1 operating + 1 standby)
Not Available
Blower Type
Centrifugal Fan
Driver Type
Electric Motor
Operating Conditions
DESIGN
NORMAL
176000
160000
ATM
ATM
300
250
36
36
Page 83 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Page 84 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
P&ID
Description
UXHS-501-A
002
UXHS-501-B
002
Actions:
No.
Initiated by
initiator No:
P&ID
Description
MXS-101
1, 2
101
MXS-102
1, 2
101
UXA-501-A
1, 2
002
UXA-501-B
1, 2
002
Note:
ESD pushbutton UXHS-501 on Aux. Console in CCC has 2 contacts: UXHS-501-A
(CCC man contact) & UXHS-501-B (CCC ESD Bypass contact)
The following ESD printout shows the logic UX-501:
Page 85 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Page 86 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
P&ID
Description
UX-501
002
General ESD
UXHS-502-A
008
UXHS-502-B
008
FXALL-534
008
TXAHH-561
008
BXALL-503-A/B
008
MGL-101/102
101
BXALL-504
008
LXAHH-509
003
High high level in NH3 rich SWS off gas KO drum A-2201D-03
10
LXAHH-501
002
11
LXAHH-504
002
High high level in H2S rich SWS Off Gas KO drum A-2201D-02
12
FXAL-534
008
Actions:
No.
Initiated by
initiator No:
P&ID
Description
UX-503
2, 3, 4, 5, 6, 004
7, 8
UX-508
2, 3, 4, 5, 6, 011
7, 8
XSY-512
1, 2, 3, 4, 5, 008
6, 7, 8
TRAINING MODULE
No.
Initiated by
initiator No:
P&ID
XSY-513
1, 2, 3, 4, 5, 008
6, 7, 8, 9
REV: 0
DATE: 21/03/08
Description
Closing of NH3 rich SWS off gas cut-off
valve XV-513
XV-513 can be open/closed from local
control panel via XHSO/C-513
XSY-514
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-557
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-558
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-515
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-559
1, 2, 3, 4, 5, 008
6, 7, 8
10
XSY-560
1, 2, 3, 4, 5, 008
6, 7, 8
11
XSY-516
1, 2, 3, 4, 5, 008
6, 7, 8, 10, 11
12
MXS-513
008
13
MXS-514
008
14
FIC-539
2, 3, 4, 5, 6, 008
7, 8
15
PIC-539
1, 2, 3, 4, 5, 008
6, 7, 8
16
TIC-560
1, 2, 3, 4, 5, 008
6, 7, 8
TRAINING MODULE
No.
Initiated by
initiator No:
P&ID
REV: 0
DATE: 21/03/08
Description
Controller TIC-560 is forced to manual
mode at 50% to put TY-560-A in manual
mode at 0% in order to close TV-560.
17
12
18
UXA-502-A
1, 2, 3, 4, 5, 008
6, 7, 8
19
UXA-502-B
1, 2, 3, 4, 5, 008
6, 7, 8
20
UXA-502-C
1, 2, 3, 4, 5, 008
6, 7, 8
Note:
[1]: The logic will open the main fuel gas and LPG pilot gas vent valves only if both
the cut-off valves are confirmed fully closed by their limit switches.
[2]: Air purge procedure:
A purge by means of air from Incinerator Combustion Air Blower (A-2201-B02A/B) is automatically started either when the shutdown chain is activated by the
initiators or when the SYSTEM RESET push button (022-UHSR-502) has been
pressed and the purge validity time mentioned here below is fully expired (preignition purge).
In both cases the logic system shall automatically: open the combustion air valve
022-FV-539 to the "air purge set point" acting on its controller 022-FIC-539.
As soon as the air flow rate exceeds the set point of 022-FT-534, the Logic shall
Illuminate the PURGE ON lamp at Local Panel 022-XL-530-B and start to compute
a 5 minutes purge time.
When the 5 minutes purge time is expired, the logic system shall:
In the event the next light-off attempt is not completed within the 15 minutes purge
validity time, the logic system shall illuminate the LIGHT-OFF TIME OUT lamp
(Local Panel) 022-XL-532-B.
Remarks:
i) The minimum air flow rate shall be continuously satisfied during the purge. In
case the air flow falls below the set-point of 022-FXAL-534 before the 5
minutes purge time is expired, the Logic shall reset the purge time counter and
light the PURGE LOW FLOW lamp at Local Panel 022-XL-534-B.
The time shall be automatically re-started by the Logic only when the minimum
air flow rate has been re-established.
Page 89 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
ii) If the validity time following a shutdown air purge is expired and the Incinerator
is still in shutdown condition (the SYSTEM RESET pushbutton 022-UHSR-502
has not been pressed), the logic system remains in shutdown condition waiting for
SYSTEM RESET. Otherwise, if the SYSTEM RESET pushbutton has been
pressed, but the ignition is not initiated within the 15 minutes of validity time, at the
end of the validity time the logic system activate the shutdown sequence.
Reset:
The incinerator ESD is reset via UHSR-502.
Page 90 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Page 91 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
P&ID
Description
UX-501
002
General ESD
UXHS-503-A
004
UXHS-503-B
004
UXHS-503-C
008
MGL-101/102
101
UX-502
002
Incinerator ESD
LXAHH-501
002
FXALL-521
004
FXALL-517
005
10
BXALL-501-A/B
004
11
PXAHH-551
004
12
LXAHH-504
002
High high level in H2S rich SWS Off Gas KO drum A-2201D-02
13
FXALL-523
004
14
FXALL-528
004
Notes:
[1]: ESD pushbutton UXHS-503-A on Aux. Console in CCC has 2 contacts: UXHS503-A (CCC man contact) & UXHS-503-B (CCC ESD Bypass contact)
Actions:
No.
Initiated by
initiator No:
P&ID
Description
XSY-501
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 12, 13
XSY-504
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
XSY-505
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
TRAINING MODULE
No.
XSY-507
Initiated by
initiator No:
11, 13
P&ID
REV: 0
DATE: 21/03/08
Description
XV-505 can be opened / closed from local
panel via XHSO/C-505
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
XSY-508
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
XSY-555
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
XSY-556
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
XSY-509
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
XSY-510
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
10
XSY-516
2, 3, 4, 7, 8, 008
9, 10, 11, 13
11
14
12
FIC-515
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
13
FIC-527
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
14
FIC-522
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
15
FIC-530
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
16
FIC-525
1, 2, 3, 4, 5, 004
TRAINING MODULE
No.
Initiated by
P&ID
initiator No:
6, 7, 8, 9, 10,
11, 13
REV: 0
DATE: 21/03/08
Description
0% to close Steam Control Valve FV-525
17
FIC-526
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
18
FIC-524
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
19
UXA-503-A
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
20
UXA-503-B
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
21
UXA-503-C
1, 2, 3, 4, 5, 004
6, 7, 8, 9, 10,
11, 13
Notes:
[2]: The logic will open the main fuel gas vent valve only if both the cut-off valves
are confirmed fully closed by their limit switches.
[3]: Nitrogen Purge Sequence:
A purge by means of nitrogen shall automatically start either when the shutdown
chain is activated by the initiators or when the SYSTEM RESET pushbutton (022UHSR-503) has been pressed and the purge validity time mentioned here below is
fully expired (pre-ignition purge).
In both cases, the logic system shall automatically open the nitrogen cut-off valve.
As soon as the nitrogen flow rate exceeds the set point 022-FXALL-528, the logic
system shall illuminate the PURGE ON lamp (Local Panel) 022-XL-521-B and
start to compute a 5 minutes purge time.
Once the 5 minutes purge time is expired, the logic system shall:
In case the burner ignition trial is not completed within the 10 minutes purge
validity time, the logic system shall illuminate the LIGHT-OFF TIME OUT lamp
Page 94 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
The purge time counting shall be automatically re-initiated by the logic system only
when a minimum nitrogen flow rate (higher than 022-FT-528 set point) has been
reestablished.
Reset:
UX-503 can be reset by local reset pushbutton UHSR-503 when all initiators
become healthy except initiators 7 & 13.
Page 95 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Page 96 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
P&ID
Description
UX-501
002
General ESD
TXAHH-525
003
TXAHH-587
003
Actions:
No.
Initiated by
initiator No:
P&ID
Description
MXS-509
ALL
003
MXS-510
ALL
003
UXA-504
ALL
003
Reset:
Once all the initiators are healthy, UX-504 can be reset via DCS software reset
pushbutton UHSR-504.
P&ID
Description
UX-501
002
General ESD
LXALL-501
002
Actions:
No.
Initiated by
initiator No:
P&ID
Description
MXS-501
ALL
002
MXS-502
ALL
002
UXA-505
ALL
002
Reset:
Page 97 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
Once all the initiators are healthy, UX-505 can be reset via DCS software reset
pushbutton UHSR-505.
P&ID
Description
UX-501
002
General ESD
LXALL-504
002
Low low level in H2S rich SWS off gas KO drum A-2201-D02
Actions:
No.
Initiated by
initiator No:
P&ID
Description
MXS-503
ALL
002
MXS-504
ALL
002
UXA-506
ALL
002
Reset:
Once all the initiators are healthy, UX-506 can be reset via DCS software reset
pushbutton UHSR-506.
P&ID Description
UX-501
002
General ESD
LXALL-507
002
Low low level in NH3 rich SWS off gas KO drum A-2201-D-03
Actions:
No.
Initiated by
initiator No:
P&ID
Description
MXS-507
ALL
002
MXS-508
ALL
002
UXA-507
ALL
002
TRAINING MODULE
REV: 0
DATE: 21/03/08
Reset:
Once all the initiators are healthy, UX-507 can be reset via DCS software reset
pushbutton UHSR-507.
P&ID
Description
UX-501
002
General ESD
MGL-101/102
101
UX-502
LXALL-525
010
MGL-509/510
003
Actions:
No.
Initiated by
initiator No:
P&ID
Description
MXS-517
1, 2, 3, 4
010
MXS-518
1, 2, 3, 4
010
UHSC-521
1, 2, 3
011
Steam to ejector cut-off valve closed UV521 by forcing UHSC-521 to close position
UHSC-522
ALL
011
UHSC-523
ALL
011
UHSC-524
ALL
011
Sulphur to degassing pit cut off valve UV524 closed by forcing UHSC-524 to close
position
UXA-508
ALL
011
Reset:
Once all the initiators are healthy, UX-508 can be reset via DCS software reset
pushbutton UHSR-508.
Page 99 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
P&ID
Description
UX-501
002
General ESD
LXALL-526
010
Actions:
No.
Initiated by
initiator No:
P&ID
Description
MXS-519
ALL
010
MXS-520
ALL
010
UXA-509
ALL
010
Reset:
Once all the initiators are healthy, UX-509 can be reset via DCS software reset
pushbutton UHSR-509.
The following ESD printout shows the logics UX-504, UX-505, UX-506, UX-507,
UX-508 and UX-509:
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Description
022-PSV
-525-A
022-PSV
-525-B
022-PSV
-527-A
022-PSV
-527-B
022-PSV
-532
022-PSV
-533
022-PSV
-535
022-PSV
-536
022-PSV
-523-A
022-PSV
-523-B
022-PSV
-540-A
022-PSV
-540-B
022-PSV
-543
022-PSV
-544
022-PSV
-556-A
022-PSV
-556-B
022-PSV
-556-C
022-PSV
-563-A
022-PSV
-563-B
022-PSV
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
Type
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
Location
PG FROM A-2201-D-01 TO
FLARE
PG FROM A-2201-D-01 TO
FLARE
PG FROM A-2201-D-02 TO
FLARE
PG FROM A-2201-D-02 TO
FLARE
CONDENSATE FROM A2201-P-01A TO B.L.
CONDENSATE FROM A2201-P-01B TO B.L.
CONDENSATE FROM A2201-P-02A TO B.L.
CONDENSATE FROM A2201-P-02B TO B.L.
PG FROM A-2201-E-02 TO
A-2201-R-01
PG FROM A-2201-E-02 TO
A-2201-R-01
PG FROM A-2201-D-03 TO
FLARE
PG FROM A-2201-D-03 TO
FLARE
PID:
Setting
(kg/cm2g)
002
5.9
002
5.9
002
7.7
002
7.7
002
6.0
002
6.0
002
7.7
002
7.7
003
1.0
003
1.0
003
3.5
003
3.5
RV
A-2201-P-03A PROT
003
RV
A-2201-P-03B PROT
003
RV
A-2201-SG-01 PROT
005
6.3
RV
A-2201-SG-01 PROT
005
6.3
RV
A-2201-SG-01 PROT
005
6.3
RV
SL FROM A-2201-E-06
007
6.3
RV
SL FROM A-2201-E-06
007
6.3
RV
SL FROM A-2201-E-06
007
6.3
Page 102 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
TAG No.
Description
-563-C
022-TSV
-556
022-PSV
-559
022-PSV
-602
(Spring)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
DATE: 21/03/08
Type
Location
PID:
Setting
(kg/cm2g)
RV
A-2201-E-07 PROT
007
9.2
RV
A-2201-B-01-A VENT
003
0.65
RV
A-2201-B-01-B VENT
003
0.65
For further details, refer to the Flare Discharge Summary of the SRU: Doc. No. 8474L022-NM-0006-001.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
8474L-018-DW-1960-002
8474L-018-DW-1514-201
The following figures are extracted from the above document and focus on the SRU and
its close surroundings only.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Figure 18: Fire & Gas Detectors Layout Legend for AREA 4
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
O2 : 0.4vol.%max.
The process equipment and pipes must not be opened to the atmosphere until the
sulphur is completely removed and the catalyst in the reactors is cooled below
150C; at temperature higher than 150C the liquid sulphur can auto ignite in
presence of oxygen.
5.2.3. Extinguishing Sulphur Pit fires
Snuffing steam shall be used in case of fire in the sulphur pit. This operation shall
be done at a safe distance from the pit by opening a LP steam valve. The steam
shall break the rupture disc and shall enter the sulphur pit. When the fire is
extinguished the steam valve shall be closed and a new rupture disc shall be
installed.
5.2.4. Sulphur Fires
All operating personnel must be aware of the possible areas susceptible to fire
and of the fire fighting procedures. In the event of a fire, Operators must comply
with the Refinery Emergency Procedures.
The spontaneous ignition temperature of sulphur in air is about 170C. When the
sulphur is ignited, it is difficult to extinguish it and it can re-ignite spontaneously. In
order to minimize the risk of sulphur fires all sulphur spillage must be removed as
soon as they occur.
When sulphur fires are extinguished with water a white toxic choking acidic fume
is released. This sulphuric acid vapor is extremely hazardous and inhalation or
contact with the skin should be avoided. While fighting a fire the fireman should
wear suitable breathing apparatus and stand on the windward side of the fire.
Care must be taken with the water used to extinguish a sulphur fire as this may
also be acidic.
After any sulphur fire a water hose must be trained into the fire area for a
reasonable time to prevent re ignition and to wash and remove any acidic water.
Sulphur fires can also be extinguished by smothering with some more sulphur, or
sand or earth. Carbon dioxide fire extinguishers or steam smothering may also be
used.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
The following Fire & Gas System printout displays the F&G layout of the area 4 (units 18,
19, 20 & 22) and shows the alarms, detectors and F&G protection system located in this
area:
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Oxygen content
Soot presence
Sulphur presence
The first two parameters are important for safe unit operation; the third can be reduced to
a minimum when the first two give values advisable limits.
Carbon monoxide can be readily detected with calorimetric glass tubes. Soot presence in
the combustor flue gas can be detected by placing a piece of wet filter paper in contact
with the gas. It will turn black in the presence of soot.
Sulphur contained as a vapor can be detected by bubbling flue gases in a glass pot
containing water. In presence of sulphur a colloidal deposit is formed (light yellow color).
Such a test is particularly interesting towards the end of a sweeping sulphur operation, so
as to ascertain, if it has been fully removed.
Control of operating parameters is essential for efficient unit operation and to minimize
maintenance. It is not necessary to conduct daily analysis, but quick checks can be made
by Operators, if are necessary, particularly during start-up and shut-down of the unit.
For all the sampling procedures, refer to the chapter 12 of the licensor operating manual
doc. No. 8474L-022-ML-001.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Service
PID
SC-501
005
SC-502
005
SC-503
005
SC-512
005
SC-506
006
SC-507
006
rd
SC-508
006
SC-511
007
Analysis of H2S/S02 in the tail gas may be required every 2 hours during plant
start-up. Analysis of H2S/SO2 in the tail gas is continuously performed by the
analyzer. Chemical analysis will be used periodically to check the results of the
continuous analyzer. Sulphur purity analysis may be required more frequently
while the plant is being stabilized and some hours after plant start-up.
In heat-up/shut-down operations, the following analyses are required:
O2 content in combustor flue gas: Every hour (for at least for a period of
four hours). Analysis may be done with standard gas chromatographic, by
Orsat or calorimetric detectors.
CO content in combustor flue gas: Every hour (for at least eight hours - at
each start-uplshut-down). Analysis can be done with colorimetric detectors.
TRAINING MODULE
REV: 0
DATE: 21/03/08
Analyzer
tag
Service
Physical
property
analyzed
SO2 content
022AE/AT-501
022AE/AT-504
SOx
(normal
operation)
Normal value of
analyzed
component
PID:
Max. Distillate:
0.2861 mole%
Max. Gasoline:
0.2802 mole%
Max. Distillate:
0.1431 mole%
8474L022A01034110300-007
Max. Distillate:
0.1400 mole%
Max. Distillate:
476.31 mg/Nm3
Max. Gasoline:
401.09 mg/Nm3
8474L022A01034110-
TRAINING MODULE
REV: 0
NOx
(Bypass
operation)
NOx
(normal
operation)
DATE: 21/03/08
Max. Distillate:
2698.51 mg/Nm3
300-008
Max. Gasoline:
2966.44 mg/Nm3
Max. Distillate:
1158.0 mg/Nm3
MAX
Max. Gasoline:
1141.7 mg/Nm3
MAX
For more details on each analyzer, refer to the following data sheets:
For H2S/SO2 Tail Gas Analyser, refer to vendor doc. No. 8474L-022-A3101-4110300-017
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
P&ID
Description
UX-501
002
General ESD
UXHS-502-A
008
UXHS-502-B
008
FXALL-534
008
TXAHH-561
008
BXALL-503-AB
008
8/9
MGL-101/102
101
10
BXALL-504
008
11
LXAHH-509
003
High high level in NH3 rich SWS off gas KO drum A-2201Page 121 of 161
TRAINING MODULE
REV: 0
DATE: 21/03/08
No.
P&ID
Description
D-03
12
LXAHH-501
002
13
LXAHH-504
002
High high level in H2S rich SWS Off Gas KO drum A-2201D-02
14
FXAL-534
008
Actions:
No.
Initiated by
initiator No:
UX-503
2, 3, 4, 5, 6, 004
7, 8
UX-508
2, 3, 4, 5, 6, 011
7, 8
XSY-512
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-513
P&ID
1, 2, 3, 4, 5, 008
6, 7, 8, 9
Description
XSY-514
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-557
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-558
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-515
1, 2, 3, 4, 5, 008
6, 7, 8
XSY-559
1, 2, 3, 4, 5, 008
6, 7, 8
10
XSY-560
1, 2, 3, 4, 5, 008
6, 7, 8
11
XSY-516
1, 2, 3, 4, 5, 008
6, 7, 8, 10, 11
12
MXS-513
008
13
MXS-514
008
TRAINING MODULE
No.
Initiated by
initiator No:
P&ID
REV: 0
DATE: 21/03/08
Description
M-2201-B-02B
14
FIC-539
2, 3, 4, 5, 6, 008
7, 8
15
PIC-539
1, 2, 3, 4, 5, 008
6, 7, 8
16
TIC-560
1, 2, 3, 4, 5, 008
6, 7, 8
17
13
18
UXA-502-A
1, 2, 3, 4, 5, 008
6, 7, 8
19
UXA-502-B
1, 2, 3, 4, 5, 008
6, 7, 8
20
UXA-502-C
1, 2, 3, 4, 5, 008
6, 7, 8
Note:
[1]: The logic will open the main fuel gas and LPG pilot gas vent valves
only if both the cut-off valves are confirmed fully closed by their limit
switches.
Reset:
Local reset pushbutton UHSR-502 resets all above actions except actions
1, 2 and 17.
The C&E chart also indicates the Maintenance Override Switches (MOS)
and Operation Override Switches (OOS) associated with the instrument
triggering the logic. These switches allow the operator to bypass the
conditions tripping the system, whenever this is required (testing,
maintenance).
In normal operation, these switches shall never be activated.
Instrument
OOS
MOS
UXHS-502-A
N/A
N/A
UXHS-502-B
N/A
N/A
Page 123 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Instrument
OOS
MOS
FXALL-534
FHS-534-B
FHS-534-A
TXAHH-561
N/A
THS-561-A
BXALL-503-A
N/A
N/A
MGL-101
N/A
MHS-101-A
MGL-102
N/A
MHS-102-A
BXALL-504
N/A
N/A
LXAHH-509
N/A
LHS-509-A
LXAHH-501
N/A
LHS-501-A
LXAHH-504
N/A
LHS-504-A
FXAL-534
N/A
FHS-534-A
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Figure 20: Simplified PFD of the SRU (BACH HO MAX GASOLINE CASE)
Page 127 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
ARU Off Gas from Unit 19 & H2S Rich Off Gas from Unit 18
Refer to P&IDs: 8474L-022-A0103-4110-300-002/003/004
927 kg/hr of ARU Off Gas is fed from the unit 19 to the ARU off gas KO drum A2201-D-01 at 50C and 0.6 kg/cm2g. The acid condens ate recovered in A-2201D-01 is pumped back to the battery limits by the duty ARU off gas KO drum pump
A-2201-P-01-A at 4.9 kg/cm2g via PG-531. This line is normally no flow (NNF) as
the condensate is pumped intermittently, on level control of the KO drum, back to
the unit 19.
74 kg/hr of H2S rich SWS off gas is fed from the unit 18 to the H2S rich off gas KO
drum A-2201-D-02 at 90C and 0.6 kg/cm2g. The acid condensate recovered by
the mist eliminator of the KO drum is pumped by the H2S rich SWS Off Gas KO
drum pump on duty, A-2201-P-01-A, back to the SWS at 4.8 kg/cm2g via PG-534.
This line is normally no flow (NNF) as the condensate is pumped intermittently, on
level control of the KO drum, back to the unit 18.
ARU off gas exits the KO drum A-2201-D-01 and flows to the ARU off gas
preheater A-2201-E-01 via PIC-529. In A-2201-E-01, ARU off gas is heated to
250C against 88 kg/hr of superheated HP steam. The duty of the ARU preheater
is 52 kW. Superheated HP steam is fed from the header to A-2201-E-01 via TV522.
The heated ARU off gas then flows to the thermal reactor A-2201-R-01 via TIC522, TI-526 and XV-505 before being split into 2 streams:
464 kg/hr of heated ARU off gas are fed to the 1st zone of the thermal reactor A2201-R-01 (reactor burner) via FV-530 and PG-552.
463 kg/hr of heated ARU off gas are fed to the 2nd zone of the thermal reactor via
FIC-524 and FV-524.
H2S rich SWS off gas exits A-2201-D-02 to be mixed with the heated ARU off gas
downstream of A-2201-E-01, via PIC-530, TI-521, FIC-515, FV-515 and XV-501.
Combustion air feeding to Claus section
Refer to P&IDs: 8474L-022-A0103-4110-300-003/004
Air required for acid gases combustion is compressed to 8.6 kg/cm2g in the
Combustion Air Blower on duty A-2201-B-01 A and flows to the combustion air
preheater A-2201-E-02 via PG-550, PIC-545 and TI-524. Excess air pressure is
vented to atmosphere at the blower discharge via PV-545 and a silencer.
Air pressure is monitored upstream the duty compressor by PG-696 and
downstream of it by PG-597.
A small fraction of the compressed air, 152 kg/hr, is sent to the Liquid Sulphur
Degassing Pit (A-2201 -TK-01), to strip H2S from the liquid elemental sulphur.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
A tiny fraction of the compressed air is also sent to the flame detectors and the
sight glass nozzles of the thermal reactor burner section via XV-510, PG-595 and
restriction orifices.
Once compressed, 533 kg/hr of combustion air is preheated to 253C in the
Combustion Air Preheater A-2201-E-02 against 44 kg/hr of HP superheated
steam. The duty of the preheater is 26 kW. The preheated combustion air flows
towards the thermal reactor A-2201-R-01 via XV-504 before being split into 2
streams to accurately adjust the flow of combustion air to the thermal reactor
according to the acid off gas flow (main combustion air) and to the H2S/SO2 ratio
in the Claus section tail gas (trim air):
These 2 combustion air streams are then recombined and 533 kg/hr of
combustion air flows to the section 1 of the thermal reactor at 250C and 0.49
kg/cm2g, via PG-547 and PXA-551.
In the 1st zone all combustion air, all H2S Rich Off gas and a fraction of
ARU Off Gas are burnt. The temperature of this zone is approx. 1240C.
In the 2nd zone the hot flue gas from the first zone and the remaining ARU
Off Gas are mixed. As the remaining ARU Off Gas is injected, temperature
is lowered and modifications in flue gas composition take place in order to
satisfy the overall heat and material balances.
Optimum temperature is achieved by-passing about 50% of ARU Off Gas to the
second zone at design flowrate.
1533 kg/hr of flue gas then leaves the reactor at 0.44 kg/cm2g and 897C and
enters into the Claus Waste Heat Boiler and Sulphur Condensers A-2201-SG-01.
The expected overall conversion of H2S to sulphur in the Thermal Reactor (A2201-R-01) is approx. 16.4% at design conditions (Max. Gasoline Case).
Claus Waste Heat Boiler and 1st Sulphur Condenser
Refer to P&IDs: 8474L-022-A0103-4110-300-005/009
815 kg/hr of boiler feed water is sent from the header to the Claus Waste Heat
Boiler and 1st sulphur Condenser A-2201-SG-01 via LV-514. 791 kg/hr of LP
steam is generated shell side and delivered to the LP steam header at 4.1
kg/cm2g and 152C, thru PIC-555, FI-531 and PV-555.
Page 130 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
24 kg/hr of blow down from A-2201-SG-01 is sent to the Claus Blowdown drum A2201-D-06, where is cooled against a 130 kg/hr of service water circulated to the
blowdown drum in open circuit. Both water streams are then discharged to the oily
water sewer at 50C max via TG-537.
The combustion products leaving the Thermal Reactor A-2201-R-01 are sent into
the tubes and are cooled down to about 240C in pas ses I & II of the Claus Waste
Heat Boiler. The process gas leaving the Claus Waste Heat Boiler is further
cooled down to about 162C in the 1 st Sulphur Condenser (A-2201-SG-01 pass
III).
29 kg/hr of sulphur produced in the A-2201-R-01 is condensed in the tube side of
A-2201-SG-01 pass III and discharged by gravity to the sulphur pit (A-2201-TK-02)
through its dedicated sulphur seal leg (A-2201-D-05 A).
The entire line of condensed sulphur from the 1st sulphur condenser to the sulphur
seal leg A-201-D-05-A and the seal leg are steam jacketed with LP steam from the
header
Level in A-2201-SG-01 is controlled by LIC-514 and is monitored locally by LG515/516.
1st Process Gas Reheater & 1st Catalytic Reactor
Refer to P&IDs: 8474L-022-A0103-4110-300-005/006
1504 kg/hr of process gas leaving the 1st Sulphur Condenser (A-2201-SG-01 pass
III) at 162C flow to the 1 st Process Gas Reheater A-2201-E-03, via TI-536 and
SC-503. In A-2201-E-03, the process gas is heated up to 240C against a flow of
35 kg/hr of HP steam.
The process gas line from the 1st sulphur condenser is steam traced until the 1st
process gas reheater.
The duty of A-2201-E-03 is 60 kW. HP steam is fed from the header to A-2201-E03 via TV-541. HP condensate exits the reheater at 253C towards the HP
condensate header.
Downstream of A-2201-E-03, 1504 kg/hr of reheated process gas flow to the 1st
catalytic reactor A-2201-R-01 at 240C and 0.33 kg/ cm2g, thru TI-583, TG-582
and TIC-541.
The process gas enters the A-2201-R-02 where the Claus reaction between H2S
and SO2 continues until equilibrium is reached at that condition, producing
elemental Sulphur.
Equilibrium temperature is approximately the temperature of process gas leaving
the reactor (A-2201-R-02), i.e. 321C.
The temperature inside A-2201-R-03 is monitored via TI-542/543/544.
2nd Condenser, 2nd Process Gas Reheater & 2nd Catalytic Reactor
Refer to P&IDs: 8474L-022-A0103-4110-300-005/006/009
Page 131 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
The process gas leaving the 1st Catalytic Reactor (A-2201-R-02) is fed to the 2nd
Sulphur Condenser (A-2201-SG-01 pass IV) at 321C v ia TI-553 and SC-506.
148 kg/hr of sulphur produced in the A-2201-R-02 is condensed in the tube side of
A-2201-SG-01 pass IV and discharged by gravity to the Sulphur Pit (A-2201-TK02) through its dedicated sulphur seal leg (A-2201-D-05B).
The entire line of condensed sulphur from the 2nd sulphur condenser to the
sulphur seal leg A-201-D-05-B and the seal leg are steam jacketed with LP steam
from the header.
1356 kg/hr of process gas leaving 2nd Sulphur Condenser (A-2201-SG-01 pass IV)
at 170C is fed to the 2 nd Process Gas Reheater (A-2201-E-04), via a mist
eleiminator at the sulphur condenser channel outlet, TI-535 and SC-502.
In A-2201-E-04 the process gas is heated up to 205C against 25 kg/hr of HP
steam. The process gas line from the 2nd sulphur condenser is steam traced until
the 2nd process gas reheater.
The duty of the reheater is 15 kW. HP steam is fed form the header to A-2201-E04 via TV-539 and HP condensate exits the reheater at 253C towards the HP
condensate header.
1356 kg/hr of process gas then flows to the 2nd Catalytic Reactor (A-2201-R-03) at
0.21 kg/cm2g and 205C thru TI-584, TG-554 and TIC- 539. In the 2nd catalytic
reactor the Claus reaction between H2S and SO2 continues until equilibrium is
reached at these conditions, producing elemental Sulphur.
Equilibrium temperature is approximately 223C.
The temperature inside A-2201-R-03 is monitored via TI-545/546/547.
3rd Condenser, 3rd Process Gas Reheater & 3rd Catalytic Reactor
Refer to P&IDs: 8474L-022-A0103-4110-300-005/006/009
The process gas leaving the 2nd Catalytic Reactor (A-2201-R-03) is fed to the 3rd
Sulphur Condenser (A-2201-SG-01 pass V) at 223C vi a TI-552 and SC-507.
27 kg/hr of sulphur produced in the A-2201-R-03 is condensed in the tube side of
A-2201-SG-01 pass V and discharged by gravity to the Sulphur Pit (A-2201-TK02) through its dedicated sulphur seal leg (A-2201-D-05C).
The entire line of condensed sulphur from the 3rd sulphur condenser to the sulphur
seal leg A-201-D-05-C, as well as the seal leg, is steam jacketed with LP steam
from the header.
1330 kg/hr of process gas leaving the 3rd Sulphur Condenser (A-2201-SG-01 pass
V) at 162C is fed to the 3 rd Process Gas Reheater (A-2201-E-05). In A-2201-E05, the process gas is heated up to 190C by means of 20 kg/hr HP steam. HP
steam is fed from the header to A-2201-E-05 via TV-540 and HP condensate exits
the reheater at 253C to the HP condensate header.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
1330 kg/hr of heated process gas then flows to the 3rd Catalytic Reactor (A-2201R-04) at 190C and 0.09 kg/cm2g via TI-585, TG-555 and TIC-540. IN the 3rd
catalytic reactor, the Claus reaction between H2S and SO2 continues until
equilibrium is reached under these conditions, producing Sulphur.
Equilibrium temperature is approximately 193C.
The temperature inside A-2201-R-04 is monitored via TI-548/549/550.
Final Sulphur Condenser and Tail Gas Coalescer
Refer to P&IDs: 8474L-022-A0103-4110-300-006/007/008/009
The process gas leaving the 3rd Catalytic Reactor (A-2201-R-04) at 193C is fed to
the tube side of the Final Sulphur Condenser (A-2201-E-06), via SC-508 and TI551, for the final cooling against boiler feed water (shell side).
8 kg/hr of sulphur produced is condensed in the tube side of A-2201-E-06 and
discharged by gravity to the Sulphur Pit (A-2201-TK-02) through its dedicated
sulphur seal leg (A-2201-D-05D).
The entire line of condensed sulphur from the final sulphur condenser to the
sulphur seal leg A-201-D-05-D, as well as the seal leg, is steam jacketed with LP
steam from the header.
44 kg/hr of vaporized BFW exits the final sulphur condenser at 121C and flows to
the steam condenser A-2201-E-07, via PIC-562 and PV-562, where it is cooled
down against 3227 kg/hr of cooling water. Spent cooling water exits the A-2201-E07 at 39.2C to the cooling water return header. Th e duty of A-2201-E-07 is 27
kW.
Cooled BFW is then returned to the final sulphur condenser A-2201-E-06 via TG558. The level in A-2201-E-06 is monitored remotely via LI-522 and locally via LG520 and LG-521.
1322 kg/hr of process gas coming from the A-2201-E-06 is fed to the Tail Gas
Coalescer (A-2201-D-04), via TI-559, to remove any sulphur mist from the process
gas. Condensed liquid elemental sulphur is then sent by gravity to the Sulphur Pit
(A-2201-TK-02) via steam jacketed sulphur seal leg (A-2201-D-05D).
1322 kg/hr of tail gas leaves the Sulphur Coalescer (A-2201-D-04) at approx.
130C and 0.02 kg/cm2g and flows directly to the I ncinerator (A-2201-H-01), via
AE-501 and SC-511.
Liquid Sulphur Storage & Degassing Pits
Refer to P&IDs: 8474L-022-A0103-4110-009/010/011
212 kg/hr of liquid sulphur collected in the 4 seal legs are sent by gravity at 145C
to the non-degassed sulphur storage section.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
18 kg/hr of sweep air is drawn into the Liquid Sulphur Storage Pit A-2201-TK-02
(non-degassed sulphur section) via FI-541 and through a steam jacketed line.
Nitrogen for bubbling is introduced inside the non-degassed liquid sulphur storage
section via 2 steam jacketed nozzles. Temperature in this section is monitored via
TI-570 and TI-571.
Sulphur pit operates under approx. -50 mmH2O (G). Air intake is sucked from A2201-TK-01 and A-2201-TK-02 through a steam jacketed line by the Pit ejector A2201-J-01 A (fully steam jacketed). The pit ejector is fed with 150 kg/hr of LP
steam from the header via UV-521, FG-544 and PG-588.
321 kg/hr of air is then discharged to the Incinerator (A-2201-H-01), via a steam
jacketed line, at 145C and 0.01 kg/cm2g.
Liquid sulphur is pumped by the sulphur circulation pump on duty A-2201-P-04 A
to the sulphur degassing pit A-2201-TK-01, via PG-581 and UV-524, by means of
a steam jacketed line.
In the sulphur degassing pit, 152 kg/hr of process air from A-2201-B-01A/B is
bubbled through the sulphur by means of perforated plates. Process air is
introduced into the degassing pit, via UV-522 and FG-545, by means of 2 steam
jacketed lines.
The temperature in the degassing pit is monitored remotely via TI-576, TI-577 &
TI-578.
Degassed elemental sulphur then flows by gravity to the degassed sulphur
storage section through a steam jacketed line with 3 inlets.
From the degassed sulphur storage section, 212 kg/hr of sulphur is pumped by the
sulphur pump on duty A-2201-P-05 A at 145C and 2.0 kg/cm2g to the sulphur
apron via PG-589 and through a steam jacketed line.
Incinerator Section
Refer to P&IDs: 8474L-022-A0103-4110-003/008 & 8474L-022-PID-0021-101
132 kg/hr of tail gas leaving the Claus section at 130C and 0.02 kg/cm2g, as well
as 321 kg/hr of vent air from the pit ejectors at 145C and 0.01 kg/cm2g, are fed to
the Incinerator (A-2201-H-01). The tail gas is fed to the incinerator via a steam
traced line, while the vent air is fed through a steam jacketed line.
In order to meet the requirements on the flue gas delivered to the atmosphere,
160000 kg/hr of dilution air from Dilution Air Blower on duty B-2203 A is fed to the
Stack via PG-101.
In normal operating conditions, NH3 Rich Off gas (from Unit 18) and CNU Off gas
(from Unit 20) are used as support fuel to achieve 750C inside the combustion
chamber:
19 kg/hr of CNU off gas from the unit 020 are fed to the incinerator burner
at 65C and 0.5 kg/cm2g, via XV-512.
927 kg/hr of NH3 rich SWS off gas is fed to the NH3 Rich Off Gas KO Drum
A-2201-D-03. The condensate recovered by the mist eliminator of the KO
drum is pumped by the NH3 rich SWS Off Gas KO drum pump on duty, APage 134 of 161
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
2201-P-03-A, back to the SWS at 4.9 kg/cm2g via PG-542. This line is
normally no flow (NNF) as the condensate is pumped intermittently, on level
control of the KO drum, back to the unit 18.
The separated off gas from A-2201-D-03 is then sent to the combustion
chamber of the incinerator A-2201-H-01 via PIC-539, FI-518, PV-539, XV513 and PG-569.
8 kg/hr of fuel gas is also fed from the fuel gas header to the combustion
chamber, via FT-535A, TV-560, XV-514 and XV-557, to guarantee the
maintenance of the required temperature in the incinerator.
2141 kg/hr of Combustion air is compressed by the incinerator combustion air
blower on duty A-2201-B-02-A and is fed to the combustion chamber of the
incinerator A-2201-H-01 at 36C and 3.3 kg/cm2g via PG-573, TI-562, FIC-539,
FV-539 and HV-562. Any air excess pressure is vent to atmosphere at the blower
discharge via FV-536 and thru a silencer.
The Claus tail gas and the vent gas from pit ejectors (A-2201-J-01 A/B) are mixed
with hot flue gas, at controlled temperature, and all sulphur bearing compounds
are oxidised to SO2.
Expected residual H2S content is lower than 10 vol.ppm.
The operating conditions of the stack are as per the following:
Flue gas flowrate: 163978 kg/hr
Temperature: 57C
8.1.2. Combustion air / acid gas ratio and Thermal Reactor temperature
During the acid gas operation the flame temperature will become considerably
higher than normal if the hydrocarbon content of acid gas increases and/or if more
air than necessary is sent to the Reaction Chamber.
A quick check of H2S/S02 ratio may be achieved by observing the temperature of
the process gas in first condenser separation. Higher temperatures mean that
more H2S than expected is burned to SO2.
H2S/S02 ratio must be in any case higher than 1; that is to say tail gas must
contain unburned residual hydrogen sulphide.
In case of H2S excess (ratio H2S/S02 higher than 2), the only problem is a
small decrease in plant efficiency.
If H2S is absent, SO3 formation may occur. The higher is the free oxygen
content, the higher is SO3 content. When water is present (in process gas it
is always present) sulphur trioxide easily reacts giving sulphuric acid which
is highly corrosive for carbon steel parts.
It is to be noted that more far is the H2S/S02 ratio from 2 and less will be the
reaction heat developed in the reactor. For plant run at design conditions, such an
increase is as high as 49C for the first reactor a nd 12C for the second reactor.
Operator shall always control temperature trends in the reactors, together with
values indicated by laboratory analyses or analyser results. In case of
Page 135 of 161
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DATE: 21/03/08
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DATE: 21/03/08
During this run the efficiency in the sulphur recovery of the plant shall be a little
lower than during the normal run.
H2S content in tail gas outside recommended limits (H2S/S02 ratio 2:1)
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
If the stripping air is interrupted for too long the off-spec sulphur will be
pumped to storage.
For more information on the process variables and the operating conditions of the SRU
during normal operation, refer to the chapter 3.3 of the licenser operating manual doc.
No. 8474L-022-ML-001.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
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SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
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SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
Make sure all air and feed gas valves are shut.
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
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SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
TRAINING MODULE
SULPHUR RECOVERY UNIT (SRU)
DATE: 21/03/08
The Thermal Reactor Burner shut-down shall be also initiated by General ESD
push button (022-UXHS-501) from Control Room.
The emergency shut-down activation should be decided by the Operators shift
supervisor only.
The SRU plant shall be re-started if the initiator generating the shut-down is no
longer active; the normal shutdown procedures shall be followed if the acid gas
operation cannot be restarted immediately.
Consequences
The plant shall trip for combustion air low flow rate and/or for
flame failure
Actions
Consequences
Sulphur production will stop and care should be taken that all
sulphur is removed from the Claus section to avoid sulphur fires
Actions
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Effects
Consequences
Actions
Consequences
The plant shall trip for air and/or acid gas low flow rates or for
flame failure
Actions
Consequences
Actions
Consequences
Plant shutdown shall occur due to low liquid level in the waste
heat boiler
Actions
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and reduce the firing rate to the burners to have a little more
time to correct the problem.
Consequences
Actions
Consequences
Actions
Consequences Incinerator shut-down for dilution air blower both machines stop
(022-MGL- 101/102, 2oo2).
Sulphur degassing section shut-down for dilution air blower both
Page 147 of 161
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8.4.12. Off Gas K.O. Drum Pumps (A-2201-P-01A/B, 02A/B, 03A/B) Failure
Effects
Consequences
Actions
Consequences
Actions
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TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
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SECTION 9 : HSE
9.1. Hazardous Areas
Refer to the following documents:
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Figure 22: Abstract of the Hazardous Area Classification Diagram for AREA 4
Page 151 of 161
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REMEMBER - JUST BECAUSE YOUR NOSE SAYS IT'S NOT THERE, DOESN'T
MEAN THAT IT IS NOT.
PPE recommendation for protection against H2S:
Ventilation
Respiratory
Protection
Eye
Protection
Skin
Protection
Skin
Protection
Eye
Protection
Other PPE
9.3.3. Sulphur
PPE recommendation for protection against Elemental Sulphur:
Respiratory
Protection
Skin
Protection
Workers whose skin may be sensitive to sulphur dust should button collars, roll
sleeves down, and gather trousers at the ankle. Gloves may be helpful
Eye
Protection
Other
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For More information, refer to the MSDS attached in the section 9.6 of the licensor
operating manual doc. No. 8474L-022-ML-001.
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Ingestion
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Eyes
Moderate to severe irritation above 8 ppm. Liquid sulfur dioxide can burn the
eye and permanently affect vision.
Long Term
Exposure
Dental caries, loss of fillings, gum disorders and the rapid and painless
destruction of teeth may result from over-exposure.
9.4.3. Sulphur
Sulphur Health Hazards Summary:
Inhalation
Sulphur dust may irritate the mucous membranes of the respiratory passages
Ingestion
Skin
Eyes
Sulphur dust in the atmosphere has a highly irritating effect upon the human
eye. Therefore the need of wearing safety goggles when working in an
atmosphere where dust contaminates the air cannot be overemphasized.
Note:
Sulphur dust clouds will ignite at a temperature of approximately 190C.
For More information, refer to the MSDS attached in the section 9.6 of the licensor
operating manual doc. No. 8474L-022-ML-001.
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DATE: 21/03/08
TRAINING MODULE
Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index
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REV: 0
DATE: 21/03/08
8474L-018-DW-1960-001
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A-2201-R-02/03/04 Catalyst