Professional Documents
Culture Documents
TRAINING MODULE
UNIT: 22
ATTENDANCE
ATTENDEES REQUIREMENTS
MODULE OBJECTIVES
INSTRUCTORS NAME/POSITION
SUMMARY/AGENDA
Page 2 of 161
IMPORTANT
THIS TRAINING MODULE HAS BEEN PREPARED BY ARAMIS FOR THE DUNG QUAT
REFINERY.
SOME DESIGN FIGURES MIGHT NOT BE IN LINE DURING THE START-UP OF THE
REFINERY.
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TABLE OF CONTENT
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TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
X
Section 2 - Process Flow Description
Section 9 - HSE
Page 9 of 161
The Sulphur recovery Unit (SRU) has been designed for the Bach Ho crude operation to convert
all suphur compounds present in the acid gas feed from the ARU and the SWS into liquid
elemental sulphur. First a part of H2S is burned and converted into SO2 while the remaining
reacts with SO2 to give elemental sulphur before being condensed. The produced liquid sulphur
is then degassed and cleared from dissolved H2S. Treated gas is finally incinerated to convert
the remaining pollutants into SO2.
The SRU is located at the south west of the area 4, next to the LCO HDT, ARU and SWS units.
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Section Purpose
Sulphur Recovery (Claus) Section based on the Claus Process where the major scope is to
Section convert H2S into elemental liquid sulphur.
Section composed of a thermal stage (Thermal Reactor) followed
by 3 catalytic steps:
The purpose of the thermal reactor is to burn approx. 1/3 of the H2S
contained in the total acid gases feed with air to convert it into SO2.
(Reaction H2S + 3/2 O2 = SO 2 + H2O)
The purpose of the catalytic converters is to make the remaining 2/3
of the H2S react with the produced SO2 to give elemental sulphur
(Reaction: 2 H2S + SO2 = 3/x SX + H2O)
In the Claus section, produced sulphur is also condensed.
The overall recovery of the Claus section is approx 96.5% at design
conditions.
Liquid Sulphur Storage The scope of the Degassing Section is to ensure the liquid sulphur
and Degassing Section degassing and to remove the dissolved H2S from the produced
sulphur, in order to avoid H2S local pollution (H2S desorbed from
liquid sulphur) and toxic/explosion hazards during sulphur handling.
With this section, H2S content in the liquid sulphur is decreased to
less than 20 wt. ppm (much below the explosivity of H2S with air)
Incinerator Section The purpose of the incinerator section is to convert residual H2S
contained in the treated gas leaving the Claus section and the
degassing section into SO2 and to finally discharge the flue gas to
the atmosphere through the stack.
NH3 rich SWS off gas and CNU off gas are also incinerated here.
Sulphur Apron The sulphur apron is where is collected the solid sulphur from the
degassing pit.
Page 13 of 161
SRU
Page 14 of 161
The Sulphur Degassing Section has been designed to treat the total sulphur
produced by the Claus Unit at design capacity.
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
Page 15 of 161
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Naphtenic / Naphtenic /
Phenolic Sour Phenolic Sweet
Sulfidic Sour Sulfidic Sweet
(Mixed Crude) (Bach Ho Crude)
(Mixed Crude) (Bach Ho Crude)
Std Vol. Flowrate 22.5 29.3 Min Min
m3 /hr
H2O wt% 7 7 7 7
H2S wt% 53 28 - -
RSH wt% - 5 - -
Fuel Gas 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
750°C inside the incinerator combustion chamber.
Page 17 of 161
Page 18 of 161
Component Specification
Purity (as S) (wt %) ≥ 99.9 (dry basis)
Organics (wt %) ≤ 0.02 (dry basis)
Ashes (wt %) ≤ 0.04 (dry basis)
Water (wt %) ≤ 0.10
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
( ): Intermittent Producer/Consumer
+: Indicates Quantity Produced
-: Indicates Quantity Consumed
r
Electrical Power (kW) o
t
e c
Mech. Consumed c
i y a
v t F
Item No. Description Rated Absorbed Normal r u e
e D g
Power Normal Active S a
s
Power Power U
Motor for Dilution Air
BM-2203A 200.0 148.00 155.60 N C 1
Blower
Motor for Dilution Air
BM-2203B 200.0 148.00 155.60 N S 0
Blower
A-2201-BM- Motor for combustion air
22.00 17.00 18.10 N C 1
01A blower
A-2201-BM-
Motor for canopy fan 0.75 0.60 0.60 N C 1
01AA
A-2201-BM- Motor for combustion air
22.00 17.00 18.10 N S 0
01B blower
A-2201-BM-
Motor for canopy fan 0.75 0.60 0.60 N S 0
01BA
A-2201-BM- Motor for incineration
30.00 18.20 19.40 N C 1
02A combustion air blower
A-2201-BM- Motor for incineration
30.00 18.20 19.40 N C 0
02B combustion air blower
A-2201-BM- Motor for incinerator
45.00 32.00 34.00 N C 1
02A combustion air blower
A-2201-BM- Motor for incinerator
45.00 32.00 34.00 N S 0
02B combustion air blower
A-2201-PM- Motor for ARU off gas
1.50 1.40 1.50 N C 1
01A KO drum pump
A-2201-PM- Motor for ARU off gas
1.50 1.40 1.50 N S 0
01B KO drum pump
A-2201-PM- Motor for H2S rich SWS
1.50 1.40 1.50 N I 0.1
02A off gas KO drum pump
A-2201-PM- Motor for H2S rich SWS
1.50 1.40 1.50 N S 0
02B off gas KO drum pump
A-2201-PM- Motor for NH3 rich SWS
1.50 1.40 1.50 N I 0.1
03A off gas KO drum pump
Page 20 of 161
r
Electrical Power (kW) o
t
e c
Mech. Consumed c
i y a
v t F
Item No. Description Rated Absorbed Normal r u e
e D g
Power Normal Active S a
s
Power Power U
A-2201-PM- Motor for NH3 rich SWS
1.50 1.40 1.50 N S 0
03B off gas KO drum pump
A-2201-PM- Motor for sulphur
3.00 3.00 3.20 N I 0.1
04A circulation pump
A-2201-PM- Motor for sulphur
3.00 3.00 3.20 N S 0
04B circulation pump
A-2201-PM-
Motor for Sulphur Pump 5.50 5.50 5.90 N I 0.1
05A
A-2201-PM-
Motor for Sulphur Pump 5.50 5.50 5.90 N S 0
05B
BFW
Item No. Steam (T/h) Condensate (T/h)
(T/h) Losses
Description
HP MP LP HP MP LP LP (T/h)
STM STM STM cond cond cond BFW
A-2201 SRU Package -0.3 -0.1 0.4 0.3 0.1 0.25 -0.8 0.15
st
1 start-up &
A-2201 (-0.4) (-0.1) (-0.4) (0.4) (0.1) (0.25) (0.15)
prior to shutdown
Page 21 of 161
1.2.4.1.5. Nitrogen
Nitrogen Nm3/h
Item No. Description
Continuous Intermittent
A-2201 SRU Package -26.0
A-2201 Start-up & shutdown -138.0
Page 22 of 161
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 Catalyst Volume to be loaded (m3)
Alumina-based catalyst 0.94
A-2201-R-02 1st reactor
Titanium oxide catalyst 0.94
nd
A-2201-R-03 2 reactor Alumina-based catalyst 1.32
A-2201-R-04 3rd reactor Alumina-based catalyst 1.88
When the SRU is processing a feed with the design feed quality, the
Claus catalyst life shall be minimum 2 years.
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1.3.1. Acronyms
COMPANIES/ORGANISATIONS
OTHERS
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Page 25 of 161
Consultant
EL Equipment List PMI Positive Material Identification
EOR End of Run PMT Project Management Team
Electronic Document
EDMS PO Purchase Order
Management System
EMC Electromagnetic Compatibility POC Paris Operating Center
Engineering Procurement,
EPC Construction and PP Project Procedure
Commissioning
ERP Enterprise Resource Planning PPB Parts per Billion
ES Ethernet Switch PPM Parts per Million
ESD Emergency Shut Down PRU Propylene Recovery Unit
ETP Effluent Treatment Plant PWHT Post Weld Heat Treatment
ETS Effluent Treatment System QA Quality Assurance
EWS Engineering Work Station QC Quality Control
FDC Feed Development Contract RA Risk Analysis
FAP Fire Alarm Panel R&D Research and Development
Real Time Database
FAT Factory Acceptance Test RDBMS
Management System
Residue Fluid Catalytic
FEL Front End Loading RFCC
Cracking
F&G Fire and Gas System RFSU Ready for Start-Up
FIU Field Interface Unit RLU Remote Line Unit
FIC Flow Indicating Controller ROW Right of Way
Refinery Performance
FM Factory Mutual (Approval body) RPMS
Management System
Resistance Temperature
FOTC Fibre Optic Termination Cabinet RTD
Detector
Fail Safe Controller (Honeywell Real Time Data Base
FSC RTDB
ESD) (System)
FTE Fault Tolerant Ethernet RTU Remote Terminal Unit
GC Gas Chromatograph SAT Site Acceptance Test
GFT Ground Fault SBT Segregated Ballast Tanks
Software Bypass Management
HAZAN Hazard Analysis Study SBMS
System
Supervisory Control and Data
HAZOP Hazard and Operability Study SCADA
Acquisition
HDT Hydrotreater SCC Satellite Control Complex
Simulation Control
HEI Heat Exchange Institution SCE
Environment
HHP High High Pressure (Steam) SCR Satellite Control Room
HGO Heavy Gas Oil SDH Synchronous Digital Hierarchy
HIC Hydrogen Induced Cracking SE Safety Earth
HP High Pressure S&E Safety & Environmental
HSE Health, Safety and Environment SGS Safeguarding System
Heating Ventilation Air
HVAC SOE Sequence of Events
Conditioning
IA Instrument Air SOR Start of Run
International Civil Aviation
ICAO SOW Scope of Work
Organisation
ICE Instrument Clean Earth SP Specification
Page 26 of 161
1.3.2. Glossary
Refer to separate glossary.
Page 27 of 161
TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
Section 9 - HSE
Page 28 of 161
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2.1.1. ARU Off Gas from Unit 19 & H2S Rich Off Gas from Unit 18
The ARU Off Gas (from Unit 19) and the H2S Rich Off gas (from Unit 18) are fed
to 2 dedicated KO drums (A-2201-D-01 & A-2201-D-02), provided with mist
eliminators, in order to separate acid condensate and all liquid carry-over coming
from upstream units. Indeed liquid carry-over is very dangerous to the life of
downstream equipment and to the correctness of operation.
2 dedicated pumps, A-2201-P-01 A/B & A-2201-P-02 A/B, send acid condensate
collected in A-2201-D-01 & A-2201-D-02 respectively to closed drain drum in unit
19 and unit 18 respectively. The pumps operate on level control of their respective
KO drum.
ARU Off gas from KO drum A-2201-D-01 is heated against HP superheated steam
in the ARU off gas preheater A-2201-E-01. The steam is fed to A-2201-E-01 on
temperature control of the ARU off gas at the discharge of the preheater. ARU off
gas is then fed to the burner of the thermal reactor A-2201-R-01 on flow control
reset by PIC-529 at the off gas outlet of A-2201-D-01. Part of the ARU off gas is
not fed to the thermal reactor burner but flows straight to the 2nd zone of the
reactor.
After being mixed with the off gas from A-2201-D-01 downstream of the ARU off
gas preheater A-2201-E-01, H2S rich SWS off gas from KO drum A-2201-D-02 is
fed to the burner of the thermal reactor A-2201-R-01 on flow control reset by PIC-
530 at the off gas outlet of A-2201-D-02..
Condensation in the separator downstream line is prevented by low pressure
steam tracing.
In case of the Claus section is temporarily out of operation, the ARU Off Gas and
the H2S Rich Off Gas are bypassed to the Incinerator (A-2201-H-01) via dedicated
lines from each K.O. drum.
Page 31 of 161
Page 32 of 161
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 A-
2201-SG-01. The water blown down is then discharged into oily surface water
sewer at a maximum temperature of 50°C.
The combustion products leaving the Thermal Reactor A-2201-R-01 are sent into
the tubes and are cooled down to about 240°C 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 162°C 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).
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:
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D 8
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T 7 4
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: 0
-
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/
0 -
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/
8 0
1
P 6
a -
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3 0
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1 1
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Page 36 of 161
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 (A-
2201-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-2201-
TK-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:
Page 37 of 161
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(
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0 N
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:
D 8
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T 7 4
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-
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0 -
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8 0
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a -
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TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
Section 9 - HSE
Page 43 of 161
The following is a description of the main control loops of the SRU. For a detailed description of
the control loops and the controllers, refer to the control narrative, vendor document No. 8474L-
022-A3505-4110-300-003.
3.1. Control narrative & operating parameters
Page 44 of 161
Since in normal operation, the ARU off gas line to the incinerator is closed by a
cut-off valve 022-XV-516, the action of PV-529 valve opening has no effect in
mitigating the pressure increase. Therefore, the ARU off gas will be flared to the
sour flare by the control valve on the upstream unit (i.e.: Amine Regeneration).
In the same manner, during SRU bypass operation, the ARU off gas line to the
Thermal Reactor is closed by a cut-off valve 022-XV-505, therefore the action of
022-FV-530 valve opening has no effect in mitigating the pressure increase and
the ARU off gas will be flared to the sour flare header by the control valve on the
upstream (i.e.: Amine Regeneration).
There is only one operating mode during which both cut off valves are opened:
This is when the plant is in bypass mode with the incinerator receiving acid gases
and the SRU is to be re-started with acid gases. In this case, FV-530 is operated
Page 45 of 161
3.1.2. H2S Rich SWS Off Gas KO Drum A-2201-D-02 Pressure Control
The pressure control of A-2201-D-02 is strictly the same than the pressure control
of A-2201-D-01:
This control system acts in order to maintain a stable pressure in the H2S rich off
gas KO drum feeding the thermal reactor when the SRU is in normal operation
mode (or the incinerator when the SRU is in bypass mode).
The pressure in A-2201-D-02 is controlled by 022-PIC-530 acting in split range
control on 2 control valves:
• 022-PV-530 controlling the H2S rich off gas flow to the incinerator A-2201-
H-01
• 022-FV-515 controlling the H2S rich off gas flow to the thermal reactor A-
2201-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.
Page 46 of 161
Since in normal operation, the H2S rich SWS off gas line to the incinerator is
closed by a cut-off valve 022-XV-516, the action of PV-530 valve opening has no
effect in mitigating the pressure increase. Therefore, H2S rich SWS off gas will be
flared to the sour flare by the control valve on the upstream unit (i.e.: SWS).
In the same manner, during SRU bypass operation, the H2S rich SWS off gas line
to the Thermal Reactor is closed by a cut-off valve 022-XV-501, therefore the
action of FV-515 valve opening has no effect in mitigating the pressure increase
and the H2S rich SWS off gas will be flared to the sour flare header by the control
valve on the SWS.
There is only one operating mode during which both cut off valves are opened:
This is when the plant is in bypass mode with the incinerator receiving acid gases
and the SRU is to be re-started with acid gases. In this case, FV-515 is operated
in manual mode (gradual opening) by acting directly on the controller FIC-515.
Page 47 of 161
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:
Page 48 of 161
Page 49 of 161
The following DCS printout shows the NH3 rich SWS off gas KO drum:
Page 50 of 161
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:
0 N
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D 8
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T 7 4
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: 0
-
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0 -
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8 0
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P 6
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5 0
1 0
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1 -
6 0
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Page 53 of 161
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5 0
4 0
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6 0
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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 H 2S/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.
Page 55 of 161
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.
The following DCS printouts show the thermal reactor, waste heat boiler and
sulphur condenser section:
Page 56 of 161
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R
U
)
R D
E O
V C
:
0 N
O
:
D 8
A 4
T 7 4
E L
: 0
-
2 2
1 2
/
0 -
3 A
0 5
/
8 0
1
P 6
a -
g 0
e 0
5 0
7 0
-
0
o 0
f 1
1 -
6 0
1 1
2
Page 58 of 161
F
i
g
u
r
e
1
0
:
C
S
o
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L
n P
t
r
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R R
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f E I
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C C I
o
N
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m V
b
E M
u
R O
s
Y D
t
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i
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N L
n
I E
T
A
(
S
i
r
R
F
U
l
)
o
w R D
r
a
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t
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e :
0 N
t
o
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:
I
n
D 8
A 4
c T 7
i
4
n
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e
: 0
-
r
2 2
a
1 2
t
/
o
0 -
3 A
r 0 5
/
8 0
P 1
6
a -
g 0
e 0
5 0
9 0
-
0
o 0
f 1
1 -
6 0
1 1
2
Page 60 of 161
S
U
L
P
H
U T
R R
R A
E I
N
C I
N
O G
V
E M
R O
Y D
U U
N L
I E
T
(
S
R
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)
R D
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V C
:
0 N
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:
D 8
A 4
T 7 4
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: 0
-
2 2
1 2
/
0 -
3 A
0 5
/
8 0
1
P 6
a -
g 0
e 0
6 0
1 0
-
0
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f 1
1 -
6 0
1 1
2
Page 62 of 161
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 1400°C 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 (A-
2201-R-01) is approx. 16.4% at design conditions (Max. Gasoline Case).
Page 63 of 161
Page 64 of 161
Page 65 of 161
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.
Page 66 of 161
Page 67 of 161
Page 68 of 161
Page 69 of 161
Page 70 of 161
Page 71 of 161
Page 72 of 161
Page 73 of 161
Page 74 of 161
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-D-
05A/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.
Page 75 of 161
Page 76 of 161
Page 77 of 161
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 A-
2201-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.
Page 78 of 161
The following table displays the operating conditions of the incinerator according
to the operating case:
n e n e
o n o t t
i
t i
l
i a
t l
e
n
e
t o s e
n
e
s t
a a l n n l
i n n l
a H y n s i a
s l
r o r i o o l a l l
a i
e s e t
s
w i o
o t s
w i i
o t t
o
/ b i
t p o p t
p a p i a a s
d r a d r i p d a y s
a s
y i
o G o D n U n r B G B D
n x . n x . r e G n
r e D - t
t a e
.
u p x u p x r S p .
U x U x
g a
i g a
i a O R a R a
s M s M T O a T O a t
e e M M S S M S M
D – D –
Page 79 of 161
n e n e
o n o t t
i
t i
l
i
t a e
n
e
t o s e
n
e
s t
l
l n n i n n l
a s i a
s l
a
r o a
r i l l H y n a l a l
e s e t
s
w o o
i
o t s
w o i
i
o t t
o
/ b i p o p i
t
p a p i d a a s p d t y s s
y i
o G o D n r a d r i U n a
r a
B G B D
n x . n x . r e G n
r e D - t
t a e
.
u p x u p x r S p .
U x U x
g a
i g a
i a O R a R a
T O a T O a t
s M s M M S M S M
e e M S
D – D –
Combustion
2500 3594 7377 8420
air (kg/h) [2]
Combustion
36 36 36 36 36 36 36
air (°C)
Flue Gas
3977 5032 3057 2727 764 8521 9582
(kg/h)
Flue Gas
27.78 27.44 27.83 27.48 27.92 28.78 28.47
M.W.
Flue Gas
750 750 750 750 750 750 750
(°C)
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
Page 80 of 161
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 Incinerator Combustion Air Blowers A-2201-B-02 A/B supply the
incinerator with the necessary air for burner operation
• 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.
Page 81 of 161
Page 82 of 161
Page 83 of 161
TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
Section 9 - HSE
Page 84 of 161
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 MXS-101 1, 2 101 Dilution Air Blower B-2203A shutdown
2 MXS-102 1, 2 101 Dilution Air Blower B-2203B shutdown
3 UXA-501-A 1, 2 002 DCS trip alarm activated
4 UXA-501-B 1, 2 002 Control room trip alarm activated
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)
Page 85 of 161
Page 86 of 161
Initiators:
No. Initiator Tag No. P&ID Description
1 UX-501 002 General ESD
2 UXHS-502-A 008 Control room ESD pushbutton
3 UXHS-502-B 008 Local panel ESD pushbutton
4 FXALL-534 008 Low low flow of combustion air
5 TXAHH-561 008 High high temperature of incinerator
6 BXALL-503-A/B 008 Flame failure (2 out of 2 voting system).
If at least one of the flame detectors confirms the presence
of the main flame, the only response of the logic system is
to close the LPG pilot gas cut-off valve 022-XV-515.
7 MGL-101/102 101 Dilution air blower B-2203-A/B stop (both machines stop: 2
out of 2 voting system)
8 BXALL-504 008 Pilot Flame Failure
Note:
Pilot flame failure causes only the closure of XV-515 in
case at least one of the main flame detectors confirms the
presence of the flame. Otherwise, total incinerator
shutdown will be initiated.
9 LXAHH-509 003 High high level in NH3 rich SWS off gas KO drum A-2201-
D-03
10 LXAHH-501 002 High high level in ARU Off Gas KO drum A-2201-D-01
11 LXAHH-504 002 High high level in H2S rich SWS Off Gas KO drum A-2201-
D-02
12 FXAL-534 008 Low flow of combustion air purge. This cause is only active
during the air purge period.
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 UX-503 2, 3, 4, 5, 6, 004 Activation of Thermal Reactor ESD after a
7, 8 delay of 20 min.
2 UX-508 2, 3, 4, 5, 6, 011 Activation of Sulphur Degassing ESD
7, 8
3 XSY-512 1, 2, 3, 4, 5, 008 Closing of CNU off gas cut-off valve XV-512
6, 7, 8
XV-512 can be open/closed from local
control panel via XHSO/C-512
Page 87 of 161
Page 88 of 161
Page 89 of 161
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
Page 91 of 161
Initiators
No. Initiator Tag No. P&ID Description
1 UX-501 002 General ESD
2 UXHS-503-A 004 Control room ESD pushbutton [1]
3 UXHS-503-B 004 Control room ESD pushbutton (Bypass) [1]
4 UXHS-503-C 008 Local panel ESD pushbutton
5 MGL-101/102 101 Dilution air blower B-2203-A/B stop (both machines stop: 2
out of 2 voting system)
6 UX-502 002 Incinerator ESD
7 LXAHH-501 002 High high level in ARU Off Gas KO drum A-2201-D-01
(active only during acid gas operation, XV-505 opened)
8 FXALL-521 004 Low low flow of combustion air to the thermal reactor
9 FXALL-517 005 Low low level in waste heat boiler A-2201-SG-01
10 BXALL-501-A/B 004 Flame failure (2 out of 2 voting system)
11 PXAHH-551 004 High high pressure in the Thermal Reactor
12 LXAHH-504 002 High high level in H2S rich SWS Off Gas KO drum A-2201-
D-02
13 FXALL-523 004 Low low flow of ARU off gas to the thermal reactor
14 FXALL-528 004 Low low flow of N2 purge
Notes:
[1]: ESD pushbutton UXHS-503-A on Aux. Console in CCC has 2 contacts: UXHS-
503-A (CCC man contact) & UXHS-503-B (CCC ESD Bypass contact)
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 XSY-501 1, 2, 3, 4, 5, 004 Closing of the H2S rich SWS off gas cut-off
6, 7, 8, 9, 10, valve XV-501.
11, 12, 13
XV-501 can be opened / closed from local
panel via XHSO/C-501
2 XSY-504 1, 2, 3, 4, 5, 004 Closing of combustion air cut-off valve XV-
6, 7, 8, 9, 10, 504.
11, 13
3 XSY-505 1, 2, 3, 4, 5, 004 Closing of the ARU off gas cut-off valve XV-
6, 7, 8, 9, 10, 505.
Page 92 of 161
Page 93 of 161
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.
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 (022-
UHSR-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:
Close the Nitrogen cut-off valve 022-XV-509
•
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
Remarks :
i) If the validity time following a shutdown purge is expired and the Claus section
is still in shutdown condition (the SYSTEM RESET pushbutton has not been
pressed), the logic system remains in shutdown condition waiting for SYSTEM
RESET. Otherwise, if the SYSTEM RESET (022-UHSR-503) pushbutton has
been pressed but BURNER ON status is not reached within the 10 minutes of
validity time, at the end of the validity time the logic system activate the all
shutdown sequence.
ii) The opening of 022-XV-509 is inhibited in case 022-PXAHH-551 is active
(Thermal Reactor high high pressure).
iii) The minimum nitrogen flow rate shall be continuously verified during the purge.
In case the nitrogen flow rate falls below 022-FXALL-528 set point before the
purge time is fully expired, the logic system shall automatically:
Reset the purge time counter
•
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
Page 96 of 161
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 MXS-509 ALL 003 Combustion air blower A-2201-B-01-A
tripped
2 MXS-510 ALL 003 Combustion air blower A-2201-B-01-B
tripped
3 UXA-504 ALL 003 DCS Trip Alarm activated
Reset:
Once all the initiators are healthy, UX-504 can be reset via DCS software reset
pushbutton UHSR-504.
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 MXS-501 ALL 002 ARU off gas KO drum pump A-2201-P-01A
is tripped
2 MXS-502 ALL 002 ARU off gas KO drum pump A-2201-P-01B
is tripped
3 UXA-505 ALL 002 DCS trip alarm activated
Reset:
Page 97 of 161
Once all the initiators are healthy, UX-505 can be reset via DCS software reset
pushbutton UHSR-505.
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 MXS-503 ALL 002 H2S rich SWS off gas KO drum pump A-
2201-P-02A is tripped
2 MXS-504 ALL 002 H2S rich SWS off gas KO drum pump A-
2201-P-02B is tripped
3 UXA-506 ALL 002 DCS trip alarm activated
Reset:
Once all the initiators are healthy, UX-506 can be reset via DCS software reset
pushbutton UHSR-506.
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 MXS-507 ALL 002 NH3 rich SWS off gas KO drum pump A-
2201-P-03A is tripped
2 MXS-508 ALL 002 NH3 rich SWS off gas KO drum pump A-
2201-P-03B is tripped
3 UXA-507 ALL 002 DCS trip alarm activated
Page 98 of 161
Reset:
Once all the initiators are healthy, UX-507 can be reset via DCS software reset
pushbutton UHSR-507.
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 MXS-517 1, 2, 3, 4 010 Sulphur circulation pump A-2201-P-04A
tripped
2 MXS-518 1, 2, 3, 4 010 Sulphur circulation pump A-2201-P-04B
tripped
3 UHSC-521 1, 2, 3 011 Steam to ejector cut-off valve closed UV-
521 by forcing UHSC-521 to close position
4 UHSC-522 ALL 011 Degassing air cut-off valve UV-522 closed
by forcing UHSC-522 to close position
5 UHSC-523 ALL 011 Steam to degassing pit cut-off valve UV-523
closed by forcing UHSC-523 to close
position
6 UHSC-524 ALL 011 Sulphur to degassing pit cut off valve UV-
524 closed by forcing UHSC-524 to close
position
7 UXA-508 ALL 011 DCS trip alarm activated
Reset:
Once all the initiators are healthy, UX-508 can be reset via DCS software reset
pushbutton UHSR-508.
Page 99 of 161
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 MXS-519 ALL 010 Sulphur pump A-2201-P-05A tripped
2 MXS-520 ALL 010 Sulphur pump A-2201-P-05B tripped
3 UXA-509 ALL 010 DCS trip alarm activated
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:
Setting
TAG No. Description Type Location PID:
(kg/cm 2g)
-563-C (Spring)
022-TSV Relief Valve
RV A-2201-E-07 PROT 007 9.2
-556 (Thermal)
022-PSV Relief Valve
RV A-2201-B-01-A VENT 003 0.65
-559 (Thermal)
022-PSV Relief Valve
RV A-2201-B-01-B VENT 003 0.65
-602 (Thermal)
For further details, refer to the Flare Discharge Summary of the SRU: Doc. No. 8474L-
022-NM-0006-001.
TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
Section 9 - HSE
The following figures are extracted from the above document and focus on the SRU and
its close surroundings only.
Figure 18: Fire & Gas Detectors Layout Legend for AREA 4
The following figures are extracted from the above document and focus on the SRU and
its close surroundings only:
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
UNIT: 22
Course Content:
Section 1 - General Description
Section 9 - HSE
During plant start-up and shut-down, when fuel gas is fired in the plant, Orsat analysis or
Firyte test will be conduced to detect the O2 and CO content in the tail gas. Flue gas
analysis is normally required any time the rate of combustion is changed.
During heating of the unit by burning fuel gas, it is necessary to control the following:
• Oxygen content
• Carbon monoxide 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.
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-A3101-4110-
300-017
• For NOx /SOx analyser, refer to vendor doc. No. 8474L-022-A3101-4110-300-025
TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
Section 9 - HSE
Note:
The cause & effect matrix Doc. No. 8474L-022-A3505-4110-300-002 details the safety
trips and protections evoked in the safeguards narrative in section 4 of this document.
The fire & gas cause and effect chart deals with all the fire & gas detection system in the
area 4 (units 018, 019, 020 and 022).
Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1 UX-503 2, 3, 4, 5, 6, 004 Activation of Thermal Reactor ESD after a
7, 8 delay of 20 min.
2 UX-508 2, 3, 4, 5, 6, 011 Activation of Sulphur Degassing ESD
7, 8
3 XSY-512 1, 2, 3, 4, 5, 008 Closing of CNU off gas cut-off valve XV-512
6, 7, 8
XV-512 can be open/closed from local
control panel via XHSO/C-512
4 XSY-513 1, 2, 3, 4, 5, 008 Closing of NH3 rich SWS off gas cut-off
6, 7, 8, 9 valve XV-513
XV-513 can be open/closed from local
control panel via XHSO/C-513
5 XSY-514 1, 2, 3, 4, 5, 008 Closing of Fuel Gas cut-off valve XV-514 [1]
6, 7, 8
6 XSY-557 1, 2, 3, 4, 5, 008 Closing of Fuel Gas cut-off valve XV-557 [1]
6, 7, 8
7 XSY-558 1, 2, 3, 4, 5, 008 Opening of fuel gas bleed valve XV-558 [1]
6, 7, 8
8 XSY-515 1, 2, 3, 4, 5, 008 Closing of LPG cut-off valve [1]
6, 7, 8
9 XSY-559 1, 2, 3, 4, 5, 008 Closing of Fuel Gas cut-off valve XV-559 [1]
6, 7, 8
10 XSY-560 1, 2, 3, 4, 5, 008 Opening of fuel gas bleed valve XV-560 [1]
6, 7, 8
11 XSY-516 1, 2, 3, 4, 5, 008 Closing of BYPASS cut-off valve XV-516
6, 7, 8, 10, 11
XV-516 can be open/closed from local
control panel via XHSO/C-516
12 MXS-513 1 008 Trip the incinerator combustion air blower
M-2201-B-02A
13 MXS-514 1 008 Trip the incinerator combustion air blower
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.
TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
Figure 20: Simplified PFD of the SRU (BACH HO – MAX GASOLINE CASE)
ARU Off Gas from Unit 19 & H2S Rich Off Gas from Unit 18
Refer to P&ID’s: 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 A-
2201-D-01 at 50°C and 0.6 kg/cm2g. The acid condens ate recovered in A-2201-
D-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 90°C 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
250°C 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 TV-
522.
The heated ARU off gas then flows to the thermal reactor A-2201-R-01 via TIC-
522, 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 A-
2201-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.
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.
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 253°C 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):
• The main combustion air flows through FIC-527 and FV-527
• The trim air flows through FIC-522 and FV-522.
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 250°C and 0.49
kg/cm2g, via PG-547 and PXA-551.
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 152°C, thru PIC-555, FI-531 and PV-555.
24 kg/hr of blow down from A-2201-SG-01 is sent to the Claus Blowdown drum A-
2201-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 50°C 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 240°C 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 162°C 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 LG-
515/516.
1504 kg/hr of process gas leaving the 1st Sulphur Condenser (A-2201-SG-01 pass
III) at 162°C 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 240°C 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-E-
03 via TV-541. HP condensate exits the reheater at 253°C 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 240°C 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. 321°C.
The temperature inside A-2201-R-03 is monitored via TI-542/543/544.
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 321°C 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-TK-
02) 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 170°C 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 205°C 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-E-
04 via TV-539 and HP condensate exits the reheater at 253°C 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 205°C 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 223°C.
The temperature inside A-2201-R-03 is monitored via TI-545/546/547.
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 223°C 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-TK-
02) 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 162°C is fed to the 3 rd Process Gas Reheater (A-2201-E-05). In A-2201-E-
05, the process gas is heated up to 190°C 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 253°C to the HP condensate header.
1330 kg/hr of heated process gas then flows to the 3rd Catalytic Reactor (A-2201-
R-04) at 190°C 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 193°C.
The temperature inside A-2201-R-04 is monitored via TI-548/549/550.
The process gas leaving the 3rd Catalytic Reactor (A-2201-R-04) at 193°C is fed to
the tube side of the Final Sulphur Condenser (A-2201-E-06), via SC-508 and TI-
551, 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 121°C 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-E-
07 at 39.2°C 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 TG-
558. The level in A-2201-E-06 is monitored remotely via LI-522 and locally via LG-
520 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.
130°C and 0.02 kg/cm2g and flows directly to the I ncinerator (A-2201-H-01), via
AE-501 and SC-511.
212 kg/hr of liquid sulphur collected in the 4 seal legs are sent by gravity at 145°C
to the non-degassed sulphur storage section.
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 A-
2201-TK-01 and A-2201-TK-02 through a steam jacketed line by the Pit ejector A-
2201-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 145°C 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 145°C and 2.0 kg/cm2g to the sulphur
apron via PG-589 and through a steam jacketed line.
Incinerator Section
Refer to P&ID’s: 8474L-022-A0103-4110-003/008 & 8474L-022-PID-0021-101
132 kg/hr of tail gas leaving the Claus section at 130°C and 0.02 kg/cm2g, as well
as 321 kg/hr of vent air from the pit ejectors at 145°C 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 750°C inside the combustion
chamber:
• 19 kg/hr of CNU off gas from the unit 020 are fed to the incinerator burner
at 65°C 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, A-
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, XV-
513 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 36°C 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: 57°C
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.
• In case of prolonged operations with rate lower than 1, catalyst life is
considerably reduced due to the superficial sulphanation of the catalyst.
• 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 49°C for the first reactor a nd 12°C 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
Because it is possible to have the same flame temperature with different air/gas
ratios (refer to the section 3.3.3.1 of the licensor operating manual), the only
operational parameter to be used to operate the SRU plant is the Claus tail gas
analysis.
During the normal acid gas operation no quench steam has to be used for
moderating the flame temperature, unless in case of upset conditions (i.e.
acid gas with very high hydrocarbons content).
The optimum inlet temperature of reactors (with the scope to reach the best
H2S/S02 conversion to sulphur) is the one that achieves the maximum
temperature difference between reactors inlet and outlet.
During this run the efficiency in the sulphur recovery of the plant shall be a little
lower than during the normal run.
and reduce the firing rate to the burners to have a little more
time to correct the problem.
8.4.12. Off Gas K.O. Drum Pumps (A-2201-P-01A/B, 02A/B, 03A/B) Failure
TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
Section 9 - HSE
X
Section 10 - Reference Document Index
SECTION 9 : HSE
SWS/ARU/CNU/SRU units
Figure 22: Abstract of the Hazardous Area Classification Diagram for AREA 4
9.3.1. H2S
The best method for prevention of H2S poisoning is to stay out of areas known or
suspected to contain it. The sense of smell is not an infallible guide as to the
presence of H2S, for although the compound has a distinct and unpleasant odor
(rotten eggs), it will frequently paralyze the olfactory nerves to the extent that
the victim does not realize that he is breathing it . This is particularly true of
higher concentrations of the gas.
Fresh air masks or gas masks suitable for use with hydrogen sulfide must
be used in all work where exposure is likely to occur. Such masks must be
checked frequently to make sure that they are not exhausted. People who must
work on or in equipment containing appreciable concentrations of H2S, must wear
fresh air masks and should work in pairs so that one may effect a rescue or call for
help should the other be overcome.
As mentioned above, the atmosphere in which people work should be checked
from time to time for appreciable concentrations of H2S.
REMEMBER - JUST BECAUSE YOUR NOSE SAYS IT'S NOT THERE, DOESN'T
MEAN THAT IT IS NOT.
9.3.3. Sulphur
PPE recommendation for protection against Elemental Sulphur:
Respiratory Dust-type respirators shall be provided for dusty conditions. Breathing
Protection apparatus must be available for emergency use in case of fire.
Skin Workers whose skin may be sensitive to sulphur dust should button collars, roll
Protection sleeves down, and gather trousers at the ankle. Gloves may be helpful
Eye Dust-tight goggles with plastic or rubber frames may be helpful in dusty
Protection conditions
Hard hat and safety shoes. Fire-retardant fabric is recommended. Sulphur
Other
impregnated clothing should not be worn.
For More information, refer to the MSDS attached in the section 9.6 of the licensor
operating manual doc. No. 8474L-022-ML-001.
9.4.3. Sulphur
Sulphur Health Hazards Summary:
Inhalation Sulphur dust may irritate the mucous membranes of the respiratory passages
Solid sulphur is virtually non-toxic. It can be taken internally in fairly large
Ingestion
doses without injury
In some individuals, sulphur dust has an irritant action, which may be
Skin
aggravated by perspiration or moisture
Sulphur dust in the atmosphere has a highly irritating effect upon the human
Eyes 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 190°C.
For More information, refer to the MSDS attached in the section 9.6 of the licensor
operating manual doc. No. 8474L-022-ML-001.
TRAINING MODULE
UNIT: 22
Course Content:
Section 1 - General Description
Section 9 - HSE
10.14. MSDS
Refer to the following MSDS in the chapter 9.6 of the licensor operating manual, doc. No.
8474L-022-ML-001:
• A-2201-R-02/03/04 Catalyst