OJSC "Giprogazoochistka" Date: 14.02.

2014
105203 Moscow Drawn: Schelb
Lukoil Komy Refinery Rev.: 00
Sulphur Granulation Plant Descr.: First issue
Page: 1/8

Sulphur Granulation Plant

Lukoil Komy Refinery

Process Description
including
Control- and Operating Description

Dwg. No.: 42703-5020

 OJSC "Giprogazoochistka" Date: 14.02.2014
105203 Moscow Drawn: Schelb
Lukoil Komy Refinery Rev.: 00
Sulphur Granulation Plant Descr.: First issue
Page: 2/8

1. PURPOSE

2. REFERENCE DOCUMENTS

3. DESCRIPTION OF PROCESS

4. ABBREVIATIONS

5. PROCESS CONTROL

6. LOCAL OPERATOR PANELS

7. HMI PANEL

Dwg. No.: 42703-5020

 OJSC "Giprogazoochistka" Date: 14.02.2014
105203 Moscow Drawn: Schelb
Lukoil Komy Refinery Rev.: 00
Sulphur Granulation Plant Descr.: First issue
Page: 3/8

1. PURPOSE

This document describes the process, control and Instrument Protective Function of the
Sulphur Granulation Plant, Lukoil Komy Refinery.

2. REFERENCE DOCUMENTS

Sandvik Dwg. No.: 42703-0020 P & I Diagram

42703-0018 Process Flow Diagram

3. DESCRIPTION OF PROCESS

The liquid sulphur will be supplied from an existing sulphur tank by sulphur transfer pumps (by others)
via heated pipelines through liquid sulphur filters (560F-01A/B) to the Rotoform systems.

To ensure that the liquid sulphur pressure at each Rotoform unit infeed is constant, a circulation
pipeline with a pressure control system (PT601104 and PCV601104) is installed. The liquid sulphur
which is not consumed by the Rotoform systems circulates back to the sulphur tank.

The sulphur granulation plant consists of 2 independent Rotoform systems. Each Rotoform system
consists of a ROTOFORM 3000TM, a steel belt cooler with internal water spray system and an exhaust
hood assembly. The ROTOFORM 3000TM continuously forms small pastilles of liquid sulphur and
deposits them on the moving steel belt. The pastilles are cooled and solidified by indirect contact with
cooled water sprayed onto the underside of the belt. The cooling water flows back (by gravity) to the
cooling water pit (by others). Water is recirculated by cooling water pumps 560P-02A/B and cooled
down in cooling water cooler 560E-01 (heat exchanger).

To ensure good detachment of the pastilles from the stainless steel belt a water-soluble, silicone-
based release agent is continuously sprayed as a very thin film on the belt just prior to the
ROTOFORM 3000TM.

The solid pastilles are discharged to bucket elevator 560ME-01 and transferred to hopper of the
weighing and bagging unit 560ME-02. The weighing and bagging unit, where the sulphur pastilles are
packed in big bags, is installed below the hopper. The full big bags are transferred out of the weighing
and bagging unit by the roller conveyor 560ME-04. At the end of the roller conveyor big bags will be
discharged by fork lift.

4. ABBREVIATIONS

PLC: Programmable Logic Controller

DCS: Distributed control system
LOP: Local operator panel

Dwg. No.: 42703-5020

 OJSC "Giprogazoochistka" Date: 14.02.2014
105203 Moscow Drawn: Schelb
Lukoil Komy Refinery Rev.: 00
Sulphur Granulation Plant Descr.: First issue
Page: 4/8

5. PROCESS CONTROL

5.1 Overall Description

The sulphur pastillation unit is a package unit, which is supplied with its own PLC based control
system (PLC), associated with local operator panels (LOPs). The PLC-system controls the Rotoform
units, exhaust fans, cooling water pumps, liquid sulphur pressure control system, release agent
system and the bucket elevator. The PLC consists of a PLC make Allen-Bradley with single CPU,
single power supply and single digital and analogue I/O modules. The PLC and clients DCS are
linked together via serial link (Modbus RTU).

5.1.1 Rotoform Unit Operation

For the Rotoform units 2 operation modes are possible, selected by a selector key switch at the
Rotoform local operator panel (LOP). The actual mode is indicated by indication lamps in LOP.
- production mode
- service mode

Usually the Rotoform unit is running in production mode. The service mode shall be used for
service, maintenance and cleaning of the Rotoform unit only.

5.1.2 Production mode

5.1.2.1 Start up sequence (operated at local control panel only)

(Description is just for line 560SBC-01-1, line 560SBC-01-2 is running with the same conditions)

Interlocking Conditions:

- bucket elevator 560ME-01 is running for hopper filling

(part of weighing and bagging unit 560ME-02)
- hopper level less than high/high (detected by LSHH601170)
- cooling water flow not low (detected by FISL601130)
- release agent tank not empty (detected by LIT601150)
- release agent pump 560P-01A/B is running
- Rotoformer temperature ok (detected by TIT601130)
- sulphur pressure at liquid sulphur supply line ok (detected by PT601104)
- exhaust fan 560B-01A or 560B-01B is running

Non interlocking Conditions:

- steel belt is clean and free of dust and foreign particles
- Rotoformer is clean
- liquid sulphur filter 560F-01A/B clean (PDAH601101)

Dwg. No.: 42703-5020

 OJSC "Giprogazoochistka" Date: 14.02.2014
105203 Moscow Drawn: Schelb
Lukoil Komy Refinery Rev.: 00
Sulphur Granulation Plant Descr.: First issue
Page: 5/8

Start steel belt cooler at LOP

- Start steel belt cooler of unit 560SBC-01-1 by pressing push button at LOP
- When steel belt cooler is running and Rotoformer temperature is high enough, (indicated
by temperature transmitter TIT601130) start Rotoformer by pressing the push button at
the LOP.
- When the steel belt cooler, Rotoformer and exhaust fan is running, open product valve
XV601120 by pressing the push button at the LOP.
- Production is running automatically now.
- During production it is not possible to stop the Rotoformer or the Cooling while the
product valve is open, indicated by ZSO601120. (except emergency stop).
Product valve closed is indicated by ZSC601120.

5.1.2.2 Shutdown sequence

- Shutdown sequence operation is activated by pressing a push button at LOP

- Product valve XV601120 closes immediately

- After a time delay of 10 minutes, when product valve is closed (indicated by

ZSC601120), the Rotoformer stops automatically.

- After an additional time delay of 10 minutes, when the Rotoformer has stopped, the steel
belt cooler stops too.

- In case of shut down of both lines only: When both steel belt coolers are stopped, the
release agent pump stops too. After an additional time delay of 10 minutes, when both
steel belt coolers and both Rotoform units have stopped, the exhaust fan stops
automatically and the bucket elevator too.

- Shutdown sequence is finished.

- The shutdown sequence can be interrupt, by starting again of steel belt cooler
Rotoformer or open product valve.

Dwg. No.: 42703-5020

 OJSC "Giprogazoochistka" Date: 14.02.2014
105203 Moscow Drawn: Schelb
Lukoil Komy Refinery Rev.: 00
Sulphur Granulation Plant Descr.: First issue
Page: 6/8

5.1.2.3 Failure handling

- Downstream equipment trip (bucket elevators)

>>> shutdown sequence of both Rotoform units starts automatically.

- Cooling water flow (detected by FISL601120) or Rotoformer temperature are low

(detected by TIT601130)
>>> shutdown sequence of relevant Rotoform unit starts automatically.

- Sulphur pressure (detected by PT601104) is high/high or low/low

>>> shutdown sequence of both Rotoform units starts automatically.

- Motor trip or speed monitoring fault (SSL601120) of steel belt cooler

>>> product valve closes and Rotoformer stops immediately.

- Motor trip or speed monitoring fault (SSL601121) of Rotoformer

>>> product valve closes immediately and steel belt cooler stops after time delay

- Exhaust fan 560B-01A and B fail

>>> shutdown sequence of both Rotoform units starts.

- Discharge knife fault (PSAL601120)

>>> product valve closes and Rotoformer stops immediately.

- Rotoformer hood open (ZSS601120)

>>> product valve closes and Rotoformer and Steel belt cooler stop immediately.

- Release agent tank level low / low (detected by LIT601150)

>>> shut down sequence of both Rotoform unit starts.

5.1.3 Service Mode

- In service mode it is possible to run the steel belt cooler and the Rotoformer or open the
product valve independent of each other and independent of exhaust fan running,
sulphur pressure or downstream equipment.
- just 2 interlocks are active: cooling water flow min. (detected by FISL601120) to avoid
damage of steel belt due to dry run) and emergency stop for the whole plant.

Dwg. No.: 42703-5020

 OJSC "Giprogazoochistka" Date: 14.02.2014
105203 Moscow Drawn: Schelb
Lukoil Komy Refinery Rev.: 00
Sulphur Granulation Plant Descr.: First issue
Page: 7/8

5.2 Liquid sulphur supply

5.2.1 Sulphur filter (560F-01A/B)

To protect the Rotoform units against pollution, a filter station is installed in the sulphur feed line.
The sulphur filter will be monitored by 2 pressure transmitters (PT601101 and PT601102). Inside the
PLC the pressure difference will be calculated. If the difference pressure is too high, a signal
(PDAH601101) will be generated in the PLC and send an alarm signal to the DCS and the operator
has to clean the filter.

5.2.2 Sulphur circulation line and pressure control

The pressure control system consists of a pressure control valve PCV601104, a pressure transmitter
PT601104 and a PLC based software controller. Set points have to be adjusted during
commissioning. Unused sulphur circulates back to clients sulphur tank.

5.3 Release agent system

In order to avoid any damage to the pastilles when being discharged a release agent system is
installed.
This system consists of:
- Release agent tank 560V-01 with a level transmitter LIT601150 for level monitoring.
- Agitator 560A-01 with motor M-V-01 to mix up the release agent.
- Release agent spraying unit with spraying nozzle bar at each Rotoform Unit

5.4 Solid sulphur weighing and packing system

Solid sulphur pastilles are packaged in big bags by using weighing and bagging unit 560ME-02. This
unit is controlled by a separate PLC with an implemented PLC based weighing system (make
SIEMENS).
Operating Details are shown in the manual of the weighing and bagging unit.

5.5 Indication system

- All running and common failures of drives and positions of product valves are indicated
by indication lamps at the local operator panels (LOP)
- Detailed informations will be sent via serial link to clients DCS in the control room.

Dwg. No.: 42703-5020

 OJSC "Giprogazoochistka" Date: 14.02.2014
105203 Moscow Drawn: Schelb
Lukoil Komy Refinery Rev.: 00
Sulphur Granulation Plant Descr.: First issue
Page: 8/8

5.6 Emergency stop system

- All pull rope switches and E-Stop push buttons (NC-contacts) are connected to a
certified emergency stop module installed in the control cabinet.
- 2 pull rope switches are installed at each Rotoform unit, 1 mushroom head pushbutton is
installed at each local operator panel (LOP).
- In case of an emergency stop, caused by pull rope switches or e-stop button at the LOP
of the Rotoform unit, all product valves close, all Rotoformers, all steel belt coolers,
exhaust fan, release agent pump, cooling water pump, bucket elevators stop
immediately.
- For safety reasons it is necessary to stop all Rotoformer units and drives together.
- To restart the plant the pull rope switches and E-stop pushbuttons have to be unlocked
and the emergency stop relay has to be reset by operation of the reset button at LOP.
Rotoformer units will be restarted as described at Item 5.1.2.1 Start up Sequence.

6. Local Control Panels

- The sulphur pastillation unit will be operated by 8 Local Operator Panels (LOP)

Functions:

TAG No. Panel Location Function:

LOP01 at steel belt cooler operating of Rotoform Unit
560SBC-01-1 560RF-01-1
LOP02 at steel belt cooler operating of Rotoform Unit
560SBC-01-2 560RF-01-2
LOP03 Close to utilities operating of utilities, like:
(where all utilities are in # Release agent system
sight) # cooling water pumps
# bucket elevator
LOP04 at weighing and packing operating weighing and
unit 560ME-02 packing unit

7. HMI Panel

- The HMI panel is mounted at the cabinet door of the PLC cabinet.
On this panel process values are displayed as well as the status of the unit.
At commissioning the software controllers are adjusted/optimized by entering
appropriate parameters and limits.

Dwg. No.: 42703-5020