SRU Original
SRU Original
SRU Original
This give the measure of unconverted H2S and SO2 content of Claus tail gas
to MCRC converters. This is very important for MCRC operation. It controls the
ratio by adjusting air demand control valve (trim air) to the ratio of H2S/SO2.
This is the fine tuning of air demand to the burners depending upon the
ADA output.
Ammonia gas if it is not destructed completely may lead to form salts in the
catalyst bed. So higher temp. is recommended to promote destruction of offending
species.
Hydrocarbon 0.13% 0 0
CO2 6% 0 0
Dew point is the temper at which the water vapor in a saturated air at
constant pressure condenses into liquid water at the same rate of which it
evaporates at temp. below due point water will leave the air.
If the temp of the line decreases, the sulphur will solidify and will be
chocked. So steam jacketing is used.
Seal pots are ‘column in pipe ‘ construction which stands a column of liquid
sulphur in side a pipe. This seal provide necessary back pressure in the respective
heat exchangers to facilitate flow of gases in the process flow direction. This seal
prevent uncondensed acid gases containing unconverted H2S in the exchanges to
escape to the product sulphur equipment. Its length is 6.093 mtrs.
Mainly CS. Due to high corrosion, the metallurgy for the suction and
discharge piping for the ejector system is changed to SS. Steam coils in sulphur pit
are also changed to SS. The top 1 meter of RF stack is of SS-316 material.
17. What will be the effect at high temp on metallurgy of claus converter?
21. What are the temperatures at I/L and O/L of claus and MCRC?
Overall claus reaction separated into thermal reaction and catalytic reaction.
In this, therminal reaction carried out in main burners. In which H2 S converted
into SO2
28. Why are we keeping 2:1 ratio and if not keeping what will be the effect on
equipments?
Claus reaction requires 1:2 ratio of SO2 to H2S. If H2S will be high, then
corrosion of metallurgy will be high.
This promotes NH3 destruction by reflecting the radiant heat back towards
the flame zone.
This reduces the operating temp of the WHB tube sheet refractory so
lengthening service.
This provides enough residence time and proper mixing for the Claus
reaction.
All molar flow rates of H2S, NH3 and he in the feed are summed up and
total air required is calculated.Air fuel ratio is set by the computation block FFC
1301 which gives the set point for the air flow controller DSFIC 1301. Which is
the slave for the ratio controller FFC 1301.
32.How much air required for H2S in acid gas &SWS acid gas for combustion ?
Combustion air required for KH2S mole of acid gas = ½ *1/0.29 *KH2S
= 1/0.58 * KH2S
hr of air
This can be used for air demand calculation for main air DSFC 1301/5301 in
AIR DEMAND calculation block.
It measure outlet flue gas O2 and SO2 composition. This gives the degree of
completion of combustibles in tale gas/Fuel gas to incinerator and also the excess
oxygen in the flue gas.
36. Why it is limited 3 MCRC, eventhough more recovery is possible with more
no. of MCRC.
We are getting 99% recovery of sulphur through entire process, if we are adding
more MCRC the amount of conversion we are getting is too low compared to the
initial investment required and maintenance.
Normally we are giving purge steam during startup and shut down,During
start up some time the condensate temp.will be less in condensers so during
change over from FG to AG , temp of condensate should be maintained in order to
maintain aid gas temp.
If there will be any emergency shutdown of air fin motors, at that time also, we
will open purge steam.
40. How much % of conversions are taking place in MCC, claus and MCRC
convertors?
In MCC – 60 to 65% recovery
Claus - 94%
MCRC - 99%
Claus converter requires 270-290oC at inlet. The effluent gases from WHB
at 315 oC passes through condenser – I and cooled to 195 oC from where S flows to
Spit. Line burner raises this temp to 270-290 o before going to Claus converter.
3. LPG to LB high-high-2kg/cm2
44. What is surging of blowers?
Surging may also occure if the I/L temperature is considerably higher than
the maximum design temperature.
IGV helps to throttle the flow during operation close to surge point there by
optimizing the anti-surge flow.
6 mt.
Sandvik.
300 tons
Belt motor and gearbox are being operated without no-load condition. By
this inclination certain load should be taken by gearbox without Sulfur loading.
The load difference should be less when sulphur loading starts.
H2S SO2
Ensure BOV is opened condition. Then start the Blower, Electrical lube oil will
start first. In main air blower as there is no mechanical lube oil pump, it will run
continuously, where as in incinerator blower mechanical pump will be started with
blower shaft, then electrical pump will stop automatically.
Then press ‘Burner sequence reset’ push button, ‘start-up bypass’ and ‘start
purge buttons simulteneusally in the local panel.
With the help of instruction from panel, latch c/v on air line, then latch 3
SDV s on LPG line. At the same time one operator should press ignition button,
ensure burner is lighted up,After this remove lance.
4. Two Sulfur rundown lines are lined up at same time in a single train.
KOD have high level switches .The safely shut down valve
at very high level is provided to prevent liquid entering in to the main burner and
claus Reactors and there by damaging the refractory/ burners and claus catalyst.
62. what are the colours of flame in MB and LB in A/G mode and FG mode ?
In FG mode In AG mode
63. What is the effect of air in case of high emission in Incinerator stack?
H2Sbearing flare line is directly going to the top of the flare without joining to
other Hydrocarbon flare line .Hydro carbon flare line is going through water seal
.But if H2S will go through water seal the water will be made acidic so corrosion
tendency will be high .so water seal is bypassed for H2S flare.
66. Why SUR feed gas (from ARU top) is called Acid gas?
Time).
5. Ensure that the plant heating system the jacketing steam for SRU is
Open.
Purgin is going on for 5 minutes then purge will complete (light on panel)
before pilot ignition close air blowers discharge B/V.
Ensure flame
Ensure flame.
71. Why ADA is provided at outlet of Claus why not at I/L of Claus convertor?
All conversion is completing at O/L of clause. Before clause COS, CS2 will be
present. So reading will not be accurate.
1.7kg/cm3.
73. As per design ‘s’ could not be drawn from WHB, but now we are getting
more Sulfur in WHB why ?
In design, WHB outlet temp is 310oC. But now it is 220oC. So below due
point (260oC) sulphur condensation starts.
300 tons
720 tones, when the pit level transmitter indicator 100% there is still a gap
of 120 tons.
DDP 32 and DDP 33 are using this when power supply will fail for a very
short period (3 second) these motors will be started automatically, immediately
after resuming the power. But now it is not working as there is no time delay
given to shutdown command in DCS panel.
2 SO2+O2 2 SO3
80. At which condition we will close clause bypass in fuel gas mode operation ?
Overall reaction
= 0.5 moles of O2
82. How much is the rpm of air blower and incinerator blower ?
84. What are the settings given in DCS for startup of Burner ?
85. If LDEA strength go below 200 ppm (sulphides), What will be its effect ?
There may be a chance of back fire in pilot barrel, if giving air for purging.
So its tip may be damaged due to high temp. N2 provides inert atmosphere inside
barrel.
87. How much time, LO electric motor of air blowers will run before and after
running of blower ?
Blower will start after 1 minute running of LO pump. LO pump will stop after 5
minutes. (after stoppage of blower)
88. Why TCV is provided in Lube Oil line of air blowers in SRU ?
TCV is provided in lube oil pump discharge line before oil cooler. This is to
maintain the lube oil temperature in gear box. When lube oil temperature goes
below because of climate condition(cold countries) this TCV will open and bypass
lube oil cooler and maintain oil temperature by a bimetallic strip inside.
SWSU
1. Plant Licensor?
EIL
2. Plant capacity?
19 T/hr (designed)
3. What is the objective of SWSU ?
The objective is to remove hydrocarbons and to strip the NH3 & H2S from sour
water to produce a water with not more than 50ppm wt H2S and NH3.
4. How much H2S removed in Ist stage stripper ?
` 94% of H2s
NH3 should not go beyond 1000 ppm wt % from stripper I top along with
H2S. At high pressure NH3 stripping will be less because of high boiling point of
NH3 than H2S. Beyond 8 kg/cm2. H2S stripping is also less. So 8 kg/cm2 is
optimum.
3. Because of this, there will be less generation of H2S & NH3, control
steam flow to re boilers.
4. Isolate sour gas to SRU, open O/H flare header for avoiding vaccum
when it cools.
15. Why the diameter of IInd stripper column at top is greater than bottom ?
16. What is the total height of siphon at the O/L of surge drum ?
HC - 0.09 wt%.
CO2- 0.89wt%.
This is necessary to provide adequate spare volume in the tank to transfer the
entire inventory from the system to tank in case of shutdown, planned or
unplanned S/D.
5. What is PVRV ?