Operating procedures for sulfur degassing and transfer

Operating Procedures Manual Winter 2010
Oil & Gas Development Company Limited Dakhni, Pakistan
DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT
Table of Contents
9. SULFUR DEGASSING AND TRANSFER.............................................................. 9-1 9.1 PURPOSE OF SYSTEM ................................................................................ 9-1 9.2 SAFETY ......................................................................................................... 9-1 9.3 PROCESS DESCRIPTION ............................................................................ 9-2 9.4 EQUIPMENT DESCRIPTION ........................................................................ 9-4 9.4.1 Degassing Air Blower, C-1903A&B ............................................................ 9-4 9.4.2 Sulfur Transfer Pump, P-1902A&B............................................................. 9-4 9.4.3 Sulfur Feed Pump, P-1903A&B.................................................................. 9-4 9.4.4 Degassed Sulfur Drain Seal Assembly, PA-1903....................................... 9-5 9.4.5 Sulfur Degassing Reactor, R-1902............................................................. 9-6 9.4.6 Bed Support and Limiter for Sulfur Degassing Reactor, R-1902-2............. 9-6 9.4.7 Sulfur Pit, TK-1901 ..................................................................................... 9-7 9.5 INSTRUMENTATION AND CONTROL SYSTEMS........................................ 9-8 9.5.1 Sulfur Feed Rate Control............................................................................ 9-8 9.5.2 Degassing Air Flow..................................................................................... 9-9 9.5.3 Sulfur Transfer Rate Control..................................................................... 9-10 9.5.4 "Ride-Through" System Considerations ................................................... 9-10 9.5.5 Sulfur Degassing Unit Startup Interlock.................................................... 9-10 9.5.6 Sulfur Degassing Shutdown System ........................................................ 9-12 9.5.6.1 Causes ............................................................................................. 9-12 9.5.6.2 Effects............................................................................................... 9-13 9.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ...................... 9-14 9.6.1 Equipment Damage.................................................................................. 9-14 9.6.2 Degassing Air Blower Operation .............................................................. 9-16 9.6.2.1 Starting a Degassing Air Blower ....................................................... 9-16 9.6.2.2 "Swapping" Degassing Air Blowers During Operation...................... 9-17 9.7 PRECOMMISSIONING PROCEDURES...................................................... 9-19 9.7.1 Preliminary Check-out .............................................................................. 9-19 9.7.2 Commissioning the Heating and Ventilation Systems .............................. 9-20 9.7.3 Purging the Sulfur Degassing Reactor ..................................................... 9-22 9.8 STARTUP PROCEDURES .......................................................................... 9-24 9.8.1 Initial Startup of the Sulfur Degassing Unit............................................... 9-24 9.8.1.1 Filling the Sulfur Drain Seal in the Sulfur Outlet Line........................ 9-24 9.8.1.2 Placing the Sulfur Degassing Reactor in Operation ......................... 9-26 9.8.2 Normal Startup of the Sulfur Degassing System ...................................... 9-29 9.8.2.1 Filling the Sulfur Degassing Reactor ................................................ 9-29 9.8.2.2 Placing the Sulfur Degassing Reactor in Operation ......................... 9-30 9.8.3 Sulfur Transfer Operation ......................................................................... 9-33 9.9 SHUTDOWN PROCEDURES ...................................................................... 9-35 9.9.1 Planned Shutdown - No Entry .................................................................. 9-35
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9.9.2 Planned Shutdown for Entry..................................................................... 9-36 9.10 SETPOINTS (CONTROLLERS, ALARMS, S/DS, PCVS, PSVS) ................ 9-38 9.10.1 DCS/PLC Device Controller and Alarm Setpoints ................................ 9-38 9.10.2 Non DCS/PLC Device Controller and Alarm Setpoints ........................ 9-38 9.10.3 DCS/PLC Device Shutdown Setpoints ................................................. 9-39 9.10.4 Non-DCS/PLC Device Shutdown Setpoints ......................................... 9-39 9.10.5 Safety Valve Setpoints ......................................................................... 9-39 9.11 OPERATING LIMITS.................................................................................... 9-40 9.11.1 Degassing Air Blower, C-1903A&B ...................................................... 9-41 9.11.2 Sulfur Transfer Pump, P-1902A&B....................................................... 9-42 9.11.3 Sulfur Feed Pump, P-1903A&B............................................................ 9-44 9.11.4 Degassed Sulfur Drain Seal Assembly, PA-1903................................. 9-46 9.11.5 Sulfur Degassing Reactor, R-1902....................................................... 9-47 9.11.6 Bed Support and Limiter for Sulfur Degassing Reactor, R-1902-2....... 9-50 9.11.7 Sulfur Pit, TK-1901 ............................................................................... 9-51 9.12 SULFUR TANK STRAPPING TABLE .......................................................... 9-52 9.13 SPECIFICATION FOR SULFUR DEGASSING REACTOR CATALYST ..... 9-56 9.14 DRAWINGS.................................................................................................. 9-57 Material Balance & Process Flow Diagrams Material Balance.......................................................... 1029-96-06-CS-001 Process Flow Diagram ............................................... 1029-09-06-DR-002 Piping & Instrument Diagrams Symbol Legend............................................................ 1029-96-06-DR-001 Sulfur Pit ...................................................................... 1029-09-06-DR-010 Sulfur Degassing ......................................................... 1029-46-06-DR-001 Sulfur Pit ...................................................................... 1029-46-06-DR-001 Cause & Effect and Logic Diagrams Sulfur Pit and Degassing ............................................. 1029-46-06-CD-004 Sulfur Pit and Startup Interlock.....................................1029-46-06-LD-008
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9. SULFUR DEGASSING AND TRANSFER

9.1 Purpose of System
The purpose of the Sulfur Degassing and Transfer system is to reduce the H2S content of the molten sulfur product to 10 PPMW or less, then transport the sulfur to the new Sulfur Solidification Unit or the existing Block Formation Unit. The raw sulfur product from the sulfur plant contains approximately 200-300 PPMW of hydrogen sulfide, which is typically reduced to 50-100 PPMW after one or more days of storage by natural "weathering". Since this natural weathering is not enough to consistently meet the 50 PPMW specification for the sulfur product, this system provides additional degassing that will ensure that the H2S content is sufficiently low before the sulfur is transferred to the Sulfur Solidification or Block Formation units.
9.2
Safety
WARNING
ALL PIPING AND VESSELS INCLUDED IN THIS UNIT EITHER CONTAIN OR HAVE THE POTENTIAL FOR CONTAINING HAZARDOUS GASES THAT MAY CAUSE SERIOUS INJURY OR DEATH. THE TWO GASES THAT ARE MOST COMMON AND HAZARDOUS IN A TOXIC WAY ARE HYDROGEN SULFIDE AND SULFUR DIOXIDE. CLOSE ATTENTION SHOULD BE PAID TO THE "GENERAL SAFETY" SECTION OF THIS MANUAL AS TO THE NATURE AND ABILITY OF THESE GASES TO CONTAMINATE OTHER ELEMENTS IN THIS UNIT. AN EMPLOYEE'S KNOWLEDGE OF THE HAZARDOUS CHEMICALS AND COMPOUNDS WITH WHICH HE WILL BE WORKING IS ONE OF THE MOST BASIC PREREQUISITES FOR HIS OWN SAFETY, THE SAFETY OF OTHERS, AND THE PROTECTION OF EQUIPMENT. ALL EMPLOYEES SHOULD REVIEW THE "GENERAL SAFETY" SECTION OCCASIONALLY TO REFRESH THEIR MEMORIES. NEW EMPLOYEES SHOULD STUDY IT UNTIL THE INFORMATION IS THOROUGHLY UNDERSTOOD. PEOPLE WHO HAVE NOT BEEN PROPERLY TRAINED SHOULD NOT BE ALLOWED TO OPERATE OR WORK IN AND AROUND THIS PLANT.
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9.3
Process Description
The Material Balance and Process Flow Diagram, Dwg. Nos. 1029-96-06-CS-001 and 1029-09-06-DR-002 respectively, are contained in Section 9.14 of this manual. Please refer to these drawings to follow this description of the process. The liquid sulfur produced in the condensers of a Claus sulfur plant is in contact with process gas containing hydrogen sulfide at elevated temperature and pressure. As a result, the raw sulfur product from Claus plants contains a significant amount of hydrogen sulfide. Some of the hydrogen sulfide in the sulfur is dissolved H2S gas, but the majority of it is hydrogen polysulfide (H2SX) formed in the condensers by the following reaction: (1) H2S + SX-1 H2SX
While the liquid sulfur is stored in the raw production section of the Sulfur Pit, TK-1901, a considerable portion of the polysulfide will break down into H2S and be released into the ventilation air circulated through the vapor space of the pit. This natural "weathering" process typically reduces the H2S content of the molten sulfur to 50-100 PPMW after one or more days of storage. However, since the natural decomposition of H2SX in the liquid sulfur is a slow and generally incomplete process, additional means of degassing the sulfur must be employed to ensure that the H2S content of the sulfur product does not exceed 50 PPMW. The sulfur degassing technology licensed by BP Amoco Corporation is used to reduce the H2S content of the freshly produced sulfur (approximately 200-300 PPMW) to less than 50 PPMW. The Sulfur Feed Pump, P-1903A&B, pumps the fresh liquid sulfur from the raw production section of the Sulfur Pit into the bottom of the Sulfur Degassing Reactor, R-1902. Compressed air from the Degassing Air Blower, C-1903A&B, is supplied to a sparger in the bottom of the reactor, so that the air and sulfur flow co-currently upward through a catalyst bed. The catalyst promotes decomposition of the polysulfide into H2S and sulfur, so that the air can strip the H2S from the sulfur and remove it from the reactor. Since reaction (1) is an equilibrium reaction, removal of the H2S by the air stream shifts the equilibrium toward the left side of the equation, allowing almost complete decomposition of the polysulfide. The degassed sulfur, containing less that 50 PPMW hydrogen sulfide, gravity-drains from the top of the reactor into the degassed section of the Sulfur Pit through the Degassed Sulfur Drain Seal Assembly, PA-1903. The drain seal has a "U"-tube that uses static head from a column of liquid sulfur to serve as a seal and prevent the degassing air from escaping. The drain
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seal is steam-jacketed to prevent sulfur from freezing and has a view hatch to allow verifying that the rundown line is flowing. The spent degassing air (containing H2S and traces of elemental sulfur vapor) leaves the top of the Sulfur Degassing Reactor and is routed to the Tailgas Thermal Oxidation system for incineration. The Sulfur Transfer Pump, P-1902A&B, pumps the degassed liquid sulfur from the Sulfur Pit to the Sulfur Solidification Unit or the Block Formation Unit.
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9.4
Equipment Description
Degassing Air Blower, C-1903A&B
Rated Capacity: Suction Pressure: Discharge Pressure: Driver: 150 SCFM each 14.3 PSIA 29.3 PSIA 18.5 kW Electric Motor
9.4.1
These Gardner Denver Model Cycloblower 3CDL5P rotary lobe blowers provide the degassing air required to strip the H2S from the sulfur in the Sulfur Degassing Reactor. The blowers are connected to the discharge piping through flexible connectors to allow the necessary freedom for the expansion and movement that occurs during normal operation. Each blower is equipped with an intake silencer and a discharge silencer.
9.4.2
Sulfur Transfer Pump, P-1902A&B

Rated Capacity: Suction Pressure: Discharge Pressure: Driver: 18.5 GPM 0.5 PSIG 93.8 PSIG 20 HP Electric Motors
These special steam-jacketed Chas S. Lewis type VSHR sump-type pumps are used to transfer the degassed molten sulfur product from the degassed section of the Sulfur Pit to the Solidification Unit or the existing Block Formation Unit. This type of pump is unique in that it uses the molten sulfur to lubricate its bearings. For this reason, the pumps should never be operated dry. The pump casing and impeller are cast iron; the steam-jacketed shaft and discharge pipe are carbon steel.
9.4.3
Sulfur Feed Pump, P-1903A&B

Rated Capacity: Suction Pressure: Discharge Pressure: Driver: 13 GPM 0.5 PSIG 49.8 PSIG 7.5 HP Electric Motors
These special steam-jacketed Chas S. Lewis type VS sump-type pumps are used to transfer the molten sulfur product from the raw
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production section of the Sulfur Pit to the Sulfur Degassing Reactor. These pumps also use the molten sulfur to lubricate their bearings. For this reason, the pumps should never be operated dry. The pump casing and impeller are cast iron; the steam-jacketed shaft and discharge pipe are carbon steel.
CAUTION DO NOT OPERATE THESE PUMPS IF THE LEVEL IN THAT SECTION OF THE SULFUR PIT IS BELOW THE MINIMUM SUBMERGENCE LEVEL (THE SHADED REGION OF THE STRAPPING TABLES IN SECTION 9.12 OF THIS MANUAL). IF THE SULFUR LEVEL IS TOO LOW, THE SHAFT BEARINGS WILL NOT RECEIVE PROPER LUBRICATION AND THE PUMP WILL BE DAMAGED.
9.4.4
Degassed Sulfur Drain Seal Assembly, PA-1903

Size: Steam Side Design: Process Side Design: 4"x6" with 4980 mm seal leg 100 PSIG @ 350/0F 14 PSIG @ 350/0F
One of Ortloff's proprietary Sulfur Drain Seal Assemblies is used for the Degassed Sulfur Drain Seal Assembly. It is designed to drain liquid sulfur from the Sulfur Degassing Reactor. The seal is built as a "U-type" trap that uses liquid sulfur to seal and prevent process gases from flowing to the Sulfur Pit along with the liquid sulfur product. The drain seal is sized to provide a seal leg which should not blow out at the maximum operating pressure of the Sulfur Degassing Reactor. The seal is fully steam-jacketed and designed to be installed in the top of the Sulfur Pit. The seal has a hinged inspection hatch to allow observation and sampling of the flow from the Sulfur Degassing Reactor. The liquid sulfur from the inspection basin flows down to the bottom of the Sulfur Pit through a drain pipe to prevent free-fall of the liquid sulfur, which could cause static electricity to build up. The drain seal is mostly carbon steel, except for the inspection hatch which is aluminum. The drain seal has a removable blind flange to allow "rodding" its rundown line, and a removable blind flange to allow "rodding" its dip leg. Before removing either flange, close the plug valve in the rundown line to prevent the escape of process gas to the surroundings
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when the plug is cleared. When the rodding operation is complete and the flange(s) are back in place, remember to reopen the plug valve.
9.4.5
Sulfur Degassing Reactor, R-1902

Size: Jacket Design Conditions: Shell Design Conditions: 42" I.D. x 18'-0" S-S 100 PSIG / F.V. @ 350/0F 50 PSIG @ 350/0F
The Sulfur Degassing Reactor contains a catalyst bed to promote the decomposition of the polysulfide into H2S and sulfur, so that the air from the Degassing Air Blowers can strip the H2S from the sulfur and remove it from the reactor. Sulfur enters the bottom of this vertical vessel and mixes with air entering through a sparger so that the air and sulfur flow co-currently upward through the catalyst bed. The degassed sulfur gravity-drains from the top of the vessel through the Degassed Sulfur Drain Seal Assembly and into the Sulfur Pit. The degassing air flows through a mist eliminator as it leaves the top of the reactor and is then routed to the Tailgas Thermal Oxidation system. Since the normal liquid level for molten sulfur in this reactor is at the top of the weir on the draw pan above the catalyst bed, the bottom head and shell of the vessel are steam-jacketed. The inlet and outlet sulfur, inlet air, outlet gas, and clean-out nozzles are also steam-jacketed. This vessel is constructed of carbon steel and was stress relieved after fabrication. It is designed and stamped per ASME Section VIII Code, and was coated with a baked phenolic lining on its interior surfaces after fabrication. Refer to Section 9.13 of this manual for the type of catalyst used in the Sulfur Degassing Reactor.
9.4.6
Bed Support and Limiter for Sulfur Degassing Reactor, R-1902-2

Size: Design Temperature: Fits a 42" I.D. vessel 350/0F
A bed support and a bed limiter fabricated from 304 S.S. AlphaPLUS Wedge Wire Screen are used to hold the catalyst bed in the Sulfur Degassing Reactor. The screens are fabricated in sections that fit through the vessel manways. One side of each screen section is equipped with flashing where it fits next to its neighbor, so that the screen sections can expand and contract without creating gaps where the catalyst could leak through.
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Both the bed support and the bed limiter are designed to have about a 12 mm gap next to the vessel shell to allow for differential thermal expansion between the bed support and the vessel. Ceramic rope packing is used to fill this gap so that catalyst cannot leak between the bed support (or bed limiter) and the vessel shell.
9.4.7
Sulfur Pit, TK-1901

Refer to Section 7.4.20 of this manual for a description of this equipment item. Note that an excessively high level in the raw production section of the Sulfur Pit will cause raw sulfur to spill over the internal weir, bypassing the Sulfur Degassing Unit and contaminating the degassed sulfur. A sample of the sulfur in the degassed section of the Sulfur Pit should be analyzed periodically to confirm that the sulfur product is within its H2S specification. Samples can be collected through a 3" breather vent nozzle at that end of the tank by temporarily removing its rain hat and lowering a sample container down into the molten sulfur.
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9.
9.5
Instrumentation and Control Systems

Sulfur Feed Rate Control
A reasonably steady sulfur feed rate to the Sulfur Degassing Reactor will help the Sulfur Degassing Unit operate smoothly. At the same time, however, the feed rate to the reactor must match the sulfur production rate into the Sulfur Pit from the SRU reasonably closely, or else the raw production section of the pit will eventually either run dry or overflow into the degassed section. A level/flow cascade control loop is used to satisfy these requirements. Traditional level measuring devices do not function reliably in molten sulfur service. For this reason, a "bubbler"-type level transmitter is most often used in this service. A steam-jacketed pipe (a bubbler tube) is mounted through the top of the Sulfur Pit and extended nearly to the bottom of the pit. A small flow of instrument air is introduced into the inner pipe, so that air slowly bubbles from the bottom of the pipe up through the sulfur. The pressure inside the bubbler tube depends on the static head imposed by the liquid sulfur in the pit, which is a linear function of the liquid level. The DCS can then convert this pressure measurement into the corresponding liquid sulfur level in the pit. This type of level measuring device is used for LT-4601 in the raw production section of the pit and for LT-0907 in the degassed section of the pit. Traditional flow measuring devices also do not function reliably in molten sulfur service. For this reason, a "Coriolis"-type mass flow meter is used to measure the liquid sulfur as it is pumped from the raw production section of the pit into the Sulfur Degassing Reactor by the Sulfur Feed Pump. The flow meter, FT-4601, is located downstream of the take-off for the spill-back line, 2.00X3.00-S-46036-A10J-2.5H, so that the sulfur feed rate into the reactor can be adjusted by varying the amount of sulfur spilling back into the pit. The level in the raw production section is controlled by LC-4601, which supplies a cascade setpoint to the sulfur feed rate controller, FC-4601. If the level is rising in the pit, the feed rate to the Sulfur Degassing Reactor will be slowly increased by raising the setpoint of FC-4601. If the level is falling, the setpoint will be lowered to slowly reduce the feed rate. In this manner, the level in the raw production section of the Sulfur Pit can be maintained at the desired value while avoiding sudden changes in the feed rate to the Sulfur Degassing Reactor.
9.5.1
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DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.5.2 Degassing Air Flow
A constant ratio of degassing air flow to sulfur flow is not necessary for the Sulfur Degassing Unit to operate smoothly. It is only necessary that the air:sulfur flow ratio be maintained above a minimum value (1.2 SCFM per LT/D) to ensure adequate stripping of the sulfur. The air flow rate to the Sulfur Degassing Reactor is not controlled, but instead is simply dictated by the capacity of the Degassing Air Blower. The design flow rate of one of these blowers is high enough to maintain the air:sulfur flow ratio above the minimum even at the design sulfur production rate. There are two reasons for using a fixed degassing air flow rate rather than controlling the air:sulfur flow ratio. The first reason is that the spent degassing air from the Sulfur Degassing Reactor is routed to the Thermal Oxidizer as a part of its feed. Keeping the degassing air flow rate at a constant value makes it easier to maintain good temperature control in the TTO. The second reason is that variations in the air flow rate can cause fluctuations in the sulfur feed rate to the Sulfur Degassing Reactor. The pumping rate of the Sulfur Feed Pump depends on the discharge pressure from the pumps, which is in turn a function of the static head imposed on the pump discharge. This static head has two components: the static head of the liquid sulfur in the discharge piping going to the Sulfur Degassing Reactor, and the static head of the sulfur/air mixture in the Sulfur Degassing Reactor. While the first static head is essentially constant because the density of liquid sulfur is relatively constant, the second static head depends on the density of the sulfur/air mixture in the reactor. Small changes in the degassing air flow rate cause very large changes in the density of the sulfur/air mixture, which then cause very large changes in the pump discharge pressure. Field experience has shown that the sulfur flow rate remains much steadier when the degassing air flow rate is held at a fixed value. If the degassing air flow rate ever drops too low (as signaled by the low flow alarm on FI-4602) and the low flow condition cannot be corrected in a reasonable length of time, the SDU should be shut down until the air flow problem has been corrected. The procedures in Section 9.9 of this manual can be used to shut down the SDU by stopping the Sulfur Feed Pump and the Degassing Air Blower.
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DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.5.3 Sulfur Transfer Rate Control
The Sulfur Transfer Pump transfers sulfur from the below-ground Sulfur Pit to the new Sulfur Solidification Unit or to the existing Block Formation Unit. A reasonably steady sulfur feed rate to the Sulfur Solidification Unit will help it to operate smoothly, so a level/flow cascade control loop is also used here. The level in the degassed section of the pit is controlled by LC-0907, which supplies a cascade setpoint to the sulfur transfer rate controller, FC-0907. If the level is rising in the pit, the feed rate to the Sulfur Solidification Unit will be slowly increased by raising the setpoint of FC-0907. If the level is falling, the setpoint will be lowered to slowly reduce the feed rate. In this manner, the level in the degassed production section of the Sulfur Pit can be maintained at the desired value while avoiding sudden changes in the feed rate to the Sulfur Solidification Unit.
9.5.4
"Ride-Through" System Considerations

The Sulfur Feed Pump, P-1903A&B, and the Degassing Air Blower, C-1903A&B, are not designed to "ride-through" short interruptions in the electric power to their motors. These pumps and blowers will shut down when the power to their motors is lost if the power outage lasts long enough for the starter contacts in the motor control center to drop out. If the Sulfur Degassing Unit shuts down during a brief power interruption, this will not cause the SRU to shut down. If the power interruption is short enough that the air blower in the SRU "rides-through" and the SRU remains on-line (see Section 7.5.6 of this manual for a discussion), the Sulfur Degassing Unit can simply be restarted to resume processing the sulfur.
9.5.5
Sulfur Degassing Unit Startup Interlock

The purpose of this interlock is to ensure the Sulfur Degassing Unit equipment is placed in operation in a safe manner. This interlock includes several permissives which must be satisfied in the correct order, or the pumps and blowers will not start. The logic flowchart for the "start" permissives is shown on drawing 1029-46-06-LD-008 contained in Section 9.14 of this manual. These permissives are (in order): (1) Start a Sulfur Feed Pump.
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(2) Allow the pump to fill the Sulfur Degassing Reactor to satisfy its low-low level shutdown (4,191 mm above the bottom seam line of the vessel). Start a Degassing Air Blower and press its "reset" push-button to open its discharge valve.
(3)
Failure to satisfy one of these permissives will prevent proceeding any further in the startup sequence. This prevents creating conditions in the Sulfur Degassing Reactor that could lead to problems (fires, etc.).
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DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.5.6 Sulfur Degassing Shutdown System
The purpose of the Sulfur Degassing Unit Emergency Shutdown system (SDU ESD) is to shut off the sulfur and degassing air flow to the Sulfur Degassing Reactor when serious problems occur. The Cause and Effect Diagram is contained in Section 9.14 of this manual. The causes and effects of the SDU ESD are explained below. 9.5.6.1 Causes Any one of the devices listed below will activate the SDU ESD: a. No Sulfur Feed Pump Running, P-1903A&B starter contacts If neither Sulfur Feed Pump is running, the loss of sulfur flow with continued degassing air flow could cause a fire in the Sulfur Degassing Reactor. The motor starter contacts are used to determine whether a pump is running, and activate the SDU ESD if neither is running. b. Sulfur Degassing Reactor High-High Temperature, TT-4601, TT-4602, and TT-4603 There is always a potential for a fire in the Sulfur Degassing Reactor since sulfur is flammable at elevated temperatures (generally above 460F) and it is in contact with air. The heat from a sulfur fire would damage the equipment if allowed to continue burning. If any of these devices detects a high temperature from a fire or a runaway reaction, it will activate the SDU ESD to shut off the sulfur and degassing air flows before equipment damage occurs. The setpoint for these devices is 350F. c. No Degassing Air Blower Running, C-1903A&B starter contacts If there is no Degassing Air Blower running, the Sulfur Degassing system is not operating properly and requires operator attention. The motor starter contacts are used to determine whether a blower is running, and activate the SDU ESD if neither of the blowers is running. d. Sulfur Degassing Reactor High-High Level, LT-4602 A high-high level in the Sulfur Degassing Reactor could allow liquid sulfur to begin to carry-over into the Thermal Oxidizer. This device activates the SDU ESD to shut off the pumps and blowers should this occur. The shutdown
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setpoint for this device is 4,902 mm above the bottom seam of the reactor. e. Sulfur Degassing Reactor Low-Low Level, LT-4602 A low-low level in the Sulfur Degassing Reactor indicates the Sulfur Degassing system is not operating properly and requires operator attention. This device activates the SDU ESD to shut off the pumps and blowers should this occur. The shutdown setpoint for this device is 4,191 mm above the bottom seam of the reactor. 9.5.6.2 Effects A Sulfur Degassing Shutdown, activated by any one of the devices listed above, has the following effects on the Sulfur Degassing Unit: a. Shuts down the Sulfur Feed Pump, P-1903A&B, to stop the flow of sulfur into the Sulfur Degassing Reactor. Shuts down the Degassing Air Blower, C-1903A&B, to stop the flow of air into the Sulfur Degassing Reactor. Closes the Degassing Air Blower discharge valves, NV-4602A and NV-4602B, to prevent back-flow and possible venting of any hazardous gases to the atmosphere. Closed the Sulfur Feed Pump discharge valves, HV-4601A and HV-4601B, and puts FC-4601 in "manual" with 0% output to prevent draining the Sulfur Degassing Reactor.
b.
c.
d.
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9.6
Process Principles and Operating Techniques

The more important considerations involved in startup, operation, shutdown, maintenance, and emergency procedures of the Sulfur Degassing and Transfer system are discussed in the remaining sections of this portion of the manual. The operator should also be thoroughly acquainted with the "Process Description" and "Equipment Description" sections in this manual before attempting to operate the plant in accordance with the operating techniques that follow. If the function of each portion of the plant equipment is understood, the sequence of steps outlined in Sections 9.8 and 9.9 will be more easily understood. In addition, the following general discussion of principles and techniques will clarify the reasons for some of the procedures.
9.6.1
Equipment Damage
After the initial startup, the Sulfur Degassing Unit will contain some sulfur throughout the system. Even when sulfur is drained out of the Sulfur Degassing Reactor, the interior of the vessel will still be coated with residual sulfur. Elemental sulfur and/or iron sulfide in the Sulfur Degassing Reactor may ignite if the Degassing Air Blower continues to run during periods when either the Sulfur Feed Pump is shut off or the reactor is not full of liquid sulfur. The heat from the fire can damage the reactor and its outlet lines if allowed to continue burning. For this reason, it is important that the degassing air not be introduced into the Sulfur Degassing Reactor until it has been filled up to its normal operating level with molten sulfur. This will ensure that if any iron sulfide ever develops on the walls of the reactor, it will be immersed in the liquid sulfur so that air cannot contact the walls directly and cause spontaneous auto-ignition of the iron sulfide. The walls of the reactor above the normal liquid level are always exposed to an oxygen-rich atmosphere, so iron sulfide should not form above the air-liquid interface level in the reactor. Note that the interior of the Sulfur Degassing Reactor is lined with a baked phenolic coating to prevent iron sulfide from forming, but over time the lining may deteriorate and expose some of the carbon steel. When air first begins flowing through the Sulfur Degassing Reactor when it is full of raw (not partially degassed) sulfur, it is possible for the H2S concentration in the degassing air leaving the reactor to be above the lower explosive limit for a short period of time if the air flow rate is too low. For this reason, it is important to raise the air flow to its normal value quickly when first starting air flow to the Sulfur Degassing Reactor with it full of raw sulfur.
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WARNING
NEVER START A DEGASSING AIR BLOWER UNLESS EACH OF THE FOLLOWING IS TRUE: 1. THE SULFUR DEGASSING REACTOR IS FILLED WITH LIQUID SULFUR UP TO ITS NORMAL OPERATING LEVEL AND SULFUR IS RUNNING OUT OF THE SULFUR DRAIN SEAL. 2. A SULFUR FEED PUMP IS RUNNING AND THE SULFUR FLOW METER (FT-4601) INDICATES SULFUR IS FLOWING. 3. THE SRU IS OPERATING SMOOTHLY IF IT IS ON-LINE. (OTHERWISE, SEE THE "WARNING" BOX IN SECTION 8.8.2 OF THIS MANUAL.) 4. THE THERMAL OXIDIZER IS ON-LINE AND OPERATING SMOOTHLY. FAILURE TO OBSERVE THESE PRECAUTIONS COULD CAUSE A FIRE AND/OR EXPLOSION IN THE SULFUR DEGASSING REACTOR.
CAUTION
NEVER "HYDROBLAST" THE STEEL SURFACES IN THE SULFUR DEGASSING EQUIPMENT. NOT ONLY DOES THIS REMOVE THE PROTECTIVE SULFIDE FILM THAT FORMS ON CARBON STEEL AND PREVENTS CORROSION, THE WATER WILL REACT WITH THE SULFUR COMPOUNDS PRESENT IN THE EQUIPMENT TO FORM A VARIETY OF ACIDS (SULFUROUS, POLYTHIONIC, ETC.) THAT WILL RAPIDLY CORRODE THE STEEL.
Issued 18Jan10
Page 9-15
DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.6.2 Degassing Air Blower Operation
The Degassing Air Blowers, C-1903A&B, are conventional rotary-lobe positive displacement air compressors. Although these air blowers operate much like conventional air compressors, the blowers do require some special attention during startup or when bringing an off-line blower into service. These cases are discussed in the sections below. 9.6.2.1 Starting a Degassing Air Blower There are a couple of issues that merit discussion regarding starting a Degassing Air Blower. First, like any positive displacement compressor or pump, these blowers must not be started up against a blocked discharge to avoid physically damaging the blower. Instead, the 1.50" bypass valve around the PSV on the blower discharge line should always be fully opened before starting a blower. This allows the blower to start in an unloaded condition, minimizing the stress on the blower and motor, and prevents any possibility of over-pressuring the blower casing or discharge piping. The second issue is related to the manner in which the Sulfur Degassing Reactor must be brought on-line. As discussed previously in Section 9.6.1, the Sulfur Degassing Reactor must be filled with liquid sulfur up to the normal operating level (the top of the side weir on its draw pan) before degassing air is introduced into the reactor. As the sulfur is filling the reactor, it will of course back into the degassing air feed line (since there is no air flow at this point) as the liquid "seeks its own level". Once the reactor has been filled with sulfur, there will be liquid sulfur in the degassing air line up to about the same elevation as the sulfur in the reactor. This section of piping is steam-jacketed so freezing of the sulfur is not a concern. What is a concern, however, is what happens when the discharge valve on the Degassing Air Blower first opens. Before the valve opens, the pressure in the vapor space of the Sulfur Degassing Reactor should be at nearly atmospheric pressure, since the spent degassing air is routed to the Thermal Oxidizer. The degassing air line will also be at low pressure because the discharge valve on the Degassing Air Blower will still be closed at this point, even though the blower may be running. But when a Degassing Air Blower is started and its "reset" push-button (HS-4602A or HS-4602B) is pressed, the PLC will
Issued 18Jan10
Page 9-16

open the discharge valve on the blower. If there is back-pressure on the Sulfur Degassing Reactor from the TTO when the discharge valve opens, the pressure inside the Sulfur Degassing Reactor will force liquid sulfur from the reactor up into the degassing air line. If the back-pressure is high enough, liquid sulfur could overflow the "loop seal" in the degassing air line, allowing sulfur to back down the line to the Degassing Air Blower. This can be prevented by "pinching" the blow-off valve on the Degassing Air Blower discharge line before pressing the "reset" push-button to allow the pressure in the line to build up before the valve opens. Then the pressure in the degassing air line will keep the sulfur from overflowing the loop seal. The procedure for commencing degassing air flow described later in this manual (Sections 9.8.1 and 9.8.2) includes the following steps: (1) (2) (3) Fully open the blow-off valve on the blower. Start the blower and let it come up to speed. Slowly "pinch" to blow-off valve until the discharge pressure increases to 1-2 PSIG. Press the "reset" push-button to open the blower discharge valve. Slowly close the blow-off valve the rest of the way.
(4)
(5) 9.6.2.2
"Swapping" Degassing Air Blowers During Operation While the Sulfur Degassing Unit is running, it is sometimes necessary to "swap" air blowers to bring the off-line blower on-line so that the other blower can be shut down. This can usually be accomplished with only a slight "bobble" to the SDU by starting and stopping the blowers in the proper sequence. The procedure given below is one technique that should make swapping blowers relatively simple and avoid any problems. A. On the off-line blower: (1) Confirm that its discharge valve (NV-4602A or NV-4602B) is closed. Fully open its 1.50" blow-off valve.
(2) B.
Start this blower using its local start/stop control station.
Issued 18Jan10
Page 9-17

C. After the off-line blower comes up to speed, press its "reset" push-button (HS-4602A or HS-4602B) to open its discharge valve. Since its blow-off valve is still wide open at this point, the blower will not be able to develop enough discharge pressure to open the check valve in its discharge line. D. Slowly "pinch" the blow-off valve on the off-line blower until its discharge pressure rises enough to open its check valve and begin sending some of its air to the Sulfur Degassing Reactor. Slowly open the blow-off valve on the on-line blower to begin venting some of its air to atmosphere. Continue to close the blow-off valve on the off-line blower and open the blow-off valve on the on-line blower. Observe the degassing air flow rate on the local indicator on flow transmitter FT-4602, and proceed slowly enough to keep the degassing air flow rate stable. G. Once the blow-off valve is fully closed on the one blower and fully open on the other blower, the off-line blower is now the on-line blower and vice versa. Use the local start/stop control on what is now the off-line blower to stop that blower and close its discharge valve, then close its blow-off valve. The blower swap is now complete. Before leaving the area, visually confirm that: (1) (2) (3) (4) The off-line blower is stopped. The discharge and blow-off valves on the off-line blower are closed. The on-line blower is running smoothly. The Sulfur Degassing Unit has returned to steady operation.
E.
F.
H.
Issued 18Jan10
Page 9-18
9.7
Precommissioning Procedures
Prior to the initial startup, there are a number of precommissioning activities that are necessary to ensure that the newly constructed plant is ready to be placed in service. The activities outlined below should serve as a guide, but there may be others required as a part of your normal plant procedures.
9.7.1
Preliminary Check-out
A. Check all equipment to ensure that it is properly installed. This will probably require consulting Manufacturer's literature as well as construction drawings. Check and lubricate all equipment, in accordance with the Manufacturer's recommendations. Check the rotation of the Degassing Air Blower, Sulfur Feed Pump, and Sulfur Transfer Pump: (1) Operate each Degassing Air Blower for a short period (20 seconds or less) with its discharge valve closed and its blow-off valve open. The Sulfur Feed Pump depends on molten sulfur to lubricate its bearings, and should not be operated dry. Remove the coupling between each pump and its motor while checking the rotation of the motor. The Sulfur Transfer Pump also depends on molten sulfur to lubricate its bearings, and should not be operated dry. Remove the coupling between each pump and its motor while checking the rotation of the motor.
B.
C.
(2)
(3)
D.
Check all piping and equipment to be sure that all blinds have been removed and that no valves are vented to atmosphere. Place the Instrument Air System in service to all instruments and check the action of controllers and control valves. Place the instrument air in service to the bubbler-type level transmitters on the Sulfur Pit, LT-4601 and LT-0907.
E.
F.
Issued 18Jan10
Page 9-19
DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.7.2 Commissioning the Heating and Ventilation Systems
The heating and ventilation systems for the Sulfur Pit, the heating system for the Sulfur Degassing Reactor, and the heating systems for the other system components can be placed in service at any time prior to the beginning of sulfur degassing. It is advantageous to place them in service prior to startup of the SRU so that any problems can be corrected without impacting the schedule for commissioning the Sulfur Degassing system. To place the heating and ventilation systems in service, proceed as follows: G. Follow the procedure given in Section 7.7.7 of this manual to commission the steam supply to the Sulfur Pit and place its ventilation system in service. Confirm that the steam supply valve(s) to the jacketed discharge piping on the Sulfur Feed Pump, P-1903A&B, are all closed, and that the steam trap stations on each pump are all blocked in. Open all of the vent valves on the jacketed discharge piping. Establish steam flow into the jacketed pipe and the pumps by opening the steam supply valve(s). Allow air (and any liquids) to purge from the vent valves. Close each vent valve as it begins to blow steam. Open the upstream block valve of the steam trap on each pump and use the bleeder on each trap to drain water (and any other liquids) from each pump. Close the bleeder on each trap once hot condensate begins flowing through the trap. Open the test valve on each trap and confirm that each trap is operating properly. Then close the test valve and open the downstream block valve on each trap to place the traps in service to the Condensate header. Repeat Steps H through M to commission the heating systems on each of the following jacketed equipment items and piping systems. Open all of the vent valves on the steam jackets long enough to vent the air from the jackets, and work from top to bottom to use the steam pressure to empty any liquids from the heating systems. (1) The sulfur spill-back line, 2.00X3.00-S-46036-A10J-2.5H and the control valve, FV-4601.
H.
I. J.
K.
L.
M.
N.
Issued 18Jan10
Page 9-20

(2) The Sulfur Transfer Pumps, P-1902A&B, and the jacketed lines leading to the Solidification Unit. The sulfur spill-back line, 2.00X3.00-S-09047-A10J-2.5H and the control valve, FV-0907. The bubbler tubes for the two level transmitters, LT-4601 and LT-0907, in the Sulfur Pit. The sulfur drain line, 4.00X6.00-S-46038-A10J-2.5H, from the Sulfur Degassing Reactor, the strainer, 74-462002, and the Degassed Sulfur Drain Seal Assembly, PA-1903. The jacket on the Sulfur Degassing Reactor, R-1902. The degassing air line, 4.00X6.00-PA-46040-A10J-2.5H, feeding the Sulfur Degassing Reactor. The spent degassing air line, 4.00X6.00-SV-46041-A10J-2.5H, from the Sulfur Degassing Reactor.
(3)
(4)
(5)
(6) (7)
(8)
Confirm that all steam traps are functioning properly before directing your attention away from these heating systems.
Issued 18Jan10
Page 9-21
DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.7.3 Purging the Sulfur Degassing Reactor
During normal operation of the Sulfur Degassing Reactor, the spent degassing air from the overhead of the vessel is routed to the Thermal Oxidizer to incinerate the traces of H2S in the air. Before operating the system, the Sulfur Degassing Reactor must be purged to ensure that there are no combustible substances in the vessel that could cause problems in the TTO. This is accomplished by using nitrogen to purge the vessel and its associated piping.
WARNING
UNTIL THE SULFUR DEGASSING REACTOR HAS BEEN PURGED, THERE MAY BE FLAMMABLE GAS MIXTURES PRESENT IN THE VESSEL AND ITS PIPING. ENSURE THAT ALL IGNITION SOURCES, INTERNAL AND EXTERNAL TO THE VESSEL, HAVE BEEN REMOVED BEFORE PROCEEDING. A. Place controller FC-4601 in the DCS in "manual" and set its output to 0%. Verify that the control valve in the spill-back line, FV-4601, is fully closed. Verify that the discharge valves on the Sulfur Feed pumps, HV-4601A and HV-4601B, are closed Close the 4" block valve in the spent degassing air line. Open the 4" block valve upstream of the strainer in the rundown line to the Degassed Sulfur Drain Seal Assembly, PA-1903. Use a temporary "jumper" to connect a nitrogen supply to the 2" steam-out valve on the spent degassing air line, then commence the flow of nitrogen into the Sulfur Degassing Reactor and out the open path through the Degassed Sulfur Drain Seal Assembly. Allow the nitrogen to continue flowing long enough to reduce the oxygen concentration in the vessel and piping to less than 1%. Use a portable oxygen analyzer to determine the oxygen concentration.
B.
C.
D. E.
F.
G.
Issued 18Jan10
Page 9-22

H. When the oxygen concentration is below 1%, set the output of controller FC-4601 to 100% Verify that the control valve in the spill-back line, FV-4601, is fully open. "Force" the PLC to open the Sulfur Feed Pump discharge valves, HV-4601A and HV-4601B. Close the 4" block valve in the rundown line to the Degassed Sulfur Drain Seal Assembly. Allow the nitrogen to continue flowing long enough to reduce the oxygen concentration in the piping to less than 1%. Use a portable oxygen analyzer to determine the oxygen concentration. When the oxygen concentration is below 1%, open the 4" block valve in the spent degassing air line to the Thermal Oxidizer. Close the following valves: (1) Adjust the output of FC-4601 in the DCS to 0% to close FV-4601. Remove the "forces" from the PLC and confirm that the automated discharge block valves on the Sulfur Feed Pumps close.
I.
J.
K.
L.
M.
N.
(2)
O.
Allow the nitrogen to continue flowing long enough to reduce the oxygen concentration in the piping to less than 1%. Use a portable oxygen analyzer to determine the oxygen concentration. Close the 2" steam-out valve where the nitrogen "jumper" is connected to stop the flow of nitrogen, and disconnect the nitrogen jumper. Open the 4" block valve in the rundown line to the Degassed Sulfur Drain Seal Assembly. Close the 4" block valve in the spent degassing air line to the Thermal Oxidizer.
P.
Q.
R.
The Sulfur Degassing System is now ready for service. Once the SRU has been started up and there has been sufficient sulfur production into the Sulfur Pit to commence operation of the Sulfur Feed Pump, sulfur degassing can begin.
Issued 18Jan10
Page 9-23
9.
9.8
Startup Procedures
This section describes the procedures for the initial startup of the Sulfur Degassing Unit (Section 9.8.1), subsequent startups of the Sulfur Degassing Unit (Section 9.8.2), and operation of the Sulfur Transfer system (Section 9.8.3).
9.8.1
Initial Startup of the Sulfur Degassing Unit

During the initial startup, the Sulfur Degassing Reactor is filled with liquid sulfur to seal the Degassed Sulfur Drain Seal Assembly in the degassed sulfur outlet line. Subsequent startups will probably not require this step. Once this has been accomplished, the system can be placed into operation.
9.8.1.1
Filling the Sulfur Drain Seal in the Sulfur Outlet Line
CAUTION
THE SHAFT BEARINGS ON THE SULFUR FEED PUMP ARE LUBRICATED BY SOME OF THE LIQUID SULFUR BEING PUMPED. TO ENSURE AN ADEQUATE SUPPLY OF SULFUR FOR THE BEARINGS, THE PUMP MANUFACTURER RECOMMENDS MAINTAINING A MINIMUM OF 285 mm OF SULFUR LEVEL ABOVE THE PUMP SUCTION WHEN OPERATING ONE OF THESE PUMPS. THE PUMP SUCTIONS ARE MOUNTED ABOUT 360 mm ABOVE THE BOTTOM OF THE PIT, PLUS IT TAKES ABOUT 8,100 kg OF SULFUR TO FILL THE SULFUR DEGASSING REACTOR, SO THE SULFUR LEVEL IN THE PIT SHOULD BE AT LEAST 795 mm ABOVE THE BOTTOM OF THE PIT BEFORE STARTING A SULFUR FEED PUMP. CHECK THE SULFUR LEVEL IN THE RAW PRODUCTION SECTION OF THE SULFUR PIT BEFORE STARTING UP THE SULFUR DEGASSING UNIT. DO NOT PROCEED UNTIL THE LEVEL MEASURES AT LEAST 795 mm ABOVE THE BOTTOM OF THE PIT. (THIS IS ABOUT 12% LEVEL ON LC-4601 IN THE DCS.)
Issued 18Jan10
Page 9-24

A. Place the sulfur feed rate controller in the DCS, FC-4601, in "manual" and set its output to 0%. Verify that the control valve in the spill-back line, FV-4601, is closed. Verify that the 4" block valve in the Sulfur Degassing Reactor overhead line is closed. Verify that the 4" block valve in the sulfur rundown line, 4.00X6.00-S-46038-A10J-2.5H is open. Verify that HV-4601A and HV-4601B in the discharge lines from the Sulfur Feed Pump are closed. Start a Sulfur Feed Pump, P-1903A or P-1903B, using its local start/stop control push-button and verify its discharge valve, HV-4601A or HV-4601B, is open. The sulfur flow meter, FT-4601, should begin to indicate that sulfur is flowing into the Sulfur Degassing Reactor. The expected full pumping flow rate is 5,280 kg/H, which is 65% of the range on the meter. It will take the Sulfur Feed Pump about 80-90 minutes to fill the Sulfur Degassing Reactor up to the top of the weir on the side of its draw pan so that sulfur begins to flow out the degassed sulfur outlet nozzle. Once it does so, it will take a few more minutes for sulfur to fill the Degassed Sulfur Drain Seal Assembly, PA-1903, and begin flowing into the degassed section of the Sulfur Pit. Open the view hatch on the Degassed Sulfur Drain Seal Assembly and confirm that sulfur is now flowing into the pit. The Degassed Sulfur Drain Seal Assembly has now been filled, and will keep the Sulfur Pit isolated from the TTO. Open the 4" block valve in the Sulfur Degassing Reactor overhead line and car-seal it open. There is no over-pressure protection on the Sulfur Degassing Reactor, so the 4" block valve in the spent degassing air line (the overhead line) must always remain open unless maintenance is being performed on the vessel.
B.
C.
D.
E.
F.
G.
H.
I.
Issued 18Jan10
Page 9-25

9.8.1.2 Placing the Sulfur Degassing Reactor in Operation At this point, liquid sulfur is flowing through the Sulfur Degassing Reactor at the full pumping rate. The sulfur feed rate can now be adjusted to maintain a relatively constant level in the raw production section of the Sulfur Pit, and degassing air flow can be established to bring the system on-line.
WARNING
NEVER START A DEGASSING BLOWER UNLESS EACH OF THE FOLLOWING IS TRUE: 1. THE SULFUR DEGASSING REACTOR IS FILLED WITH LIQUID SULFUR UP TO ITS NORMAL OPERATING LEVEL AND SULFUR IS RUNNING OUT OF THE SULFUR DRAIN SEAL. A SULFUR FEED PUMP IS RUNNING AND THE SULFUR FLOW METER (FT-4601) INDICATES SULFUR IS FLOWING. THE SRU IS OPERATING SMOOTHLY IF IT IS ON-LINE. (OTHERWISE, SEE THE "WARNING" BOX IN SECTION 8.8.2 OF THIS MANUAL.) THE THERMAL OXIDIZER OPERATING SMOOTHLY. IS ON-LINE AND
2.
3.
4.
FAILURE TO OBSERVE THESE PRECAUTIONS COULD CAUSE A FIRE AND/OR EXPLOSION IN THE SULFUR DEGASSING REACTOR. A. Confirm that the setpoint of FC-4601 is tracking its current reading, then switch it to "automatic" (not "cascade"). Slowly adjust the setpoint as necessary so that the spill-back valve opens to regulate the sulfur feed rate to roughly the same value as the current sulfur production rate. Note: 1 metric ton per day = 42 kg/H
Issued 18Jan10
Page 9-26

B. Confirm that the 4" block valve in the spent degassing air line is open. Confirm that both the Degassing Air Blower discharge valves (NV-4602A and NV-4602B) are fully closed. Start a Degassing Air Blower: (1) Open the 1" blow-off valve on the blower discharge line. Start the blower using its local start/stop control push-button. Once the blower comes up to speed, slowly "pinch" to blow-off valve until the discharge pressure increases to 1-2 PSIG. Press the "reset" push-button on the blower (HS-4602A or HS-4602B) to open its discharge valve. Slowly close the 1" blow-off valve on the blower discharge line the rest of the way. Do not allow the blower discharge pressure to exceed 16.7 PSIG, as this would cause the relief valve on the blower discharge line (PSV-4601A or PSV-4601B) to open in order to relieve the excessive pressure.
C.
D.
(2)
(3)
(4)
(5)
NOTE:
E.
As degassing air begins to flow into the Sulfur Degassing Reactor and aerate the sulfur inside, the discharge pressure on the Sulfur Feed Pump will begin to drop, which will change the sulfur feed rate to the reactor. Be prepared to take control of FC-4601 in the DCS if necessary to stabilize the sulfur feed rate. Confirm that the degassing air flow rate indicated on FI-4602 in the DCS is 150 SCFM or higher. Place the level controller for the raw production section of the Sulfur Pit in service as follows: (1) Confirm that the level controller in the DCS, LC-4601, is in "automatic". Confirm that the remote setpoint LC-4601 is supplying to FC-4601 matches the current local sulfur feed rate setpoint on the controller.
F.
G.
(2)
Issued 18Jan10
Page 9-27

(3) Switch FC-4601 to "cascade" mode so that the setpoint for the sulfur feed rate will now be adjusted automatically by LC-4601. The setpoint of LC-4601 will be set at the last reading. Adjust the setpoint to its normal value, 50%.
(4)
H.
The Sulfur Degassing Unit is now in operation. Before directing your attention away from this system make sure that: (1) (2) The sulfur feed rate controller is functioning properly. The level in the raw production section of the Sulfur Pit is under control. The degassing air flow rate is at its normal value or above. Sulfur is draining freely from the Degassed Sulfur Drain Seal Assembly. All steam heating systems are in service and functioning properly. The TTO is operating smoothly.
(3)
(4)
(5)
(6)
Issued 18Jan10
Page 9-28
DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.8.2 Normal Startup of the Sulfur Degassing System
To place the Sulfur Degassing Unit back in operation, the Sulfur Degassing Reactor must be filled with sulfur and degassing air flow established. Prior to commencing startup: 1. Check for the completion of all maintenance work (connecting lines, removing blinds, etc.) if such work was performed. Place all steam heating systems in service. Check all steam traps for proper operation, and use the vent valves to sweep non-condensibles out of the steam spaces. Filling the Sulfur Degassing Reactor
2.
9.8.2.1
CAUTION CHECK THE SULFUR LEVEL IN THE RAW PRODUCTION SECTION OF THE SULFUR PIT BEFORE STARTING UP THE SULFUR DEGASSING UNIT. DO NOT PROCEED UNTIL THE LEVEL MEASURES AT LEAST 795 mm ABOVE THE BOTTOM OF THE PIT. (THIS IS ABOUT 12% LEVEL ON LC-4601 IN THE DCS.) A. Place the sulfur feed rate controller in the DCS, FC-4601, in "manual" and set its output to 0%. Verify that the control valve in the spill-back line, FV-4601, is closed. Verify that the 4" block valve in the Sulfur Degassing Reactor overhead line is open. Verify that the 4" block valve in the sulfur rundown line, 4.00X6.00-S-46038-A10J-2.5H, is open. Verify that HV-4601A and HV-4601B in the discharge lines from the Sulfur Feed Pump are closed. Start a Sulfur Feed Pump, P-1903A or P-1903B, using its local start/stop control push-button and verify its discharge valve, HV-4601A or HV-4601B, is open.
B.
C.
D.
E.
F.
Issued 18Jan10
Page 9-29

G. The sulfur flow meter, FT-4601, should begin to indicate that sulfur is flowing into the Sulfur Degassing Reactor. The expected full pumping flow rate is 5,280 kg/H, which is 65% of the range on the meter. If the Sulfur Degassing Reactor is completely empty, it will take the Sulfur Feed Pump about 80-90 minutes to fill it up to the top of the weir on the side of its draw pan so that sulfur begins to flow out the degassed sulfur outlet nozzle. If the reactor is still partially full, it will not take as long for sulfur to begin flowing out of the reactor. Open the view hatch on the Degassed Sulfur Drain Seal Assembly and observe when sulfur begins to flow into the pit. When sulfur begins to flow out of the Degassed Sulfur Drain Seal Assembly, proceed with the next section to complete the startup of the Sulfur Degassing Unit.
H.
I.
9.8.2.2
Placing the Sulfur Degassing Reactor in Operation WARNING NEVER START A DEGASSING BLOWER UNLESS EACH OF THE FOLLOWING IS TRUE: 1. THE SULFUR DEGASSING REACTOR IS FILLED WITH LIQUID SULFUR UP TO ITS NORMAL OPERATING LEVEL AND SULFUR IS RUNNING OUT OF THE SULFUR DRAIN SEAL. A SULFUR FEED PUMP IS RUNNING AND THE SULFUR FLOW METER (FT-4601) INDICATES SULFUR IS FLOWING. THE SRU IS OPERATING SMOOTHLY IF IT IS ON-LINE. (OTHERWISE, SEE THE "WARNING" BOX IN SECTION 8.8.2 OF THIS MANUAL.) THE THERMAL OXIDIZER OPERATING SMOOTHLY. IS ON-LINE AND
2.
3.
4.
FAILURE TO OBSERVE THESE PRECAUTIONS COULD CAUSE A FIRE AND/OR EXPLOSION IN THE SULFUR DEGASSING REACTOR.
Issued 18Jan10
Page 9-30

A. Confirm that the setpoint of FC-4601 is tracking its current reading, then switch it to "automatic" (not "cascade"). Slowly adjust the setpoint as necessary so that the spill-back valve opens to regulate the sulfur feed rate to roughly the same value as the current sulfur production rate. Note: B. 1 metric ton per day = 42 kg/H
Confirm that both the Degassing Air Blower discharge valves (NV-4602A and NV-4602B) are fully closed. Start a Degassing Air Blower: (1) Open the 1" blow-off valve on the blower discharge line. Start the blower using its local start/stop control push-button. Once the blower comes up to speed, slowly "pinch" to blow-off valve until the discharge pressure increases to 1-2 PSIG Press the "reset" push-button on the blower (HS-4602A or HS-4602B) to open its discharge valve. Slowly close the 1" blow-off valve on the blower discharge line the rest of the way. Do not allow the discharge pressure to exceed 16.7 PSIG.
C.
(2)
(3)
(4)
(5)
NOTE:
D.
Be prepared to take control of FC-4601 in the DCS if necessary to stabilize the sulfur feed rate as the degassing air begins flowing into the Sulfur Degassing Reactor. Confirm that the degassing air flow rate indicated on FI-4602 in the DCS is 150 SCFM or higher. Place the level controller for the raw production section of the Sulfur Pit in service as follows: (1) Confirm that the level controller in the DCS, LC-4601, is in "automatic". Confirm that the remote setpoint LC-4601 is supplying to FC-4601 matches the current local sulfur feed rate setpoint on the controller.
E.
F.
(2)
Issued 18Jan10
Page 9-31

(3) Switch FC-4601 to "cascade" mode so that the setpoint for the sulfur feed rate will now be adjusted automatically by LC-4601. The setpoint of LC-4601 will be set at the last reading. Adjust the setpoint to its normal value, 50%.
(4)
G.
The Sulfur Degassing System is now in operation. Before directing your attention away from this system make sure that: (1) (2) The sulfur feed rate controller is functioning properly. The level in the raw production section of the Sulfur Pit is under control. The degassing air flow rate is at its normal value or above. Sulfur is draining freely from the Degassed Sulfur Drain Seal Assembly. All steam heating systems are in service and functioning properly. The TTO is operating smoothly.
(3)
(4)
(5)
(6)
Issued 18Jan10
Page 9-32
DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.8.3 Sulfur Transfer Operation
Once a level of liquid sulfur has been established in the degassed section of the Sulfur Pit, transfer of sulfur to the Sulfur Solidification or Block Formation units can commence.
CAUTION
THE SHAFT BEARINGS ON THE SULFUR TRANSFER PUMP ARE LUBRICATED BY SOME OF THE LIQUID SULFUR BEING PUMPED. TO ENSURE AN ADEQUATE SUPPLY OF SULFUR FOR THE BEARINGS, THE PUMP MANUFACTURER RECOMMENDS MAINTAINING A MINIMUM OF 325 mm OF SULFUR LEVEL ABOVE THE PUMP SUCTION WHEN OPERATING ONE OF THESE PUMPS. THE PUMP SUCTIONS ARE MOUNTED ABOUT 355 mm ABOVE THE BOTTOM OF THE PIT, SO THE SULFUR LEVEL IN THE PIT SHOULD BE AT LEAST 680 mm ABOVE THE BOTTOM OF THE PIT BEFORE STARTING A SULFUR TRANSFER PUMP. CHECK THE SULFUR LEVEL IN THE DEGASSED SECTION OF THE SULFUR PIT BEFORE TRANSFERRING ANY SULFUR. DO NOT PROCEED UNTIL THE LEVEL MEASURES AT LEAST 680 mm ABOVE THE BOTTOM OF THE PIT. (THIS IS ABOUT 9% LEVEL ON LC-0907 IN THE DCS.) A. Confirm that the steam-jacket heating systems are operating properly on the Sulfur Transfer Pumps and their discharge piping and valves. Place the sulfur transfer rate controller in the DCS, FC-0907, in "manual" and set its output to 0%. Verify that the control valve in the spill-back line, FV-0907, is closed. Verify that HV-0908A and HV-0908B in the discharge lines from the Sulfur Transfer Pumps are closed. Start a Sulfur Transfer Pump, P-1902A or P-1902B, using its local start/stop control push-button, and verify its discharge valve, HV-0908A or HV-0908B, is open.
B.
C.
D.
E.
Issued 18Jan10
Page 9-33

F. The sulfur flow meter, FT-0907, should begin to indicate that sulfur is flowing to the Sulfur Solidification Unit or Block Formation Unit. The expected full pumping flow rate is 7,500 kg/H, which is 92% of the range on the meter. Place the level controller for the degassed section of the Sulfur Pit in service as follows: (1) Confirm that the level controller in the DCS, LC-0907, is in "automatic". Confirm that the remote setpoint LC-0907 is supplying to FC-0907 matches the current local sulfur transfer rate setpoint on the controller. Switch FC-0907 to "cascade" mode so that the setpoint for the sulfur feed rate will now be adjusted automatically by LC-0907. The setpoint of LC-0907 will be set at the last reading. Adjust the setpoint to its normal value, 50%.
G.
(2)
(3)
(4)
Issued 18Jan10
Page 9-34
9.9
Shutdown Procedures
The procedures to be used in performing a planned shutdown of the Sulfur Degassing Unit will vary depending on the extent and type of work to be performed in and around the Sulfur Degassing Reactor during the downtime period. If there are no plans for entering the Sulfur Degassing Reactor, no special procedures are required in performing the shutdown. However, if you plan to enter any vessels for inspection or maintenance, the procedure in Section 9.9.2 should be followed to accomplish a satisfactory shutdown and minimize the time required for performance of the desired maintenance work. Typical shutdown procedures are outlined and discussed in the sections that follow for the more common cases. Your existing company procedures and common sense operational judgement should be used to modify these procedures as needed to serve the purpose of any given planned shutdown situation.
9.9.1
Planned Shutdown - No Entry

If there are no plans to enter the Sulfur Degassing Reactor during the shutdown, the Sulfur Degassing Reactor can remain full of liquid. This will allow placing the Sulfur Degassing Unit back on-line quicker, since there will be no delay while the vessel is filled with sulfur. A. Place the sulfur feed rate controller in the DCS, FC-4601, in "manual" and set its output to 0% to close the control valve in the spill-back line. Stop the Sulfur Feed Pump using its local start/stop control push-button. This should activate the SDU ESD system to shut down the Degassing Air Blower. C. Visually confirm that: (1) Both Sulfur Feed Pumps are stopped, and that HV-4601A and HV-4601B in the discharge lines are closed. Both Degassing Air Blowers are stopped and their discharge valves, NV-4602A and NV4602B, are closed. Control valve FV-4601 in the spill-back line is closed.
B.
(2)
(3) D.
Confirm that all steam heating services are still functioning and the steam traps are operating properly.
Issued 18Jan10
Page 9-35

The Sulfur Degassing Unit can remain in this condition indefinitely. Periodically confirm that the steam heating services are functioning properly so that solid sulfur cannot form anywhere in the system.
9.9.2
Planned Shutdown for Entry

Use the following steps to shut down the Sulfur Degassing Unit for maintenance or inspection. A. Stop the Sulfur Feed Pump using its local start/stop control push-button. This should activate the SDU ESD system to shut down the Degassing Air Blower. B. Visually confirm that: (1) Both Sulfur Feed Pumps are stopped, and that HV-4601A and HV-4601B in the discharge lines are closed. Both Degassing Air Blowers are stopped and their discharge valves, NV-4602A and NV4602B, are closed.
(2)
C.
Confirm that the 4" block valve in the spent degassing air line is open to the TTO. This will prevent creating a vacuum in the Sulfur Degassing Reactor as the sulfur is drained back into the Sulfur Pit.
D.
Place the sulfur feed rate controller in the DCS, FC-4601, in "manual" and set its output to 100%. This will fully open FV-4601 in the spill-back line and allow all of the liquid sulfur to empty from the Sulfur Degassing Reactor back into the raw production section of the Sulfur Pit.
E.
Once the Sulfur Degassing Reactor is empty, set the output from FC-4601 to 0%. Confirm that FV-4601 in the spill-back line is fully closed.
F.
Use MP steam or nitrogen to purge the gases in the Sulfur Degassing Reactor out to the TTO by temporarily connecting a hose to the 2" steam-out valve on the degassing air line. Isolate the Sulfur Degassing Reactor from all potential contaminating gases using slip blinds or by disconnecting the piping. In particular, isolate the Sulfur Degassing Reactor from the TTO using slip-blinds, etc.
G.
Issued 18Jan10
Page 9-36

H. Close the 4" block valve in the sulfur drain line to isolate the Sulfur Degassing Reactor from the drain seal and the Sulfur Pit.
WARNING
THE OVER-PRESSURE PROTECTION FOR THE SULFUR DEGASSING REACTOR IS ITS OVERHEAD LINE TO THE THERMAL OXIDIZER AND ITS SULFUR DRAIN SEAL. HOWEVER, ONCE THE REACTOR HAS BEEN ISOLATED FROM THE TTO AND THE DRAIN SEAL, STEPS MUST BE TAKEN TO ENSURE THAT THE REACTOR IS NOT COMPLETELY BLOCKED-IN BY CREATING ANOTHER OPENING FROM THE REACTOR TO THE ATMOSPHERE SO THAT IT CANNOT BE OVER-PRESSURED. Once the Sulfur Degassing Reactor is isolated, it can be opened for entry. Refer to the "General Safety" section of this manual for procedures to be followed when performing maintenance work on this plant.
Issued 18Jan10
Page 9-37
9.
9.10 Setpoints (Controllers, Alarms, S/Ds, PCVs, PSVs)

9.10.1
Device No. FC-0907
DCS/PLC Device Controller and Alarm Setpoints

Description Sulfur Flow to Solidification High Flow Alarm Low Flow Alarm Sulfur Flow to Degassing Reactor High Flow Alarm Low Flow Alarm Degassing Air Flow High Flow Alarm Low Flow Alarm Sulfur Pit Level (degassed) High Level Alarm Low Level Alarm Sulfur Pit Level (raw production) High Level Alarm Low Level Alarm Sulfur Degassing Reactor Level High Level Alarm Low Level Alarm Sulfur Temperature (raw production) High Temperature Alarm Low Temperature Alarm Sulfur Temperature (degassed) High Temperature Alarm Low Temperature Alarm Degassing Rx Top Temperature High Temperature Alarm Low Temperature Alarm Degassing Rx Mid Temperature High Temperature Alarm Low Temperature Alarm Degassing Rx Btm Temperature High Temperature Alarm Low Temperature Alarm Setpoint
5,715 kg/H (70%) 950 kg/H (12%) 5,715 kg/H (70%) 950 kg/H (12%) 154 SCFM (99%) 75 SCFM (48%) 3220 mm abv btm (50%) 4760 mm abv btm (75%) 1685 mm abv btm (25%) 2800 mm abv btm (50%) 4100 mm abv btm (75%) 1475 mm abv btm (25%) 4598 mm abv btm seam (26%) 4293 mm abv btm seam (11%) 310F 260F 310F 260F 320F 260F 320F 260F 320F 260F
FC-4601
FI-4602
LC-0907
LC-4601
LI-4602
TI-0951
TI-0952
TI-4601
TI-4602
TI-4603
9.10.2
Non DCS/PLC Device Controller and Alarm Setpoints

Device No. starter contacts ZSC/ZSO-0908A&B ZSC/ZSO-4601A&B ZSC/ZSO-4602A&B Description Neither Sulfur Transfer Pump Running Valve Malfunction Valve Malfunction Valve Malfunction Setpoint N/A N/A N/A N/A
Alarm No. XAL-0903 ZA-0908A&B ZA-4601A&B ZA-4602A&B
Issued 18Jan10
Page 9-38
DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT 9.10.3

Alarm No. LAHH-4602 LALL-4602 QA-4601 TAHH-4604
DCS/PLC Device Shutdown Setpoints

Device No. LT-4602 LT-4602 PLC logic TT-4601 TT-4602 TT-4603 Description Degassing Reactor High-High Level Degassing Reactor Low-Low Level Degassing System Shutdown Degassing Reactor High-High Temp. Setpoint 4902 mm abv btm seam (42%) 4191 mm abv btm seam (6%) N/A 350F
9.10.4
Alarm No. WAH-4601A&B XAL-4601 XAL-4602
Non-DCS/PLC Device Shutdown Setpoints

Device No. WSH-4601A&B starter contacts starter contacts Description Degassing Air Blower High Vibration Neither Sulfur Feed Pump Running Neither Degassing Air Blower Running Setpoint fixed N/A N/A
9.10.5
Safety Valve Setpoints

Description "A" Degassing Air Blower "B" Degassing Air Blower Setpoint 16.7 PSIG 16.7 PSIG
Tag No. PSV-4601A PSV-4601B
Issued 18Jan10
Page 9-39
9.11 Operating Limits

This section addresses desired operating ranges for process parameters such as temperature, pressure, flow rate, composition, etc. It includes safe operating limits for these process parameters, consequences of deviations, and how to respond to deviations. This section is organized by major equipment item. Two tables are provided for each piece of equipment: The first table, Safe Operating Limits, lists the pertinent operating parameters and their normal operating ranges, safe minimum and maximum values, and the associated instrumentation (indicators, controllers, alarms, shutdowns, and relief valves). For this plant, most of the instrumentation is in the DCS. Local instrumentation is indicated by a . Instrumentation that annunciates both locally and in the DCS is indicated by a . This table does not list the instrumentation setpoints. Setpoints for the controllers, alarms, shutdowns, regulators, relief valves, and packaged equipment (if any) in this system are summarized in Setpoints (Controllers, Alarms, S/Ds, PCVs, PSVs), Section 9.10. The second table, Deviations and Corrective Actions, lists operating parameter deviations and their potential consequences. It also includes a troubleshooting guide listing the most likely causes of the deviations and the corresponding corrective actions.
Special attention should be paid to changes in the operating limits and alarms during modes other than normal operation, (e.g., startup and shutdown).
Issued 18Jan10
Page 9-40
Issued 18Jan10
Operating Procedures Manual Oil & Gas Development Company Limited Winter 2010 Dakhni, Pakistan DAKHNI EXPANSION PROJECT - SULFUR RECOVERY UNIT
9.11.1
Degassing Air Blower, C-1903A&B

= local instrument , = has both local & DCS annunciators MINIMUM 60 SCFM N/A 0 PSIG 32F 32F MAXIMUM 180 SCFM N/A 16.7 PSIG 122F 350F INDICATORS CONTROLLER ALARMS FI-4602 NONE FAL/FAH on FI-4602 NONE NONE NONE PI-4601A NONE NONE PI-4601B NONE NONE NONE NONE NONE NONE SHUTDOWNS RELIEF (PSV) NONE N/A NONE NONE NONE NONE NONE PSV-4601A PSV-4601B N/A N/A
Safe Operating Limits

PARAMETER Flow Rate Suction Pressure Discharge Pressure NORMAL 150 SCFM 0 PSIG 15 PSIG
Suction Temperature ambient Discharge 246-350F Temperature
Sulfur Degassing and Transfer Page 9-41
Deviations and Corrective Actions

DEVIATION Low Flow Rate POTENTIAL CONSEQUENCES Blower damage due to operation at low rate. Poor sulfur degassing performance. Possible release of toxic gas if process gas backs down the air line. No reasonable scenario for development. Possible motor overload and blower shutdown. Possible blower damage due to high discharge temperature. POSSIBLE CAUSES 1. Plugging in Sulfur Degassing Reactor or piping. 2. Manual block valve closed in spent degassing air line. 3. Blow-off valve open. 4. Discharge valve closed. CORRECTIVE ACTIONS 1. Perform pressure drop survey to find problem and correct it. 2. Open manual block valve. 3. Close blow-off valve. 4. Open discharge valve.
High Flow Rate High Discharge Pressure
High Discharge Temperature
Possible blower damage.
1. Perform a pressure survey and isolate area of high pressure drop in the plant. Shut down the degassing system and correct the problem. 2. Discharge valve or discharge 2. Start spare blower and place it in service. Repair discharge valve or check valve. check valve closed or pinched. See High Discharge Pressure, See High Discharge Pressure, this item. this item. 1. Plugging of piping or equipment downstream of this item.
Issued 18Jan10
9.11.2
Sulfur Transfer Pump, P-1902A&B

= local instrument , = has both local & DCS annunciators MINIMUM 9 GPM 0 GPM MAXIMUM 160 GPM 160 GPM INDICATORS CONTROLLER ALARMS NONE NONE NONE FC-0907 NONE SHUTDOWNS RELIEF (PSV) NONE N/A

PARAMETER Flow Rate (thru pump) Flow Rate (to process) Discharge Pressure NORMAL 18.5 GPM 11.5 GPM
FAL/FAH on NONE NONE FC-0907 94 PSIG N/A 95 PSIG LC-0907 NONE LAL/LAH on NONE N/A LC-0907 Suction Level varies 680 mm (1) N/A NONE NONE NONE NONE NONE Jacket Pressure 50 PSIG Full vacuum 100 PSIG NONE NONE NONE NONE N/A Jacket Temperature 297F 0F 350F NONE NONE NONE NONE N/A (1) The level in the pit is measured relative to the bottom of the pit when gauging through one of the breather vents in the top of the pit. See Section 9.12 for the strapping table.

DEVIATION Low Flow Rate POTENTIAL CONSEQUENCES Damage to pump bearings due to inadequate lubrication (bearings are lubricated by the liquid sulfur). High level in the Sulfur Pit. See "High Level", item TK-1901, for potential consequences. POSSIBLE CAUSES CORRECTIVE ACTIONS 1. Loss of suction due to low sulfur 1. Shut down pump. Do not resume level. transferring sulfur until sufficient level builds in the pit. 2. Sulfur transfer line plugged. 2. Shut down pump. Do not resume transferring sulfur until plugging has been corrected. 3. Manual block valve closed. 3. Open manual block valve. 4. High sulfur viscosity due to high 4. See "High Jacket Temperature", this item. sulfur temperature
Issued 18Jan10
DEVIATION Low Discharge Pressure
Low Suction Level
Low Jacket Temperature
High Jacket Temperature
POTENTIAL CONSEQUENCES POSSIBLE CAUSES CORRECTIVE ACTIONS 1. Loss of suction due to low sulfur 1. Shut down pump. Do not resume pumping No or low flow from pump. until sufficient level builds in the pit. level. See "Low Flow Rate", this item, 2. Remove pump and correct problem, then 2. Pump suction blocked or for other potential reinstall and resume pumping. Use spare plugged. consequences. pump until repairs completed. 3. Shut down pump. Check steam supply and 3. Pump discharge plugged. trap. Do not resume pumping until plugging is removed. 4. Remove pump and replace impeller. Use 4. Pump impeller damaged. spare pump until repairs completed. Shut down Sulfur Transfer Pump. Do not See "Low Flow Rate", this item. Pumping down level in pit too low. resume transferring sulfur until a sufficient level accumulates in the pit. 1. Manual block valve(s) closed in 1. Open manual block valve(s). Plugging of pump with solid steam supply line or condensate sulfur. outlet line. Possible equipment damage. High level in the sulfur pit. See 2. Accumulation of condensate in 2. Repair or replace trap. jacket due to malfunctioning "High Level", item TK-1901, for trap. potential consequences. 3. Accumulation of 3. Open vent valve(s) on jacket briefly to non-condensible vapors in the sweep non-condensibles out of jacket. jacket. 4. Upset in steam header pressure 4. Correct problem in steam header pressure control. control. 1. Upset in steam header pressure 1. Correct problem in steam header pressure No or low flow from pump due control. control. to high sulfur viscosity. 2. See "High Outlet Temperature", item Possible equipment damage. 2. Superheated steam in steam header. PA-5001
Issued 18Jan10
9.11.3
Sulfur Feed Pump, P-1903A&B

= local instrument , = has both local & DCS annunciators MINIMUM 3 GPM 0 GPM MAXIMUM 70 GPM 14 GPM INDICATORS CONTROLLER ALARMS NONE NONE NONE NONE FC-4601 SHUTDOWNS RELIEF (PSV) NONE N/A

PARAMETER Flow Rate (thru pump) Flow Rate (to process) Discharge Pressure NORMAL 13 GPM 11 GPM
FAL/FAH on NONE NONE FC-4601 50 PSIG N/A 54 PSIG NONE LC-4601 LAL/LAH on NONE N/A LC-4601 Suction Level varies 645 mm (1) N/A NONE NONE NONE NONE NONE Jacket Pressure 50 PSIG Full vacuum 100 PSIG NONE NONE NONE NONE N/A Jacket Temperature 297F 0F 350F NONE NONE NONE NONE N/A (1) The level in the pit is measured relative to the bottom of the pit when gauging through one of the breather vents in the top of the pit. See Section 9.12 for the strapping table.

DEVIATION Low Flow Rate POTENTIAL CONSEQUENCES Damage to pump bearings due to inadequate lubrication (bearings are lubricated by the liquid sulfur). High level in the Sulfur Pit. See "High Level", item TK-1901, for potential consequences. POSSIBLE CAUSES 1. Loss of suction due to low sulfur level. 2. Sulfur feed piping to Sulfur Degassing Reactor plugged. 3. Manual block valve closed. 4. High sulfur viscosity due to high sulfur temperature CORRECTIVE ACTIONS 1. Shut down pump. Do not resume pumping until sufficient level builds in the pit. 2. Shut down pump. Do not resume pumping until plugging has been corrected. 3. Open manual block valve. 4. See "High Jacket Temperature", this item.
Issued 18Jan10
DEVIATION Low Discharge Pressure
POTENTIAL CONSEQUENCES POSSIBLE CAUSES 1. Loss of suction due to low No or low flow from pump. sulfur level. See "Low Flow Rate", this item, 2. Pump suction blocked or for other potential plugged. consequences.
Low Suction Level
Low Jacket Temperature
High Jacket Temperature
CORRECTIVE ACTIONS 1. Shut down pump. Do not resume pumping until sufficient level builds in the pit. 2. Remove pump and correct problem, then reinstall and resume pumping. Use spare pump until repairs completed. 3. Shut down pump. Check steam supply and 3. Pump discharge plugged. trap. Do not resume pumping until plugging is removed. 4. Remove pump and replace impeller. Use 4. Pump impeller damaged. spare pump until repairs completed. See "Low Flow Rate", this item. Pumping down level in pit too low. Shut down Sulfur Feed Pump. Do not restart sulfur degassing until a sufficient level accumulates in the pit. 1. Manual block valve(s) closed in 1. Open manual block valve(s). Plugging of pump with solid steam supply line or sulfur. condensate outlet line. Possible equipment damage. High level in the sulfur pit. See 2. Accumulation of condensate in 2. Repair or replace trap. jacket due to malfunctioning "High Level", item TK-1901, for trap. potential consequences. 3. Accumulation of 3. Open vent valve(s) on jacket briefly to non-condensible vapors in the sweep non-condensibles out of jacket. jacket. 4. Upset in steam header 4. Correct problem in steam header pressure pressure control. control. 3. Upset in steam header 3. Correct problem in steam header pressure No or low flow from pump due pressure control. control. to high sulfur viscosity. 4. See "High Outlet Temperature", item Possible equipment damage. 4. Superheated steam in steam header. PA-5001
Issued 18Jan10
9.11.4
Degassed Sulfur Drain Seal Assembly, PA-1903

= local instrument , = has both local & DCS annunciators MINIMUM Full vacuum 0F 0 PSIG 0F MAXIMUM 100 PSIG 350F 14 PSIG 350F INDICATORS NONE NONE NONE NONE CONTROLLER NONE NONE NONE NONE ALARMS NONE NONE NONE NONE SHUTDOWNS NONE NONE NONE NONE RELIEF (PSV) NONE N/A NONE N/A

PARAMETER Jacket Pressure Jacket Temperature Process Pressure Process Temperature NORMAL 50 PSIG 297F 0-0.5 PSIG 280F

DEVIATION Low Jacket Temperature POTENTIAL CONSEQUENCES Plugging of process side with solid sulfur. Accumulation of liquid sulfur in Sulfur Degassing Reactor. Possible carry-over of liquid sulfur from Sulfur Degassing Reactor into TTO. Possible equipment damage and/or rupture. Possible release of toxic gas. Not a concern in this item. See "Low Jacket Temperature", this item. See "High Jacket Temperature", this item. Low flow on process side due to high sulfur viscosity. See "Low Jacket Temperature", this item for other potential consequences. POSSIBLE CAUSES 1. Manual block valve(s) closed in steam supply line or condensate outlet line. 2. Accumulation of condensate in jacket due to malfunctioning trap. 3. Accumulation of noncondensible vapors in the jacket. 4. Upset in steam header pressure control. 1. Low jacket temperature. 2. Steam leak into process. See "High Jacket Temperature", this item. 1. Upset in steam header pressure control. 2. Superheated steam in steam header. CORRECTIVE ACTIONS 1. Open manual block valve(s).
2. Repair or replace trap.
3. Open vent valve(s) on jacket briefly to sweep non-condensibles out of jacket. 4. Correct problem in steam header pressure control. 1. See "Low Jacket Temperature", this item. 2. Shut down SDU and repair leak. See "High Jacket Temperature", this item. 1. Correct problem in steam header pressure control. 2. See "High Outlet Temperature", item PA-5001
Low/High Process Pressure Low Process Temperature High Process Temperature High Jacket Temperature
Issued 18Jan10
9.11.5
Sulfur Degassing Reactor, R-1902

= local instrument , = has both local & DCS annunciators MAXIMUM 4,902 mm above btm seam 50 PSIG 350F INDICATORS CONTROLLER ALARMS LI-4602 NONE LAL/LAH on LI-4602 LAHH-4602 LALL-4602 NONE NONE NONE TI-4601 NONE TAL/TAH on TI-4602 TI-4601 TI-4603 TAL/TAH on TI-4602 TAL/TAH on TI-4603 TAHH-4604 NONE FC-4601 FAL/FAH on FC-4601 FI-4602 NONE FAL/FAH on FI-4602 SHUTDOWNS RELIEF (PSV) LT-4602 N/A

PARAMETER Level NORMAL MINIMUM 4,293-4,598 mm 4,191 mm above btm seam above btm seam 0-0.5 PSIG 280F 0 PSIG 0F
Operating Pressure Operating Temperature
NONE TT-4601 TT-4602 TT-4603
PA-1903 N/A
Sulfur Feed Rate Degassing Air Feed Rate
8350 lb/H 150 SCFM
0 Lb/H 60 SCFM
12,600 lb/H 180 SCFM
NONE NONE
N/A N/A

DEVIATION Low Level POTENTIAL CONSEQUENCES POSSIBLE CAUSES Low sulfur feed rate. Possible fire in the Sulfur Degassing Reactor. Possible damage to vessel and loss of containment. Possible release of toxic gas. Possible release of molten sulfur. CORRECTIVE ACTIONS See " Low Sulfur Feed Rate ", this item.
Issued 18Jan10
DEVIATION High Level
POTENTIAL CONSEQUENCES Possible carry-over of liquid sulfur into the Thermal Oxidizer. Possible damage to the Thermal Oxidizer and loss of containment. Possible release of toxic gas. Possible high emissions from Thermal Oxidizer Stack.
Low Operating Pressure High Operating Pressure
High Differential Pressure
Low Operating Temperature
High Operating Temperature
POSSIBLE CAUSES CORRECTIVE ACTIONS 1. See "Low Jacket Temperature ", item 1. Plugging or restriction in PA-1903. Degassed Sulfur Drain Seal Assembly. 2. Plugging of piping downstream 2. Shut down SDU. Do not resume degassing until plugging has been of this item. corrected. 3. Open manual valve. 3. Manual valve closed in sulfur rundown line. 4. Shut down SDU. Clear strainer, then restart 4. Plugging in strainer, SDU. 74-462002. Blocking-in equipment and allowing Follow proper steam out procedures. Possible collapse if vacuum it to cool following steam out. created. 1. Plugging of mist eliminator with Perform a pressure survey and isolate area of Possible over-pressure of high pressure drop in the plant. Shut down the solid sulfur. equipment and/or piping. degassing system and correct the problem. Possible release of toxic gas. 2. Plugging of equipment or piping downstream of this item. 3. Manual valve closed in spent degassing air line. Possible damage to bed limiter Plugging of catalyst bed with solid See "Low Operating Temperature", this item. sulfur due to low temperature. and loss of catalyst containment. Possible plugging of outlet drain line. Possible over-pressure of equipment and/or piping due to restricted flow. Possible release of toxic gas. Possible sulfur freezing leading 1. Low temperature in Sulfur Pit. 1. See "Low Temperature", item TK-1901. to over-pressure of equipment 2. Loss of steam supply to vessel 2. Re-establish heating steam to jacket. jacket. and/or piping. Possible poor degassing performance. High temperature in Sulfur Pit. See "High Temperature, item TK-1901. Possible poor degassing performance.
Issued 18Jan10
DEVIATION High Catalyst Bed Temperature
Low Sulfur Feed Rate
High Sulfur Feed Rate
Low Degassing Air Feed Rate High Degassing Air Feed Rate
POTENTIAL CONSEQUENCES Possible damage to bed support or limiter and loss of catalyst containment. See "High Differential Pressure" this item for other potential consequences. Possible damage to vessel and loss of containment. Possible release of toxic gas. Possible release of molten sulfur. Possible high level in Sulfur Pit. See "High Level", item TK-1901, for additional consequences. Possible loss of liquid level in reactor. See "High Catalyst Bed Temperature", this item, for other possible consequences. Possible low level in Sulfur Pit. See "Low Level", item TK-1901, for additional consequences. Possible poor degassing performance. Possible poor degassing performance. Not a concern in this item.
POSSIBLE CAUSES 1. Auto-ignition of iron sulfide on vessel walls.
2. Auto-ignition of liquid sulfur in vessel.
CORRECTIVE ACTIONS 1. Shut down Degassing Air Blower to stop air flow and extinguish fire. Follow proper procedures to start sulfur flow first, then air flow after vessel is filled with sulfur. 2. Shut down Degassing Air Blower to stop air flow and extinguish fire. Follow proper procedures to start sulfur flow first, then air flow after vessel is filled with sulfur.
1. Sulfur Feed Pump malfunction. 2. Malfunction of sulfur flow control. 3. Malfunction of pit level control. 4. Discharge valve open on off-line pump.
1. See "Low Flow Rate", item P-1903A&B . 2. Correct problem with sulfur flow control. 3. Correct problem with pit level control. 4. Close discharge valve on off-line pump.
1. Correct problem with sulfur flow control. 1. Malfunction of sulfur flow control. 2. Malfunction of pit level control. 2. Correct problem with pit level control.
Degassing Air Blower malfunction. See "Low Flow Rate", item C-1903A&B.
Issued 18Jan10
9.11.6
Bed Support and Limiter for Sulfur Degassing Reactor, R-1902-2

= local instrument , = has both local & DCS annunciators MINIMUM 0.0 PSI 2.5 PSI 0F MAXIMUM 5 PSI 2.5 PSI 350F INDICATORS CONTROLLER ALARMS NONE NONE NONE NONE TI-4601 TI-4602 TI-4603 NONE NONE NONE TAL/TAH on TI-4601 TAL/TAH on TI-4602 TAL/TAH on TI-4603 TAHH-4604 SHUTDOWNS RELIEF (PSV) NONE N/A NONE TT-4601 TT-4602 TT-4603 N/A N/A

PARAMETER NORMAL Differential Pressure 0-5 PSI (Bed Limiter) Differential Pressure 2.5 PSI (Bed Support) Temperature 280F

DEVIATION High Differential Pressure High Temperature POTENTIAL CONSEQUENCES See "High Differential Pressure", item R-1902. See "High Catalyst Bed Temperature", item R-1902. POSSIBLE CAUSES See "High Differential Pressure", item R-1902. See "High Catalyst Bed Temperature", item R-1902. CORRECTIVE ACTIONS See "High Differential Pressure", item R-1902. See "High Catalyst Bed Temperature", item R-1902.
See Section 7.11.12 of this manual for the Safe Operating Limits and the Deviations and Corrective Actions tables for this item.
9.11.7
Sulfur Pit, TK-1901
Issued 18Jan10
Page 9-51
9.12 Sulfur Tank Strapping Table
An internal weir divides the Sulfur Pit, TK-1901, into two sections: one for the raw production from the SRU, and one for the degassed sulfur from the Sulfur Degassing system. Both sections are sloped from one end to the other and the degassed section contains a boot at the end opposite from the dividing weir. The sulfur quantities in the strapping tables below are based on measuring the sulfur level through the 3" breather vents and above the bottom of the tank in each section.
Issued 18Jan10
Page 9-52

Strapping Table for Raw Production Section
METRIC TONS OF SULFUR PER 5 mm INCREMENT @ 138C (maintain the tank level within the non-shaded regions below)
mm 0 mm 5 mm 10 mm 15 mm 20 mm 25 mm 30 mm 35 mm 40 mm 45 mm 50 mm 55 mm 60 mm 65 mm 70 mm 75 mm 80 mm 85 mm 90 mm 95 mm 0 100 200 300 400 1.66 7.36 12.46 17.96 23.65 1.94 7.64 12.71 18.24 23.93 2.22 7.91 12.96 18.53 24.22 2.51 8.19 13.21 18.82 24.50 2.79 8.46 13.48 19.10 24.78 3.08 8.73 13.74 19.38 25.06 3.36 9.00 14.01 19.67 25.35 3.65 9.26 14.28 19.95 25.63 3.93 9.52 14.55 20.24 25.91 4.22 9.77 14.83 20.52 26.19 4.51 10.02 15.11 20.81 26.48 4.79 10.26 15.39 21.09 26.76 5.07 10.51 15.68 21.38 27.04 5.36 10.75 15.96 21.67 27.32 5.65 11.00 16.24 21.95 27.61 5.93 11.24 16.53 22.23 27.89 6.21 11.48 16.82 22.52 28.17 6.50 11.73 17.10 22.80 28.46 6.79 11.97 17.39 23.08 28.74 7.07 12.21 17.67 23.37 29.02
500 600 700 800 900 29.30 34.96 40.61 46.27 51.92 29.59 35.24 40.89 46.55 52.20 29.87 35.52 41.17 46.83 52.48 30.15 35.80 41.46 47.11 52.77 30.43 36.09 41.74 47.40 53.05 30.72 36.37 42.02 47.68 53.33 31.00 36.65 42.30 47.96 53.61 31.28 36.93 42.59 48.24 53.90 31.56 37.22 42.87 48.53 54.18 31.85 37.50 43.15 48.81 54.46 32.13 37.78 43.44 49.09 54.74 32.41 38.07 43.72 49.37 55.03 32.69 38.35 44.00 49.66 55.31 32.98 38.63 44.28 49.94 55.59 33.26 38.91 44.57 50.22 55.87 33.54 39.20 44.86 50.50 56.16 33.83 39.48 45.14 50.79 56.44 34.11 39.76 45.42 51.07 56.72 34.39 40.04 45.70 51.35 57.01 34.67 40.33 45.98 51.64 57.29
1000 1100 1200 1300 1400 57.57 63.22 68.88 74.53 80.18 57.85 63.51 69.16 74.81 80.46 58.14 63.79 69.44 75.09 80.74 58.42 64.07 69.72 75.37 81.03 58.70 64.35 70.01 75.66 81.31 58.98 64.64 70.29 75.94 81.59 59.27 64.92 70.57 76.22 81.87 59.55 65.20 70.85 76.50 82.16 59.83 65.48 71.13 76.79 82.44 60.11 65.77 71.42 77.07 82.72 60.40 66.05 71.70 77.35 83.01 60.68 66.33 71.98 77.64 83.29 60.96 66.62 72.26 77.92 83.57 61.25 66.90 72.55 78.20 83.85 61.53 67.18 72.83 78.48 84.14 61.81 67.46 73.11 78.77 84.42 62.09 67.75 73.40 79.05 84.70 62.38 68.03 73.68 79.33 84.98 62.66 68.31 73.96 79.61 85.27 62.94 68.59 74.24 79.90 85.55
1500 1600 1700 85.83 91.48 97.14 86.11 91.77 97.42 86.40 92.05 97.71 86.68 92.33 97.99 86.96 92.62 98.27 87.24 92.90 98.55 87.53 93.18 98.84 87.81 93.46 99.12 88.09 93.75 99.40 88.38 94.03 99.68 88.66 94.31 88.94 94.59 89.22 94.88 89.51 95.16 89.79 95.44 90.07 95.72 90.35 96.00 90.64 96.29 90.92 96.57 91.20 96.85
99.97 100.25 100.53 100.82 101.10 101.38 101.66 101.95 102.23 102.51
1800 102.79 103.08 103.36 103.64 103.92 104.21 104.49 104.77 105.05 105.34 105.62 105.90 106.19 106.47 106.75 107.03 107.32 107.60 107.88 108.16 1900 108.45 108.73 109.01 109.29 109.58 109.86 110.14 110.42 110.71 110.99 111.27 111.56 111.84 112.12 112.40 112.69 112.97 113.25 113.53 113.82 2000 114.10 114.38 114.66 114.95 115.23 115.51 115.80 116.08 116.36 116.64 116.93 117.21 117.49 117.77 118.06 118.34 118.62 118.90 119.19 119.47 2100 119.75 120.03 120.32 120.60 120.88 121.16 121.44 121.73 122.01 122.29 122.58 122.86 123.14 123.42 123.71 123.99 124.27 124.55 124.84 125.12 2200 125.40 125.68 125.97 126.25 126.53 126.81 127.10 127.38 127.66 127.95 128.23 128.51 128.79 129.08 129.36 129.64 129.92 130.21 130.49 130.77 2300 131.05 131.34 131.62 131.90 132.19 132.47 132.75 133.03 133.32 133.60 133.88 134.16 134.45 134.73 135.01 135.29 135.58 135.86 136.14 136.42 2400 136.71 136.99 137.27 137.56 137.84 138.12 138.40 138.69 138.97 139.25 139.53 139.82 140.10 140.38 140.66 140.95 141.23 141.51 141.79 142.08 2500 142.36 142.64 142.93 143.21 143.49 143.77 144.06 144.34 144.62 144.90 145.19 145.47 145.75 146.03 146.32 146.60 146.88 147.16 147.44 147.73 2600 148.01 148.29 148.58 148.86 149.15 149.43 149.71 149.99 150.28 150.56 150.84 151.13 151.41 151.69 151.97 152.26 152.54 152.82 153.10 153.39 2700 153.67 153.95 154.23 154.52 154.80 155.08 155.37 155.65 155.93 156.21 156.50 156.78 157.06 157.34 157.63 157.91 158.19 158.47 158.76 159.04 2800 159.32 159.60 159.89 160.17 160.45 160.74 161.02 161.30 161.58 161.87 162.15 162.43 162.71 163.00 163.28 163.56 163.84 164.13 164.41 164.69 2900 164.98 165.26 165.54 165.82 166.11 166.39 166.67 166.95 167.24 167.52 167.80 168.08 168.37 168.65 168.93 169.21 169.50 169.78 170.06 170.35 3000 170.63 170.91 171.19 171.48 171.76 172.04 172.32 172.60 172.89 173.17 173.45 173.73 174.02 174.30 174.58 174.86 175.15 175.43 175.71 175.99 3100 176.28 176.56 176.84 177.13 177.41 177.69 177.97 178.26 178.54 178.82 179.10 179.39 179.67 179.95 180.23 180.52 180.80 181.08 181.36 181.65 3200 181.93 182.21 182.50 182.78 183.06 183.34 183.63 183.91 184.19 184.47 184.76 185.04 185.32 185.60 185.89 186.17 186.45 186.74 187.02 187.30 3300 187.58 187.87 188.15 188.43 188.71 189.00 189.28 189.56 189.84 190.13 190.41 190.69 190.97 191.26 191.54 191.82 192.11 192.39 192.67 192.95 3400 193.24 193.52 193.80 194.08 194.37 194.65 194.93 195.21 195.50 195.78 196.06 196.35 196.63 196.91 197.19 197.47 197.75 198.04 198.32 198.60 3500 198.89 199.17 199.45 199.73 200.02 200.31 200.59 200.87 201.15 201.44 201.72 202.00 202.28 202.57 202.85 203.13 203.41 203.70 203.98 204.26 3600 204.55 204.83 205.11 205.39 205.68 205.96 206.24 206.52 206.81 207.09 207.37 207.65 207.94 208.22 208.50 208.78 209.07 209.35 209.63 209.92 3700 210.20 210.48 210.76 211.05 211.33 211.61 211.89 212.18 212.46 212.74 213.02 213.31 213.59 213.87 214.15 214.44 214.72 215.00 215.29 215.57 3800 215.85 216.13 216.42 216.70 216.98 217.26 217.55 217.83 218.11 218.39 218.68 218.96 219.24 219.53 219.81 220.09 220.37 220.66 220.94 221.22 3900 221.50 221.79 222.07 222.35 222.63 222.91 223.20 223.48 223.76 224.04 224.33 224.61 224.89 225.17 225.46 225.74 226.02 226.31 226.59 226.87 4000 227.15 227.44 227.72 228.00 228.28 228.57 228.85 229.13 229.41 229.70 229.98 230.26 230.54 230.83 231.11 231.39 231.68 231.96 232.24 232.52 4100 232.81 233.09 233.37 233.65 233.94 234.22 234.50 234.78 235.07 235.35 235.63 235.92 236.20 236.48 236.76 237.05 237.33 237.61 237.89 238.18 4200 238.46 238.74 239.02 239.31 239.59 239.87 240.15 240.44 240.72 241.00 241.29 241.57 241.85 242.13 242.42 242.70 242.98 243.26 243.55 243.83 4300 244.11 244.39 244.68 244.96 245.24 245.52 245.81 246.09 246.37 246.66 246.94 247.22 247.50 247.78 248.07 248.35 248.63 248.91 249.20 249.48 4400 249.76 250.04 250.33 250.61 250.89 251.17 251.46 251.75 252.03 252.31 252.59 252.88 253.16 253.44 253.72 254.01 254.29 254.57 254.86 255.14 4500 255.42 255.70 255.99 256.27 256.55 256.83 257.12 257.40 257.68 257.96 258.25 258.53 258.81 259.10 259.38 259.66 259.94 260.23 260.51 260.79 4600 261.07 261.36 261.64 261.92 262.20 262.49 262.77 263.05 263.33 263.62 263.90 264.18 264.47 264.75 265.03 265.31 265.60 265.88 266.16 266.44 4700 266.73 267.01 267.29 267.57 267.86 268.14 268.42 268.71 268.99 269.27 269.55 269.84 270.12 270.40 270.68 270.97 271.25 271.53 271.81 272.10 4800 272.38 272.66 272.94 273.22 273.51 273.79 274.07 274.35 274.64 274.92 275.20 275.49 275.77 276.05 276.33 276.62 276.90 277.18 277.46 277.75 4900 278.03 278.31 278.59 278.88 279.16 279.44 279.72 280.01 280.29 280.57 280.86 281.14 281.42 281.70 281.99 282.27 282.55 282.83 283.12 283.40 5000 283.68 283.96 284.25 284.53 284.81 285.09 285.38 285.66 285.94 286.23 286.51 286.79 287.07 287.36 287.64 287.92 288.20 288.49 288.77 289.05 5100 289.33 289.62 289.90 290.18 290.47 290.75 291.03 291.31 291.60 291.88 292.16 292.44 292.73 293.01 293.29 293.57 293.86 294.14 294.42 294.70 5200 294.99 295.27 295.55 295.84 296.12 296.40 296.68 296.97 297.25 297.53 297.81 298.09 298.38 298.66 298.94 299.22 299.51 299.79 300.07 300.35 5300 300.64 300.92 301.20 301.48 301.77 302.05 302.33 302.62 302.90 303.18 303.47 303.75 304.04 304.32 304.60 304.88 305.17 305.45 305.73 306.01 5400 306.22 306.33
Issued 18Jan10
Page 9-53

Strapping Table for Degassed Section
mm 0 mm 5 mm 10 mm 15 mm 20 mm 25 mm 30 mm 35 mm 40 mm 45 mm 50 mm 55 mm 60 mm 65 mm 70 mm 75 mm 80 mm 85 mm 90 mm 95 mm 0 100 200 300 400 0.00 1.23 2.53 3.83 8.35 0.02 1.30 2.60 3.88 8.72 0.07 1.37 2.67 3.91 9.09 0.13 1.43 2.73 3.95 9.46 0.20 1.50 2.80 4.02 9.83 0.26 1.56 2.86 4.11 10.19 0.32 1.62 2.92 4.23 10.55 0.39 1.69 2.99 4.38 10.90 0.45 1.75 3.05 4.55 11.26 0.52 1.82 3.12 4.74 11.61 0.58 1.88 3.18 4.95 11.95 0.65 1.95 3.25 5.19 12.29 0.72 2.02 3.32 5.46 12.62 0.78 2.08 3.38 5.77 12.96 0.85 2.15 3.45 6.11 13.29 0.91 2.21 3.51 6.49 13.61 0.97 2.27 3.57 6.86 13.94 1.04 2.34 3.64 7.23 14.25 1.10 2.40 3.70 7.61 14.57 1.17 2.47 3.77 7.98 14.89
500 600 700 800 900 15.21 22.21 29.67 37.14 44.60 15.53 22.58 30.05 37.51 44.97 15.85 22.95 30.42 37.88 45.35 16.17 23.33 30.79 38.26 45.72 16.50 23.70 31.16 38.63 46.09 16.82 24.07 31.54 39.00 46.47 17.16 24.45 31.92 39.37 46.84 17.49 24.82 32.28 39.75 47.21 17.84 25.19 32.66 40.12 47.59 18.19 25.56 33.03 40.49 47.96 18.54 25.94 33.40 40.87 48.33 18.90 26.31 33.78 41.24 48.70 19.25 26.68 34.15 41.61 49.08 19.61 27.06 34.52 41.99 49.46 19.98 27.43 34.89 42.36 49.82 20.34 27.81 35.27 42.73 50.20 20.72 28.18 35.65 43.10 50.57 21.09 28.55 36.01 43.48 50.94 21.46 28.93 36.39 43.86 51.32 21.83 29.30 36.76 44.22 51.69
1000 1100 1200 1300 1400 52.06 59.53 67.00 74.46 81.92 52.43 59.90 67.37 74.83 82.29 52.81 60.27 67.74 75.21 82.67 53.19 60.65 68.11 75.57 83.04 53.56 61.02 68.48 75.95 83.41 53.93 61.40 68.86 76.33 83.79 54.30 61.76 69.23 76.70 84.16 54.68 62.14 69.60 77.07 84.54 55.05 62.52 69.97 77.44 84.91 55.42 62.89 70.35 77.81 85.28 55.80 63.26 70.73 78.19 85.66 56.17 63.63 71.10 78.56 86.03 56.54 64.01 71.47 78.94 86.40 56.92 64.38 71.84 79.30 86.77 57.29 64.75 72.22 79.68 87.14 57.66 65.13 72.59 80.06 87.52 58.03 65.50 72.96 80.43 87.89 58.41 65.87 73.34 80.80 88.27 58.79 66.25 73.71 81.17 88.64 59.16 66.62 74.08 81.55 89.01
1500 1600 89.39 96.85 89.76 97.22 90.13 97.60 90.50 97.97 90.88 98.34 91.25 98.71 91.62 99.09 92.00 99.46 92.37 92.75 93.12 93.49 93.87 94.24 94.61 94.99 95.36 95.73 96.10 96.48
99.83 100.21 100.58 100.95 101.32 101.69 102.07 102.44 102.81 103.19 103.56 103.93
1700 104.30 104.68 105.05 105.42 105.79 106.16 106.54 106.91 107.28 107.66 108.03 108.40 108.77 109.14 109.52 109.89 110.26 110.63 111.00 111.38 1800 111.75 112.13 112.50 112.87 113.24 113.61 113.99 114.36 114.73 115.10 115.47 115.85 116.23 116.59 116.97 117.34 117.71 118.08 118.45 118.83 1900 119.20 119.57 119.94 120.32 120.69 121.06 121.44 121.81 122.18 122.55 122.92 123.30 123.67 124.04 124.42 124.79 125.16 125.53 125.91 126.28 2000 126.65 127.02 127.39 127.77 128.14 128.51 128.89 129.26 129.63 130.01 130.37 130.75 131.12 131.49 131.87 132.24 132.61 132.98 133.36 133.73 2100 134.10 134.47 134.84 135.22 135.59 135.96 136.34 136.71 137.08 137.45 137.82 138.20 138.57 138.94 139.31 139.69 140.06 140.43 140.81 141.18 2200 141.55 141.92 142.29 142.67 143.04 143.41 143.78 144.15 144.53 144.90 145.28 145.65 146.02 146.39 146.76 147.14 147.51 147.88 148.25 148.62 2300 149.00 149.38 149.74 150.12 150.49 150.86 151.24 151.60 151.98 152.35 152.72 153.10 153.47 153.84 154.21 154.59 154.96 155.33 155.70 156.07 2400 156.45 156.82 157.19 157.57 157.94 158.31 158.68 159.06 159.43 159.80 160.17 160.54 160.92 161.29 161.66 162.04 162.41 162.78 163.15 163.52 2500 163.90 164.27 164.64 165.02 165.39 165.76 166.13 166.51 166.88 167.25 167.62 167.99 168.37 168.74 169.11 169.49 169.86 170.23 170.61 170.97 2600 171.35 171.72 172.09 172.47 172.84 173.21 173.58 173.96 174.33 174.70 175.07 175.44 175.82 176.19 176.56 176.93 177.30 177.68 178.05 178.43 2700 178.80 179.17 179.54 179.91 180.29 180.66 181.03 181.40 181.77 182.15 182.53 182.89 183.27 183.64 184.01 184.39 184.75 185.13 185.50 185.87 2800 186.25 186.62 186.99 187.36 187.74 188.11 188.48 188.85 189.22 189.60 189.97 190.34 190.72 191.09 191.46 191.84 192.21 192.58 192.95 193.32 2900 193.70 194.07 194.44 194.81 195.19 195.56 195.93 196.30 196.67 197.05 197.42 197.79 198.17 198.54 198.91 199.28 199.66 200.03 200.40 200.77 3000 201.14 201.52 201.89 202.26 202.64 203.01 203.38 203.76 204.12 204.50 204.87 205.24 205.62 205.98 206.36 206.73 207.11 207.48 207.85 208.22 3100 208.59 208.97 209.34 209.71 210.08 210.45 210.83 211.21 211.58 211.95 212.32 212.69 213.07 213.44 213.81 214.18 214.55 214.92 215.30 215.68 3200 216.04 216.42 216.79 217.16 217.54 217.90 218.28 218.65 219.02 219.40 219.77 220.14 220.51 220.89 221.26 221.63 222.00 222.37 222.75 223.13 3300 223.50 223.87 224.24 224.61 224.99 225.36 225.73 226.10 226.47 226.85 227.22 227.59 227.96 228.34 228.71 229.08 229.45 229.82 230.20 230.57 3400 230.94 231.32 231.69 232.06 232.44 232.81 233.18 233.55 233.92 234.29 234.67 235.04 235.41 235.79 236.16 236.53 236.91 237.27 237.65 238.02 3500 238.39 238.77 239.13 239.51 239.88 240.26 240.63 241.00 241.37 241.74 242.12 242.49 242.86 243.23 243.60 243.98 244.36 244.73 245.10 245.47 3600 245.84 246.22 246.59 246.96 247.33 247.70 248.08 248.45 248.83 249.19 249.57 249.94 250.31 250.69 251.05 251.43 251.80 252.17 252.55 252.92 3700 253.29 253.66 254.04 254.41 254.78 255.15 255.52 255.90 256.28 256.64 257.02 257.39 257.76 258.14 258.51 258.88 259.25 259.62 260.00 260.37 3800 260.74 261.11 261.49 261.86 262.23 262.60 262.97 263.35 263.72 264.09 264.47 264.84 265.21 265.59 265.96 266.33 266.70 267.07 267.45 267.82 3900 268.19 268.56 268.94 269.31 269.68 270.06 270.42 270.80 271.17 271.54 271.92 272.28 272.66 273.03 273.41 273.78 274.15 274.52 274.89 275.27 4000 275.64 276.01 276.38 276.75 277.13 277.51 277.88 278.25 278.62 278.99 279.37 279.74 280.11 280.48 280.85 281.23 281.60 281.97 282.34 282.72 4100 283.09 283.46 283.84 284.20 284.58 284.96 285.33 285.70 286.07 286.44 286.82 287.19 287.56 287.93 288.30 288.68 289.05 289.43 289.79 290.17 4200 290.54 290.91 291.29 291.66 292.03 292.40 292.77 293.15 293.52 293.89 294.26 294.64 295.01 295.38 295.75 296.12 296.50 296.87 297.24 297.62 4300 297.99 298.36 298.74 299.11 299.48 299.85 300.22 300.60 300.97 301.34 301.71 302.09 302.46 302.83 303.21 303.57 303.95 304.32 304.69 305.07 4400 305.43 305.81 306.19 306.56 306.93 307.30 307.67 308.05 308.42 308.79 309.16 309.53 309.91 310.28 310.66 311.03 311.40 311.77 312.14 312.52 4500 312.89 313.26 313.63 314.00 314.38 314.75 315.12 315.49 315.87 316.24 316.61 316.99 317.35 317.73 318.11 318.48 318.85 319.22 319.59 319.97 4600 320.34 320.71 321.08 321.45 321.83 322.20 322.58 322.94 323.32 323.69 324.06 324.44 324.80 325.18 325.55 325.92 326.30 326.67 327.04 327.42 4700 327.79 328.16 328.53 328.90 329.28 329.65 330.02 330.39 330.77 331.14 331.51 331.89 332.26 332.63 333.00 333.37 333.75 334.12 334.49 334.86 4800 335.24 335.61 335.98 336.36 336.72 337.10 337.47 337.84 338.22 338.58 338.96 339.34 339.71 340.08 340.45 340.82 341.20 341.57 341.94 342.31 4900 342.68 343.06 343.43 343.81 344.18 344.55 344.92 345.29 345.67 346.04 346.41 346.78 347.15 347.53 347.90 348.27 348.65 349.02 349.39 349.76 5000 350.13 350.50 350.88 351.26 351.63 352.00 352.37 352.74 353.12 353.49 353.86 354.23 354.60 354.98 355.35 355.73 356.09 356.47 356.84 357.21 5100 357.59 357.95 358.33 358.70 359.07 359.45 359.82 360.19 360.57 360.94 361.31 361.68 362.05 362.43 362.80 363.17 363.54 363.92 364.29 364.66 5200 365.04 365.41 365.78 366.15 366.52 366.90 367.27 367.64 368.02 368.39 368.76 369.13 369.51 369.87 370.25 370.62 370.99 371.37 371.73 372.11 5300 372.49 372.86 373.23 373.60 373.97 374.35 374.72 375.09 375.46 375.83 376.21 376.58 376.96 377.33 377.70 378.07 378.44 378.82 379.19 379.56 5400 379.94 380.31 380.68 381.05 381.42 381.80 382.17 382.54 382.91 383.28 383.66 384.03 384.41 384.78 385.15 385.52 385.89 386.27 386.64 387.01
Issued 18Jan10
Page 9-54

mm 0 mm 5 mm 10 mm 15 mm 20 mm 25 mm 30 mm 35 mm 40 mm 45 mm 50 mm 55 mm 60 mm 65 mm 70 mm 75 mm 80 mm 85 mm 90 mm 95 mm 5500 387.38 387.75 388.13 388.50 388.88 389.24 389.62 389.99 390.36 390.74 391.10 391.48 391.85 392.22 392.60 392.97 393.34 393.72 394.09 394.46 5600 394.83 395.20 395.58 395.95 396.32 396.69 397.07 397.44 397.81 398.19 398.56 398.93 399.30 399.67 400.05 400.42 400.79 401.17 401.54 401.91 5700 402.28 402.66 403.03 403.40 403.77 404.14 404.52 404.89 405.26 405.64 406.01 406.38 406.75 407.12 407.50 407.87 408.24 408.61 408.98 409.36 5800 409.73 410.11 410.48 410.85 411.22 411.59 411.97 412.34 412.71 413.09 413.46 413.83 414.20 414.57 414.95 415.32 415.69 416.06 416.43 416.81 5900 417.18 417.56 417.93 418.30 418.67 419.04 419.42 419.79 420.16 420.53 420.90 421.28 421.65 422.03 422.40 422.77 423.14 423.51 423.89 424.26 6000 424.63 425.00 425.37 425.75 426.12 426.49 426.87 427.24 427.61 427.99 428.35 428.73 429.10 429.47 429.84 430.22 430.59 430.96 431.34 431.71 6100 432.08 432.45 432.82 433.20 433.57 433.94 434.32 434.69 435.06 435.43 435.81 436.18 436.55 436.92 437.29 437.67 438.04 438.41 438.79 439.16 6200 439.53 439.90 440.27 440.65 441.02 441.39 441.77 442.14 442.51 442.88 443.26 443.63 444.00 444.37 444.74 445.12 445.49 445.86 446.24 446.61 6300 446.98 447.36 447.72 448.10 448.47 448.84 449.21 449.58 449.96 450.33 450.71 451.08 451.45 451.82 452.19 452.57 452.94 453.31 453.68 454.05 6400 454.43 454.80 455.18 455.55 455.92 456.29 456.66 457.04 457.41 457.78 458.15 458.52 458.90 459.27 459.64 460.02 460.39 460.76 461.14 461.50 6500 461.88 462.25 462.62 463.00 463.37 463.74 464.11 464.49 464.86 465.23 465.60 465.97 466.35 466.72 467.09 467.47 467.84 468.21 468.58 468.96 6600 469.33 469.70 470.07 470.37
Issued 18Jan10
Page 9-55
9.13 Specification for Sulfur Degassing Reactor Catalyst
Issued 18Jan10
Page 9-56
9.14 Drawings
The following drawings are included in this section: Material Balance & Process Flow Diagrams Material Balance.......................................................... 1029-96-06-CS-001 Process Flow Diagram ............................................... 1029-09-06-DR-002 Piping & Instrument Diagrams Symbol Legend............................................................ 1029-96-06-DR-001 Sulfur Pit Raw Production Section............................... 1029-09-06-DR-010 Sulfur Degassing ......................................................... 1029-46-06-DR-001 Sulfur Pit Degassed Section........................................ 1029-46-06-DR-001 Cause & Effect and Logic Diagrams Sulfur Pit and Degassing ............................................. 1029-46-06-CD-004 Sulfur Pit and Startup Interlock.....................................1029-46-06-LD-008
Issued 18Jan10
Page 9-57

Operating procedures for sulfur degassing and transfer

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Operating procedures for sulfur degassing and transfer

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Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

9. SULFUR DEGASSING AND TRANSFER

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Sulfur Transfer Pump, P-1902A&B

Sulfur Feed Pump, P-1903A&B

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Degassed Sulfur Drain Seal Assembly, PA-1903

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Sulfur Degassing Reactor, R-1902

Bed Support and Limiter for Sulfur Degassing Reactor, R-1902-2

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Sulfur Pit, TK-1901

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Instrumentation and Control Systems

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

"Ride-Through" System Considerations

Sulfur Degassing Unit Startup Interlock

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

DAKHNI EXPANSION PROJECT SULFUR RECOVERY UNIT

Sulfur Degassing and Transfer

Operating Procedures Manual Winter 2010

Oil & Gas Development Company Limited Dakhni, Pakistan

Sulfur Degassing and Transfer