SRU Testing and Operator Checks

>> YOUR LINK HERE: ___ http://youtube.com/watch?v=5K_TpH1Cma0

This video is the fifth in the SRU Optimization series, which describes how to optimize the performance of each individual process unit, and covers 2 case studies from past testing experiences at SRE. • Performance evaluations must be conducted to ascertain the current operating conditions for each of the individual units. Prior to beginning the testing of the SRU, it is imperative to ensure that the plant is steady and that the H2S:SO2 ratio is approximately 2:1. The air demand signal should be oscillating between +/- 0.5 percent. SRE is able to safely collect high risk samples such as amine acid gas and sour water stripper feed streams, where H2S contents can be over 80 percent sometimes. • This is a picture of the chromatogram that is produced when we analyze a sample in the GC. The areas of these peaks are calculated to determine the exact chemical compositions of the samples. DCS data is then collected for the test period, which includes trends of all flows, temperatures, and pressures throughout the SRU, this data is plugged into the VMG simulation. - Overall, this simulation allows for a comprehensive review for each of the individual units and can be used for base lining the plant, troubleshooting, optimization, making capacity evaluations, retrofitting designs, and we can provide proper preparation guidelines for maintenance and repairs during a turnaround. • So, what else will our testing results consist of? Evaluate the Amine and SWS acid gas feed stream compositions: looking for Elevated HCs? BTEX level? Ammonia? Are the compositions swinging? What is the water content? • We will also evaluate the combustion air control system: Is the air demand signal oscillating within the optimum range of +/ 0.5 percent? Are the main and trim air valves acting too slowly? Too quickly? • -We’ll evaluate the accuracy of the tail gas analyzer H2S and SO2 concentrations: Because Good combustion air control is impossible without adequate operation of the tail gas analyzer. • We talked about evaluating the contaminant destruction efficiency of the reaction furnace: looking at HCs, BTEX, Ammonia breakthrough? Is the initial conversion efficiency within industry norms? What is the reaction furnace temperature and does it agree with instrumentation? • More results include the catalyst activity: Is the Claus reaction reaching equilibrium? If not, what is the deactivation mechanism? What are the sulfur dewpoint margins in the second and third Converters? • Hydrolysis: Is it consistent with industry norms for alumina, promoted, or full titanium? Are the optimum bed temperatures being achieved for maximum COS and CS2 hydrolysis rates. • Are the interstage condensers operating with the recommended outlet temperatures? Are they consistent with design values? Any indication of liquid sulfur entrainment? Any sign of tube sheet leaks? • Operating at recommended temperature? Liquid sulfur entrainment? Is the recovery efficiency to the tail gas the same as the recovery efficiency in the stack? If not, is there any other appreciable source of sulfur going to the incinerator? • We evaluate the reheater performance, ensuring the right outlet temps are achieved, and verifying the Burner Management System for DFRs. Then we will check is there are there any anomalous pressure drops across any of the units. If so, is it from sooting a Converter, tube or tube sheet leak, flooded condenser, could be from a converter operating below sulfur dewpoint temperature and causing sulfur buildup on the catalyst. • From there, we will discuss things that all SRU operators should be checking periodically. First they should check all the pressure gauges daily, and also verify that the sample valving is functional. Check that any steam or drain valves weren’t left open from a turnaround. Then checking for steam leaks and verifying steam traps. Then blowing down transmitters periodically is important too. • And a few more good operator checks would be confirming condenser water levels, verifying rundown flows, checking the RF temperature, and ensuring all sample valves have plugs in them. • All these operator checks are important for maintaining consistent performance from the unit, but only formal testing can clearly show what is happening under the hood to determine the specific optimization and troubleshooting techniques. For example, regular clients typically have an evaluation 6-8 months before a turnaround to determine if they need to replace catalyst, this has the potential to save big money if things are good! • Thanks for watching! For more videos on sulfur recovery, subscribe to our page. Also visit our website http://sulfurrecovery.com/, and sign up for our monthly newsletter here: http://sulfurrecovery.com/Newsletter/

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