STANDARD OPERATING PROCEDURE

PLANT START UP
1. Drain out drip acid from the drain valves of tube side (at bottom) and shell
side (just above) Hot Heat Exchanger (HHE), Cold Heat Exchanger (CHE) &
Economizer. If drip acid comes out of shell side drain the tubes may be
damaged.
2. Drain out condensate from the Blow Down Tank.
3. Check that the drain valve situated in front of Plate Heat Exchanger (PHE)1 and the ball valve in front of PHE-2 are closed.
4. Check that the valve over Final Absorption Tower (FAT) Chimney is in fully
closed condition for scrubbing of SO2.
5. Manually open the Steam Drum Inlet Water Valve and Export Valve to fully
open condition.
6. Start De-mineralized (DM) water pump & Boiler Feed Water (BFW) pump
after setting both in ready mode from operator console. Check for
cooling water circulation in the pumps.
7. Check that the sample taking valve over Acid Circulation Tank (PAT) is fully
closed and operate the circulation valve in such a manner that it is
slightly open.
8. Switch on Acid Circulation Pump after setting in ready mode from
operator console and start acid feed to Drying Tower (DT) keeping its inlet
valve 50% open, Intermediate Absorption Tower (IAT) keeping its inlet
valve 70% open & FAT keeping its inlet valve 50% open and then fully
open the circulation valve over PAT.
9. Start scrubbing system by starting scrubbing pump and maintain pH of
circulating liquid at 12 with 5% Caustic Soda (NaOH) soln. in scrubbing
system. Add NaOH soln. if required from Caustic Preparation Tank if pH
falls below 8.
10. Check Sulfur pump for its freeness and Sulfur pipeline for its throughness by blowing compressed air. If line is jam, check that steam is going
through the jacket (remove condensate if required) and heat the valves by
burning Coke Oven gas over them. Clean pit Sulfur temperature to be kept
at 130-140OC with elemental Sulfur of 99.5% purity.
11. Manually open air inlet valve over Sulfur Burner & discharge and bypass valves of Economizer to box up the system so that Sulfur Burner
temperature does not fall quickly.
12. Switch on Air Blower after setting in ready mode from operator
console and adjust discharge pressure to 1200 mm WC initially if Sulfur
Burner temperature is below 500OC & 1500 mm WC if Sulfur Burner
temperature is around 700OC.
13. Set Sulfur gun discharge valve at 20% open if Sulfur Burner
temperature is below 500OC or 10% open if Sulfur Burner temperature is
around 700OC and switch on the Sulfur Feed Pump after setting in ready

mode from operator console. Close the drain valve if any Sulfur is coming
from the drain line.
14. Check from the peep hole of Sulfur Burner for proper spray and flame
of Sulfur.
15. The plant should be run at low production at first and then raised in
steps.

PLANT OPERATION
1. Increase first the Sulfur slowly till temperature reaches around 750 OC and
then the air slowly so that Converter 1st stage inlet temperature is around
430OC. This is to be done by adjusting the Waste Heat Boiler (WHB) 1
shut off (FCV 0230) and by pass valves.
2. Adjust gas ducting valves in such a manner that the Converter
temperature in the various stages is as follows after 1st stage conversion:
STAG
INLET
TAG NO.
OUTLET
TAG NO.
E
TEMPERATURE
TEMPERATURE
1ST
430OC
TIA 0403
615OC
TIA 0407
ND
O
O
2
435 C
TIA 0402
508 C
TIA 0408
RD
O
O
3
425 C
TIA 0409
450 C
TIA 0412
4TH
425OC
TIA 0413
439OC
TIA 0404
TH
O
O
5
425 C
TIA 0405
426 C
TIA 0406
3. Check the concentration of acid in the Acid Recirculation Tank (PAT) so
that it is around 98.5% by either adding fresh conc. Sulfuric Acid from the
Storage Tanks or adding dilution water by regulating Rota meter valve.
4. When the temperature of circulating acid reaches 60 OC start Cooling
Water (CW) Pump and supply cooling water to the PHEs.
5. Norms of other critical parameters is as follows:
TAG
PARAMETER
NORM
TAG
PARAMETER
NORM
O
Sulfur
Melter 125-135 OC
0401 Hot Gas Filter Inlet 550
C
Temperature
Temp.
(max)
Pure Pit Level
1.0-1.7 m
0510 Acid Circulation Tank 1.10-1.30 m
Level
L010 Clean Pit Level
0.8-1.6 m
Acid Circulation Tank 80-90 OC
4
Temp.
T010 Clean Pit Temperature 130-140 OC
0508 Acid Pump Load (max) 135 amp
4
0306 Boiler Steam Pressure 4.55.5 0509 Acid Concentration
98.5%
2
kg/cm
0101 Air Pressure (max)
4000
mm 0515 Acid
Inlet 60-75 OC
WC
Temperature(FAT)
0501 Air Flow (max)
15000 m3/hr 0504 DT
Acid
Outlet 60-80 OC

Blower Current
0202
0313
0301
0304
0327
0305
0306

18-32 amp

Sulfur
Burner 800-980 OC
Temperature
Sulfur
Burner 800-980 OC
Temperature
DM Water Level
700-2700
mm
Deaerator
Water 600-750
Level
mm
Deaerator
Water
Temp.
Steam Drum Water 250-300
Level
mm
Steam Drum Pressure 8-10 kg/cm2

0417
0418
0505
0517

0506

Temperature
DT
Gas
Inlet
Temperature
DT
Gas
Outlet
Temperature
IAT
Gas
Inlet 160-220OC
Temperature
IAT
Gas
Outlet
Temperature
IAT
Acid
Outlet
Temperature
FAT
Gas
Inlet 180-250OC
Temperature
FAT
Gas
Outlet
Temperature
FAT
AcidOutlet
Temperature
Cooling Water Outlet
Temp.
Cooling Water Inlet pH around 7

Steam Drum Inlet 180-240 OC

1101
Temp.
Boiler
FW 200-240 OC
Temperature
Boiler
Inlet
Water 90-100 OC
Condensate
Blow around 7
Temp.
Down pH
0312 Boiler
Outlet 340-370 OC
P035 Economizer Inlet Water
Temperature
3
Pr.
6. Check that all the interlocks are working.
7. In case of sudden stoppages of blower, on re-starting purge the whole
system with dry air from blower for 5 minutes.
8. Monitor pH levels in Cooling Water outlet and Boiler Feed Water
outlet/Economizer and check that it lies around 7 so as to avoid Hydrogen
formation due to corrosive action of dilute H2SO4.
0306
A
T035
3
0327

PLANT SHUT DOWN

1. Stop Sulfur pump and drain the Sulfur line on pump side and gun side &
check whether any liquid Sulfur is at the bottom of Sulfur Burner through
peep hole.
2. Run the Blower till all the Sulfur inside the Sulfur Burner has got burnt for
at least 10 min.
3. Blow air in Sulfur line to clean pipeline from Sulfur Burner to Clean Pit and
ensure that air comes out from the bypass line in Clean Pit.
4. Stop the Air Blower.
5. Stop the dilution water in the Acid Recirculation Tank.
6. Check that steam is going in the Sulfur jacket line and Sulfur Pump.

SAFETY PRECAUTIONS
1. Do not tamper or bypass safety devices and controls.
2. Mandatory PPEs Safety helmet and Safety shoes are a must for entering
the plant.
3. Specific PPEs PVC Suit, Face Shield, Rubber Hand gloves and Gum boots
with PVC Pant over the boot are to be worn while near the Acid
Recirculation Tank.
4. Unauthorized entry within the plant premises is strictly prohibited.
5. Employees must remain in their specific work zones.
6. Sitting or resting near Acid Recirculation Tank is strictly prohibited.
7. Match/lighters or other means of causing sparks/flames like naked lights
are not to be used.
8. Smoking within the plant premises is strictly prohibited.
9. Cover acid pipeline flanges so that leakage may not cause acid spray.
10. Avoid contact of Sulfur, Sulfuric acid, Sulfur dioxide, Sulfur trioxide,
Caustic Soda, Tri Sodium Phosphate, Hydrazine and Vanadium Pent oxide
catalyst with eyes, skin or clothing.
11. Keep water and steam available near Sulfur Burner at all times.
12. Do the specified job in the minimum possible time near running
equipments; dont loiter.
13. Walking on pipelines or drain covers is prohibited.
14. In case of emergency reach the Assembly Point.

DOS

DONTS

Always add Sulfuric acid to water.

Always add Caustic Soda to water.
Always use spark resistant tools while
handling solid Sulfur.

Never add water to Sulfuric acid.

Never add water to Caustic Soda.
Dont come near Sulfur Melter or Pits
as a hazardous amount of H2S is
produced.
Dont come near burning Sulfur as a
hazardous amount of SO2 is
produced.
Dont remove solidified Sulfur from
skin. Immerse in cold water for 20

Always use steam to snuff out fire in

molten Sulfur in closed spaces.
Use fine water spray to snuff out fire
in solid Sulfur piles.

Cordon off the area in case of

leakages.

min.
Dont operate electric switch/start
vehicles.