Operating Guidelines PDF

SAMSUNG TOTAL PETROCHEMICALS CO., LTD.
SULFUR BLOCK
NO. 2 AROMATICS COMPLEX

DAESAN, KOREA
OPERATING GUIDELINES
Prepared by
Ortloff Engineers, Ltd.
Midland, Texas USA
Project 507000
Fall 2011
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.
Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
1. INTRODUCTION .......................................................................................................... 1-1
2. GENERAL SAFETY ..................................................................................................... 2-1

2.1 DEFINITION OF TERMS ....................................................................................... 2-1
2.2 HYDROGEN SULFIDE (H2S) ................................................................................ 2-3
2.2.1 Description and Properties ............................................................................. 2-3
2.2.2 First Aid .......................................................................................................... 2-7
2.2.3 Precautions (remember these facts) .............................................................. 2-8
2.2.4 Good Work Practices...................................................................................... 2-9
2.3 SULFUR DIOXIDE (SO2) ..................................................................................... 2-10
2.3.1 Description and Properties ........................................................................... 2-10
2.3.2 First Aid ........................................................................................................ 2-13
2.3.3 Precautions................................................................................................... 2-14
2.4 SULFUR .............................................................................................................. 2-15
2.4.2 Precautions................................................................................................... 2-20
2.4.3 Fire Fighting.................................................................................................. 2-21
2.5 AMMONIA (NH3) .................................................................................................. 2-22
2.5.2 First Aid ........................................................................................................ 2-26
2.5.3 Precautions................................................................................................... 2-26
2.6 METHYLDIETHANOLAMINE (MDEA, CH3-N-(CH2-CH2-OH)2)........................... 2-28
2.6.2 First Aid ........................................................................................................ 2-29
2.6.3 Precautions................................................................................................... 2-30
2.7 SODIUM HYDROXIDE (CAUSTIC SODA, NAOH) ............................................. 2-31
2.7.2 First Aid ........................................................................................................ 2-35
2.7.3 Precautions................................................................................................... 2-36
2.8 SULFUR PLANT SAFETY ................................................................................... 2-37
2.8.1 Hydrogen Sulfide .......................................................................................... 2-37
2.8.2 Sulfur Dioxide ............................................................................................... 2-37
2.8.3 Sulfur Storage Tank...................................................................................... 2-38
2.9 HOT WORK ......................................................................................................... 2-39
2.10 VESSEL ENTRY.................................................................................................. 2-39
2.11 PIPES AND LINES .............................................................................................. 2-41
2.11.1 General ......................................................................................................... 2-41
2.11.2 Before Breaking Lines .................................................................................. 2-42
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2.11.3 When Breaking Lines ................................................................................... 2-42
2.12 ELECTRICAL EQUIPMENT ................................................................................ 2-42
2.12.1 Electrical Repairs.......................................................................................... 2-43
2.12.2 Grounding ..................................................................................................... 2-43
2.12.3 Conduit, Cables, and Wires .......................................................................... 2-43
2.12.4 Fuses ............................................................................................................ 2-43
2.12.5 Switching ...................................................................................................... 2-43
2.12.6 Hand Tools and Portable Equipment............................................................ 2-44
2.12.7 Miscellaneous ............................................................................................... 2-44
2.13 BOILERS AND OTHER DIRECT-FIRED EQUIPMENT ...................................... 2-45
2.13.1 General ......................................................................................................... 2-45
2.13.2 Boilers........................................................................................................... 2-45
2.13.3 Direct-Fired Equipment................................................................................. 2-46
2.14 LABORATORY SAFETY ..................................................................................... 2-47
2.14.1 Good Housekeeping ..................................................................................... 2-47
2.14.2 Equipment .................................................................................................... 2-47
2.14.3 Chemical Sorting and Identification .............................................................. 2-47
2.14.4 Chemical Handling ....................................................................................... 2-48
2.15 MATERIAL SAFETY DATA SHEETS (MSDS) .................................................... 2-49
3. GENERAL .................................................................................................................... 3-1
3.1 ORGANIZATION ................................................................................................... 3-1
3.2 GENERAL PRECOMMISSIONING PROCEDURES ............................................. 3-2
3.2.1 Mechanical ..................................................................................................... 3-2
3.2.2 Electrical ......................................................................................................... 3-3
3.2.3 Instrumentation ............................................................................................... 3-5
3.3 DESIGN BASIS ..................................................................................................... 3-7
3.3.1 Plant Capacity ................................................................................................ 3-7
3.3.2 Sulfur Block Feed Streams ............................................................................. 3-7
3.3.3 Effluent Stream Conditions ........................................................................... 3-12
3.3.4 Other Design Requirements ......................................................................... 3-13
3.3.5 Utility Information .......................................................................................... 3-14
3.3.6 Plant Site Conditions .................................................................................... 3-16
4. POWER DISTRIBUTION .............................................................................................. 4-1
4.1 PURPOSE OF SYSTEM ....................................................................................... 4-1
4.2 SAFETY ................................................................................................................. 4-1
4.2.1 General ........................................................................................................... 4-1
4.2.2 Hazardous (Classified) Areas ......................................................................... 4-1
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4.3 EQUIPMENT DESCRIPTION ................................................................................ 4-2
4.3.1 Motors and Motor Controls ............................................................................. 4-2
5. PLANT CONTROL SYSTEMS ..................................................................................... 5-1
5.1 DISTRIBUTED CONTROL SYSTEM .................................................................... 5-1
5.2 PROGRAMMABLE LOGIC CONTROL SYSTEM ................................................. 5-2
5.3 EMERGENCY SHUTDOWN SYSTEMS ............................................................... 5-3
5.4 LOCAL CONTROL PANELS ................................................................................. 5-3
6. UTILITY SYSTEMS ...................................................................................................... 6-1
6.2 SYSTEM DESCRIPTION ...................................................................................... 6-1
6.2.1 Nitrogen Supply .............................................................................................. 6-1
6.2.2 C4 LPG and Treated Fuel Gas Supply .......................................................... 6-2
6.2.3 Hydrogen Supply ............................................................................................ 6-2
6.2.4 Plant Air .......................................................................................................... 6-3
6.2.5 Instrument Air ................................................................................................. 6-3
6.2.6 Sour Water Disposal....................................................................................... 6-3
6.2.7 Steam, Condensate, Boiler Feed Water, and Blowdown ............................... 6-4
6.3 PRECOMMISSIONING, STARTUP, AND SHUTDOWN PROCEDURES............. 6-8
7. AMINE TREATING & AMINE REGENERATION ......................................................... 7-1
7.2 SAFETY ................................................................................................................. 7-1
7.3 PROCESS DESCRIPTION.................................................................................... 7-2
7.3.1 General ........................................................................................................... 7-2
7.3.2 Water Washing ............................................................................................... 7-2
7.3.3 Sour Gas Contacting ...................................................................................... 7-3
7.3.4 Solvent Regeneration ..................................................................................... 7-3
7.4.1 Wash Water Column, A2-DA1510 .................................................................. 7-6
7.4.2 Amine Absorber, A2-DA1511 ......................................................................... 7-6
7.4.3 Flash Gas Contactor, A2-DA1512 .................................................................. 7-6
7.4.4 Stripper, A2-DA1513 ...................................................................................... 7-6
7.4.5 Wash Water Column Packing, A2-DB1510 .................................................... 7-7
7.4.6 Amine Absorber Trays, A2-DB1511 ............................................................... 7-7
7.4.7 Stripper Trays, A2-DB1513 ............................................................................ 7-7
7.4.8 Amine Absorber Overhead Cooler, A2-EA1510 ............................................. 7-8
7.4.9 Lean/Rich Exchanger, A2-EA1511A/B ........................................................... 7-8
7.4.10 Stripper Reboiler, A2-EA1512A/B .................................................................. 7-8
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7.4.11 Stripper Reflux Condenser, A2-EC1511......................................................... 7-8
7.4.12 Lean Amine Cooler, A2-EC1510 .................................................................... 7-8
7.4.13 Wash Water Feed Knock-Out Drum, A2-FA1510 ........................................... 7-8
7.4.14 Amine Absorber Feed Knock-Out Drum, A2-FA1511 ..................................... 7-9
7.4.15 Amine Absorber Overhead Knock-Out Drum, A2-FA1512 ............................. 7-9
7.4.16 Rich Amine Flash Drum, A2-FA1513 ............................................................. 7-9
7.4.17 Stripper Reflux Accumulator, A2-FA1514..................................................... 7-10
7.4.18 Stripper Reboiler Condensate Pot, A2-FA1515A/B ...................................... 7-10
7.4.19 ATU Skim Oil Sump, A2-FA1516 ................................................................. 7-10
7.4.20 ATU Skim Oil Pump Sump, A2-FA1517A/B ................................................. 7-10
7.4.21 ATU Amine Drips Tank, A2-FA1580............................................................. 7-11
7.4.22 MDEA Storage Tank, A2-FB1580 ................................................................ 7-11
7.4.23 Wash Water Filter, A2-FD1510A/B ............................................................... 7-11
7.4.24 Rich Amine Filter, A2-FD1511A/B ................................................................ 7-11
7.4.25 Lean Amine Filter, A2-FD1512 ..................................................................... 7-11
7.4.26 Lean Amine Carbon Filter, A2-FD1513 ........................................................ 7-12
7.4.27 Lean Amine After-Filter, A2-FD1514 ............................................................ 7-12
7.4.28 ATU Amine Drips Filter, A2-FD1580 ............................................................ 7-12
7.4.29 Wash Water Pump, A2-GA1510A/B ............................................................. 7-13
7.4.30 Lean Amine Pump, A2-GA1511A/B ............................................................. 7-13
7.4.31 ATU Skim Oil Pump, A2-GA1512A/B ........................................................... 7-13
7.4.32 Rich Amine Pump, A2-GA1513A/B .............................................................. 7-13
7.4.33 Lean Amine Booster Pump, A2-GA1514A/B ................................................ 7-13
7.4.34 Stripper Reflux Pump, A2-GA1515A/B ......................................................... 7-13
7.4.35 MDEA Transfer Pump, A2-GA1580.............................................................. 7-14
7.5 INSTRUMENTATION AND CONTROL SYSTEMS ............................................. 7-15
7.5.1 Treated Fuel Gas H2S Analyzer ................................................................... 7-15
7.5.2 ATU Emergency Shutdown Systems ........................................................... 7-15
7.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ............................. 7-19
7.6.1 Amine Absorber Operation ........................................................................... 7-19
7.6.2 Stripper Operation ........................................................................................ 7-22
7.6.3 Amine Water Balance ................................................................................... 7-24
7.6.4 Amine Loss ................................................................................................... 7-27
7.6.5 Operation at Low Flow Rates ....................................................................... 7-29
7.7 PRECOMMISSIONING PROCEDURES ............................................................. 7-30
7.7.1 Preliminary Check-out .................................................................................. 7-30
7.7.2 Shutdown System Check-out ....................................................................... 7-31
7.7.3 Leak Testing the Process Piping and Equipment ......................................... 7-31
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7.7.4 Washing the Wash Water System ................................................................ 7-33
7.7.5 Washing the Amine System ......................................................................... 7-38
7.7.6 Purging the Low Pressure Columns ............................................................. 7-50
7.8 STARTUP PROCEDURES.................................................................................. 7-52
7.8.1 Wash Water and Amine Systems ................................................................. 7-52
7.8.2 Sour Fuel Gas Flow to the Columns............................................................. 7-53
7.9 SHUTDOWN PROCEDURES ............................................................................. 7-56
7.9.1 Planned Shutdown - ATU ............................................................................ 7-57
7.9.2 Planned Shutdown - ATU and ARU ............................................................. 7-60
7.9.3 Emergency Shutdown .................................................................................. 7-62
7.9.4 Effects of Shutdowns and Outages in Other Systems.................................. 7-63
7.10 ANALYTICAL PROCEDURES ............................................................................ 7-64
7.10.1 General Procedures for Analyzing ATU/ARU Solvent, ................................. 7-64
7.10.2 Determination of Amine Concentration in ATU/ARU Solvent ....................... 7-68
7.10.3 Determination of Total Acid Gas Loading in ATU/ARU Solvent ................... 7-70
7.10.4 Determination of H2S and CO2 Loading in ATU/ARU Solvent ...................... 7-72
7.10.5 Determination of Foaming Tendency of ATU/ARU Solvent .......................... 7-76
7.10.6 H2S Conc. in Amine Absorber Ovhd by the Tutweiler Method ..................... 7-78
7.10.7 H2S Conc. in Amine Absorber Ovhd Using Gas Detector Tubes ................. 7-79
8. SOUR WATER STRIPPING ......................................................................................... 8-1
8.2 SAFETY ................................................................................................................. 8-1
8.3.1 General ........................................................................................................... 8-2
8.3.2 Sour Water Collection..................................................................................... 8-2
8.3.3 Sour Water Stripping ...................................................................................... 8-3
8.4.1 Sour Water Stripper, A2-DA1520 ................................................................... 8-5
8.4.2 Sour Water Stripper Packing and Internals, A2-DB1520 ................................ 8-5
8.4.4 SWS Cross Exchanger, A2-EA1520 .............................................................. 8-5
8.4.5 Sour Water Stripper Reboiler, A2-EA1521 ..................................................... 8-6
8.4.6 SWS Quench Water Cooler, A2-EC1520 ....................................................... 8-6
8.4.7 SWS Bottoms Cooler, A2-EC1521 ................................................................. 8-6
8.4.8 Sour Water Flash Drum, A2-FA1520.............................................................. 8-6
8.4.9 SWS Skim Oil Sump, A2-FA1522 .................................................................. 8-7
8.4.10 SWS Skim Oil Pump Sump, A2-FA1523A/B .................................................. 8-7
8.4.11 Sour Water Tank, A2-FB1520 ........................................................................ 8-7
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8.4.12 Sour Water Filter, A2-FD1520A/B .................................................................. 8-7
8.4.13 Sour Water Transfer Pump, A2-GA1520A/B .................................................. 8-7
8.4.14 SWS Feed Pump, A2-GA1521A/B ................................................................. 8-8
8.4.15 SWS Quench Water Pump, A2-GA1522A/B .................................................. 8-8
8.4.16 SWS Bottoms Pump, A2-GA1523A/B ............................................................ 8-8
8.4.17 SWS Skim Oil Pump, A2-GA1524A/B ............................................................ 8-8
8.5 INSTRUMENTATION AND CONTROL SYSTEMS ............................................... 8-9
8.5.1 SWS Shutdowns and Alarms ......................................................................... 8-9
8.6.1 SWS Stripper Operation ............................................................................... 8-11
8.6.2 Quench Water Circulation ............................................................................ 8-12
8.6.3 pH Control .................................................................................................... 8-13
8.7.2 Washing the Sour Water System ................................................................. 8-15
8.8.1 Initial Startup of the SWS ............................................................................. 8-19
8.8.2 Normal Startup of the SWS .......................................................................... 8-23
8.9.1 Planned Shutdown ....................................................................................... 8-29
9. SULFUR RECOVERY .................................................................................................. 9-4
9.2 SAFETY ................................................................................................................. 9-4
9.3.1 Overview......................................................................................................... 9-5
9.3.2 General ........................................................................................................... 9-6
9.3.3 Feed Gas Processing ..................................................................................... 9-6
9.3.4 Thermal Processing........................................................................................ 9-7
9.3.5 Catalytic Processing ....................................................................................... 9-8
9.3.6 Air Control System.......................................................................................... 9-9
9.3.7 Molten Sulfur Handling ................................................................................. 9-10
9.3.8 Steam Production ......................................................................................... 9-10
9.4 EQUIPMENT DESCRIPTION .............................................................................. 9-11
9.4.1 Reactor Furnace, A2-BA1530 (A2-BA1540) ................................................. 9-11
9.4.2 Acid Gas Burner Assembly, A2-BA1531 (A2-BA1541) ................................ 9-12
9.4.3 Acid Gas Knock-Out Drum, A2-FA1530 (A2-FA1540) ................................. 9-12
9.4.4 SWS Gas Knock-Out Drum, A2-FA1531 (A2-FA1541) ................................ 9-12
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9.4.5 Reactor, A2-DC1530 (A2-DC1540) .............................................................. 9-13
9.4.6 Catalyst for Sulfur Plant Reactors, A2-MC1530 (A2-MC1540) ..................... 9-13
9.4.7 Acid Gas Preheater, A2-EA1530 (A2-EA1540) ............................................ 9-13
9.4.8 Sulfur Condenser, A2-EA1531 (A2-EA1541) ............................................... 9-13
9.4.9 Reactor No. 1 Feed Heater, A2-EA1532 (A2-EA1542) ................................ 9-14
9.4.12 Sulfur Surge Tank, A2-FB1530 (A2-FB1540) ............................................... 9-15
9.4.13 Acid Gas Knock-Out Drum Pump, A2-GA1530A/B (A2-GA1540A/B) .......... 9-16
9.4.14 SWS Gas Knock-Out Drum Pump, A2-GA1531A/B (A2-GA1541A/B) ......... 9-17
9.4.15 Sulfur Storage Tank Vent Ejector, A2-EE1530 (A2-EE1540) ....................... 9-17
9.4.16 Process Air Blower, A2-GB1530A/B (A2-GB1540A/B)................................. 9-18
9.4.17 Air Blower Suction Screen/Silencer, A2-FD1530A/B (A2-FD1540A/B) ........ 9-19
9.4.18 Process Air Vent Silencer, A2-FG1530A/B (A2-FG1540A/B) ....................... 9-19
9.4.19 Sulfur Drain Seal Assembly, A2-ME1530A-D (A2-ME1540A-D) .................. 9-19
9.4.20 Refractory for Reactor Furnace and Waste Heat Boiler, A2-MR1530
(A2-MR1540) .............................................................................................................. 9-20
9.4.21 Ceramic Ferrules for Waste Heat Boiler, A2-MR1532 (A2-MR1542) ........... 9-20
9.4.22 Refractory for Waste Heat Boiler, A2-MR1533 (A2-MR1543) ...................... 9-20
9.4.23 Refractory for Sulfur Condenser, A2-MR1534 (A2-MR1544) ....................... 9-20
9.4.24 Refractory for Reactor, A2-MR1535 (A2-MR1545) ...................................... 9-21
9.4.25 Rainshield for Reactor Furnace, A2-ME1531 (A2-ME1541) ........................ 9-21
9.4.26 Ceramic Ferrule for Reactor Furnace, A2-MR1531 (A2-MR1541) ............... 9-21
9.4.27 Waste Heat Boiler, A2-BF1530 (A2-BF1540) ............................................... 9-22
9.5.1 SRU Air:Acid Gas Ratio Control Loop .......................................................... 9-24
9.5.2 Acid Gas Burner Management System ........................................................ 9-30
9.5.3 Process Air Blower Controls ......................................................................... 9-34
9.5.4 Reactor Furnace Temperature Control......................................................... 9-39
9.5.5 Knock-Out Drum Pump Control .................................................................... 9-41
9.5.6 "Ride-Through" System Considerations ....................................................... 9-41
9.5.7 Boiler Low-Low Level S/D Transmitter Testing ............................................ 9-44
9.5.8 SRU Emergency Shutdown Systems ........................................................... 9-46
9.6.1 Equipment Damage ...................................................................................... 9-56
9.6.2 Cold Catalyst Bed Startup ............................................................................ 9-58
9.6.3 Sulfur Solidification ....................................................................................... 9-60
9.6.4 Ammonia Salt Formation .............................................................................. 9-61
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9.6.5 Catalyst Fouling ............................................................................................ 9-62
9.6.6 Operation of SRUs in Parallel....................................................................... 9-62
9.6.7 Process air Blower Operation ....................................................................... 9-65
9.6.8 Reactor Furnace Temperature ..................................................................... 9-70
9.6.9 Ammonia Destruction Considerations .......................................................... 9-73
9.6.10 Sulfur Recovery Efficiency............................................................................ 9-76
9.6.12 Pressure Drop Surveys ................................................................................ 9-82
9.6.13 Boiler Water Treatment ................................................................................ 9-84
9.7.4 Purging the Inlet Knock-Out Drums .............................................................. 9-93
9.7.5 Commissioning Fuel Gas and Instrument Air to the Process ....................... 9-95
9.7.6 Commissioning Nitrogen to the Process ...................................................... 9-99
9.7.7 Commissioning the Sulfur Surge Tank Heating and Ventilation ................. 9-102
9.7.8 Pre-filling the Sulfur Drain Seal Assemblies ............................................... 9-104
9.8 STARTUP PROCEDURES................................................................................ 9-105
9.8.1 Initial Firing / Refractory Cure-out............................................................... 9-105
9.8.2 Amine Acid Gas Flow ................................................................................. 9-117
9.8.3 SWS Gas Flow ........................................................................................... 9-124
9.8.4 Routing SRU Tailgas to the TGCU ............................................................. 9-127
9.8.5 Normal Startup - Cold System .................................................................... 9-129
9.8.6 Normal Startup - Hot System...................................................................... 9-146
9.8.7 Firing Supplemental Fuel Gas .................................................................... 9-158
9.9 SHUTDOWN PROCEDURES ........................................................................... 9-164
9.9.1 Planned Shutdown - No Reactor Entry....................................................... 9-165
9.9.2 Planned Shutdown for Reactor Entry ......................................................... 9-170
9.9.3 Shutting Down When Boiler Tubes Are Leaking ........................................ 9-180
9.9.4 Emergency Shutdown ................................................................................ 9-181
9.9.5 Effects of Shutdowns and Outages in Other Systems................................ 9-183
9.10 ANALYTICAL PROCEDURES .......................................................................... 9-187
9.10.1 Procedure for Sampling and Titrating with a Tutweiler Apparatus ............. 9-187
9.10.2 H2S Concentration in Acid Gas by the Tutweiler Method ........................... 9-189
9.10.3 H2S and SO2 Concentration in Tailgas by the Tutweiler Method ................ 9-192
9.10.4 Tailgas Analysis Table................................................................................ 9-196
9.10.5 Tailgas Analysis Operating Chart ............................................................... 9-197
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9.10.6 Essential Apparatus for Tutweiler Analysis ................................................ 9-199
9.10.7 Materials for Tutweiler Analysis .................................................................. 9-200
9.10.8 H2S and SO2 Conc. in Tailgas Using Gas Detector Tubes ......................... 9-200
9.11 ADJUSTING STACKMATCH® IGNITOR/PILOTS ............................................. 9-205
10. SULFUR DEGASSING, STORAGE & LOADING .................................................. 10-3
10.1 PURPOSE OF SYSTEM ..................................................................................... 10-3
10.2 SAFETY ............................................................................................................... 10-4
10.3 PROCESS DESCRIPTION.................................................................................. 10-5
10.4.1 Sulfur Degassing Reactor, A2-DC1550 ........................................................ 10-7
10.4.2 Sulfur Storage Tank, A2-FB1550 ................................................................. 10-7
10.4.3 Sulfur Feed Pump, A2-GA1532A/B (A2-GA1542A/B) .................................. 10-8
10.4.4 Sulfur Loading Pump, A2-GA1550A/B ......................................................... 10-8
10.4.5 Degassing Air Blower, A2-GB1550A/B ......................................................... 10-9
10.4.6 Bed Support and Limiter for Sulfur Degassing Reactor, A2-DC1551 ........... 10-9
10.4.7 Degassed Sulfur Drain Seal Assembly, A2-ME1550.................................... 10-9
10.5 INSTRUMENTATION AND CONTROL SYSTEMS ........................................... 10-11
10.5.1 Sulfur Feed Rate Control ............................................................................ 10-11
10.5.2 Degassing Air Flow..................................................................................... 10-12
10.5.3 Sulfur Degassing Unit Startup Interlock ...................................................... 10-13
10.5.4 Snuffing Steam ........................................................................................... 10-13
10.5.5 Sulfur Loading ............................................................................................ 10-14
10.5.6 Sulfur Loading Pump Local Stop Switches................................................. 10-17
10.5.7 Sulfur Degassing Shutdown System .......................................................... 10-18
10.5.8 Sulfur Loading ESD System ....................................................................... 10-21
10.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ........................... 10-23
10.6.1 Equipment Damage .................................................................................... 10-23
10.6.2 Degassing Air Blower Operation ................................................................ 10-26
10.6.3 Sulfur Solidification ..................................................................................... 10-29
10.6.4 Sulfur Pumping ........................................................................................... 10-29
10.7 PRECOMMISSIONING PROCEDURES ........................................................... 10-31
10.7.1 Preliminary Check-out ................................................................................ 10-31
10.7.2 Commissioning the Heating and Ventilation Systems ................................ 10-32
10.7.3 Purging the Sulfur Degassing Reactor ....................................................... 10-37
10.8.1 Initial Startup of the Sulfur Degassing Unit ................................................. 10-40
10.8.2 Normal Startup of the Sulfur Degassing System ........................................ 10-46
10.8.3 Initial Sulfur Loading Operation .................................................................. 10-51
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10.8.4 Normal Sulfur Loading Operation ............................................................... 10-53
10.9.3 Shutdown for Tank Entry ............................................................................ 10-57
11. TAILGAS CLEANUP .............................................................................................. 11-1
11.2 SAFETY ............................................................................................................... 11-2
11.3.1 General ......................................................................................................... 11-3
11.3.2 Tailgas Hydrogenation/Hydrolysis ................................................................ 11-3
11.3.3 Process Gas Cooling .................................................................................... 11-4
11.3.4 Gas Contacting ............................................................................................. 11-5
11.3.5 Solvent Regeneration Section ...................................................................... 11-6
11.3.6 Steam Production/Consumption ................................................................... 11-7
11.4.1 TGCU Quench Column, A2-DA1560 ............................................................ 11-8
11.4.2 TGCU Quench Column Packing, A2-DB1560 .............................................. 11-8
11.4.3 TGCU Contactor, A2-DA1561 ...................................................................... 11-8
11.4.4 TGCU Contactor Packing & Internals, A2-DB1561 ...................................... 11-8
11.4.5 TGCU Stripper, A2-DA1562 ......................................................................... 11-9
11.4.6 TGCU Stripper Trays, A2-DB1562 ............................................................... 11-9
11.4.7 TGCU Reactor, A2-DC1560 ....................................................................... 11-10
11.4.8 TGCU Stripper Reflux Accumulator, A2-FA1560 ....................................... 11-10
11.4.9 Catalyst for TGCU Reactor, A2-MC1560 ................................................... 11-10
11.4.10 TGCU Stripper Reboiler Condensate Pot, A2-FA1562 ........................... 11-10
11.4.11 TGCU Reactor Feed Heater, A2-EA1560 ............................................... 11-11
11.4.12 TGCU Waste Heat Reclaimer, A2-EA1561 ............................................ 11-11
11.4.13 TGCU Quench Water Trim Cooler, A2-EA1562A/B ................................ 11-11
11.4.14 TGCU Lean/Rich Exchanger, A2-EA1564 .............................................. 11-11
11.4.15 TGCU Stripper Reboiler, A2-EA1565 ..................................................... 11-12
11.4.16 TGCU Lean Amine Trim Cooler, A2-EA1563 ......................................... 11-12
11.4.17 TGCU Quench Water Cooler, A2-EC1560 ............................................. 11-12
11.4.18 TGCU Stripper Reflux Condenser, A2-EC1562 ...................................... 11-12
11.4.19 TGCU Lean Amine Cooler, A2-EC1561 ................................................. 11-12
11.4.20 TGCU Quench Water Pump, A2-GA1560A/B......................................... 11-13
11.4.21 TGCU Rich Amine Pump, A2-GA1561A/B ............................................. 11-14
11.4.22 TGCU Stripper Reflux Pump, A2-GA1563A/B ........................................ 11-14
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Table of Contents
11.4.23 TGCU Lean Amine Pump, A2-GA1562A/B ............................................. 11-14
11.4.24 TGCU Start-Up Blower, A2-GB1560 ....................................................... 11-14
11.4.25 Refractory for TGCU Reactor, A2-MR1560 ............................................ 11-15
11.4.26 TGCU Reactor Feed Mixer, A2-ME1560 ................................................ 11-16
11.4.27 TGCU Quench Water Filter, A2-FD1560A/B .......................................... 11-16
11.4.28 TGCU Rich Amine Filter, A2-FD1562A/B ............................................... 11-16
11.4.29 TGCU Lean Amine Filter, A2-FD1563 .................................................... 11-17
11.4.30 TGCU Amine Carbon Filter, A2-FD1564 ................................................ 11-17
11.4.31 TGCU Amine After-Filter, A2-FD1565 .................................................... 11-17
11.4.32 pH Meter Sample Filter, A2-FD1561A/B ................................................. 11-17
11.5.1 TGCU Reactor Feed Control Loops ........................................................... 11-18
11.5.2 Hydrogen and Hydrogen Sulfide Analyzer, A2-AE15858/A2-AE15859 ...... 11-23
11.5.3 Boiler Low-Low Level S/D Transmitter Testing .......................................... 11-24
11.5.4 Tailgas Switching Valve Controls ............................................................... 11-26
11.5.5 TGCU Shutdown System ........................................................................... 11-33
11.6.2 Catalyst Fouling .......................................................................................... 11-40
11.6.3 TGCU Reactor Operation ........................................................................... 11-41
11.6.4 TGCU Catalyst ........................................................................................... 11-43
11.6.5 TGCU Start-Up Blower Operation .............................................................. 11-44
11.6.6 TGCU Quench Column Operation.............................................................. 11-45
11.6.7 TGCU Contactor Operation ........................................................................ 11-48
11.6.8 TGCU Stripper Operation ........................................................................... 11-52
11.6.9 TGCU Amine Water Balance...................................................................... 11-55
11.6.10 TGCU Amine Loss .................................................................................. 11-59
11.6.11 Operation at Low Flow Rates.................................................................. 11-60
11.6.12 Pressure Drop Surveys ........................................................................... 11-61
11.6.13 Boiler Water Treatment ........................................................................... 11-63
11.7.2 Shutdown System Check-out ..................................................................... 11-65
11.7.3 Commissioning Nitrogen and Utility Air to the Process .............................. 11-66
11.7.4 Commissioning Hydrogen to the Process .................................................. 11-72
11.7.5 Leak Testing the Process Piping and Equipment ....................................... 11-75
11.7.6 Washing the Quench Water System .......................................................... 11-79
11.7.7 Washing the Amine System ....................................................................... 11-85
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Table of Contents
11.7.8 Purging the Low Pressure TGCU Columns ................................................ 11-97
11.8 STARTUP PROCEDURES.............................................................................. 11-102
11.8.1 Initial Startup of the TGCU ....................................................................... 11-102
11.8.2 Pre-Sulfiding the TGCU Catalyst .............................................................. 11-107
11.8.3 Routing SRU Tailgas to the TGCU ........................................................... 11-115
11.8.4 Quench Water and Amine Systems ......................................................... 11-122
11.8.5 Process Gas Flow to the TGCU Columns ................................................ 11-124
11.8.6 Normal Startup of the TGCU .................................................................... 11-128
11.9 SHUTDOWN PROCEDURES ......................................................................... 11-144
11.9.1 Planned Shutdown - No Reactor Entry..................................................... 11-145
11.9.2 Planned Shutdown for Reactor Entry ....................................................... 11-151
11.9.3 Shutting Down When Boiler Tubes Are Leaking ...................................... 11-158
11.9.4 Special Precaution During Shutdowns ..................................................... 11-159
11.9.5 Emergency Shutdown .............................................................................. 11-163
11.9.6 Effects of Shutdowns and Outages in Other Systems.............................. 11-164
11.10 ANALYTICAL PROCEDURES ..................................................................... 11-167
11.10.1 General Procedures for Analyzing TGCU Solvent, ............................... 11-167
11.10.2 Determination of Amine Concentration in TGCU Solvent ..................... 11-171
11.10.3 Determination of Total Acid Gas Loading in TGCU Solvent ................. 11-173
11.10.4 Determination of H2S and CO2 Loading in TGCU Solvent .................... 11-175
11.10.5 Determination of Foaming Tendency of TGCU Solvent ........................ 11-179
11.10.6 H2S Conc. in TGCU Contactor Ovhd by the Tutweiler Method ............. 11-181
11.10.7 H2S Conc. in TGCU Contactor Ovhd Using Gas Detector Tubes ......... 11-182
11.10.8 Monitoring the Performance Level of TGCU Catalyst ........................... 11-185
12. TAILGAS THERMAL OXIDIZER ............................................................................ 12-2
12.2 SAFETY ............................................................................................................... 12-2
12.4.1 Thermal Oxidizer, A2-BA1570 ...................................................................... 12-4
12.4.2 Thermal Oxidizer Burner, A2-BA1571 .......................................................... 12-4
12.4.3 Steam Knock-out Drum, A2-FA1570 ............................................................ 12-4
12.4.4 Thermal Oxidizer Air Blower, A2-GB1570A/B .............................................. 12-4
12.4.5 Thermal Oxidizer Vent Stack, A2-ME1570 ................................................... 12-5
12.4.6 Refractory for Thermal Oxidizer, A2-MR1570 .............................................. 12-5
12.4.7 Thermal Oxidizer Waste Heat Boiler, A2-BF1570 ........................................ 12-5
12.5.1 Thermal Oxidizer Burner Management System ........................................... 12-7
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Table of Contents
12.5.2 Thermal Oxidizer Temperature Control ...................................................... 12-10
12.5.3 Thermal Oxidizer Excess Oxygen Control.................................................. 12-10
12.5.5 Thermal Oxidizer Shutdown System .......................................................... 12-13
12.6.2 Effect of Upstream Operations on the Thermal Oxidizer ............................ 12-21
12.6.3 "Swapping" Air Blowers During Operation .................................................. 12-23
12.6.4 Boiler Water Treatment .............................................................................. 12-24
12.7.3 Commissioning Fuel Gas, Pilot Gas, and I/A to the Process ..................... 12-28
12.8.2 Normal Startup ........................................................................................... 12-48
12.9.1 Planned Shutdown - No Entry .................................................................... 12-59
12.9.2 Planned Shutdown for Entry ....................................................................... 12-61
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1. INTRODUCTION
THE INFORMATION IN THESE GUIDELINES IS CONFIDENTIAL. SOME OF

THE PROCESSES, DESIGNS, EQUIPMENT, AND/OR PROCEDURES
DESCRIBED HEREIN ARE PROPRIETARY AND/OR LICENSED BY
BP AMOCO CORPORATION, SHELL GLOBAL SOLUTIONS (US) INC., UOP
LLC. AND/OR ORTLOFF ENGINEERS, LTD. DISCLOSURE, REPRODUCTION,
OR USE OF THESE GUIDELINES FOR ANY REASON OTHER THAN
OPERATION OF THIS FACILITY IS IN VIOLATION OF WRITTEN SECRECY
AGREEMENTS.
These Operating Guidelines have been prepared by Ortloff Engineers, Ltd. as a guide
for the initial operation of the new Sulfur Block at Samsung Total Petrochemicals Co.,
Ltd.’s Daesan No. 2 Aromatics Complex. The new Sulfur Block consists of an Amine
Treating Unit (ATU), an Amine Regeneration Unit (ARU), a Sour Water Stripper
(SWS), two parallel Sulfur Recovery Units (SRUs), and a common Sulfur Degassing
Unit (SDU), Tailgas Cleanup Unit (TGCU) and Tailgas Thermal Oxidation Unit (TTO).
These units are to process sour gas and sour water streams to remove the contained
sulfur and produce treated fuel gas for consumption in the complex, treated water
safe for reuse or disposal, and commercial grade molten sulfur for sales. These
guidelines contain information concerning the design, startup, operation, and
shutdown of the new facility to assist plant personnel in developing familiarity with
and understanding of the process, equipment, and overall plant operation, and to
supplement equipment manufacturers' operating instructions.
We have tried to present all of the information from an operations viewpoint by

breaking the facility into separate systems for the ease of understanding and startup.
The information for the systems is organized as follows, although some systems will
not require every category:
1. Purpose of System
2. Safety
3. Process Description
4. Instrumentation and Control Systems
5. Operating Principles and Techniques
6. Precommissioning Procedures
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7. Startup Procedures
8. Shutdown Procedures
9. Setpoints (Controllers, Alarms, Shutdowns, PCVs, PSVs)
10. Analytical Procedures
The instructions in these guidelines are based on past experience with similar plants
and equipment. They are to be used as guidelines for developing detailed operating
procedures customized for your plant and its actual operating conditions. These
instructions are not intended in any way to supersede or supplant operating
procedures and safety practices established by Samsung Total Petrochemicals Co.,
Ltd., nor are they intended to be used independently of equipment manufacturers’
operating instructions. In preparing these instructions, it has been assumed that all
startup and operating personnel have been trained in and are knowledgeable of the
operating instructions provided by the manufacturers of the equipment included in this
facility.
It is expected that Samsung Total Petrochemicals Co., Ltd. will revise and improve
upon the operating instructions in this manual as operating experience is gained, and
as required to incorporate any changes resulting from Samsung Total Petrochemicals
Co., Ltd.'s Process Safety Management program. Update and maintenance of this
manual is Samsung Total Petrochemicals Co., Ltd.'s responsibility and is not within
Ortloff's scope of responsibility.
Operating values and numbers quoted in this manual are design values. They are
presented to enable the operator to have a "ball park" idea of plant operating values.
Actual plant operating conditions may deviate from the design figures, yet yield
satisfactory operations and products. We recommend that operating parameters
such as temperatures, pressures, and flow rates be recorded on a routine basis.
Good data, properly gathered and maintained, form a valuable base for plant studies
and performance evaluations.
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Table of Contents
2. GENERAL SAFETY ..................................................................................................... 2-1
2.1 DEFINITION OF TERMS ....................................................................................... 2-1
2.2 HYDROGEN SULFIDE (H2S) ................................................................................ 2-3
2.2.1 Description and Properties ............................................................................. 2-3
2.2.1.1 General.................................................................................................... 2-3
2.2.1.2 Toxicity Information ................................................................................. 2-3
2.2.1.3 Permissible Exposure Limits ................................................................... 2-3
2.2.1.4 Odor ........................................................................................................ 2-3
2.2.1.5 Physical Data .......................................................................................... 2-3
2.2.1.6 Reactivity Data ........................................................................................ 2-4
2.2.1.7 Corrosivity Data ....................................................................................... 2-5
2.2.1.8 Water Solubility ....................................................................................... 2-5
2.2.1.9 Other Characteristics............................................................................... 2-5
2.2.1.10 Fire and Explosion Hazard ...................................................................... 2-6
2.2.1.11 Life Hazard .............................................................................................. 2-6
2.2.2 First Aid .......................................................................................................... 2-7
2.2.3 Precautions (remember these facts) .............................................................. 2-8
2.2.4 Good Work Practices...................................................................................... 2-9
2.3 SULFUR DIOXIDE (SO2) ..................................................................................... 2-10
2.3.1.1 General.................................................................................................. 2-10
2.3.1.2 Toxicity Information ............................................................................... 2-10
2.3.1.3 Permissible Exposure Limits ................................................................. 2-10
2.3.1.4 Odor ...................................................................................................... 2-11
2.3.1.5 Physical Data ........................................................................................ 2-11
2.3.1.6 Reactivity Data ...................................................................................... 2-11
2.3.1.7 Corrosivity Data ..................................................................................... 2-12
2.3.1.8 Water Solubility ..................................................................................... 2-12
2.3.1.9 Fire and Explosion Hazard .................................................................... 2-12
2.3.1.10 Life Hazard ............................................................................................ 2-12
2.3.2 First Aid ........................................................................................................ 2-13
2.3.3 Precautions................................................................................................... 2-14
2.4 SULFUR .............................................................................................................. 2-15
2.4.1.1 General.................................................................................................. 2-15
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2.4.1.4 Odor ...................................................................................................... 2-15

2.4.1.5 Physical Data ........................................................................................ 2-15
2.4.1.6 Reactivity Data ...................................................................................... 2-16
2.4.1.8 Other Characteristics............................................................................. 2-19
2.4.1.10 Life Hazard ............................................................................................ 2-20
2.4.2 Precautions................................................................................................... 2-20
2.4.3 Fire Fighting.................................................................................................. 2-21
2.5 AMMONIA (NH3) .................................................................................................. 2-22
2.5.1.1 General.................................................................................................. 2-22
2.5.1.4 Odor ...................................................................................................... 2-22
2.5.1.5 Physical Data ........................................................................................ 2-23
2.5.1.6 Reactivity Data ...................................................................................... 2-23
2.5.1.10 Life Hazard ............................................................................................ 2-25
2.5.2 First Aid ........................................................................................................ 2-26
2.5.3 Precautions................................................................................................... 2-26
2.6 METHYLDIETHANOLAMINE (MDEA, CH3-N-(CH2-CH2-OH)2)........................... 2-28
2.6.1.1 General.................................................................................................. 2-28
2.6.1.4 Odor ...................................................................................................... 2-28
2.6.1.5 Physical Data ........................................................................................ 2-28
2.6.1.6 Reactivity Data ...................................................................................... 2-28
2.6.1.10 Life Hazard ............................................................................................ 2-29
2.6.2 First Aid ........................................................................................................ 2-29
2.6.3 Precautions................................................................................................... 2-30
2.7 SODIUM HYDROXIDE (CAUSTIC SODA, NAOH) ............................................. 2-31
2.7.1.1 General.................................................................................................. 2-31
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2.7.1.4 Odor ...................................................................................................... 2-31
2.7.1.5 Physical Data ........................................................................................ 2-32
2.7.1.6 Reactivity Data ...................................................................................... 2-32
2.7.1.10 Life Hazard ............................................................................................ 2-35
2.7.2 First Aid ........................................................................................................ 2-35
2.7.3 Precautions................................................................................................... 2-36
2.8 SULFUR PLANT SAFETY ................................................................................... 2-37
2.8.1 Hydrogen Sulfide .......................................................................................... 2-37
2.8.2 Sulfur Dioxide ............................................................................................... 2-37
2.8.3 Sulfur Storage Tank...................................................................................... 2-38
2.8.3.1 Poisonous Gases .................................................................................. 2-38
2.8.3.2 Explosion and Fire................................................................................. 2-38
2.9 HOT WORK ......................................................................................................... 2-39
2.10 VESSEL ENTRY.................................................................................................. 2-39
2.11 PIPES AND LINES .............................................................................................. 2-41
2.11.1 General ......................................................................................................... 2-41
2.11.2 Before Breaking Lines .................................................................................. 2-42
2.11.3 When Breaking Lines ................................................................................... 2-42
2.12 ELECTRICAL EQUIPMENT ................................................................................ 2-42
2.12.1 Electrical Repairs.......................................................................................... 2-43
2.12.2 Grounding ..................................................................................................... 2-43
2.12.3 Conduit, Cables, and Wires .......................................................................... 2-43
2.12.4 Fuses ............................................................................................................ 2-43
2.12.5 Switching ...................................................................................................... 2-43
2.12.6 Hand Tools and Portable Equipment............................................................ 2-44
2.12.7 Miscellaneous ............................................................................................... 2-44
2.13 BOILERS AND OTHER DIRECT-FIRED EQUIPMENT ...................................... 2-45
2.13.1 General ......................................................................................................... 2-45
2.13.2 Boilers........................................................................................................... 2-45
2.13.2.1 Repair and Maintenance ....................................................................... 2-45
2.13.2.2 Operations ............................................................................................. 2-46
2.13.3 Direct-Fired Equipment................................................................................. 2-46
2.14 LABORATORY SAFETY ..................................................................................... 2-47
2.14.1 Good Housekeeping ..................................................................................... 2-47
2.14.2 Equipment .................................................................................................... 2-47
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2.14.3 Chemical Sorting and Identification .............................................................. 2-47

2.14.4 Chemical Handling ....................................................................................... 2-48
2.15 MATERIAL SAFETY DATA SHEETS (MSDS) .................................................... 2-49
A. Hydrogen Sulfide
B. Sulfur Dioxide
C. Sulfur
D. Ammonia
E. Methyldiethanolamine
F. Sodium Hydroxide
G. UOP/ESM S-2001 Sulfur Conversion Catalyst
H. Criterion 234 Tailgas Treating Catalyst
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2. GENERAL SAFETY
General
The safety information published herein is for guidance only and is not intended to
supersede or replace your company's safety procedures program where a conflict of
terminology or procedure may exist.
Safety Considerations
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 following
information occasionally to refresh their memories. New employees should study this
information until it is thoroughly understood.
2.1 Definition of Terms

A. Auto-Ignition Temperature
The minimum temperature to which a substance (the substance may be

solid, liquid, or gaseous) must be heated to ignite independent of other
ignition sources.
B. Flammability Limits (explosive limits)
When flammable vapors are mixed in air, there is a minimum

concentration below which the propagation of flame does not occur upon
contact with a source of ignition. There is also a maximum concentration
above which propagation of flame does not occur. These boundary line
concentrations of vapor in air are called flammable or explosive limits.
Many people are familiar with lower and upper flammability limits in
connection with engine carburetors which, when adjusted improperly, will
prevent the engines from running if the fuel mixture is either too "lean" or
too "rich".
C. Flash Point
Flash point is the lowest temperature of a liquid at which sufficient vapors

are evolved to form an ignitable mixture with air.
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D. Specific Gravity (solids and liquids)
Specific gravity of solids and liquids is the ratio of the weight of any solid
or liquid to the weight of an equal volume of water. Therefore, if the
specific gravity of a substance is a number less than one, it is lighter than
water, and if the number is greater than one, it is heavier than water.
E. Specific Gravity (gases)
Specific gravity of gases is the ratio of weight of any gas to the weight of
an equal volume of air. Therefore, if the specific gravity of a gas is a
number less than one, it is lighter than air, and if the number is greater
than one, it is heavier than air.
F. Specific Volume
Specific volume of a substance is the volume of a unit mass of the

substance, i.e., the reciprocal of its density. The units used in this manual
are cubic feet per pound, unless otherwise noted.
G. Toxicity
Toxicity is the ability of a chemical or compound to produce injury once it

reaches a susceptible site in or on the body.

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2.2 Hydrogen Sulfide (H2S)

2.2.1 Description and Properties
2.2.1.1 General
Hydrogen sulfide is a colorless, very flammable, highly toxic gas.
2.2.1.2 Toxicity Information

LCLo: 600 PPM / 30 minutes (death of humans after
inhalation)
LCLo: 800 PPM / 5 minutes (death of humans after

inhalation)
LCLo (Lethal Concentration Low) is the lowest concentration of a

substance in air which has been reported to have caused death in
humans or animals. In other words, exposure to 600 PPM of H2S for
30 minutes or to 800 PPM of H2S for 5 minutes can cause death.
2.2.1.3 Permissible Exposure Limits

TLV: 10 PPM in air
TLV (Threshold Limit Value) is the highest level of exposure to a

toxic chemical at which no deleterious effect is noted. The American
Conference of Government Industrial Hygienists (ACGIH) has set
such levels for human exposure in industry. OSHA now uses this
10 PPM limit as the maximum allowable concentration for continuous
exposure during an eight hour working day.
2.2.1.4 Odor
In low concentrations, H2S smells like rotten eggs. Higher
concentrations quickly damage the ability to smell and cannot be
detected by the characteristic rotten egg odor.
2.2.1.5 Physical Data

a. Melting Point: -122°F (-86°C)
b. Boiling Point: -77°F (-61°C)
c. Lower Explosive Limit: 4.3% H2S (by volume) vapor in air
d. Upper Explosive Limit: 46% H2S (by volume) vapor in air
e. Auto-Ignition Temperature: 500°F (260°C)
f. Vapor Specific Gravity: 1.2 (heavier than air)

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2.2.1.6 Reactivity Data

Hydrogen sulfide is dangerously reactive with the following
substances:
Formula Name
C2H4O acetaldehyde
BaO + Hg2O + air barium oxide + mercury oxide in air
BaO + NiO + air barium oxide + nickel monoxide in air
BaO2 barium peroxide
BrF5 bromine pentafluoride
C6H4BrN2Cl p-bromobenzene diazonium chloride
ClO chlorine monoxide
ClF3 chlorine trifluoride
CrO3 chromium trioxide (chromic anhydride, chromic
acid)
Cu copper
Fe2O3·nH2O di-iron trioxide hydrate
F2 fluorine
hydrated iron oxide
PbO2 lead dioxide (lead peroxide)
metal oxides
metals
HNO3 nitric acid
NCl3 nitrogen trichloride
NF3 nitrogen trifluoride
NI3 nitrogen triiodide
oxidizing materials
OF2 oxygen difluoride
ClO3F perchloryl fluoride
C6H5N2Cl phenyl diazonium chloride
rust
Ag2C2N2O2 silver fulminate
NaOH + CaO soda lime (a mixture of sodium hydroxide and
calcium oxide)
Na sodium
NaOH + CaO + air sodium hydroxide + calcium oxide (lime) in air
Na2O2 sodium peroxide

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2.2.1.7 Corrosivity Data

a. H2S readily attacks copper and most copper alloys (brass,
bronze, etc.), so such materials should not be exposed to the
process gases in an SRU, or to the atmosphere around an
SRU.
b. H2S can cause sulfide stress cracking (SSC) in a variety of

materials as discussed in NACE Standard Material
Requirements MR-01-75, "Sulfide Stress Cracking Resistant
Metallic Materials for Oilfield Equipment". Most sulfur plant
equipment operates at sufficiently low pressure to be outside
the conditions at which SSC would be expected and so is not
constructed in accordance with NACE MR-01-75. The
upstream equipment (including the Knock-Out drums and/or
pumps in the SRU, in some cases) is generally constructed of
carbon steel and stress relieved, or is constructed of austenitic
stainless steel, in accordance with NACE MR-01-75.
c. At elevated temperature (generally, above 650°F/343°C), H2S

will cause rapid corrosion of carbon steel even under low
pressure conditions like those in a sulfur plant. Such steel
surfaces are usually protected by refractory linings, water
cooling, and/or coating the steel surface with a protective
coating (such as Alonizing).
d. H2S is considered to be non-corrosive to aluminum, glass, and

Teflon®.
2.2.1.8 Water Solubility

Hydrogen sulfide is soluble in water. At 60°F (15°C), approximately
3 parts (by volume) H2S will dissolve in one part water.
2.2.1.9 Other Characteristics

Hydrogen sulfide is soluble in liquid sulfur and many hydrocarbons.
Many porous materials, such as muds and residues, tend to absorb
hydrogen sulfide. Increased temperature or mechanical disturbance
tends to release the absorbed gas.

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2.2.1.10 Fire and Explosion Hazard

H2S is a dangerous fire hazard when exposed to an ignition source.
2.2.1.11 Life Hazard

Hydrogen sulfide is extremely toxic even in very low concentrations.
The maximum allowable concentration for continuous exposure
during an eight hour working day (per current OSHA regulations) is
10 parts per million by volume, or 0.001%.
Hydrogen sulfide poisoning is not cumulative like mercury, lead, and

some other materials. Repeated exposure to small doses will not
have the same effect as exposure to one long dose.
Hydrogen sulfide is highly irritating to the eyes and mucous

membranes. When inhaled, hydrogen sulfide is both an irritant and
an asphyxiant. Low concentrations of 20-150 PPM cause irritation of
the eyes; slightly higher concentrations may cause irritation of the
upper respiratory tract, and, if exposure is prolonged, pulmonary
edema may result. (Edema is a condition in which irritated tissues
swell, collect fluid, and slowly excrete a watery fluid, in this case into
the lungs or voice box.) The irritation action has been explained on
the basis that H2S combines with the alkali present in moist surface
tissues to form sodium sulfide, a caustic compound. (This compound
is used by the leather industry to help remove hair from animal
hides.)
With higher concentrations, the action of H2S on the nervous system

becomes more prominent. A 30 minute exposure to 500 PPM results
in headache, dizziness, excitement, staggering gait, diarrhea, and
dysuria, followed sometimes by bronchitis or bronchopneumonia.
The action on the nervous system is, with small amounts, one of
depression; in larger amounts, it stimulates; and, with very high
amounts, the respiratory center is paralyzed. Exposure to
800-1000 PPM may be fatal in 30 minutes, and higher
concentrations are instantly fatal. Fatal hydrogen sulfide poisoning
may occur even more rapidly than that following exposure to a
similar concentration of hydrogen cyanide. H2S does not combine
with the hemoglobin of the blood; its asphyxiant action is due to
paralysis of the respiratory center (which is usually the cause of
death).

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With repeated exposures to low concentrations, conjunctivitis,

photophobia, corneal bullae, tearing, pain, and blurred vision are the
most common findings. Higher concentrations may cause rhinitis,
bronchitis, and occasionally pulmonary edema. Exposure to very
high concentrations results in immediate death. Chronic poisoning
results in headache, inflammation of the conjunctivae and eyelids,
digestive disturbances, loss of weight, and general debility. H2S is a
common air contaminant. It is an insidious poison since sense of
smell may be fatigued and fail to give warning of high concentrations.
The following table from the U.S. Bureau of Mines represents the
degree of inhalation hazard with varying concentrations of hydrogen
sulfide:
HYDROGEN SULFIDE INHALATION HAZARDS

PERIOD OF EXPOSURE EXPOSURE
PPM PERCENT
Maximum allowable concentration for 10 0.001

prolonged exposure
Slight symptoms after exposure of several 70-150 0.007-0.015

hours
Maximum concentration that can be inhaled 170-300 0.017-0.03

for one hour without serious consequences
Dangerous after exposure of thirty minutes 400-500 0.04-0.05

to one hour
Fatal in exposures of thirty minutes or less 600 & above 0.06 & above
Concentrations exceeding 0.1% are considered rapidly fatal.
2.2.2 First Aid

Anyone overcome by H2S should be removed immediately to fresh air,
preferably a warm, well ventilated room. If breathing has stopped, begin
artificial respiration immediately. The arm lift-back pressure method of
artificial respiration is recommended. Since H2S paralyzes the respiratory
system, time is very important. Administer oxygen (or carbogen,
97% oxygen and 3% carbon dioxide) if available and if someone trained
with oxygen inhalation apparatus is present. Attempts to give oxygen by
someone unfamiliar with the use of the apparatus may result in the loss of
valuable time or may be harmful to the patient.

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For severe irritation of the eyes, hold the lids open and pour clean water
over the eyeball and lids (or use an eye irrigation fountain). Wash
thoroughly in this fashion for 15 minutes. A physician, preferably an eye
specialist, should be summoned immediately.
2.2.3 Precautions (remember these facts)

1. Odor is not a reliable test for the presence of hydrogen sulfide.
2. Since hydrogen sulfide is heavier than air, it settles when released

into the atmosphere and becomes more concentrated near the
ground and in low places.
3. Water at room temperature will dissolve approximately three times its

volume of hydrogen sulfide. Heating or agitation of the water will
cause the hydrogen sulfide to be released.
4. Hydrogen sulfide dissolves in liquid sulfur and is a hazard in storage

tanks and pits.
5. H2S is a serious fire and explosion hazard.
6. Low concentrations of hydrogen sulfide hinder the ability of an

individual to think clearly and function properly.
7. H2S concentrations higher than 0.06% can be fatal within 30 minutes

and concentrations higher than 0.1% are rapidly fatal.
8. In the Sulfur Block, H2S will always be present in the following

locations:
a. In most of the process gas streams.
b. In the rich and lean amine streams in the Amine Treating Unit.
c. In the rich and lean amine streams in the Amine Regeneration

Unit.
d. In the Sour Water Stripper liquid streams.
e. In the Acid Gas Knock-Out Drum and the SWS Knock-Out

Drum liquids, TGCU quench water, TGCU solvent, and the
TGCU Stripper reflux.
f. In the amine acid gas, the TGCU recycle gas, and the SWS gas
(the feed gases for the Sulfur Recovery Unit).

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g. In all of the Sulfur Recovery, Tailgas Cleanup, Tailgas Thermal

Oxidation, and Sulfur Degassing system process gases, with
the exception of the incinerated vent gas.
h. In the vapors from the molten sulfur storage tank.
2.2.4 Good Work Practices

Know the above facts and use caution when working around any
equipment that may contain H2S. If H2S will be a hazard in any operation:
1. Make adequate plans to cope with any situation that may develop.
2. Adequate respiratory protective equipment is essential; have it

available and use it. Persons who must work in an atmosphere
contaminated with H2S should use either a self-contained breathing
unit or a hose mask with a hand-operated blower.
3. Observe the wind direction. Stay upwind if possible and warn others
who may be downwind.
4. Keep ignition sources away from the area.
5. Two men should always be present when opening a flange or

performing any other work where the release of H2S is possible.
6. When one man is working in an area of potential H2S exposure, the

other man should concentrate on the wind direction and on the action
of the man performing the work. At the first sign of loss of
coordination or illogical action, the worker should be removed
immediately to fresh air. If a man is being overcome by H2S, he will
be outwardly sluggish and poorly coordinated (although inwardly he
will be peacefully unconcerned) and he will then begin illogical
actions as his mind begins to imagine things. Any sign of actions
that are out of the ordinary is a last minute warning.

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2.3 Sulfur Dioxide (SO2)

2.3.1.1 General
Sulfur dioxide is a colorless, nonflammable, highly toxic gas.

LCLo: 400 PPM / 1 minute (death of humans after
inhalation)

humans or animals. In other words, exposure to 400 PPM of SO2 for
1 minute can cause death.
TCLo: 3 PPM / 5 days (pulmonary system effects on

humans after inhalation)
TCLo: 4 PPM / 1 minute (pulmonary system effects on

man after inhalation)
TCLo (Toxic Concentration Low) is the lowest concentration of a

substance in air to which humans or animals have been exposed for
any given period of time that has produced any toxic effect in
humans or produced a carcinogenic, neoplastigenic, or teratogenic
effect in animals or humans. In other words, exposure to 3 PPM SO2
for 5 days or to 4 PPM SO2 for 1 minute have both been reported to
have toxic effects on the human pulmonary system.

TLV: 2 PPM in air

such levels for human exposure in industry. OSHA regulations set a
limit of 5 PPM TWA (Time Weighted Average) concentration for
continuous exposure during an eight hour working day.

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2.3.1.4 Odor
Sulfur dioxide has a pungent, suffocating odor that can be detected
at very low concentrations, 0.3 to 1.0 PPM, possibly by taste rather
than odor.

b. Boiling Point: 14°F (-10°C)
c. Lower Explosive Limit: N/A (SO2 will not burn)
d. Upper Explosive Limit: N/A
e. Auto-Ignition Temperature: N/A
f. Vapor Specific Gravity: 2.2 (heavier than air)
Sulfur dioxide is dangerously reactive with the following substances:
Formula Name
C3H4O acrolein
Al aluminum
CsHC2 cesium hydrogencarbide
Cs2O cesium oxide
x-ClO3 chlorates
Cr chromium
FeO ferrous oxide
F2 fluorine
lithium acetylene carbide diammino
Mn manganese
KHC2 potassium carbide
KClO3 potassium chlorate
Rb2C2 rubidium carbide
Na sodium
Na2C2 sodium carbide
SnO tin monoxide

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Sulfur dioxide is incompatible with the following substances:
Formula Name
halogens or interhalogens
LiNO3 lithium nitrate
x-C2H metal acetylides
metal oxides
metals
polymeric tubing
NaH sodium hydride

a. Dry SO2 causes only mild corrosion of carbon steel and
stainless steel.
b. Wet SO2 (sulfurous acid) is very corrosive to carbon steel and

most stainless steels. Certain alloy materials (Carpenter
®
20Cb-3 , for instance) are relatively impervious to attack by wet
SO2.
c. SO2 is considered to be non-corrosive to graphite, glass, and

Teflon®.

Sulfur dioxide will dissolve readily in water to form a weak solution of
sulfurous acid (H2SO3). At 60°F (15°C), about 50 parts (by volume)
SO2 will dissolve in one part water.

None

Like hydrogen sulfide, sulfur dioxide is extremely toxic in very low
concentrations. The serious life threat is through paralysis of the
respiratory system. The maximum allowable concentration for
continuous exposure during an eight hour working day (per current
OSHA regulations) is 5 parts per million by volume, or 0.0005%.
Sulfur dioxide is highly irritating to skin, eyes, and mucous

membranes. When inhaled, sulfur dioxide is very irritating and can
cause pulmonary distress. This gas is dangerous to the eyes, as it

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causes irritation at 20 PPM and inflammation of the conjunctiva. It

has a suffocating odor and is a corrosive and poisonous material. In
moist air or fogs, it combines with water to form sulfurous acid, but is
only slowly oxidized to sulfuric acid. Concentrations of 6-12 PPM
cause immediate irritation of the nose and throat, while 0.3-1 PPM
can be detected by the average individual, possibly by taste rather
than by sense of smell. 3 PPM has an easily noticeable odor and
20 PPM is the least amount which is irritating to the eyes.
10,000 PPM is an irritant to moist areas of the skin within a few
minutes of exposure.
SO2 chiefly affects the upper respiratory tract and the bronchi. It may
cause edema of the lungs or glottis, and can produce respiratory
paralysis. (Edema is a condition in which irritated tissues swell,
collect fluid, and slowly excrete a watery fluid, in this case into the
lungs or voice box.)
This material is so irritating that it provides its own warning of toxic

concentrations. 400-500 PPM is immediately dangerous to life, and
50-100 PPM is considered to be the maximum permissible
concentration for exposures of 30-60 minutes. Excessive exposures
to high enough concentrations of this material can be fatal. Its
toxicity is comparable to that of hydrogen chloride. However, less
than fatal concentrations can be borne for fair periods of time with no
apparent permanent damage. It is used as a fumigant, insecticide
and fungicide, and a chemical preservative food additive. It is a
common air contaminant.
2.3.2 First Aid

In cases of inhalation, remove the victim to fresh air and begin artificial
respiration immediately if breathing has ceased. The arm lift-back
pressure method of artificial respiration is recommended. If an oxygen
apparatus is available, oxygen (100%) should be administered only by
someone trained in the use of the apparatus. Preferably, oxygen should
be administered against a positive exhalation pressure of 1.25 inches of
water.
Oxygen inhalation must be continued as long as necessary to maintain

the normal color of the skin and mucous membranes. In cases of severe
exposure, the patient should breathe 100% oxygen under positive
exhalation pressure for 30 minute periods every hour for at least 3 hours.

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If there are no signs of lung congestion at the end of this period, and if the
breathing is easy and the color is good, oxygen inhalation may be
discontinued. Throughout this time, the patient should be kept
comfortably warm, but not hot.
For irritation of the eyes, flush them with large amounts of warm water for
at least 15 minutes. It is advisable to irrigate the eyes gently with water at
room temperature in order to minimize additional pain and discomfort.
Take the patient to a physician, preferably an eye specialist, at once.
2.3.3 Precautions
Special precautions should be observed when fighting sulfur fires. Sulfur
fires should be approached from an upwind direction if possible, and
respiratory equipment should be used in the case of larger fires or when
fires are in enclosed areas. SO2 is always present in the following
locations:
1. In all of the Sulfur Recovery Unit process gases downstream of the

Reactor Furnace, up through and including the TGCU Reactor in the
TGCU Unit.
2. In the stack or flare gases in any process where sulfur or hydrogen

sulfide is being burned, including the Thermal Oxidizer.
3. In the vapors from the molten sulfur storage tank.
4. In the fumes from sulfur fires.

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2.4 Sulfur
2.4.1.1 General
Sulfur is a yellow solid at normal ambient temperatures. However, it
is normally handled in bulk quantities in plant operations as a liquid.

Sulfur is nontoxic. Sulfur dust in air can produce irritation of the
human eye at concentrations of 6 PPM or above, resulting in its
classification as a nuisance dust. Repeated inhalation can cause
irritation to the mucous membranes.

There are no standards or regulations concerning sulfur.
2.4.1.4 Odor
Pure sulfur is odorless.

a. Melting Point: 246°F (119°C)
b. Boiling Point: 832°F (444°C)
c. Auto-Ignition Temperature: 450°F (232°C) for liquid sulfur
374°F (190°C) for sulfur dust
suspended in air
d. Flash Point: 405°F (207°C)
e. Liquid Specific Gravity: 1.8 (almost twice as heavy as
water)
f. Color Pure sulfur is bright yellow when
solid. Sulfur produced by Claus
sulfur plants may be contaminated
with hydrocarbons, causing the
color to be orange, green, tan,
brown, gray, or black. The color of
liquid sulfur ranges from bright
yellow to dark orange (almost red),
depending on its temperature.

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Sulfur can react violently with the following substances:
Formula Name
alkali metal nitrides
Al aluminum
Al + Cu aluminum + copper
Al + Nb2O5 aluminum + niobium pentoxide
NH3 ammonia
NH4NO3 ammonium nitrate
NH4ClO4 ammonium perchlorate
Ba(BrO3)2·H2O barium bromate
BaC2 barium carbide
Ba(ClO3)2·H2O barium chlorate
Ba(IO3)2 barium iodate
B boron
BrF3 bromine trifluoride
Cd cadmium
Ca calcium
Ca(BrO3)2·H2O calcium bromate
CaC2 calcium carbide
Ca(ClO3)2 calcium chlorate
Ca(ClO)2 calcium hypochlorite
Ca(IO3)2 calcium iodate
Ca3P2 calcium phosphide
Ca + VO + H2O calcium + vanadium oxide + water carbides
Cs3N cesium nitride
C + impurities charcoal
ClO2 chlorine dioxide
ClO3 chlorine trioxide
Cr(ClO)2 chromium oxychloride (chromyl chloride)
CrO3 chromium trioxide (chromic acid) anhydride,
chromic
Cu + x-ClO3 copper + chlorates
As2S3 diarsenic trisulfide

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Formula Name
Cl2O dichlorine monoxide
(C2H5)2O diethyl ether
fiberglass + iron filings
F2 fluorine
halogenates
halogenites
halogens
Ag7NO11 heptasilver nitrate octaoxide
CxHy hydrocarbons
In indium
interhalogens
IF5 iodine pentafluoride
IO5 iodine pentoxide
C lampblack (carbon black)
Pb(ClO3)2 lead chlorate
PbCl2 lead chloride
Pb(ClO2)2 lead chlorite
PbCrO4 lead chromate
PbO2 lead dioxide (lead peroxide)
Li lithium
Li + NH3 lithium dissolved in ammonia
Li2C2 lithium carbide
Mg magnesium
Mg(BrO3)2·6H2O magnesium bromate
Mg(ClO3)2 magnesium chlorate
Mg(IO3)2·4H2O magnesium iodate
Hg(NO3)2·H2O mercuric nitrate
HgO mercury(II) oxide (mercuric oxide)
Hg2O mercury(I) oxide (mercurous oxide)
x-C2H metal acetylides of carbides
x-(ClO3)n metal chlorates
x-(zO3)n metal halogenates
x-On metal oxides
metals
RbC2H monorubidium acetylide (rubidium acetylene
carbide)
Ni nickel

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Formula Name
NO2 nitrogen dioxide
Os osmium
oxidants
Pd palladium
x-(ClO4)n inorganic perchlorates
x-(MnO4)n permanganates
P phosphorus (phosphorus, red)
P4 phosphorus, white (phosphorus, yellow)
P2O3 phosphorus trioxide
K potassium
KBrO3 potassium bromate (bromic acid)
KClO potassium chlorite (potassium hypochlorite)
KIO3 potassium iodate
KNO3 + As2S3 potassium nitrate (saltpeter) + arsenic sulfide
K3N potassium nitride
KClO4 potassium perchlorate
KMnO4 potassium permanganate
K + SnI4 potassium + tin(IV) iodide (stannic iodide)
Rh rhodium
Rb rubidium
Se selenium
SeC2 selenium carbide
AgBrO3 silver bromate
AgClO3 silver chlorate
AgClO2 silver chlorite
AgNO3 silver nitrate
Ag2O silver oxide
Na sodium
NaBrO3 sodium bromate
NaClO3 sodium chlorate
NaClO2 sodium chlorite
NaH sodium hydride
NaIO3 sodium iodate
NaNO3 + charcoal sodium nitrate + charcoal
Na2O2 sodium peroxide

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Formula Name
Na + SnI4 sodium + tin(IV) iodide (stannic iodide)
SrC2 strontium carbide
SrC2+ Se strontium carbide + selenium
SCl2 sulfur dichloride
(C6H5)4Pb tetraphenyl lead
Tl2O3 thallic oxide (thallium peroxide)
Th thorium
ThC2 thorium carbide
Sn tin
U uranium
UC2 uranium carbide (uranium dicarbide)
Zn zinc
Zn(BrO3)2·6H2O zinc bromate
Zn(ClO3)2 zinc chlorate
Zn(IO3)2 zinc iodate

Dry sulfur is not corrosive but in the presence of moisture it will
attack steel rapidly.
2.4.1.8 Other Characteristics

a. Both hydrogen sulfide and sulfur dioxide will dissolve in liquid
sulfur.
b. At temperatures up to about 317°F (158°C), the viscosity of

pure liquid sulfur decreases as the temperature increases. As
the temperature increases from 317°F to 370°F (158°C to
188°C), the viscosity of pure liquid sulfur rises rapidly to a
tremendously high maximum, causing the liquid to become a
dark, sticky, plastic material impossible to pump. However,
sulfur produced by Claus sulfur plants contains dissolved H2S
that lowers the viscosity of the molten sulfur so that fluidity is
not normally a concern, regardless of the temperature.

a. Solid Sulfur
The primary hazard in handling solid sulfur results from the fact
that sulfur dust suspended in the air ignites easily. Even though

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the explosion hazard is considered moderate, an explosion

occurring in a confined area could cause considerable damage.
Sulfur, being a very poor conductor of electricity, tends to

develop static electric charges when it is in motion. Ignition of
sulfur dust by static-caused sparks is not uncommon. Frictional
heat in equipment has also been responsible for starting sulfur
fires.
b. Liquid Sulfur
The fire hazards of liquid sulfur result primarily from the low
ignition point of sulfur and from the presence of hydrogen
sulfide.

a. Solid Sulfur
Solid elemental sulfur is considered to be more of a nuisance

dust with a very low toxicity. Occasionally, sulfur dust will
irritate the inner surfaces of the eyelids.
b. Molten Sulfur
Molten sulfur is capable of inflicting severe burns.
2.4.2 Precautions
1. Employees operating equipment containing molten sulfur should
wear clothing capable of protecting the chest and arms, trousers
without cuffs, high top shoes, safety glasses with side shields, and
heat resistant gloves. When making connections or other changes in
molten sulfur piping, full-face shields (in addition to safety glasses)
and leather protective clothing may be needed.
2. Every reasonable step should be taken to minimize formation of dust

during the handling of solid sulfur.
3. Eliminate ignition sources where sulfur dust may be produced.

Enclosed areas are considered Class II hazardous locations
according to the United States National Electrical Code. Where
static electricity is a hazard, equipment should be grounded.
4. Eliminate ignition sources near liquid sulfur where H2S may be

liberated.

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5. Sulfur spills and drips should be cleaned up to avoid accumulations

of sulfur. Sulfur dust should never be allowed to accumulate in
buildings.
2.4.3 Fire Fighting

1. Small sulfur fires may be extinguished by smothering them with dirt
or sand or by using a fire extinguisher. Water is the most satisfactory
extinguishing agent but should be used as a fine spray or fog.
Steam smothering can be used in storage pits and in other relatively
small enclosures. Carbon dioxide is also a satisfactory fire
extinguishing agent.
2. Sulfur fires should be approached very carefully, from the upwind

side if possible, because burning sulfur emits highly toxic fumes of
sulfur dioxide.

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2.5 Ammonia (NH3)

2.5.1.1 General
Ammonia is a colorless, flammable, toxic gas.

LCLo: 5,000 PPM / 1 minute (death of mammals after
inhalation)

humans or animals. In other words, exposure to 5,000 PPM of NH3
for 1 minute can cause death.
TCLo: 20 PPM (toxic and irritant effects on

humans after inhalation)
TCLo (Toxic Concentration Low) is the lowest concentration of a

substance in air to which humans or animals have been exposed for
any given period of time that has produced any toxic effect in
humans or produced a carcinogenic, neoplastigenic, or teratogenic
effect in animals or humans. In other words, exposure to 20 PPM
NH3 has been reported to have toxic and irritant effects on humans.

TLV: 25 PPM in air

limit of 50 PPM TWA (Time Weighted Average) concentration for
2.5.1.4 Odor
Ammonia has a pungent odor that can be detected at low
concentrations, 20 to 50 PPM.

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b. Boiling Point: -28°F (-33°C)
c. Lower Explosive Limit: 15% NH3 (by volume) in air
d. Upper Explosive Limit: 28% NH3 (by volume) in air
e. Auto-Ignition Temperature: 1204°F (651°C)
f. Vapor Specific Gravity: 0.6 (lighter than air)
Ammonia is incompatible with the following substances:
Formula Name
C2H4O acetaldehyde
C3H4O acrolein
H8N2O8S2 ammonium peroxo disulfate
Sb antimony
SbH3 antimony hydride
B boron
boron halides
BI3 boron triiodide
HClO3 chloric acid
ClN3 chlorine azide
x-ClO2 chlorites
SiHxCl4-x chlorosilane
CrO3 chromium trioxide (chromic anhydride, chromic
acid)
CrCl2 chromyl chloride
Cl2O dichlorine oxide
C2H4Cl2 + NH3 (liq) ethylene dichloride + liquid ammonia
C2H4O ethylene oxide
Au gold
AuCl3 gold (III) chloride
halogens
C3N6Cl6 hexachloromelamine
H4N2 + Li, Na, etc. hydrazine + alkali metals
HBr hydrogen bromide (hydrobromic acid)

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Formula Name
HOCl hypochlorous acid
H2O2 hydrogen peroxide
Mg(ClO4)2 magnesium perchlorate
Hg mercury
HNO3 nitric acid
NO2 nitrogen dioxide (nitrogen peroxide)
N2O4 nitrogen tetraoxide
NCl3 nitrogen trichloride
NF3 nitrogen trifluoride
NO2Cl nitryl chloride
OF2 oxygen difluoride
O2 + Pt oxygen + platinum
P2O5 phosphorus pentoxide
P2O3 phosphorus trioxide
C6H3N3O7 picric acid
K + AsH3 potassium + arsine
K3Fe(CN)6 potassium ferricyanide
K2Hg(CN)4 potassium mercuric cyanide
K + PH3 potassium + phosphine
K + NaNO2 potassium + sodium nitrite
Ag silver
AgCl silver chloride
AgNO3 silver nitrate
Ag2O silver oxide
Na + CO sodium + carbon monoxide
S sulfur
SCl2 sulfur dichloride
TeCl4 tellurium chloride
tellurium hydropentachloride
(CH3)4N2COH2 tetramethyl ammonium amide
SOCl2 thionyl chloride
N3S4Cl thiotrithiazyl chloride
C3H3N6Cl3 trichloromelamine
O3F2 trioxygen difluoride

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a. Iron and carbon steel are recommended for ammonia service.
b. Moist ammonia will rapidly attack copper, tin, zinc, and their
alloys.
c. Mixtures of ammonia and hydrogen sulfide are often very

corrosive to carbon and stainless steels when wet. The
corrosivity appears to increase when hydrogen cyanide (HCN)
is present. (Hydrogen cyanide is a common contaminant in the
sour water processed in many refineries.)
d. Ammonia is considered to be non-corrosive to glass and

Teflon®.

Ammonia will dissolve very readily in water. At 60°F (15°C), about
800 parts (by volume) NH3 will dissolve in one part water.

Ammonia is a low fire hazard when exposed to heat or flame
because it is difficult to ignite. It is a moderate explosion hazard
when exposed to flame or fire. Air-ammonia mixtures can detonate
in a fire.

Ammonia is toxic in moderate concentrations. However, its pungent
odor will provide ample warning of its presence, so it is unlikely that
an individual would unknowingly become overexposed. The
maximum allowable concentration for continuous exposure during an
eight hour working day (per current OSHA regulations) is 50 parts
per million by volume, or 0.005%.
Ammonia is highly irritating to the eyes and mucous membranes.

When inhaled, ammonia is both an irritant and an asphyxiant, and
can cause respiratory distress. This gas is dangerous to the eyes,
as it causes irritation at 40-100 PPM. Prolonged exposure to
700 PPM or more can cause extensive injuries to the eyes - irritation,
hemorrhages, swollen lids, corneal ulcers, even partial or total loss of
sight. Ammonia will also irritate the skin, particularly if the skin is
moist, to the point of causing chemical burns from prolonged
exposure.

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The life hazard from ammonia is due to its damage to the lungs when
inhaled. This material is so irritating that it provides its own warning
well below toxic concentrations. Ammonia can usually be detected
at levels of 20-50 PPM. There will be noticeable irritation of the eyes
and nasal passages when exposed to 100 PPM, severe irritation of
the throat, nasal passages, and upper respiratory tract at 400 PPM,
and severe eye irritation at 700 PPM. At 1700 PPM, there will be
severe coughing and bronchial spasms, and an exposure of
30 minutes or less may be fatal. Concentrations of 5000 PPM and
above are fatal almost immediately, causing serious edema of the
lungs, strangulation, and asphyxiation. (Edema is a condition in
which irritated tissues swell, collect fluid, and slowly excrete a watery
fluid, in this case into the lungs.)
2.5.2 First Aid

Anyone overcome by ammonia should be removed immediately to fresh
air, preferably a warm, well-ventilated room. If breathing has stopped,
begin artificial respiration immediately (by trained personnel only). The
arm lift-back pressure method of artificial respiration is recommended. Be
aware that excessive force during artificial respiration will further injure the
lungs. Administer oxygen if available and if someone trained with oxygen
inhalation apparatus is present.
For severe irritation of the eyes, hold the lids open and pour clean water
over the eyeball and lids (or use an eye irrigation fountain). Wash
thoroughly in this fashion for 15 minutes. A physician, preferably an eye
specialist, should be summoned immediately.
2.5.3 Precautions
In this part of the complex, ammonia will usually be found mixed with
hydrogen sulfide. Ammonia will always be present in the following
locations:
1. In the process gas and liquid streams in the Sour Water Stripping
Unit.
2. In the Sour Water Stripper off-gas feeding the sulfur plant.
3. In the SWS Gas Knock-Out Drum liquids, the TGCU quench water,
and the TGCU Stripper reflux.

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4. In the overhead gas from the TGCU Stripper, and possibly in the
TGCU recycle gas.

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2.6 Methyldiethanolamine (MDEA, CH3-N-(CH2-CH2-OH)2)

2.6.1.1 General
MDEA is a colorless, viscous liquid.

Ingestion of MDEA is moderately toxic, and may cause nausea,
vomiting, and abdominal discomfort. Single dose oral toxicity is low.
MDEA can cause moderate irritation of the eyes, with possible

corneal damage. Prolonged or repeated exposure can cause skin
irritation or burns. Inhalation of vapors is unlikely at room
temperature due to its low vapor pressure. MDEA at elevated
temperature may produce sufficient vapor to cause moderately
severe eye and upper respiratory irritation.

There are no standards or regulations concerning MDEA.
2.6.1.4 Odor
MDEA has a slight odor of amine.

c. Vapor Pressure: <0.01 mm Hg @ 68°F (20°C)
d. Flash Point: 260°F (127°C)
e. Lower Explosive Limit: not determined
f. Upper Explosive Limit: not determined
g. Specific Gravity: 1.042 (about the same as water)
h. Color: Clear to light straw color

MDEA is incompatible with strong oxidizers and strong acids. MDEA
should not be allowed to contact sodium nitrite (NaNO2) or other
nitrosating agents, as nitrosamines (suspected cancer-causing
agents) could be formed.

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a. MDEA and MDEA-water solutions are generally non-corrosive
to carbon and stainless steels.
b. Acid gas (H2S and/or CO2) dissolved in MDEA-water solutions

can cause appreciable corrosion of carbon steel, particularly in
areas subjected to erosion.
c. Copper, copper alloys, and galvanized steel should not be

exposed to MDEA. Aluminum should not be exposed to MDEA
at elevated temperatures.
d. Oxygen will degrade MDEA by forming corrosive organic acids.
e. MDEA is considered to be non-corrosive to glass, asbestos,

Teflon®, and EPDM.

MDEA is completely soluble in water.

MDEA is considered a slight fire hazard when exposed to heat or
flame.

The toxicity of MDEA is low. Ingestion of MDEA can cause nausea
and vomiting. MDEA will irritate the skin and eyes, and can cause
damage to the eyes. If heated, sufficient MDEA vapor may be
evolved to irritate the nose and/or eyes.
2.6.2 First Aid

If large amounts of MDEA are ingested, induce vomiting, then take the
patient to a physician.
If MDEA vapors are inhaled, remove the patient to fresh air. A physician
should be consulted.
In case of eye contact, flush the eyes with large amounts of water for at
least 15 minutes. Take the patient to a physician, preferably an eye
specialist, at once.
In case of skin contact, flush the affected area with plenty of water. If
exposure has produced a burn, it should be treated like a thermal burn,

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with treatment based on the physician's judgment. Contaminated clothing

should be removed and washed before reuse.
2.6.3 Precautions
1. When handling MDEA, employees should wear protective clothing
resistant to MDEA. The choice of gloves, boots, apron, or full-body
suit will depend on the tasks to be performed. Chemical-resistant
goggles should always be worn.
2. Good general ventilation should be sufficient for most operations. If

vapor concentrations are high, use local exhaust ventilators.
3. If irritation of the nose and/or respiratory system is experienced, use

an approved air-purifying respirator.
4. Minimize the exposure of MDEA to oxygen to avoid forming organic

acids.

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2.7 Sodium Hydroxide (Caustic Soda, NaOH)

2.7.1.1 General
Pure sodium hydroxide is a white solid. When dissolved in water,
NaOH forms a clear, colorless or water-white, strongly alkaline liquid.

Sodium hydroxide has acute oral toxicity if ingested. It will cause
severe burns, including perforation and scarring, on the mouth,
throat, esophagus, and stomach, and death may result. Cases of
squamous cell carcinoma of the esophagus have occurred years
after ingestion.
Sodium hydroxide, both solid and in solution, has a markedly

corrosive action on all body tissues. Inhalation of dust or mist can
cause injury to the entire respiratory tract. The effects of inhalation
depend on the severity of the exposure, ranging from mild irritation of
the mucous membranes to severe pneumonitis. Contact with the
eyes may cause irritation and, with greater exposure, severe burns
and possible blindness. Skin contact may cause burns, frequently
with deep ulceration and scarring. Prolonged contact, even with
dilute solutions, can cause tissue damage.

TLV: 2 mg/m3 in air (approximately 2 PPM by weight)

limit of 2 mg/m3 TWA (Time Weighted Average) concentration for
2.7.1.4 Odor
Sodium hydroxide has no odor, in pure form or when dissolved in
water.

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Solid Form
a. Melting Point: 608°F (320°C)

c. Auto-Ignition Temperature: Not combustible
d. Flash Point: N/A
e. Specific Gravity: 2.1 (more than twice as heavy as
water)
f. Color: White
Water Solutions
25 wt% 50 wt%
a. Melting Point: -2°F (-19°C) 50°F (10°C)
b. Boiling Point: 232°F (111°C) 288°F (142°C)
c. Auto-Ignition Temp.: Not combustible Not combustible
d. Flash Point: N/A N/A
e. Specific Gravity: 1.27 1.53
f. Color: Colorless or Colorless or
water-white water-white

Adding water to sodium hydroxide or sodium hydroxide solutions
may cause localized overheating and spattering.
Under the proper conditions, sodium hydroxide can react violently

with the following substances:
Formula Name
C2H2O acetaldehyde
C2H2O2 acetic acid
C2H6O3 acetic anhydride
C3H4O acrolein
C3H3N acrylonitrile
C3H6O allyl alcohol
C3H5Cl allyl chloride
Al aluminum
CHCl3 + CH3OH chloroform + methanol

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Formula Name
C3H7ClO2 chlorohydrin (chlorhydrin)
C7H7ClO 4-chloro-2-methylphenol
C7H6ClNO2 chloronitrotoluene
ClHSO3 chlorosulfonic acid (chlorosulfuric acid)
C9H8O cinnamaldehyde
Cu copper
CN4 cyanogen azide
B2H6 diborane (boron hydride)
C2H2Cl2 1,2-dichloroethylene
C2H4F2 difluoroethane
C3H5NO ethylene cyanohydrin (hydracrylonitrile)
C2H2O2 glyoxal
HCl hydrochloric acid (hydrogen chloride)
HF hydrofluoric acid (hydrogen fluoride)
C6H6O2 hydroquinone
Mg magnesium
C4H2O3 maleic anhydride
CH3OH + C6H2Cl4 methanol + tetrachlorobenzene
C7H7NO3 4-methyl-2-nitrophenol
3-methyl-2-penten-4-yn-1-ol
HNO3 nitric acid
C2H5NO2 nitroethane (forms shock-sensitive salts)
CH3NO2 nitromethane (forms shock-sensitive salts)
CxH2x+1NO2 nitroparaffins (forms shock-sensitive salts)
C3H7NO2 nitropropane (forms shock-sensitive salts)
H2SO4 SO3 oleum (fuming sulfuric acid)
C5H12O pentol
P phosphorus
P2O5 phosphorus pentoxide
C3H4O2 ß-propiolactone (2-oxetanone)
strong mineral or organic acids
H2SO4 sulfuric acid
C6H2Cl4 1,2,4,5-tetrachlorobenzene
C4H8O tetrahydrofuran
Sn tin
C2H3Cl3O 1,1,1-trichloroethanol

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Formula Name
C2HCl3 trichloroethylene
CCl3NO2 trichloronitromethane
H2O water
Zn zinc
Zr zirconium

a. At ambient temperature, sodium hydroxide solutions will cause
only slight corrosion of carbon steel.
b. Carbon steel can experience caustic embrittlement and

intergranular corrosion when exposed to sodium hydroxide
solutions at elevated temperature. Stress relieving the carbon
steel after fabrication may reduce the susceptibility to this.
c. If sodium hydroxide solutions must be handled at elevated

temperatures, special resistant alloys should be used. Nickel
and copper are common components in such alloys.
d. Aluminum, tin, zinc, and their alloys are rapidly attacked by

sodium hydroxide solutions, and should not be allowed to come
in contact with NaOH.
e. Sodium hydroxide is considered to be non-corrosive to glass,

natural rubber, EPDM, and Teflon®.

Sodium hydroxide will dissolve readily in water, with the amount
depending on the solution temperature. If a solution of sodium
hydroxide is cooled below its saturation temperature, it will
precipitate solid hydrates. At 60°F (15°C), sodium hydroxide will
dissolve in water to produce solutions exceeding 50 wt% NaOH.

Sodium hydroxide and its water solutions are not flammable.
However, adding water to NaOH or solutions of NaOH can cause
localized overheating due to its heat of dilution.
Sodium hydroxide will generate gaseous hydrogen (which is

flammable and/or explosive) when in contact with aluminum, copper,
tin, zinc, and their alloys.

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Sodium hydroxide will cause damage to any tissue it contacts. It is
acutely toxic if swallowed, causing severe burns and scarring to the
mouth, throat, esophagus, and stomach, and may lead to death.
Squamous cell carcinoma of the esophagus can occur years after
the exposure.
Contact with the skin, eyes, nose, or respiratory passages can result
in severe burns and scarring. In the case of eye contact, blindness
can occur rapidly.
2.7.2 First Aid

If swallowed, do not induce vomiting - this will cause further damage to the
throat and esophagus. Dilute by giving water to the patient immediately.
Vinegar, 1% acetic acid solution, citrus fruit juices, or 5% citric acid
solution may also be administered to help neutralize the alkaline solution.
Follow this with milk, egg white in water, or milk of magnesia. Keep the
patient warm and still, and summon a physician immediately.
If dust or mist is inhaled, remove the patient to fresh air at once. If

breathing has stopped, begin artificial respiration immediately. The air
lift-back pressure method of artificial respiration is recommended. Keep
the patient warm and still, and summon a physician immediately.
In case of eye contact, immediately begin flushing the eyes with large
amounts of water, preferably with an eye wash fountain. Continue
flushing for at least 15 minutes, forcibly holding the eyelids apart and
rotating the eyeball, to ensure complete irrigation of all eye and lid tissue.
A physician, preferably an eye specialist, should be summoned
immediately.
In case of skin contact, immediately flush the affected areas with large
amounts of water. If large areas of the body are contaminated, or if
clothing has been penetrated to the skin, immediately use a safety
shower, preferably removing clothing while under the shower. Continue
flushing the areas for at least 15 minutes. If available, follow the water
flush with a generous application of vinegar or 1% acetic acid solution to
neutralize the residual NaOH. After the acid treatment, apply a good
protective dressing as with any other burn and take the patient to a
physician. Contaminated clothing should be washed before reuse.
Contaminated leather articles (shoes, belts, etc.) should be discarded.

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2.7.3 Precautions
1. Employees should wear impervious rubber, neoprene, or vinyl
gloves, boots, and overalls or full-body suits, plus tightly fitting
goggles and face shields.
2. If dust or mist is present, use an appropriate respirator.
3. When diluting sodium hydroxide, use agitation (mixing) and add the
concentrated sodium hydroxide to water at a controlled rate to
control the heat of dilution and avoid spattering. Never add water to
sodium hydroxide.

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2.8 Sulfur Plant Safety

2.8.1 Hydrogen Sulfide
Hydrogen sulfide will be present in all of the process gas streams flowing
in the ATU, the SWS, the SRU, the SDU, the TGCU, and the Thermal
Oxidizer. The hydrogen sulfide content will decrease as the sulfur is
extracted from the gas stream and will reach its lowest concentration in
the incinerated vent gas. Some hydrogen sulfide will be dissolved in the
liquid sulfur produced. Review the characteristics of this poisonous gas
often, and be fully familiar with them.
Avoid all possibility of exposure to hydrogen sulfide. Plan and think

ahead, so that when there is a possibility of hydrogen sulfide release, you
will know what to do. Plant safety procedures should be established that
require the presence of at least two men before a flange is loosened, or
any other opening is created, to allow a possible H2S release. The man
doing the work should either wear a gas mask with canister, manufactured
specifically for hydrogen sulfide protection, or a fresh air pack. The
second man should stand on the side a few yards away, upwind, with the
oxygen supply in his hands.
If the job requires entering a vessel or enclosure which might contain

some hydrogen sulfide, a safety harness with lifeline shall be attached to
the man entering the vessel. Two men should remain outside the vessel
to pull the man who entered the vessel to safety if he should be overcome.
If a man who is working in a hydrogen sulfide exposure should begin

moving sluggishly or lose coordination, the man who is standing by should
remove him immediately to fresh air. Any sign of actions that are out of
the ordinary is a last minute warning. After an extended exposure, a man
will be unusually sensitive to even small concentrations of H2S gas.
2.8.2 Sulfur Dioxide

Sulfur dioxide will not be present within the SRU, the SDU, the TGCU unit,
and the Thermal Oxidizer as a pure gas but will be present in the
following:
1. Most process gas streams (reactor gases, tailgas, and stack gas).
2. Sulfur tank gases.
3. Smoke from any sulfur fire.

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The maximum allowable concentration in which it is safe to work is

5 PPM. Reactor gases, tailgas, and stack gas may have concentrations
up to 10,000 PPM and vapors from sulfur fires may have concentrations
up to 100,000 PPM.
The most likely source of sulfur dioxide in sufficient concentration to cause

problems is a fire in the sulfur storage tank. The simplest way to stop
such a fire is to smother it by covering all openings to the air, then putting
water into the storage tank. This water will vaporize to steam and help
smother the fire. Smothering a sulfur fire with plant steam is also
effective.
2.8.3 Sulfur Storage Tank

Molten sulfur produced in each SRU flows through the drain seals and is
stored in the sulfur surge tanks. These drain seals and tanks present a
combination of principle hazards.
2.8.3.1 Poisonous Gases

Hydrogen sulfide and sulfur dioxide are present in the vapor space
above the molten sulfur. They should not be inhaled as they are
extremely toxic.
2.8.3.2 Explosion and Fire

The surge tanks are equipped with steam-powered eductors to
provide ventilation of the vapor space. Each tank also has a
steam-jacketed stack that can provide natural-draft ventilation if its
eductor system is not functioning. These ventilation systems are
designed to sweep sufficient fresh air through the vapor space to
prevent hydrogen sulfide liberated from the sulfur from reaching
explosive concentrations. However, common sense dictates that no
ignition sources should be allowed near the tanks in case some
obstruction of the ventilation system should occur and allow an
explosive concentration of H2S to build up. Therefore, tools which
might cause a spark or open flame, should not be brought into the
area around the sulfur surge tanks without special review and
precautions, and smoking must be prohibited in the area.
Operators should be aware of the possible existence of an explosive

mixture in the sulfur surge tanks, as there is some history of
explosions in European sulfur pits and at least one U.S. pit. The
breather vents, where the air is sucked into the tanks, should be

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checked regularly for adequate air flow. The motive steam supply to
the eductors, as well as the steam supply to and condensate from
the ventilation system jacketing, should also be monitored.
Sulfur fires may occur in the tanks. Molten sulfur has an auto-ignition
temperature of approximately 450°F (232°C). This is a spontaneous
reaction; no spark or flame is required. Steam system temperatures
are normally well below the auto-ignition point of sulfur. However,
some iron-sulfur corrosion compounds are unstable and can ignite,
or decompose, at lower temperatures to create localized hot spots
and sulfur burning.
SECTIONS 2.9 THROUGH 2.14 LIST SOME IMPORTANT SAFETY

CONSIDERATIONS THAT PERSONNEL SHOULD KEEP IN MIND WHEN
WORKING IN THE PLANT. THESE SECTIONS ARE NOT A COMPLETE LIST OF
SAFETY CONSIDERATIONS AND DO NOT OUTLINE COMPLETE OPERATING
OR MAINTENANCE PROCEDURES. ALL PERSONNEL SHOULD FOLLOW
THEIR EMPLOYER'S DETAILED SAFETY PROCEDURES FOR ANY WORK
DONE IN THE PLANT.
2.9 Hot Work

Any work which requires the use of equipment that is capable of being an
ignition source in an area where flammable vapors or materials may be present
is defined as "Hot Work". Examples of equipment considered as ignition
sources are: welding equipment, open lights, gasoline engines, grinders, etc.
"Hot Work" normally requires specific approval by plant management and
should be implemented by following detailed instructions for obtaining "Hot
Work" permits.
2.10 Vessel Entry

The procedures used for vessel entry shall be in conformance with ANSI Z117.1
(latest edition), the "American National Standard Safety Requirements for
Confined Spaces". The discussion in this section is a general information
supplement to ANSI Z117.1. In all cases, consult ANSI Z117.1 and any
applicable Samsung Total Petrochemicals policies for specific precautions and
procedures regarding each instance of vessel entry.
Vessel entry refers to any tank, vessel, equipment, or other enclosed place
where there is a hazard of: 1) a toxic, corrosive, or flammable substance;

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2) insufficient oxygen; or 3) severe restrictions that would hinder escape or

rescue. Vessel entry normally requires specific approval by plant management.
Almost all of the vessels in this facility fit at least one of the three categories
mentioned above, due to the potential presence of hydrocarbon gas, caustic or
corrosive chemicals, or toxic H2S and SO2. All vessels should be assumed
unsafe for normal entry until prescribed vessel entry procedures have been
followed.
Consider the precautions advised for vessel entry when gauging tanks,
sampling, and blowing down lines or instruments.
Some or all of the following items should be considered for most vessel entry
jobs:
A. Disconnect and blank off all lines to the vessel.
B. Remove all sources of ignition before removing manway covers.
C. Check all internal lines and liquid traps to verify they are free of hazardous
liquid.
D. Clean the vessel as thoroughly as possible by draining, purging with inert

gas, steaming, ventilating, or other suitable means.
If steam is used, guard against static electricity by grounding the steam

nozzle. After steaming, allow the vessel to cool slowly. Sudden cooling
with water spray may cause a static electric charge. Also, it is not good
practice to allow the inside surfaces of the sulfur plant process piping and
vessels to become water wetted. Excessive corrosion occurs when
oxygen and water are present.
E. Test the Atmosphere for:
(1) Oxygen - The atmosphere must contain 19.5-23.5% oxygen and the
vessel should have adequate ventilation, either forced or natural.
(2) Explosive mixture - A vessel may not be entered if the testing

instrument indicates an air-vapor mixture that exceeds 10% of the
lower explosive limit, or the value specified in your organization's
safety procedures.
(3) Toxic fumes - The presence of any toxic fumes requires the use of
respiratory protective equipment, normally an air supplied mask with

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hand blower, or a self-contained breathing unit; otherwise, additional

cleaning or purging of the vessel is indicated.
F. A safety harness and a lifeline shall be worn by the person entering the
vessel if respiratory equipment is required.
G. Personal protective clothing suitable for the job inside the vessel should
be worn.
H. An observer should be stationed outside the vessel. His duty should be to

watch the person inside the vessel. When respiratory equipment is
required for the person entering the vessel, the observer should also have
the suitable respiratory equipment available.
I. Fire extinguisher and other emergency equipment should be available as

required.
2.11 Pipes and Lines

In the discussion that follows, line breaking is defined as the opening of any line,
the contents of which are flammable, corrosive, toxic, or under high pressure.
All other line opening jobs or work are excluded from this definition. Line
breaking usually requires specific approval by plant management.
The following items should be considered in all work involving lines and valves:
2.11.1 General
1. Know the contents of each line being worked on.
2. Know the pressure ratings of the pipes and fittings. Never install low
pressure connections on high pressure lines.
3. Never hammer on high-pressure lines.
4. Use extreme caution when thawing frozen lines.
5. Never use fire to locate leaks of flammable materials.
6. Be very cautious when attempting to tighten steam pipe fittings while

pressure is on a line.
7. When opening valves, do so slowly to allow pressure to equalize

before opening the valve fully.

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8. When removing blinds, loosen bolts and allow any pressure to bleed
down. Gas sometimes leaks into the space between the blind and
the valve.
2.11.2 Before Breaking Lines

1. Drain the contents into a tank or to the lowest point.
2. Lock out, tag out, and try the pump. All gauges and sight glasses
should be checked for zero readings.
3. Close and tag the nearest upstream and downstream valves.
2.11.3 When Breaking Lines

1. Wear suitable personal protective equipment, such as full clothing.
At times, rubber suits should be worn to guard against chemical
splash. Goggles should be worn to protect eyes against chemical
splash and flying particles.
2. Always assume a line is full and under maximum possible pressure.
3. The placement of a deflector over the flange joint is usually desirable

for the initial "cracking" of flanges in lines containing corrosive or
toxic material.
4. The worker should slowly open the bolts on the far side, so that if
there is a spray it will be away from him.
5. Sections that have been removed should be handled carefully until

they are inspected for trapped material or residues and flushed if
required.
2.12 Electrical Equipment

Everyone recognizes that high voltages can be very dangerous. However,
some people fail to realize that so-called "low-voltage" can be hazardous and
under certain conditions can produce fatal injuries. Deaths have occurred
because of contact with circuits of less than 50 volts. It is not voltage but
amperage that kills. Under certain conditions, as little as 1/10 ampere is
sufficient to cause death. The following may be used as a guide when working
with electrical equipment.

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2.12.1 Electrical Repairs

When electrical equipment is to be repaired, switches must be locked
open, tagged, and the circuit "tried" to confirm the power is off. Working
on "hot circuits" normally requires the permission of plant management.
Refer to detailed plant tag-out procedures before proceeding.
2.12.2 Grounding
1. All electrical equipment is to be grounded.
2. If it is necessary to move any equipment, the ground should be

replaced before the equipment is used.
2.12.3 Conduit, Cables, and Wires

1. Electrical conduits should not be used to support other equipment.
2. Exposed ends of electrical wires must be taped.
3. Unused and abandoned electric wires must be removed or

disconnected at each end.
2.12.4 Fuses
1. Fuses should be replaced only by authorized personnel.
2. Fuse tongs and/or rubber electrical gloves should be used and the
disconnect should be opened. Rubber gloves must always be used
for voltages in excess of 150 volts.
3. Never use coins or tin foil in lieu of fuses.
4. Never use fuses of greater capacity than is specified by the

equipment manufacturer.
2.12.5 Switching
1. When starting electric motors, handle all switches according to
instructions. Make contact so as to prevent arcs. Stand in a safe
position.
2. Never pull a disconnect switch under load except in an emergency.
3. Always be certain that hands are dry and that the footing is dry when
operating switches or plugging in electrical appliances.
4. Keep rubber mats in front of switchboards where possible.

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5. Switch-panel fronts should be kept closed.
6. Maintain clear access to disconnects/switches.
2.12.6 Hand Tools and Portable Equipment

1. Extension lights without bulb protectors must not be used. Use only
low voltage lights with isolating transformers in boilers and similar
places.
2. All extension cords should be the grounded type. Before each period
of use, examine extension cords carefully for any failure of the outer
insulation, particularly at terminal points where the cord enters a plug
or a fixture.
3. Lights and tools should not be disconnected from an extension cord

while the other end of the cord is in a socket or receptacle.
4. The ground cable with which each tool is equipped should be

secured to a suitable ground before the tool is plugged into a source
of electricity.
2.12.7 Miscellaneous
1. Contact with electrical conductors should be avoided whether they
are energized or not.
2. Fenced sub-station areas should be entered only by authorized

personnel.
3. Faulty electrical equipment must not be used. Report it immediately.
4. Before changing broken light bulbs, be certain the current is turned

off.
5. No employee may work within 15 feet of a high voltage power line

except by special authorization of plant management.

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2.13 Boilers and Other Direct-Fired Equipment

2.13.1 General
1. In this facility, the Waste Heat Boiler, Sulfur Condenser, TGCU
Waste Heat Reclaimer, and Thermal Oxidizer Waste Heat Boiler are
classified as boilers, but they are not direct-fired. The Reactor
Furnace and Thermal Oxidizer are the direct-fired pieces of
equipment.
2. Work on the Waste Heat Boiler, Sulfur Condenser, TGCU Waste

Heat Reclaimer, Thermal Oxidizer Waste Heat Boiler, Reactor
Furnace, and Thermal Oxidizer should be approved as required by
local procedures.
3. Control valves should be operated only when necessary by the

operator in charge.
4. Refer to detailed vendor instructions for specific descriptions of

actual safety procedures and equipment on the direct-fired
equipment in this plant.
2.13.2 Boilers
2.13.2.1 Repair and Maintenance
a. Only boiler inspectors or the State boiler agency should
determine a new setting for safety relief valves. Seals on safety
relief valves should never be removed. If a valve leaks, remove
it to a Code-authorized shop for repairs.
b. Before entering a boiler fire box:
(1) Ventilate the fire box.
(2) Lock, tag, and try the blower valve.
(3) Blank or disconnect fuel gas lines.
c. Before entering the drum or shell:
(1) Feed water lines and blow-off lines should be blinded or

suitably locked.
(2) Blank the steam line between the stop valve and the
boiler.

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(3) If blinding is prevented by piping connections, non-return

and main stop valves should be locked and vents between
valves should be opened.
d. If valves are to be locked, the man entering the boiler shall

supervise the operations and retain the keys to the locks.
e. After repairs, examine the boiler carefully for tools and other
matter before replacing the manhole cover.
f. Before filling begins, all locks should be removed by the man, or

men, who have retained keys to the locks.
2.13.2.2 Operations
a. Open steam valves very slowly to allow cold lines to heat up
and water to drain out before pressure builds.
b. Open blow-off valves or cocks slowly. Before a boiler is blown

out, it is advisable to attain a high water level so that scale and
sediment can be blown out without lowering the water to a
dangerous level.
2.13.3 Direct-Fired Equipment

1. Before attempting to light burners, be certain that combustible gases
are purged from the system.
2. Stand to one side of openings when lighting burners.
3. Ignite each burner or pilot as described in operating instructions.
4. Observation ports should be used with care when lighting burners

because of the chance of high positive pressures and explosion.
5. Before entering a fire box:
a. Ventilate the fire box.
b. Lock, tag, and try the blower valve.
c. Blank or disconnect fuel gas and tailgas lines.

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2.14 Laboratory Safety

2.14.1 Good Housekeeping
1. Cleanliness and orderliness are essential to the operations of
laboratories.
2. A continuous program should be in effect to prevent the

accumulation of rubbish, rags, partly used samples, dismantled
equipment, etc.
2.14.2 Equipment
1. Inspect all gas hoses for leaks each day that they are used.
2. Extinguish all gas burners when they are not in use.
3. Glassware
a. Discard all cracked, broken, or scrap glassware.
b. Fire-polish all chipped edges on burettes, beakers, graduates,

etc.
c. Avoid thermal shock with all glassware.
d. Use only glass tubing with fire-polished ends.
e. Before attempting to insert glass tubing into stopper holes, be

certain that the holes are the proper size. Always moisten the
stopper hole and the glass tubing with water, and rotate the
glass tube as it is inserted, pushing it away from the body.
When rubber tubing or stoppers stick on glassware, cut them
away.
f. Do not drink or eat out of laboratory glassware.
2.14.3 Chemical Sorting and Identification

1. Adequately label or mark bottles and containers to identify the
chemical within.
2. Keep chemicals stored in their proper place. Solvents should not be

brought into laboratory in quantities greater than five gallons.
3. Keep volatile combustible liquids in safety containers and away from

direct flames or sources of heat.

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2.14.4 Chemical Handling

1. When handling acids or caustics in quantities, always wear protective
clothing and eye protection.
2. Always pour acids and caustics into water, never the reverse.
3. If acids or caustics enter the eye, flush with plenty of water and
report for first aid treatment.
4. Wash hands immediately after handling chemicals bearing poison

labels. Wash hands after handling mercury and clean up mercury
spills at once.
5. Use large quantities of water when disposing of acids or caustic

materials through the drains.
6. Refer to vendor information for specifics on the safe handling of

individual types of chemicals and first aid steps for accidents
involving them.

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2.15 Material Safety Data Sheets (MSDS)

This section contains Material Safety Data Sheets (MSDS) for the hazardous
chemicals listed below that operating personnel in this part of the complex may
encounter while operating the unit and systems described in this manual. Of
necessity, these MSDS are generic in nature. As they become available,
Samsung Total Petrochemicals Co. should replace and/or supplement the
MSDS provided in this manual with those prepared by the manufacturers and/or
suppliers of the specific chemicals used in the complex.
A. Hydrogen Sulfide
B. Sulfur Dioxide
C. Sulfur
D. Ammonia
E. Methyldiethanolamine
F. Sodium Hydroxide
G. UOP/ESM S-2001 Sulfur Conversion Catalyst
H. Criterion 234 Tailgas Treating Catalyst

MATERIAL SAFETY DATA SHEET
HYDROGEN SULFIDE
SECTION I - PRODUCT IDENTIFICATION
Substance: HYDROGEN SULFIDE CAS Number: 7783-06-4
Trade Names / Synonyms: Hepatic Gas; Hydrosulfuric Acid; Stink Damp; Sulfureted Hydrogen; Sulfur
Hydride
Molecular Formula: H2S Molecular Weight: 34.08
General or Generic ID: Inorganic Gas
SECTION II - COMPONENTS
Component: Hydrogen Sulfide Percent: > 99.0
Other Contaminants: Methyl Mercaptan; Carbon Disulfide; Oxides of Carbon and Sulfur
Exposure Limits: Hydrogen Sulfide

20 PPM OSHA acceptable ceiling concentration
50 PPM / 10 minutes OSHA peak
10 PPM ACGIH TWA
10 PPM ACGIH STEL
15 mg/m3 (10 PPM) NIOSH recommended 10 minute ceiling
SECTION III - PHYSICAL DATA
Description: Colorless gas at atmospheric temperature and pressure, with the odor of
rotten eggs.
Melting Point: -122°F (-86°C) Boiling Point: -77°F (-60°C)
Liquid Specific Gravity: 1.54 Vapor Specific Gravity: 1.18

(water = 1.0) (air = 1.0)
Vapor Pressure: 294 PSI (20 atm) @ 78°F (25°C)
Odor Threshold: 0.05 PPM
Solubility in Water: 4.2 g/l @ 60°F (15°C), 3.2 g/l @ 78°F (25°C)
Other Solvents Carbon Disulfide, Weak Acids, Ethanol, Gasoline, Kerosene, Crude Oil, Liquid
Sulfur
Other Physical Data: Solubility decreases with increasing temperature or with mechanical
disturbance (agitation), causing evolution of dissolved gas.
ISSUE DATE: 06/12/95 SUPERSEDES: 02/19/93 PAGE 1 OF 6

HYDROGEN SULFIDE
SECTION IV- FIRE AND EXPLOSION INFORMATION
Fire and Explosion Hazard: Highly flammable gas when exposed to heat, flame, or oxidizers.
Moderate explosion hazard. Gas-air mixtures are explosive. Vapors
are heavier than air, and may travel a considerable distance to a
source of ignition and flash back.
Auto-Ignition Temperature: 500°F (260°C) Flash Point Temperature: N/A
Explosive Limits in Air: Lower: 4.3% Upper: 46%
Extinguishing Media: Let burn unless leak can be stopped immediately.

(1984 Emergency Response Guidebook, DOT P 5800.3).
For larger fires, use water spray, fog, or foam.

(1984 Emergency Response Guidebook, DOT P 5800.3).
Fire-Fighting Procedures: Extinguish only if flow can be stopped; use water in flooding amounts
as fog. Apply from as far a distance as possible. Avoid breathing
poisonous vapors, keep upwind. Evacuate to a radius of 2500 feet for
uncontrollable fires. Evacuate downwind areas as required for leaks.
Fire-Fighting Phases: Stop flow of gas. Use water to keep fire-exposed containers cool and
to protect personnel effecting the shut off. (NFPA 49, Hazardous
Chemicals Data, 1975).
SECTION V - HEALTH HAZARD DATA
Permissible Exposure Level: 10 PPM
Threshold Limit Value: 10 PPM
Health Effects from Exposure
Swallowing: Ingestion of a gas is unlikely.
Inhalation: Corrosive/Neurotoxin/Toxic. 300 PPM immediately dangerous to life or health.
Acute Exposure - Low concentrations may produce nasal and respiratory tract irritation.
At 50 PPM, anosmia, anoxia, headache, nausea, dizziness, vomiting, confusion,
weakness, ataxia, irritability, and insomnia may occur. Rhinitis, pharyngitis, coughing,
bronchitis, and pneumonitis are also possible. At 500-1000 PPM, coma, convulsions,
and death may occur within 30 minutes. At extremely high concentrations, respiratory
paralysis and death from asphyxia may be immediate. Non-fatal exposures may result
in sequelae including residual cough, cardiac dilation, slow pulse, peripheral neuritis,
albuminuria, amnesia, psychic disturbances, and permanent brain damage.

HYDROGEN SULFIDE
SECTION V- HEALTH HAZARD DATA (continued)
Inhalation: Chronic Exposure - Prolonged or repeated exposure to low concentrations may cause
(continued) hypotension, nausea, anorexia, weight loss, incoordination, and chronic cough.
Prolonged exposure to 250 PPM has led to pulmonary edema.
Eye Contact: Corrosive.
Acute exposure - 50 PPM for one hour has caused conjunctivitis, pain, lacrimation,
photophobia, and appearance of haloes around lights. Within a few hours or days,
symptoms may progress to keratoconjunctivitis and vesiculation of the corneal
epithelium. Higher concentrations may cause severe irritation, lacrimation, and intense
pain.
Chronic Exposure - Prolonged or repeated exposure may cause conjunctivitis.
Skin Contact: Corrosive.
Acute Exposure - High vapor concentrations may cause severe irritation of the skin.
Chronic Exposure - A high incidence of furunculosis has been reported in industrial

hydrogen sulfide workers.
First Aid Measures
Swallowing: Treat symptomatically and supportively. Get medical attention immediately. If vomiting
occurs, keep head lower than hips to prevent aspiration.
Inhalation: Remove from exposure area to fresh air immediately. If breathing has stopped, give
artificial respiration. Maintain airway and blood pressure and administer oxygen if
available. Keep affected person warm and at rest. Administration of oxygen should be
performed by qualified personnel. Get medical attention immediately.
Eye Contact: Wash eyes immediately with large amounts of water, occasionally lifting upper and
lower lids, until no evidence of chemical remains (at least 15-20 minutes). In case of
burns, apply sterile bandages loosely without medication. Get medical attention
immediately.
Skin Contact: Flush affected areas with large amounts of water. Consult a physician for further
treatment.
Antidote: Amyl nitrite or sodium nitrite can be used to aid in the formation of sulfmethemoglobin,
thus removing sulfide from combination in tissues. Pyridoxine 25 mg/kg intravenously,
or 10% urea, 1 g/kg intravenously, has been suggested as a sulfide acceptor.
Administration of antidotes should be performed by qualified medical personnel. The
nitrite antidote is toxic; therapy is dangerous. (Dreisbach, Handbook of Poisoning, 11th
ed.)

HYDROGEN SULFIDE
SECTION VI- REACTIVITY DATA
Reactivity: Stable under normal temperatures and pressures.
Incompatibilities: Acetaldehyde: Violent reaction.

Barium Oxide, Mercurous Oxide, and Air: Incandescent reaction or explosion.
Barium Oxide, Nickel Oxide, and Air: Incandescent reaction or explosion.
Barium Peroxide: Ignition reaction.
Bromine Pentafluoride: Fire and explosion hazard.
Chlorine Monoxide: Ignition reaction on contact.
Chlorine Trifluoride: Explosive reaction.
Chromic Anhydride: Incandescent reaction on heating.
Copper: Intense exothermic reaction.
Copper Powder: Intense reaction.
Diiron Trioxide Hydrate: Formation of combustible substance.
Fluorine: Ignition reaction.
Metals: Attacks most metals, especially in the
presence of water.
Metal oxides: Combustion, incandescent reaction, or
explosion.
Lead Dioxide: Combustion reaction.
Nitric Acid: Incandescent reaction.
Nitric Acid (Fuming or Concentrated): Violent reaction.
Nitrogen Trichloride: Explosive reaction.
Nitrogen Trifluoride: Formation of explosive mixture.
Nitrogen Triiodide and Ammonia: Explosive reaction.
Oxidants: Violent reaction.
Oxygen Difluoride: Explosive reaction on mixing.
Perchloryl Fluoride: Ignition or explosion at 100-300°C.
Phenyl Diazonium Chloride: Formation of explosive substance.
Rust: Hydrogen sulfide may ignite if passed
through rusty iron pipes.
Silver Fulminate: Violent reaction at ambient
temperatures.
Soda Lime and Air: Incandescent reaction.
Sodium: Rapid reaction on contact with moist gas.
Sodium Peroxide: Violent reaction or ignition, even in the
absence of air.
Decomposition: Thermal decomposition products may include toxic and hazardous hydrogen, sulfur,
and oxides of sulfur.
Polymerization: Hazardous polymerization has not been reported to occur under normal temperatures
and pressures.

HYDROGEN SULFIDE
SECTION VII- SPILL OR LEAK PROCEDURES
Steps to Be Taken in Case Material is Released or Spilled
Shut off ignition sources. Stop leak if you can do it without risk. Use water spray to reduce vapors.
Isolate area until gas has dispersed. No smoking, flames, or flares in hazard area! Keep unnecessary
people away; isolate hazard area and deny entry. Ventilate closed spaces before entering. Evacuate
area endangered by gas.
Waste Disposal Method
Water used to knock-down vapors is corrosive and toxic, and should be diked for containment. Add
suitable agent to neutralize to 7 pH prior to disposal.
SECTION VIII - PROTECTIVE EQUIPMENT TO BE USED
Ventilation: Provide local exhaust or process enclosure ventilation to meet the published exposure
limits. Ventilation equipment must be explosion-proof.
Respirator: The following respirators and maximum use concentrations are recommendations by the
U.S. Department of Health and Human Services; NIOSH Pocket Guide to Chemical
Hazards or NIOSH Criteria Documents; or, Department of Labor, 29CFR1910,
Subpart Z.
The specific respirator selected must be based on contamination levels found in the work
place and be jointly approved by the National Institute of Occupational Safety and Health
and the Mine Safety and Health Administration.
Hydrogen Sulfide:
100 PPM - Supplied-air respirator.
Self contained breathing apparatus.
250 PPM - Supplied-air respirator operated in continuous flow mode.

Self-contained breathing apparatus.
300 PPM - Self-contained breathing apparatus.

Supplied-air respirator with full facepiece.
Escape - Air-purifying full facepiece respirator (gas mask) with chin-style or front-
or back-mounted canister.
Escape-type self-contained breathing apparatus.

HYDROGEN SULFIDE
SECTION VIII - PROTECTIVE EQUIPMENT TO BE USED (continued)
Respirator For firefighting and other immediately dangerous to life or health conditions:
(continued):
Self-contained breathing apparatus with full facepiece operated in pressure-demand
or other positive pressure mode.
Supplied-air respirator with full facepiece and operated in pressure-demand or other

positive pressure mode in combination with an auxiliary self-contained breathing
apparatus operated in pressure-demand or other positive pressure mode.
Clothing: Wear protective clothing. Prevent any possibility of repeated or prolonged vapor contact
with skin.
Gloves: Wear full protective gloves.
Eye Protection: Employee must wear splash-proof or dust-resistant safety goggles and a faceshield to
prevent contact with this substance.
Where there is any possibility that an employee's eyes may be exposed to this substance,
the employer shall provide an eye-wash fountain within the immediate work area for
emergency use.
SECTION IX - SPECIAL PRECAUTIONS OR OTHER COMMENTS
1. Odor is not a reliable test for the presence of hydrogen sulfide.
2. Since hydrogen sulfide is heavier than air, it settles when released into the atmosphere and becomes
more concentrated near the ground and in low places.
3. Hydrogen sulfide dissolves in liquid sulfur and is a hazard in storage tanks and pits.
Disclaimer
The information contained herein is believed to be accurate, but is not warranted to be, whether originating within the company or not. Health and safety precautions in this data sheet
may not be adequate for all individuals and/or situations. Recipients are advised to confirm in advance of need that the information is current, applicable, and suitable to their
circumstances. It is the end user’s responsibility to evaluate and use this product safely, and to comply with all applicable laws and regulations. No statement made in this data sheet
shall be construed as a permission or recommendation for use of any product in a manner that might infringe existing patents. No warranty is made, either expressed or implied.

SULFUR DIOXIDE
Substance SULFUR DIOXIDE CAS Number: 7446-09-5
Trade Names / Synonyms: Sulfurous Acid Anhydride; Sulfurous Anhydride; Sulfurous Oxide;
Sulfur Oxide
Molecular Formula: SO2 Molecular Weight: 64.06
Component: Sulfur Dioxide Percent: > 99.0
Other Contaminants: Hydrogen Sulfide
Exposure Limits: Sulfur Dioxide

5 PPM OSHA TWA per 8-hour working day
2 PPM ACGIH TWA
0.5 PPM NIOSH recommended TWA
Description: Colorless gas at atmospheric temperature and pressure, with an irritating,

suffocating odor.
Melting Point: -104°F (-76°C) Boiling Point: 14°F (-10°C)

(water = 1.0) (air = 1.0)
Vapor Pressure: 49 PSIA (3.3 atm) @ 70°F (21°C)
Odor Threshold: 0.47 PPM
Solubility in Water: 129 g/l @ 60°F (15°C), 102 g/l @ 68°F (20°C)
Other Solvents: Sulfur
Other Physical Data:
ISSUE DATE: 02/19/93 SUPERSEDES: PAGE 1 OF 5

SULFUR DIOXIDE
Fire and Explosion Hazard: None
Auto-Ignition Temperature: N/A Flash Point Temperature: N/A
Explosive Limits in Air: Lower: N/A Upper: N/A
Extinguishing Media: Material is nonflammable. Use what is appropriate to the surrounding fire.
SO2 will form a corrosive acidic mist with water fog or steam.
Fire-Fighting Procedures: Fire fighters must use full protective clothing, eye protection, and self-
contained breathing equipment when this material is involved in a fire
situation.
Fire-Fighting Phases: N/A
Inhalation: Chiefly affects the upper respiratory tract and the bronchi, causing irritation, difficulty
with breathing, pulmonary edema, and, at high levels, respiratory paralysis. Short
exposures above 50-100 PPM can be dangerous, and, above 400-500 PPM,
immediately life threatening.
Systemic effects of acute or chronic exposure are not fully known. Statistical evidence
has been reported to show increased pulmonary function impairment at chronic SO2
levels of 1-4 PPM. Mixture with smoke particulate or aerosols may increase the
hazards of SO2 inhalation.
Eye Contact: At 20 PPM and above, irritation and inflammation of the conjunctiva.
Skin Contact: At 10,000 PPM, irritating to moist areas within a few minutes.

SULFUR DIOXIDE
SECTION V- HEALTH HAZARD DATA (continued)
First Aid Measures
Inhalation: The victim must be carried at once to an uncontaminated atmosphere and effective
artificial respiration started immediately if breathing has ceased. Oxygen (100%)
should be administered (by trained personnel only) as soon as possible after a severe
exposure, preferably against a positive exhalation pressure of 1.25 inches of water.
Oxygen inhalation must be continued as long as necessary to maintain the normal

color of the skin and mucous membranes. In cases of severe exposure, the patient
should breathe 100% oxygen under positive exhalation pressures for 30 minute
periods every hour for at least 3 hours. If there are no signs of lung congestion at the
end of this period, and if the breathing is easy and the color is good, oxygen inhalation
may be discontinued. Throughout this time, the patient should be kept comfortably
warm, but not hot.
Eye Contact: If sulfur dioxide has contacted the eyes, they should be washed promptly with large
quantities of water for at least 15 minutes. Chemical neutralizers are not advisable. It
is advisable to irrigate the eyes gently with water at room temperature in order to
minimize additional pain and discomfort. Refer the victim at once to a physician,
preferably an eye specialist.
Skin Contact: On skin contact with sulfur dioxide, use an emergency safety shower at once. Clothing
and shoes contaminated with sulfur dioxide should be removed under the shower.
Sulfur dioxide should be washed off with very large quantities of water. Wash skin
areas with large quantities of soap and water. Do not apply salves or ointments to
chemical burns for 24 hours.

SULFUR DIOXIDE
Incompatibilities: Acrolein Manganese

Aluminum Metal Acetylides
Cesium Hydrogencarbide Metal Oxides
Cesium Oxide Metals
Chlorates Polymeric Tubing
Chlorine Trifluoride Potassium Carbide
Chromium Potassium Chlorate
Ferrous Oxide Rubidium Carbide
Fluorine Sodium
Halogens or Interhalogens Sodium Carbide
Lithium Acetylene Carbide Diammino Sodium Hydride
Lithium Nitrate Tin Monoxide
and pressures.
Notify safety personnel of significant leaks. Exclude all from area except those assigned to leak and
spill control who are using full protective gear (see Section VIII). Provide ventilation. Locate and control
leakage.
If water is used to knock-down vapors, it will be corrosive and toxic, and should be diked for
containment. Add suitable agent to neutralize to 7 pH prior to disposal.

SULFUR DIOXIDE
limits. (Treatment of exhausted air to remove SO2 may be necessary before discharge
to the outside environment.)
Respirator: For fire fighting and other immediately dangerous to life or health conditions:
Self-contained breathing apparatus with full facepiece operated in

pressure-demand or other positive pressure mode.
Supplied-air respirator with full facepiece and operated in pressure-demand or

other positive pressure mode in combination with an auxiliary self-contained
breathing apparatus operated in pressure-demand or other positive pressure
mode.
(An approved cartridge respirator can be used when contamination is known to

be below 20 PPM.)
Clothing: Wear protective clothing. Prevent any possibility of repeated or prolonged vapor
contact with skin.
Gloves: Wear full protective gloves.
Eye Protection: Employee must wear splash-proof or dust-resistant safety goggles and a faceshield to
Where there is any possibility that an employee's eyes may be exposed to this
substance, the employer shall provide an eye-wash fountain within the immediate work
area for emergency use.
Disclaimer

SULFUR
Substance: SULFUR CAS Number: 7704-34-9
Trade Names / Synonyms: Asulfa-Supra; Bensulfoid; Brimstone; Colloidal Sulfur; Cosan; Devisulphur;
Flowers of Sulfur; Ground Vocle Sulphur; Hexasul; Kumulus; Microwetsulf;
Precipitated Sulfur; Precipitated Sulphur; S-590; S-594; S-595;
Solid Sulfur; Solid Sulphur; Sublimed Sulfur; Sublimed Sulphur; Sulfex;
Sulfran; Sulphur; Uni350
Molecular Formula: S Molecular Weight: 32.06
General or Generic ID: Non-metallic Element
Component: Sulfur Percent: > 99.0
Other Contaminants: Hydrogen Sulfide, Sulfur Dioxide, Hydrocarbons, Carbon
Exposure Limits: The Nuisance Dust TLV should govern exposure to solid sulfur in the absence of
other standards:
10 mg/m3 (8 PPMW) ACGIH TWA for total dust

5 mg/m3 (4 PPMW) ACGIH TWA for respirable dust
Liquid sulfur may release hydrogen sulfide and/or sulfur dioxide as gases. Refer
to the specific Material Safety Data Sheets for these substances giving the
applicable exposure limits.
Description: Solid sulfur is odorless, tasteless, yellow rhombic or monoclinic crystals, lumps,
granules, or powder. Sulfur contaminated with hydrocarbon or carbon may be
orange, green, tan, brown, or black in color. Liquid sulfur is viscous and odorless,
with a color ranging from bright yellow to dark orange (almost red) depending on
temperature. Contaminants (particularly hydrogen sulfide) sometimes give sulfur
the odor of rotten eggs.
Melting Point: 246°F (119°C) Boiling Point: 832°F (444°C)
Liquid Specific Gravity: 1.80 Solid Specific Gravity: 2.07

(water = 1.0) (water = 1.0)
Vapor Pressure: 0.05 PSIA (2.50 mm Hg) @ 400°F (204°C)
Odor Threshold: N/A
Solubility in Water: Negligible

SULFUR
SECTION III- PHYSICAL DATA (continued)
Other Solvents: Other Solvents:

Slightly soluble in Ethyl Alcohol; Ethyl Ether; Benzene; Toluene; Olive Oil.
Other Physical Data: At temperatures up to about 317°F (158°C), the viscosity of pure liquid sulfur
decreases as the temperature increases. As the temperature increases from
317°F to 370°F (158°C to 188°C), the viscosity of pure liquid sulfur rises rapidly to
a tremendously high maximum, causing the liquid to become a dark, sticky,
plastic material impossible to pump.
SECTION IV - FIRE AND EXPLOSION INFORMATION
Fire and Explosion Hazard: Solid - The primary hazard in handling solid sulfur results from the fact that
sulfur dust suspended in the air ignites easily. Even though the explosion
hazard is considered moderate, an explosion occurring in a confined area
could cause considerable damage.
Sulfur, being a very poor conductor of electricity, tends to develop static

electric charges when it is in motion. Ignition of sulfur dust by static-caused
sparks is not uncommon. Frictional heat in equipment has also been
responsible for starting sulfur fires.
Liquid - The fire hazards of liquid sulfur result primarily from the low ignition
point of sulfur and from the presence of hydrogen sulfide.
Auto-Ignition Temperature: 450°F (232°C) for liquid sulfur

374°F (190°C) for sulfur dust suspended in air
Flash Point Temperature: 405°F (207°C)
Explosive Limits in Air: Lower: 35 g/m3 (2.9% by wt) Upper: 1400 g/m3 (53% by wt)
Extinguishing Media: Small Fires: Water, dry chemical, soda ash, or sand.
(1987 Emergency Response Guidebook, DOT P 5800.4)
Larger fires: Use water spray, fog, or standard foam.

(1987 Emergency Response Guidebook, DOT P 5800.4)
Steam smothering can be used in storage pits and other relatively small
enclosures. Carbon dioxide is also a satisfactory fire extinguishing agent.
Fire-Fighting Procedures: Straight streams of water from a nozzle can scatter molten sulfur and
disperse sulfur dust into the air. Sulfur dust is a moderate explosion hazard
when dispersed in air. As sulfur burns, it generates sulfur dioxide, a toxic
gas. Wear self-contained breathing apparatus.
Unusual Hazards: Small dust explosions may disperse larger quantities of dust into the air,
resulting in a serious explosion, particularly in confined areas.

SULFUR
SECTION V- HEALTH HAZARD DATA
Permissible Exposure Level: None indicated.
Threshold Limit Value: None indicated.
Swallowing: Acute Exposure - A man has survived ingestion of 60 grams of sulfur over a period of
24 hours. Large doses (15 grams) by mouth may lead to hydrogen sulfide production
in vivo, chiefly due to bacterial action within the colon. Small particles are generally
more toxic than large ones. If high levels of impurities are present, sore throat, nausea,
headache, dullness, and possible unconsciousness may occur.
Chronic Exposure - In medicine, it is used as a laxative. No adverse effects have been

reported.
Inhalation: Irritant.
Acute Exposure - Inhalation of large amounts of dust may cause catarrhal inflammation
of the nasal mucosa which may lead to hyperplasia with abundant nasal secretions.
Tracheobronchitis is a frequent occurrence, with dyspnea, persistent cough, and
expectoration, which may sometimes be streaked with blood.
Chronic Exposure - Prolonged inhalation of dust may cause bronchopulmonary

disease which, after several years, may be complicated by emphysema and
bronchiectasis. Early symptoms in sulfur miners often include upper respiratory tract
catarrh, with cough and expectoration which is mucoid and may even contain granules
of sulfur. Asthma is a frequent complication. The maxillary and frontal sinuses may be
affected; involvement is usually bilateral and pansinusitis may occur. Pulmonary
function may be reduced. Radiological examinations have revealed irregular opacities
in the lungs and occasionally nodulation has been reported.
Eye Contact: Irritant.
Acute Exposure - 8 PPM has caused irritation of human eyes. Dust may cause
irritation, redness and pain with lacrimation, photophobia, conjunctivitis, and
blepharoconjunctivitis; cases of damage to the crystalline lens have been reported
with the formation of opacities and even cataract and focal chorioretinitis.
Chronic Exposure - Low levels may cause conjunctivitis. Higher levels may cause
symptoms similar to acute exposure.

SULFUR
SECTION V - HEALTH HAZARD DATA (continued)
Skin Contact: Irritant.
Acute Exposure - In highly purified form, the dust is low in irritation effects, but
frequently impurities of hydrogen sulfide are present and may produce irritation or
possibly burns.
Chronic Exposure - Soaps, ointments, gels, and drugs containing sulfur are used as
fungicides and parasiticides in the treatment of cutaneous disorders such as psoriasis,
seborrhea, eczema-dermatitis, and scalp disorders. Sulfur possesses a keratolytic
property which may be the basis of its therapeutic reaction. Prolonged local use of
sulfur may result in characteristic dermatitis venenata, possibly with erythematous and
eczematous lesions and signs of ulceration.
Molten sulfur - Capable of inflicting severe burns.
First Aid Measures
Swallowing: Give water or fluids. Emesis is not necessary. Treat supportively and symptomatically.
If irritation or digestive upset occurs, get medical attention.
Inhalation: Remove from exposure area to fresh air immediately. If breathing has stopped,
perform artificial respiration. Keep person warm and at rest. Get medical attention
immediately.
Eye Contact: Wash eyes immediately with large amounts of water, occasionally lifting upper and
lower lids, until no evidence of chemical remains (approximately 15-20 minutes). Get
medical attention immediately.
Skin Contact: Remove contaminated clothing and shoes immediately. Wash affected area with soap
or mild detergent and large amounts of water until no evidence of chemical remains
(approximately 15-20 minutes). Get medical attention immediately.

SULFUR
Incompatibilities: Alkali Metal Nitrides: Highly flammable mixture which evolves

ammonia and hydrogen sulfide in contact with
water.
Aluminum Powder: Possible explosion if ignited with a magnesium
fuse.
Aluminum Powder: Violent reaction.
Aluminum and Copper: Possible explosion when heated in a closed
container.
Aluminum and Niobium Oxide: Ignition.
Ammonia: Possible formation of an explosive product.
Ammonia Nitrate: Possible explosion on impact.
Ammonia Perchlorate: Possible explosion on impact.
Barium Bromate: When both are finely divided, explosion with heat,
percussion, or friction.
Barium Carbide: Ignites in sulfur vapor at 150°C and incandesces.
Barium Chlorate: Possible spontaneous ignition at 108°C. When
both are finely divided, explosion with heat,
Barium Iodate: When both are finely divided, explosion with heat,
Boron: Incandesces at 600°C.
Bromine Pentafluoride: Violent reaction with possible ignition.
Bromine Trifluoride: Incandescence on contact.
Cadmium: Vigorous reaction.
Calcium: Burns in the vapor at 400°C. Explodes on
ignition.
Calcium Bromate: When both are finely divided, explosion with heat,
Calcium Carbide: Ignites in the vapor at 400°C.
Calcium Chlorate: When both are finely divided, explosion with heat,
Calcium Hypochlorite Powder: Explosion if heated in closed vessel.
Calcium Hypochlorite: With damp sulfur, produces a crimson flash with
scattering of molten sulfur.
Calcium Iodate: When both are finely divided, explosion with heat,
Calcium Phosphide: Incandesces at 300°C.
Calcium, Vanadium Oxide, and Ignition.
Water:
Cesium Nitride: Intense reaction.
Charcoal, Freshly Calcined: Ignites spontaneously.
Chlorate and Copper: Probable explosion.
Chlorine Dioxide: Ignition and possible explosion.
Chlorine Monoxide: Violent explosion.

SULFUR
SECTION VI - REACTIVITY DATA (continued)
Incompatibilities: Chlorine Trifluoride: Violent reaction with possible ignition.

(continued) Chlorine Trioxide: Possible violent reaction.
Chromic Anhydride: Ignition on heating, possible explosion.
Chromium Trioxide: Ignition on warming.
Chromyl Chloride: Ignition.
Copper: Attacked corrosively.
Copper Alloy: Attacked corrosively.
Diarsenic Trisulfide: Formation of explosion mixture.
Dichlorine Monoxide: Probable explosion.
Diethyl Ether: Possible explosion on evaporation.
Fiberglass and Iron Filings: Exothermic reaction above 125°C.
Fluorine: Ignition at ambient temperatures.
Halogen Oxides: Possible explosion.
Heptasilver Nitrate Octaoxide: Explosion on impact.
Hydrocarbons: Explosive products produced on contact with
molten sulfur.
Indium: Ignition and incandescence on heating.
Interhalogens: Possible ignition or incandescent reaction.
Iodine Pentafluoride: Incandescence on contact.
Iodine Pentoxide: Explosive reaction on warming.
Lampblack: Spontaneous ignition.
Lead Chlorate: Possible spontaneous ignition at 63°C.
Lead Chloride: Explosion.
Lead Chlorite: Explosion.
Lead Chromate: Pyrophoric mixture.
Lead Dioxide: Explosion.
Lead (IV) Oxide: Ignition on grinding or addition of sulfuric acid.
Lithium: When either is molten, explosively violent
reaction.
Lithium dissolved in Ammonia: Vigorous reaction, even at -33°C.
Lithium Carbide: Burns in sulfur vapor.
Magnesium: Vigorous reaction with molten sulfur or its vapor.
Magnesium Bromate: When both are finely divided, explosion with heat,
Magnesium Chlorate: When both are finely divided, explosion with heat,
Magnesium Iodate: When both are finely divided, explosion with heat,
Mercuric Nitrate: Possible explosion.
Mercuric Oxide: Explosion when heated.
Mercurous Oxide: Ignition on light impact.
Mercury (I) Oxide: Ignition on frictional initiation.
Mercury (II) Oxide: Explosion on heating.
Metal Acetylides of Carbides: Possible ignition.
Metal Chlorates: Powerfully explosive, sensitive to friction or
shock.

SULFUR
Incompatibilities: Metal Halogenates: Possible violent or explosive reaction.

(continued) Metal Oxides: Possible ignition or explosion on initiation.
Metals: Possible ignition or explosion.
Monorubidium Acetylide: Ignites in molten sulfur.
Nickel Powder: Ignition and incandescence in boiling sulfur or its
vapor at 600°C.
Nitrogen Dioxide: Sulfur burns vigorously.
Osmium: Ignition and incandescence in boiling sulfur or its
vapor at 600°C.
Oxidants: Possible ignition or explosion.
Palladium: Ignition and incandescence on heating.
Perchlorates (Inorganic): Explosive on impact.
Permanganates: Formation of an explosive mixture.
Phosphorus: Ignition or explosion.
Phosphorus, Red: Violent exothermic reaction or explosion.
Phosphorus, Yellow: Ignition or explosion on heating.
Phosphorus Trioxide: Violent reaction or explosion.
Potassium: Violent reaction on warming.
Potassium: Vapors of both react with chemiluminescence at
300°C and low pressure.
Potassium Bromate: Unstable mixture which may ignite after several
hours. When both are finely divided, explosion
may occur with heat, percussion, or friction.
Potassium Chlorate: Ignition at 160-162°C. When both are finely
divided, explosion with heat, percussion, or
friction.
Potassium Chlorite: Violent reaction.
Potassium Iodate: When both are finely divided, explosion with heat,
Potassium Nitrate and Arsenic Pyrotechnic formulation.
Trisulfide:
Potassium Nitride: Highly flammable mixture which evolves
ammonia and hydrogen sulfide.
Potassium Perchlorate: Explosion on moderately strong impact.
Potassium Permanganate: Possible explosion on heating.
Rhodium: Ignition and incandescence on heating.
Rubidium (Molten): Ignition in the vapor at 200-300°C.
Rubidium Acetylene Carbide: Ignition.
Selenium: Ignition.
Selenium Carbide: When heated, incandesces with the vapor.
Silver Bromate: Ignition at 73-75°C. Explosive reaction in
presence of water.
Silver Chlorate: Possible spontaneous ignition. Ignition at 74°C.
Silver Chlorite: Explosion on rubbing.
Silver Nitrate: Explosion on percussion.

SULFUR
Incompatibilities: Silver Oxide: Ignition on grinding.

(Continued) Sodium: Violent or explosive reaction with heat or friction.
Sodium Bromate: When both are finely divided, explosion with heat,
Sodium Chlorate: When both are finely divided, explosion with heat,
Sodium Chlorite: Ignition in presence of water.
Sodium Hydride: Vigorous reaction with vapors.
Sodium Iodate: When both are finely divided, explosion with heat,
Sodium Nitrate and Charcoal: Explosion.
Sodium Peroxide: Explosive mixture.
Stannic Iodide and Potassium: Explosion on impact.
Stannic Iodide and Sodium: Explosion on impact.
Static Discharges: Easily ignited due to very low minimum ignition
energy.
Steel: Attacked corrosively in presence of moisture.
Strontium Carbide: Incandescence or ignition in vapors about 500°C.
Strontium Carbide and Selenium: Incandescence at 500°C.
Sulfur Dichloride: Very violent explosion on impact.
Tetraphenyllead: Possible explosion.
Thallic Oxide: Explosion on grinding.
Thorium: Ignition and incandescence with heating.
Thorium Carbide: Incandesces when heated. Ignites in the vapors
about 500°C.
Tin: Vigorous reaction with incandescence. Ignition
on heating.
Uranium: Incandescence and ignition with boiling sulfur or
its vapor.
Uranium Carbide: Ignition in the vapors about 500°C.
Zinc Bromate: When both are finely divided, explosion with heat,
Zinc Chlorate: When both are finely divided, explosion with heat,
Zinc Iodate: When both are finely divided, explosion with heat,
Zinc Powder: Explosive reaction on warming.
Decomposition: Combustion may release toxic oxides of sulfur, some of which may react with air and
moisture to produce corrosive sulfurous and sulfuric acids. Toxic and corrosive
hydrogen sulfide may be generated by molten sulfur.
and pressures.

SULFUR
Small Spill: Shut off ignition sources. Do not touch spilled material. With clean shovel, place material
into clean, dry container and cover; move containers from spill area.
Large Spill: Shut off ignition sources. Do not touch spilled material. Wet down with water and dike
for later disposal. No smoking, flames, or flares in hazard area! Keep unnecessary
people away. Isolate hazard area and deny entry.
Waste should be mixed with four times its weight of crushed limestone, marble, or shell, and then buried
at a permitted disposal site.
SECTION VIII- PROTECTIVE EQUIPMENT TO BE USED
Respirator: In routine handling of molten sulfur in adequately ventilated premises, respiratory

protective equipment is not required, but should be available nearby.
For areas containing sulfur dust, the specific respirator selected must be based on the
contamination levels found in the work place, must not exceed the working limits of
the respirator, and be jointly approved by the National Institute for Occupational Safety
and Health and the Mine Safety and Health Administration.
The following respirators are recommended based on the data found in the Physical
Data and Health Hazard Data sections. They are ranked in order from minimum to
maximum respiratory protection:
Chemical cartridge respirator with an organic vapor cartridge(s) with a high-

efficiency particulate filter and full facepiece.
High-efficiency particulate respirator with a full facepiece.
Powered air-purifying respirator with a high-efficiency filter with a full facepiece.
Type "C" supplied-air respirator with a full facepiece operated in

pressure-demand or other positive pressure mode, or with a full facepiece,
helmet, or hood operated in continuous-flow mode.
Self-contained breathing apparatus with a full facepiece operated in


SULFUR
SECTION VIII- PROTECTIVE EQUIPMENT TO BE USED
Respirator: For firefighting and other immediately dangerous to life or health conditions:
(continued)
Self-contained breathing apparatus with a full facepiece operated in
Supplied-air respirator with a full facepiece operated in pressure-demand or other

positive pressure mode in combination with an auxiliary self-contained breathing
apparatus operated in pressure-demand or other positive pressure mode.
Clothing: Employees operating equipment containing molten sulfur should wear clothing capable
of protecting the chest and arms, trousers without cuffs, and high-top shoes. When
making connections or other changes in molten sulfur piping, leather protective clothing
may be needed.
Gloves: Employee must wear heat-resistant gloves when working with molten sulfur.
Eye Protection: Employee must wear splash-proof or dust-resistant safety goggles to prevent eye
contact with this substance. When making connections or other changes in molten
sulfur piping, full face shields (in addition to safety glasses or goggles) should be worn.
Disclaimer

AMMONIA
Substance: AMMONIA CAS Number: 7664-41-7
Trade Names / Synonyms: Ammonia Anhydrous; Ammonia Gas; Spirit of Hartshorn
Molecular Formula: NH3 Molecular Weight: 17.03
Component: Ammonia Percent: > 99.0
Other Contaminants:
Exposure Limits: Ammonia

50 PPM OSHA TWA per 8-hour working day
35 PPM ACGIH STEL
50 PPM NIOSH recommended 5 minute ceiling
Description Colorless gas at atmospheric temperature and pressure, with a pungent odor.
Melting Point: -108°F (-78°C) Boiling Point: -28°F (-33°C)

(water = 1.0) (air = 1.0)
Vapor Pressure: 147 PSIA (10 atm) @ 78°F (25°C)
Odor Threshold: 20 PPM
Solubility in Water: 579 g/l @ 60°F (15°C), 444 g/l @ 68°F (20°C)
Other Solvents:

AMMONIA
SECTION IV - FIRE AND EXPLOSION INFORMATION
Fire and Explosion Hazard: Ammonia is a low fire hazard when exposed to heat or flame
because it is difficult to ignite. It is a moderate explosion hazard
when exposed to flame or fire. Air-ammonia mixtures can detonate
in a fire.
Auto-Ignition Temperature: 1204°F (651°C) Flash Point Temperature: N/A
Explosive Limits in Air: Lower: 15% Upper: 28%
Extinguishing Media: Water Fog.
Hazardous Decomposition Products: Toxic fumes of NH3 and NOX.
Fire-Fighting Procedures: Stop flow of gas. Wear self-contained breathing apparatus with a
full facepiece operated in pressure-demand mode and full body
protection when fighting fires.
SECTION V- HEALTH HAZARD DATA
Inhalation: The life hazard from ammonia is due to its damage to the lungs when inhaled. When
inhaled, ammonia is both an irritant and an asphyxiant, and can cause respiratory
distress. Ammonia can usually be detected at levels of 20-50 PPM. There will be
noticeable irritation of the eyes and nasal passages when exposed to 100 PPM, and
severe irritation of the throat, nasal passages, and upper respiratory tract at 400 PPM.
At 1700 PPM, there will be severe coughing and bronchial spasms, and an exposure of
30 minutes or less may be fatal. Concentrations of 5000 PPM and above are fatal
almost immediately, causing serious edema of the lungs, strangulation, and
asphyxiation.
Eye Contact: This gas is dangerous to the eyes, as it causes irritation at 40-100 PPM. Prolonged
exposure to 700 PPM or more can cause extensive injuries to the eyes - irritation,
hemorrhages, swollen lids, corneal ulcers, even partial or total loss of sight.
Skin Contact: Ammonia will irritate the skin, particularly if the skin is moist, to the point of causing
chemical burns from prolonged exposure.

AMMONIA
First Aid Measures
Inhalation: Where breathing is weak, administer oxygen or mixtures of carbon dioxide and oxygen,
containing not more than 5% carbon dioxide. It should be administered intermittently
for periods of two minutes over a total time not to exceed fifteen minutes. If breathing
has ceased, start artificial respiration immediately, by trained personnel only. Artificial
respiration, when administered by an inexperienced person, is definitely hazardous
following exposure to ammonia, and should be avoided where possible. The use of a
pulmotor is definitely not recommended as its more violent action will irritate and may
severely injure the lungs. A resuscitator used with oxygen and operated by a trained
person is recommended. Keep the patient warm and still, and get medical attention
immediately.
Eye Contact: Hold the lids open and pour clean water over the eyeball and lids (or use an eye
irrigation fountain). Wash thoroughly in this way for 15 minutes. A doctor, preferably
an eye specialist, should be summoned immediately
Skin Contact: Speed is essential. Strip the ammonia-saturated clothing from the body immediately.
Flood affected areas continuously with clean water for at least 15 minutes. Do not
cover burns with clothing or dressings. Allow them to remain open to the air.

AMMONIA
Incompatibilities: Acetaldehyde Nitrogen Dioxide

Acrolein Nitrogen Tetraoxide
Ammonium Peroxo Disulfate Nitrogen Trichloride
Antimony Nitrogen Trifluoride
Antimony Hydride Nitryl Chloride
Boron Oxygen + Platinum
Boron Halides Oxygen Difluoride
Boron Triiodide Phosphorus Pentoxide
Bromine Pentafluoride Phosphorus Trioxide
Chloric Acid Picric Acid
Chlorine Azide Potassium + Arsine
Chlorine Monoxide Potassium + Phosphine
Chlorine Trifluoride Potassium + Sodium Nitrite
Chlorites Potassium Chlorate
Chlorosilane Potassium Ferricyanide
Chromium Trioxide Potassium Mercuric Cyanide
Chromyl Chloride Silver
Dichlorine Oxide Silver Chloride
Ethylene Dichloride + Liquid Ammonia Silver Nitrate
Ethylene Oxide Silver Oxide
Gold Sodium + Carbon Monoxide
Gold (III) Chloride Sulfur
Halogens Sulfur Dichloride
Hexachloromelamine Tellurium
Hydrazine + Alkali Metals Tellurium Chloride
Hydrogen Bromide Tellurium Hydropentachloride
Hydrogen Peroxide Tetramethyl Ammonium Amide
Hypochlorous Acid Thionyl Chloride
Magnesium Perchlorate Thiotrithiazyl Chloride
Mercury Trichloromelamine
Nitric Acid Trioxygen Difluoride
Polymerization: Cannot occur.
SECTION VII - SPILL OR LEAK PROCEDURES

Notify safety personnel of significant leaks. Exclude all from area except those assigned to leak and spill
control who are using full protective gear (see Section VIII). Provide ventilation. Locate and control
leakage.

If water is used to knock-down vapors, it will be corrosive and toxic, and should be diked for containment.
Add suitable agent to neutralize to 7 pH prior to disposal.

AMMONIA
Respirator: If work place exposure limit(s) of product or any component is exceeded (see Section
II), a NIOSH/MSHA approved air supplied respirator is advised in absence of proper
environmental control. OSHA regulations also permit other NIOSH/MSHA respirators
(negative pressure type) under specified conditions (see your safety equipment
supplier). Engineering or administrative controls should be implemented to reduce
exposure.
Clothing: To prevent repeated or prolonged skin contact, wear impervious clothing and boots.
Gloves: Wear resistant gloves such as neoprene, nitrile rubber, butyl rubber.
Eye Protection: Employee must wear splash-proof or dust resistant safety goggles and a faceshield to
Where there is any possibility that an employee's eyes may be exposed to this
substance, the employer shall provide an eye-wash fountain within the immediate work
area for emergency use.
DISCLAIMER
The information contained herein is believed to be accurate, but is not warranted to be, whether originating within the company or not. Health and safety precautions in this data
sheet may not be adequate for all individuals and/or situations. Recipients are advised to confirm in advance of need that the information is current, applicable, and suitable to their
circumstances. It is the end user's responsibility to evaluate and use this product safely, and to comply with all applicable laws and regulations. No statement made in this data
sheet shall be construed as a permission or recommendation for use of any product in a manner that might infringe existing patents. No warranty is made, either expressed or
implied.

METHYLDIETHANOLAMINE
Substance: METHYLDIETHANOLAMINE CAS Number: 105-59-9
Trade Names / Synonyms: MDEA; n-Methyldiethanolamine; n-Methyliminodiethanol;

n-Methyl-2,2'-iminodiethanol; N,N-di(2-hydroxyethyl)-N-methylamine; 2,2'-
(Methylimino) bis-ethanol
Molecular Formula: CH3-N-(CH2CH2OH)2 Molecular Weight: 119.17
General or Generic ID: Organic Base
Component: Methyldiethanolamine Percent: > 99.0
Other Contaminants: Often stored and transported as an aqueous solution containing about 10% water
by weight.
Exposure Limits: Methyldiethanolamine
There are no standards or regulations concerning MDEA.
Description: Clear, colorless, viscous liquid.
Melting Point: -6F (-21C) Boiling Point: 477F (247C)
Liquid Specific Gravity: 1.042 Vapor Specific Gravity 4.11

(water = 1.0) (air = 1.0)
Vapor Pressure: < 0.0002 PSIA (0.01 mm Hg) @ 68F (20C)
Odor Threshold: MDEA has a slight ammoniacal odor.
Solubility in Water: MDEA is completely soluble in water.
Other Solvents:


Fire and Explosion Hazard: MDEA is considered a slight fire hazard when exposed to heat or flame.
Auto-Ignition Temperature: N/A Flash Point Temperature: 260F (127°C)
Explosive Limits in Air: not determined
Extinguishing Media: Small Fire - dry chemical or CO2.

Large Fire - water fog, alcohol foam, polymer foam, ordinary foam.
Fire-Fighting Procedures: Wear positive pressure, self-contained breathing apparatus.

Permissible Exposure Level: None established.
Threshold Limit Value: None established.
Swallowing: Single dose oral toxicity is low. The oral LD50 for rats is 4780 mg/kg for MDEA.
Amounts ingested incidental to industrial handling are not likely to cause injury;
however, ingestion of larger amounts may cause injury. Ingestion of MDEA can
cause nausea, vomiting, and abdominal discomfort.
Inhalation:: At room temperature, exposure to vapors is unlikely due to physical properties.

Higher temperatures may generate vapor levels sufficient to cause irritation.
Eye Contact: May cause moderately severe irritation with corneal injury.
Skin Contact: Prolonged or repeated exposure may cause skin irritation, even a burn. A single
prolonged exposure is not likely to result in the material being absorbed through
skin in harmful amounts. The dermal LD50 has not been determined.
Systemic Effects: Repeated excessive exposures may cause kidney effects.
First Aid Measures
Swallowing: Induce vomiting if large amounts are ingested. Consult medical personnel.
Inhalation: Remove to fresh air if effects occur. Consult a physician.
Eye Contact: Flush eyes with large amounts of water for at least 15 minutes. Take the patient to a
physician, preferably an eye specialist, at once.
Skin Contact: Flush the affected area with plenty of water. If exposure has produced a burn, it
should be treated like a thermal burn, with treatment based on the physician's
judgement. Contaminated clothing should be removed and washed before reuse.
Contaminated leather articles (shoes, belts, etc.) should be removed and destroyed.
Reactivity: Stable under normal storage conditions.
Incompatibilities: Incompatible with strong oxidizers and strong acids. Do not allow
MDEA to contact sodium nitrite (NaNO2) or other nitrosating
agents, as nitrosamines (suspected cancer-causing agents) could
be formed.
Hazardous Decomposition Products: Nitrous oxides, carbon monoxide, and/or carbon dioxide.
Polymerization Hazardous polymerization will not occur.
Wear suitable protective equipment, especially eye protection. Collect for disposal. Toxic to fish; avoid
discharge to natural waters.
Burn in approved incinerator. Follow all local, state, and federal requirements for disposal.
Ventilation: General (mechanical) room ventilation is expected to be satisfactory.
Respirator: None required in normal use. If irritation of the nose and/or respiratory system is
experienced, use an approved air-purifying respirator.
Clothing: Use protective clothing impervious to this material. Selection of specific items such as
boots, apron, or full-body suit will depend on operation.
Gloves: Use gloves impervious to this material, such as rubber.
Eye Protection: Use chemical goggles.
Avoid contact with eyes, skin, and clothing when handling and storing MDEA. Wash thoroughly after
handling.
Disclaimer

SODIUM HYDROXIDE

Substance: SODIUM HYDROXIDE CAS Number: 1310-73-2
Trade Names / Synonyms: Caustic; Caustic Soda; Caustic Soda Liquid; Liquid Caustic; Lye;
Lye Solution; Soda Lye; Sodium Hydrate; Quaker Caustic Blend;
White Caustic
Molecular Formula: NaOH Molecular Weight: 40.00
General or Generic ID: Alkali
Component: Sodium Hydroxide Percent: > 99.0
Other Contaminants: Often stored and transported as an aqueous solution. Common strengths are
25, 50, and 73 weight percent NaOH.
Exposure Limits: Sodium Hydroxide

2 mg/m3 (2 PPM) OSHA TWA for an 8-hour working day
2 mg/m3 (2 PPM) ACGIH ceiling
2 mg/m3 (2 PPM) NIOSH recommended ceiling

Description: Pure sodium hydroxide is a white solid. When dissolved in water, NaOH forms
a clear, colorless or water-white, strongly alkaline liquid. Neither form has an
odor.
Melting Point: Solid: 608°F (320°C)

25 wt% solution: -2°F (-19°C)
50 wt% solution: 50°F (10°C)
Boiling Point: Solid: 2534°F (1390°C)

Specific Gravity: Solid: 2.13

(water = 1.0) 25 wt% solution: 1.27
50 wt% solution: 1.53
Vapor Pressure: Solid: 0.02 PSIA (1 mm Hg) @ 1362°F (739°C)
Odor Threshold: N/A
Solubility in Water: At 60°F (15°C), more than 50 wt% will dissolve in water.
Other Solvents:

SODIUM HYDROXIDE
Fire and Explosion Hazard: Sodium hydroxide and its water solutions are not flammable. However,
adding water to NaOH or solutions of NaOH can cause localized
overheating due to its heat of dilution.
Sodium hydroxide will generate gaseous hydrogen (which is flammable

and/or explosive) when in contact with aluminum, copper, tin, zinc, and
their alloys.
Auto-Ignition Temperature: N/A Flash Point Temperature: N/A
Explosive Limits in Air: Lower: N/A Upper: N/A
Extinguishing Media: Not combustible. Use extinguishing agents as may be suitable for
material in surrounding fire.
Fire-Fighting Procedures: Not combustible. Use clothing and safety equipment as may be suitable
for sodium hydroxide and materials in the surrounding fire.
Permissible Exposure Level: 2 mg/m3 (approximately 2 PPMW)
Threshold Limit Value: 2 mg/m3 (approximately 2 PPMW) ceiling
Swallowing: Acutely toxic if swallowed, causing severe burns and scarring to the mouth,
throat, esophagus, and stomach, and may lead to death. Squamous cell
carcinoma of the esophagus can occur years after the exposure.
Inhalation: Inhalation of dust or mist can cause injury to the entire respiratory tract. The
effects of inhalation depend on the severity of the exposure, ranging from mild
irritation of the mucous membranes to severe pneumonitis.
Eye Contact: Contact with the eyes may cause irritation and, with greater exposure, severe
burns and possible blindness.
Skin Contact: Skin contact may cause burns, frequently with deep ulceration and scarring.
Prolonged contact, even with dilute solutions, can cause tissue damage.

SODIUM HYDROXIDE
First Aid Measures
Swallowing: Do not induce vomiting - this will cause further damage to the throat and
esophagus. Dilute by giving water to the patient immediately. Vinegar, 1% acetic
acid solution, citrus fruit juices, or 5% citric acid solution may also be administered
to help neutralize the alkaline solution. Follow this with milk, egg white in water, or
milk of magnesia. Keep the patient warm and still, and summon a physician
immediately.
Inhalation: Remove the patient to fresh air at once. If breathing has stopped, begin artificial
respiration immediately. Keep the patient warm and still, and summon a physician
immediately.
Eye Contact: Immediately begin flushing the eyes with large amounts of water, preferably with
an eye wash fountain. Continue flushing for at least 15 minutes, forcibly holding
the eyelids apart and rotating the eyeball, to ensure complete irrigation of all eye
and lid tissue. A physician, preferably an eye specialist, should be summoned
immediately.
Skin Contact: Immediately flush the affected areas with large amounts of water. If large areas of
the body are contaminated, or if clothing has been penetrated to the skin,
immediately use a safety shower, preferably removing clothing while under the
shower. Continue flushing the areas for at least 15 minutes. If available, follow
the water flush with a generous application of vinegar or 1% acetic acid solution to
neutralize the residual NaOH. After the acid treatment, apply a good protective
dressing as with any other burn and take the patient to a physician. Contaminated
clothing should be washed before reuse. Contaminated leather articles (shoes,
belts, etc.) should be discarded.

SODIUM HYDROXIDE
Reactivity: Stable.
Incompatibilities: Acetaldehyde Hydroquinone

Acetic Acid Magnesium
Acetic Anhydride Maleic Anhydride
Acrolein Methanol + Tetrachlorobenzene
Acrylonitrile 4-Methyl-2-nitrophenol
Allyl Alcohol 3-Methyl-2-penten-4-yn-1-ol
Allyl Chloride Nitric Acid
Aluminum Nitroethane (forms shock-sensitive salts)
Chlorine Trifluoride Nitromethane (forms shock-sensitive salts)
Chloroform + Methanol Nitroparaffins (forms shock-sensitive salts)
Chlorohydrin (Chlorhydrin) Nitropropane (forms shock-sensitive salts)
4-Chloro-2-methylphenol Oleum (fuming Sulfuric Acid)
Chloronitrotoluene Pentol
Chlorosulfonic Acid Phosphorus
(Chlorosulfuric Acid) Phosphorus Pentoxide
Cinnamaldehyde ß-Propiolactone (2-Oxetanone)
Copper Strong Mineral or Organic Acids
Cyanogen Azide Sulfuric Acid
Diborane (Boron Hydride) 1,2,4,5-Tetrachlorobenzene
1,2-Dichloroethylene Tetrahydrofuran
Difluoroethane Tin
Ethylene Cyanohydrin 1,1,1-Trichloroethanol
(Hydracrylonitrile) Trichloroethylene
Glyoxal Trichloronitromethane
Hydrochloric Acid Trifluoride
(Hydrogen Chloride) Water
Hydrofluoric Acid Zinc
(Hydrogen Fluoride) Zirconium
Polymerization: Hazardous polymerization cannot occur.
Other Hazards: Adding water to sodium hydroxide or sodium hydroxide solutions may cause
localized overheating and spattering.

SODIUM HYDROXIDE
Cleanup personnel must wear proper protective equipment (refer to Section VIII). Completely contain
spilled material with dikes, sandbags, etc., and prevent run-off into ground or surface waters or
sewers. Recover as much material as possible into containers for disposal. Remaining material may
be diluted with water and neutralized with dilute hydrochloric acid. Neutralization products, both liquid
and solid, must be recovered for disposal.
Recovered solids or liquids may be sent to a licensed reclaimer or disposed of in a permitted waste
management facility. Consult federal, state, or local disposal authorities for approved procedures.
Ventilation: Ventilation is not usually required for caustic solutions. Avoid creation of mist or
spray. If present, wear appropriate safety clothing and provide local exhaust
systems.
Respirator: Provide mist protection where applicable. Use NIOSH or MSHA approved
respirators.
Clothing: Employees should wear impervious rubber, neoprene, or vinyl boots, overalls, and/or
full-body suits.
Gloves: Use impervious rubber, neoprene, or vinyl gloves.
Eye Protection: Use chemical goggles and face shield.
When diluting sodium hydroxide, use agitation (mixing) and add the concentrated sodium hydroxide to
water at a controlled rate to control the heat of dilution and avoid spattering. Never add water to sodium
hydroxide.
Disclaimer

1. CHEMICAL PRODUCT AND COMPANY INFORMATION
Product Name: Activated Alumina S-2001/ESM-221

Product Use: Alumina
ASM Catalysts, LLC Euro Support B.V.

8550 United Plaza Blvd., Suite 702 Kortegracht 26
Baton Rouge, LA 70809-0200 3811 KH Amersfoort
USA The Netherlands
Tel.: +1-225-752-4276 Tel: +31-33-4650465
Fax: +1-225-922-4550 Fax: +31-33-4650721
2. HAZARDS IDENTIFICATION
Emergency Overview:
Repeated or prolonged exposure may irritate eyes, skin and respiratory system. The product gets hot as it first adsorbs
water.
Form: Spheres
Color: White
Potential Health Effects:
Primary Routes of Exposure: Contact with skin and eyes. Exposure may also occur via inhalation or
ingestion if product dust is generated.
Eye Contact: Dust and/or product may cause eye discomfort and/or irritation seen as tearing and reddening.
Skin Contact: Repeated or prolonged exposure may cause skin irritation.
Ingestion: The product is considered to have a low order of oral toxicity.
Inhalation: Exposure to dust particles generated from this material may cause irritation of the respiratory tract.
Irritation may be accompanied by coughing and chest discomfort.
Chronic Effects: Prolonged or repeated inhalation of dust generated from this material may cause lung injury.
Activated Alumina S-2001/ESM-221 Revision Number: 1

Page 1 of 9 June 2008
Carcinogenicity Classification:
International Agency for Research on Cancer (IARC):

Neither the product nor the components are classified.
U.S. National Toxicology Program (NTP):

Neither the product nor the components are classified.
U.S. Occupational Safety and Health Administration (OSHA):

Neither the product nor the components are classified or regulated.
American Conference of Governmental Industrial Hygienists (ACGIH):

Aluminum oxide – Not Classifiable as a Human Carcinogen (A4).
3. COMPOSITION/INFORMATION ON INGREDIENTS
INGREDIENT % WEIGHT ACGIH TLV-TWA OSHA PEL-TWA UNITS
& CAS NO.
Aluminum oxide (non-fibrous) <95 1(R) 15 (TD) mg/m3
1344-28-1 5(R)
Water <10 N.E. N.E. N.A.
7732-18-5
Abbreviations:
N.A. - Not Applicable RD - Respirable Dust Fu - Fume IS - Insoluble
N.E. - None Established R - Respirable Fraction I - Inhalable FuD - Fume and Dust
STEL - Short Term Exposure Limit F - Respirable Fibers TD - Total Dust SC - Soluble Compounds
4. FIRST AID MEASURES

Eye contact: Flush immediately with plenty of water for at least 15 minutes. If eye irritation persists, consult a physician.
Skin contact: Wash off with soap and plenty of water. If skin irritation persists, call a physician.
After inhalation: Remove the victim into fresh air. If symptoms persist, call a physician.
After ingestion: Drink at least 2 glasses of water. Obtain medical attention. Never give anything by mouth to an
unconscious person.
Notes to physician: This product is a desiccant and generates heat as it adsorbs water. Symptomatic treatment is
advised. The used product can retain material of a hazardous nature. Identify that material and treat symptomatically.

5. FIRE FIGHTING MEASURES
Suitable extinguishing media: Non-combustible. Use extinguishing media for surrounding fire.
Unsuitable extinguishing media: N.A.
Fire and explosion hazards: The product itself does not burn. The used product can retain material of a hazardous
nature. Identify that material and inform the fire fighters.
Special protective equipment: In the case of respirable dust and/or fumes, use self-contained breathing apparatus and
dust impervious protective suit.
Flash point: N.A.
6. ACCIDENTAL RELEASE MEASURES

Personal protection: See Section 8.
Environmental precautions: No special environmental precautions required.
Clean-up: Sweep, shovel or vacuum spilled product into appropriate containers (do not use a vacuum if material has
contacted a hydrocarbon material). Pick-up and arrange disposal without creating dust. Never use spilled product. Spilled
product should be disposed of in accordance with all applicable government regulations.
7. HANDLING AND STORAGE

Handling: Handle and open container with care. Avoid formation of dust particles. Avoid contact with skin and eyes.
Provide an electrical ground connection during loading and transfer operations to avoid static discharge in an explosive
atmosphere and to prevent persons handling the product from receiving static shocks.
Storage: Store in original container. Keep in a dry place.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION

Engineering measures: Where natural ventilation is inadequate, especially in confined areas, use mechanical
ventilation, other engineering controls or respiratory protection to prevent inhalation of product dust.
Personal protection equipment: Handle in accordance with good industrial hygiene and safety practice.
Eye protection: Safety glasses or goggles.
Hand protection: Protective gloves.
Skin and body protection: Work uniform and gloves to prevent prolonged contact.
Respiratory protection: In case of insufficient ventilation, wear suitable respiratory equipment. Air-purifying
respirator with NIOSH classification N-95 filter or P-95 (or equivalent) if oil/liquid aerosols are present (42 CFR 84).

9. PHYSICAL AND CHEMICAL PROPERTIES
These data do not represent technical or sales specifications.
Form: Spheres Color: White
Odor: None pH: 9 – 11 (AS)
Boiling point/range: None Melting point/range: N.A.
Flash point: N.A. Autoignition temperature: N.A.
Bulk density: 38-60 lbs/ft3 Explosion limits: N.A.
Vapor pressure: N.A. Relative density/Specific gravity: 3.0
Vapor density: N.A. Viscosity: N.A.
Water solubility: Insoluble Solubility: N.D.
10. STABILITY
Stability: Stable
Hazardous Decomposition Products: No decomposition if used as directed. Hydrocarbons and other materials that
contact the product during normal use can be retained on the product. It is reasonable to expect that decomposition
products will come from these retained materials of use. If the product is subject to extreme temperatures or chemical
conditions, decomposition may occur and he product will include the oxides shown in Section 3.
Conditions/Materials to avoid: Reacts violently with chlorine trifluoride, producing flames. May cause ethylene oxide
to polymerize violently, releasing heat.

11. TOXICOLOGICAL INFORMATION
Acute toxicity:
LD50/oral/rat: No data available.
LD50/dermal/rabbit: No data available.
LD50/inhalation/rat: No data available.
Chronic toxicity: Classification of Ingredients
EC Carcinogenic: Carcinogenicity (ACGIH):

Not listed. A4 (Aluminum oxide)
EC Mutagenic: IARC classification:

Not listed. Not listed.
EC Toxic for Reproduction:

Not listed.
Routes of exposure: Exposure may occur via inhalation, contact with skin and eyes.
Irritation:
Skin (rabbit): No data available.
Eye (rabbit): No data available.
Additional product information:

Avoid repeated exposure.
Additional component information:

No data available.
12. ECOLOGICAL INFORMATION

Mobility: Biodegradation:
No data available. No data available.
Bioaccumulation: Aquatic toxicity:

No data available. No data available.
Further Information:
No information available.

13. DISPOSAL CONSIDERATIONS
Provisions relating to waste: EPA – Resource Conservation and Recovery Act (RCRA) Hazardous and Solid Waste
Management Regulations.
Disposal information: This product (in its fresh unused state) is not listed by generic name or trademark name in the
U.S. EPA’s RCRA regulations and does not possess ay of the four identifying characteristics of hazardous waste
(ignitability, corrosivity, reactivity or toxicity). Materials of a hazardous nature that contact the product during normal use
may be retained on this product. The user of the product must identify the hazards associated with the retained material
in order to assess the waste disposal options.
14. TRANSPORT INFORMATION

UN-No.: Proper shipping name: Packing group:
N.A. Not applicable. N.A.
Transport mode Class Additional Information Remarks
U.S. DOT: Not regulated. Reportable N.A. N.A.

Quantity:
Marine Pollutant DOT: No
ADR/RID: Not regulated. Danger Code: N.A. N.A.
IMDG: Not regulated. Marine pollutant: No N.A.

EmS: N.A.
IATA: Not regulated. Instr. Passenger: N.A. N.A.

Instr. Cargo: N.A.

15. REGULATORY INFORMATION
United States
Toxic Substances Control Act (TSCA): All the ingredients of this mixture are registered on the TSCA Chemical
Substance Inventory.
CERCLA (Comprehensive Environmental Response, Compensation, and Liability Act) Reportable Quantity:
The following component(s) of this product is/are subject to release reporting under 40 CFR 302 when release exceeds
the Reportable Quantity (RQ):
--None—
SARA Title III (Superfund Amendments and Reauthorization Act of 1986):

Section 302 (Extremely Hazardous Substances):
The following component(s) of this product is/are subject to the emergency planning provisions of 40 CFR 355 when
there are amounts equal to or greater than the Threshold Planning Quantity (TPQ):
--None—
Section 313 (toxic Chemicals):

The following component(s) have been specified as Toxic Chemicals under SARA Section 313 and may be subject to the
Toxic Release Inventory (TRI) reporting requirements under 40 CFR 372:
--None—
The following components are listed in U.S. State Regulations:

State Reg Reference: State Reg Reference:
California – Proposition 65: None.
Massachusetts Right-to-Know: Aluminum oxide
New Jersey Right-To-Know: Aluminum oxide
Pennsylvania Right-to-Know: Aluminum oxide
Note: Other U.S. State Regulations may exist, check your local sources if available.

Canada
Canadian Hazardous Products Act:

This product is not classified as a controlled product under regulations pursuant to the Federal Hazardous Product Act
(e.g. WHMIS).
Canadian Environmental Protection Act: All the ingredients of this mixture are notified to CEPA and on the DSL
(Domestic Substances List).
European Union (EU)
European Inventory of Existing Commercial Chemical Substances: All components of this product are included in
EINECS/ELINCS.
Council of European Communities Directive on Classification, Packaging and Labeling of Dangerous

Substances/Preparation (67/548/EEC & 1999/45/EC, as amended):
No Dangerous Goods Label Required.
Additional Governmental Inventories
Australia – Inventory of Chemical Substances (AICS): All the ingredients of this mixture appear on the AICS.
China – All the ingredients of this mixture appear on the China Inventory.
Japan – Existing and New Chemical Substances (ENCS): All the ingredients of this mixture appear on the
ENCS.
Korea – Existing and Evaluated Chemical Substances (ECL): All the ingredients of this mixture appear on the
ECL.
Philippines – Inventory of Chemicals and Chemical Substances (PICCS): All the ingredients of this mixture
appear on the PICCS.

16. OTHER INFORMATION
HMIS™ - Hazardous Material Identification System:

HMIS™ Ratings: 0-minimal hazard, 1-slight hazard, 2-moderate hazard, 3-serious hazard, 4-severe hazard
HEALTH: 1
FLAMMABILITY: 0
REACTIVITY: 1
For additional information concerning this product, contact the following:
ASM Catalysts, LLC Euro Support B.V.

8550 United Plaza Blvd., Suite 702 Kortegracht 26
Baton Rouge, LA 70809-0200 3811 KH Amersfoort
USA The Netherlands
Tel: +1-225-752-4276, Fax: +1-225-922-4550 Tel: +31-33-465-0465, Fax: +31-33-465-0721
The data and recommendations presented in this data sheet concerning the use of our product and the materials contained therein are believed to be
accurate and are based on information which is considered reliable as of the date hereof. However, the customer should determine the suitability of
such materials for his purpose before adopting them on a commercial scale. Since the use of our products by others is beyond our control, no
guarantee, express or implied, is made and no responsibility assumed for the use of this material or the results to be obtained therefrom. Information on
this form is furnished for the purpose of compliance with Government Health and Safety Regulations and shall not be used for any other purposes.
Moreover, the recommendations contained in this data sheet are not to be construed as a license to operate under or a recommendation to infringe, any
existing patents, nor should they be confused with state, municipal or insurance requirements, or with national safety codes.

Material Safety Data Sheet (MSDS)
MSDS Number: 6179-12 01/26/2010
EMERGENCY ASSISTANCE CHEMTREC (US): 1-800-424-9300
CANUTEC (Canada): 613-996-6666 CHEMTREC (International): +1-703-527-3887

(Call Collect)
SECTION I. MATERIAL IDENTIFICATION

PRODUCT: CRITERION 234 CATALYST
COMMON NAME: Metal Oxide
PRODUCT USE: Hydrotreating Catalyst
SECTION 2. COMPOSITION/INFORMATION ON INGREDIENTS

COMPONENTS OF THE MATERIAL
Component Chemical CAS Concentration
Formula
Aluminum oxide Al2O3 1344-28-1 74 - 98 %
Cobalt oxide CoO 1307-96-6 1-5%
Molybdenum oxide MoO3 1313-27-5 10 - 19 %
SECTION 3. HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
Physical Appearance: Blue Extrudates or Spheres. Odorless
Human Health Hazards:
Irritating to eyes and respiratory system.
May cause allergic reaction (rash) with skin contact and asthma-like allergic reaction by inhalation in
sensitive individuals.
Physical Hazards:
No specific hazards.
Environmental Hazards:
Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment.
Page 1 of 8
CRITERION 234 CATALYST MSDS Number: 6179
Potential Health Effects

Eye:
Mildly irritating to eyes.
Skin:
Mildly irritating to the skin. May cause contact dermatitis (allergic skin rash) in cobalt sensitive
individuals.
Inhalation:
Dusts may be irritating to the nose, throat and respiratory tract. May cause sensitization by inhalation
due to presence of a cobalt compound. Existing respiratory diseases may be aggravated by exposure to
this material.
Ingestion:
Low-level cobalt ingestion is known to cause effects on the heart after a short-term exposure. The
symptoms of heart damage may be a swelling of the feet (edema) and shortness of breath on exertion
or when lying flat on the back (supine).
Other Health Effects:

Molybdenum compounds have a low order of toxicity, may be irritating and may cause anemia.
SECTION 4. FIRST AID MEASURES

Eye Contact:
Flush eyes with water. If persistent irritation occurs, get medical attention.
Skin Contact:
Wash skin with water and, if available, soap. If persistent irritation occurs, get medical attention.
Inhalation:
Move to fresh air. If rapid recovery does not occur, get medical attention.
Ingestion:
Do not induce vomiting. Give nothing by mouth. Get medical attention immediately.
Note to Physicians:
Treat symptomatically. If skin sensitization has developed and a causal relationship has been
confirmed, further exposure should not be allowed.
SECTION 5. FIRE FIGHTING MEASURES

Extinguishing Media:
Material will not burn; use an extinguishing medium appropriate for the surrounding fire.
SECTION 6. ACCIDENTAL RELEASE MEASURES

Precautionary Measures:
Do not breathe dust. Avoid contact with skin and eyes. Avoid dust generation. Wear suitable
protective clothing and gloves. Wear a NIOSH approved respirator if there is a possibility of exposures
above the established occupational exposure limits. (See Section 8 for exposure limits.)
Spill Management:
Prevent contamination of soil and water. Do not wash spills into sewers or other public water systems.
Prevent further leakage or spillage and prevent from entering drains.
Page 2 of 8
Spill Disposal:
Shovel up and place in a labeled, sealable container for subsequent safe disposal.
Environmental Compliance:
Refer to latest state or local regulations to determine if there are disposal or reporting requirements.
SECTION 7. HANDLING AND STORAGE

Handling Recommendations:
Avoid contact with skin and eyes.
Avoid dust generation.
Do not breathe dust.
Do not eat, smoke or drink in areas where catalyst is present.
Use only in well ventilated areas. Use local exhaust extraction.
Take precautionary measures against static discharge.
Ground all equipment.
Storage Recommendations:
Keep container tightly closed and dry.
Reseal plastic liner.
SECTION 8. EXPOSURE CONTROLS/PERSONAL PROTECTION

Engineering Controls:
Use only in well ventilated areas. Use local exhaust extraction.
Hygiene Measures:
Avoid contact with material. Wash hands thoroughly after handling. Do not reuse clothing if
contaminated until thoroughly decontaminated.
Respiratory Protection:
Use either an atmosphere-supplying respirator or an air-purifying respirator for particulates.
Eye Protection:
Wear safety goggles or glasses to prevent eye contact.
Hand Protection:
Wear neoprene, nitrile, PVC or latex gloves to prevent contact.
Body Protection:
When there is a possibility of exposure wear a one piece coated overall with integral hood, safety
boots, chemical-resistant without lace holes.
Chemical Name Authority Limits Special Notations
Aluminum oxide OSHA PEL 15 mg/m³ total dust

Aluminum oxide OSHA PEL 5 mg/m³ respirable dust
Aluminum oxide ACGIH TWA 10 mg/m³ total dust
Cobalt oxide OSHA PEL 0.1 mg/m³ metal dust & fumes; as Co;
Cancer: 3
Cobalt oxide ACGIH TWA 0.02 mg/m³ as Co
Cobalt oxide ACGIH BEI 15 µg/m³ as creatinine
Cobalt oxide ACGIH BEI 20 µg/m³ BEI
Molybdenum oxide OSHA PEL 15 mg/m³ as Mo; total dust
Page 3 of 8
Molybdenum oxide OSHA PEL 5 mg/m³ as Mo; respirable dust

Molybdenum oxide ACGIH TWA 10 mg/m³ as Mo; total dust
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES
Product
Physical & Chemical Properties Characteristics
Appearance and Odor: Blue Extrudates or Spheres. Odorless
Solubility in water: <5%
Bulk density (solids): 0.48 g/cc
Melting point: ~3700
SECTION 10. STABILITY AND REACTIVITY

Stability:
Stable. Hygroscopic.
Materials To Avoid:
Strong acids, strong bases, strong oxidizing agents.
SECTION 11. TOXICOLOGICAL INFORMATION

The hazard determination and the information presented below is based on available data derived from
testing for the material, hazardous components of this material and/or a testing on a substantially
similar material(s). The material tested is indicated in the data.
Acute Lethality
Route Material Tested LD/LC50 Species
Dermal Molybdenum oxide >2000 mg/kg Rat
Sensitization
Route Material Tested Description Species
Dermal Cobalt oxide Sensitizer Human
Inhalation Cobalt oxide Sensitizer Human
Other Health Effects:
Cobalt was used as a defoaming agent in beer at 1 ppm. After a few weeks of exposure beer drinkers were found
to have myocardial effects. Deaths were reported. Medical evaluations found myocardial infarction.
In a lifetime feeding study with cobalt in hamsters, no statistically significant increases in tumors were seen.
Carcinogenicity:
Cobalt oxide is classified by:
IARC as a possible human carcinogen (Group 2B)
Page 4 of 8
SECTION 12. ECOLOGICAL INFORMATION

Ecotoxicological data have not been determined specifically for this material. The information given
below is based on knowledge of the components and the ecotoxicology of similar products.
Toxicity to Aquatic Organisms:

Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment.
Persistence & Bioaccumulation:

Not inherently biodegradable.
Mobility:
Sinks in water. If product enters soil, one or more constituents will be mobile and may contaminate
groundwater.
Sewage Treatment:
Not toxic at the limit of water solubility.
SECTION 13. DISPOSAL CONSIDERATIONS

Product disposal:
Recover or recycle, if possible. Otherwise: Send to an approved contractor for regeneration or metal
recovery or dispose with a licensed disposal contractor.
Waste Disposal:
If product is unused, see above. If used, evaluate the toxicity and physical properties of the material
you have generated and dispose of the material in accordance with local, state and federal regulations.
Container Disposal:
Empty containers may contain residues. Ensure container is properly cleaned. Remove all packaging
for recovery or waste disposal. DO NOT USE CONTAINER FOR OTHER PURPOSES.
Regulatory Controls:
Comply with all federal, state and local laws regulating the handling and disposal of wastes.
SECTION 14. TRANSPORTATION INFORMATION

Transport Statement:
Not dangerous for conveyance under USA DOT, Canadian TDG, and IATA/ICAO codes. Consult
local laws to determine transportation regulations.
U. S. A. - DEPARTMENT OF TRANSPORTATION (DOT)

Not regulated by DOT (USA).
CANADA - TRANSPORTATION OF DANGEROUS GOODS (TDG)

Not dangerous for conveyance under Canadian TDG.
Maritime transport (IMO)

UN No. UN 3077
Proper Shipping Name ENVIRONMENTALLY HAZARDOUS SUBSTANCE, SOLID,
N.O.S. ( Cobalt compounds )
Class 9
Packing Group III , MARINE POLLUTANT
Hazard symbol MISCELLANEOUS DANGEROUS SUBSTANCES AND ARTICLES
ENVIRONMENT
Page 5 of 8
Air transport ICAO/IATA

Not dangerous for conveyance under IATA/ICAO codes.
SECTION 15. REGULATORY INFORMATION
National Inventories
National Authority Country Status
EINECS/ELINCS EC All ingredients listed.
TSCA USA All ingredients listed.
MITI Japan All ingredients listed.
DSL/NDSL Canada All ingredients listed.
TCCL Korea All ingredients listed.
AICS Australia All ingredients listed.
PICCS Philippines All ingredients listed.
IECS China All ingredients listed.
PRODUCT SAFETY CLASSIFICATIONS

Canada WHMIS
Canadian - Workplace Hazardous Materials Information System (WHMIS)
Class D - Toxic and Infectious Materials Division 2 - Materials Causing other Toxic Effects
Subdivision A - Very Toxic Materials
California Proposition 65
Name on List Classification
Cobalt oxide Carcinogen
Massachusetts
Aluminum oxide Right-To-Know Substances List
Pennsylvania
Aluminum oxide Right-To-Know Hazardous Substance
Molybdenum oxide PA Environmental Hazard E (1 % threshold)
Page 6 of 8
European Community
Label Name CONTAINS COBALT OXIDE / MOLYBDENUM OXIDE
Hazard Symbols Xn: Harmful
N: Dangerous to the Environment
Classification Harmful Dangerous to the Environment
Risk Phrases R48/20/22: Harmful: danger of serious damage to health by prolonged
exposure through inhalation and if swallowed.
R42/43: May cause sensitization by inhalation and skin contact.
R36/37: Irritating to eyes and respiratory system.
R51/53: Toxic to aquatic organisms, may cause long-term adverse
effects in the aquatic environment.
Safety Phrases S22: Do not breathe dust.
S24: Avoid contact with skin.
S37/39: Wear suitable gloves and eye/face protection.
S61: Avoid release to the environment. Refer to special
instructions/Safety data sheets.
NATIONAL ENVIRONMENTAL AND SAFETY REGULATIONS
Superfund Amendments and Reauthorization Act (SARA)
SARA 311/312 Classification: Immediate (acute) health hazard

Delayed health hazard
SARA 313 Chemicals: Cobalt compounds Molybdenum oxide
SECTION 16. OTHER INFORMATION
COMPANY NAME: Criterion Catalysts & Technologies L.P.

16825 Northchase Drive,
2 Greenspoint Plaza
Houston, Tx. 77060 (USA)
+1 281 874 2600
+1 281 874 2641 (FAX)
MSDS Prepared By: CRI/Criterion, Inc.

16825 Northchase Drive, Suite #1110
Houston, TX 77060 (USA)
+1 281-874-2600 (USA CST)
Product.Steward@CRI-Criterion.com
Uses and restrictions:

Use as a raw material/intermediate for catalyst manufacture, as a catalyst for refinery processing or for
petrochemicals manufacture.
MSDS Distribution:
The information in this document should be made available to all who may handle the product.
Page 7 of 8
Amendment Notation:
Amendments from the previous version of the MSDS are indicated by two vertical bars in the left
margin and the section is highlighted.
Disclaimer:
This information is based on our current knowledge and is intended to describe the product for the
purposes of health, safety and environmental requirements only. It should not, therefore, be construed
as guaranteeing any specific property of the product.
Issue Date:
01/25/2010
US/Canada - (English)
Page 8 of 8
SULFUR BLOCK
Table of Contents
3. GENERAL .................................................................................................................... 3-1
3.1 ORGANIZATION ................................................................................................... 3-1
3.2 GENERAL PRECOMMISSIONING PROCEDURES ............................................. 3-2
3.2.1 Mechanical ..................................................................................................... 3-2
3.2.2 Electrical ......................................................................................................... 3-3
3.2.3 Instrumentation ............................................................................................... 3-5
3.3 DESIGN BASIS ..................................................................................................... 3-7
3.3.1 Plant Capacity ................................................................................................ 3-7
3.3.2 Sulfur Block Feed Streams ............................................................................. 3-7
3.3.3 Effluent Stream Conditions ........................................................................... 3-12
3.3.4 Other Design Requirements ......................................................................... 3-13
3.3.5 Utility Information .......................................................................................... 3-14
3.3.6 Plant Site Conditions .................................................................................... 3-16
Issued 30 August 2011 General Page 3-i

SULFUR BLOCK
3. GENERAL
3.1 Organization
This manual discusses the startup and operation of the new Sulfur Block,
consisting of an Amine Treating Unit, an Amine Regeneration Unit, a Sour
Water Stripping Unit, two Sulfur Recovery Units, a common Tailgas Thermal
Oxidation Unit, Tailgas Cleanup Unit, and Sulfur Degassing Unit, on a systems
basis. The systems are discussed individually, but are also grouped together
into two main categories. The categories and systems, in order of presentation,
are:
A. UTILITY SYSTEMS
1. Power Distribution
2. Plant Control Systems
3. Utility Systems
B. PROCESS SYSTEMS
1. Amine Treating / Amine Regeneration
2. Sour Water Stripping
3. Sulfur Recovery
4. Tailgas Thermal Oxidation
5. Tailgas Cleanup
6. Sulfur Degassing and Transfer
7. Solvent Storage and Drain
The systems are presented in the sequence required for a normal startup. That
is, electric power is usually the first system commissioned and the Sulfur
Degassing system is usually the last.
Issued 30 August 2011 General Page 3-1

SULFUR BLOCK
3.2 General Precommissioning Procedures

Prior to placing each of the Amine Treating, Sour Water Stripping, Sulfur
Recovery, Tailgas Thermal Oxidation, Tailgas Cleanup, Sulfur Degassing, and
associated systems in operation, check-out of the various systems should be
made in as much detail as practical. This will help eliminate problems during
startup and familiarize personnel with the plant equipment.
3.2.1 Mechanical
A complete check of all plant construction should be made to assure it is
in accordance with the Piping & Instrument Diagrams and equipment
manufacturer's recommendations. Any discrepancies or defects should
be corrected before attempting to put the plant in operation. Each piece of
equipment should be checked against the vendor's recommendations and
guidelines. Some of the steps that should be taken to ensure the plant is
mechanically ready for startup include:
A. Make an internal check of vessels for correct installation of mist

pads, support grids, trays, vortex breakers, etc.
B. Check to ensure suction strainers are installed in all pump suction

lines before the pumps are operated for any reason.
C. Perform all necessary pressure tests. After tests, remove the test
blinds, giving special attention to those below relief valves.
D. Check the nameplate on each relief valve to ensure it has been

installed in the proper location.
E. Clear the plant area involved in startup of construction equipment

and debris that could cause fire or injuries.
F. Check for proper rotation of all motors.
G. Check all motors and rotating equipment to ensure proper lubrication

and that belts are free and properly aligned.
H. Check pumps for packing where required (follow manufacturer's

instructions).
I. Check filters to ensure they contain properly installed filter elements

or charcoal media and that adequate spare elements are on hand.

SULFUR BLOCK
J. Prior to commencement of startup, the following items should be on

hand:
(1) Spare parts
(2) Lubricants, greases, etc.
(3) Chemicals, or provisions to provide chemicals
(4) Spare filter elements
(5) Any special tools required
(6) Fire extinguishers
(7) Safety equipment
(8) Oxygen analyzer
(9) Laboratory test equipment
(10) Pertinent test procedures
3.2.2 Electrical
The purpose of commissioning electrical components and control systems
prior to the startup of a plant is to ensure correct performance per
specifications under simulated operating conditions.
WARNING
POWER SHOULD NOT BE APPLIED TO ANY ELECTRICAL

DEVICE, CONTROL PANEL, CONTROL SYSTEM, OR MOTOR IN
THE FACILITY UNTIL SUCH TIME THAT ALL POWER AND
CONTROL WIRING FOR THE FACILITY HAS BEEN TERMINATED
AND PROPERLY MADE-UP ON EACH CONDUCTOR END.
Electrical power circuits must be energized in order to make an electrical

check-out prior to startup. Some of the following procedures may be
accomplished during construction; however, before the plant is put in
operation the following should be completed:

SULFUR BLOCK
A. Test each circuit with a megger, phase-to-phase and

phase-to-ground.
B. Test the motor feeder with the motor out of the circuit. After motors
are connected, make phase-to-ground tests on the motor circuit.
C. Test the control circuit with the push-buttons and over-current

devices connected.
D. Test the feeders to the panel-boards with the branch circuits open.
E. Test the power feeder with switches and circuit breakers in place.
F. Megger the power and control circuits of the switchgear and motor
control centers.
G. Check the control switches, alarm and shutdown devices, indicating

lights, and meters for proper operation.
H. Install thermal overload heaters where required after checking them

against the manufacturer's heat tables and motor nameplate data to
ensure the heaters are of the proper size and rating. Check
operation of time-delay under-voltage devices for proper timing,
proper restart, and dropout action.
I. Megger motor windings and transformer windings for ground.

Examine them for moisture accumulation. If evidence of moisture
accumulation is found, the equipment must be dried before being
placed in operation.
J. Check circuit breakers, motor starters, switches, relays, and other

equipment for loose connections (both mechanical and electrical)
and to see that contacts and working parts are correctly aligned and
free from dust and foreign material.
K. Check motors for proper rotation, lubrication, and alignment.
L. For circuit breakers with adjustable trips, check the thermal rating
against the value shown on the drawings and adjust the magnetic
setting to the "LO" position. On magnetic-only (instantaneous trip)
breakers in combination starters, the instantaneous setting should be
adjusted so that the setting is just above the motor in-rush current.
Lower the setting to the point where the contacts open when the
motor is started, then raise the setting in small increments to the
point where the breaker allows the motor to start.

SULFUR BLOCK
M. Ensure that all individual motor starter and feeder breakers are in the
"OFF" position.
N. Provide power to the MCC by engaging the main feeder breaker.
O. Turn the MCC feeder breakers to the "ON" positions, applying power
to all individual circuit breakers, contactors, and motor switches.
P. In order to initially energize any motor, pump, or fan, the shutdown

control system should first be energized and the emergency
shutdown system reset.
3.2.3 Instrumentation
The purpose of commissioning instruments prior to the startup of the
facility is to ensure correct performance per specifications under simulated
operating conditions. Handling of instruments after calibration should be
kept to a minimum.
The instruments have been ordered pre-calibrated and set. It should be

necessary only to verify the factory calibration and zero of the instruments.
In the event that an instrument requires re-calibration or major mechanical
adjustments, the manufacturer's recommendations and guidelines should
be adhered to, and will be considered the applicable standard.
All instruments, components, and accessory devices (including charts,

scales, dials, gauges, switches, etc.) should be checked against their
specification sheets for agreement.
Specific steps that should be taken to ensure the plant pneumatic

instrumentation system is ready for startup include:
A. The instrument air system must be put into operation in order to

check-out the instrument loops. The individual block valves for each
air user should be closed as the air system is pressurized. Once
operating pressure is reached, dirt and pipe scale should be blown
from the headers. The individual instrument lines should then be
disconnected at the instruments and any debris blown from the entire
tubing run.
B. All air supply regulators should be adjusted to the recommended

settings.
C. Once the instrument air system is pressurized, the piping and tubing
should be checked for leaks.

SULFUR BLOCK
D. All instrument loops should be checked to ensure the instruments

and control devices are properly interconnected. The controllers
should be set to the proper control action with the proper control
modes and tuning characteristics.
E. "Stroke" the control valves to ensure the valves move in the proper
direction.
F. Check orifice plates for proper bore and direction of installation.
G. Level switches and transmitters should be put in service and

checked for proper actuation. Calibration of level devices may be
completed after liquid levels are established.
H. Check the tag numbers on the steam traps to confirm that each trap
has been installed in the proper location.
I. In plants controlled by a distributed control system (DCS), confirm

that the range stored in the DCS for each field instrument matches
the actual range of the instrument. This is particularly important for
flow meters used in ratio control loops, as an incorrect range may
prevent the control loop from functioning properly. It is also
important on flow loops to confirm that either the transmitter or the
DCS (and not both) is extracting the square root of the signal.

SULFUR BLOCK
3.3 Design Basis

The information used to design the Sulfur Block is given in this section.
Unless stated otherwise, the design conditions presented below are assumed to
be available at the battery limits for the new units.
3.3.1 Plant Capacity

The feedstock basis for the Sulfur Block is a nominal sulfur production of
35 MT/D. In order to provide a design margin for the Sulfur Recovery
Units, each unit is designed for 75% of the normal feed rates, which
results in a nominal sulfur production of 52 MT/D.
3.3.2 Sulfur Block Feed Streams

3.3.2.1 Amine Treating Unit Feed Gas (Max Contaminate Case)
Combined Sour
Composition, mol fraction
Offgas
H2 0.583538
H2S 0.133806
NH3 0.000146
Methane 0.023661
Ethane 0.018913
Propane 0.016896
i-Butane 0.008563
n-Butane 0.115412
i-Pentane 0.057487
n-Pentane 0.030181
nC6 0.00264
H2O 0.008757
Naphtha + -
Total, kgmol/hr 463.85
Total, kg/hr 9902
Temp, °C 38
Press, kg/cm2(g) 6

SULFUR BLOCK
3.3.2.2 Rich Amine to Amine Regeneration Unit

Rich MDEA
Composition, Rich MDEA from LPG
kmol/hr from DHT RGS Absorber
H2O 752.79 1027.14
MDEA 61.32 83.56
H2S 14.31 11.49
NH3 0.00088 -
CO2 - 8.24
H2 0.51 -
Methane 0.01 -
Ethane 0.004 0.04
Propane 0.002 0.09
i-Butane 0.0004 0.04
n-Butane 0.0004 0.12
Heptane 0.0006
C1/C2 RSH - 0.04
Total 828.95 1130.75
Total, kg/hr 21358 29231
Temp, °C 63 41
Press, kg/cm2(g) 4.5 4.5

SULFUR BLOCK
3.3.2.1 Sour Water to SWS (Max Contaminant Case)

Sour
Sour Sour Sour Sour Water
Composition
Water Water Water Water from UOP
kgmol/hr
from from from from Guard
NHT (1) KHT DHT CFU Bed
H2 --- 0.23 0.16 --- ---
NH3 0.03 0.06 0.22 0.02 0.0005
H2S 0.53 0.58 0.50 0.02 0.0010
H2O 834.34 425.94 320.09 447.70 0.7986
Total 834.90 426.81 320.97 447.75 0.8000
Total - kg/hr 15050 7695 5788 8067 14
Temp, °C 52 55 54 60 38
Press,
kg/cm2(g) 3.0 3.0 3.0 3.0 3.0
Note (1) The maximum NHT sour water rate is 19585 kg/h containing 35 wt
ppm H2S and 18 wt ppm NH3 when running 100% NWS Narrow
feed.

SULFUR BLOCK
3.3.2.2 Fuel Gas Streams

Fuel gas for the Sulfur Block is supplied from the treated fuel gas
header. The treated fuel gas is used only for the fuel to the Thermal
Oxidizer Burner. Vaporized C4 LPG is supplied to the Acid Gas
Burner, Acid Gas Burner Pilot, and the Thermal Oxidizer Burner
Pilot.
Treated Fuel
Composition, mole %
Gas
Hydrogen 67.353
H2S 0.010
Water Vapor 1.067
Methane 2.729
Ethane 2.180
Propane 1.948
i-Butane 0.988
n-Butane 13.306
i-Pentane 6.633
n-Pentane 3.481
C6 + 0.305
Totals 100.000
Temperature, °C 38
Pressure, kg/cm2(g) (min) 3.5
LHV, kcal/kg 10,425

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3.3.2.3 Hydrogen Stream (Reducing Gas)
Composition, mole % PSA Hydrogen

Hydrogen 99.9
Nitrogen ---
CO & CO2 20 ppm
Methane 0.1
Ethane ---
Propane ---
i-Butane ---
n-Butane ---
Totals 100.0
Temperature, °C 40
Pressure, kg/cm2(g) (min) 25

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3.3.3 Effluent Stream Conditions

3.3.3.1 Treated Fuel Gas from ATU
Stream: Treated Gas
Temperature °C normal / max 38 / 40
2
Pressure kg/cm (g) min / max 3.5 / 4.2
H2S ppmv max (dry) 100
3.3.3.1 Treated Water from SWS

Stream: Treated water
Temperature °C max 60
2
Pressure kg/cm (g) min 5.0
H2S ppmw max 20
NH3 ppmw max 20
3.3.3.1 Incinerated Effluent from TTO

Min. Norm. Max.
Temperature °C 232 288 400
Pressure kg/cm2 (g) atm.
SO2 ppmv (dry, 0% oxygen) 200
H2S ppmv 10
(1) ppmv
CO 50
NOX ppmw 65
Note (1) For oxidation of H2S to SO2, the normal operating

temperature for the Tailgas Thermal Oxidizer (TTO) is
about 650°C. If CO emissions must be limited and,
therefore, the CO must be oxidized to CO2, then the
normal operating temperature for the TTO is about
816°C.

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3.3.3.1 Molten Sulfur

Min. Norm. Max.
Temperature °C 119 138
2
Pressure kg/cm (g) atm.
Purity % (dry basis) 99.9
H2S ppmw 10
Carbon % 0.2
Color “Texas Bright”
3.3.4 Other Design Requirements

3.3.4.1 The Lean Amine from the Amine Regeneration Unit is a 35 wt%
MDEA solution with a residual loading of 0.01 mole acid gas / mole
MDEA.
3.3.4.2 The Rich Amine from the DHT, LPG Absorber and Amine Treating
Unit will go to the Amine Regeneration Unit for regeneration. The
maximum Rich Amine loading will be 0.40 mole acid gas / mole
MDEA.
3.3.4.3 Liquid sulfur from the SRU is to be degassed to convert H2SX

species to H2S and reduce the concentration of H2S to less than
10 PPMW for safe handling.
3.3.4.4 In general, the Sulfur Block is to be designed for a 3-4 year run
length between turnarounds. Mechanical turnaround duration is
usually 3-7 days for each unit.
3.3.4.5 All units are to be designed individually for a 98% or better

on-stream factor.
3.3.4.6 Critical equipment is to be spared, to permit on-line maintenance.

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3.3.5 Utility Information

3.3.5.1 Electricity
Service Voltage Phase Cycles
Motors above 132 kW 6,600 V 3 60
Motors 0.2 kW up to and including 132 kW 440 V 3 60
Fractional kW motors up to 0.2 kW 440 V 3 60
3.3.5.2 Steam
Operating Pressure: Operating Temp. Mechanical
kg/cm²(g) °C Design
Press: Temp:
Min Norm Max Min Norm Max kg/cm²(g) °C
HP Steam 44 45 46 380 400 420 50 427
MP Steam 16 17 17.5 275 280 300 20 350
IP Steam 13.7 14.4 15.1 202 204 206 16.7 227
LP Steam 3 3.5 4 190 195 210 5.5 300
3.3.5.3 Condensate
Condensate Destination Grade Level Battery Limit

or Designation Pressure: kg/cm²(g)
HP Steam HP Condensate 19
MP Steam MP Condensate 6
IP Steam LP Condensate 1.5
LP Steam LP Condensate 1.5
3.3.5.4 Boiler Feed Water

Min. Normal Max. Design
BFW Temperature, °C 132 132 132 160
BFW Pressure, kg/cm2(g) 57 57 58 63
Dissolved Solids, PPMW (avg) <5

Conductivity, µS/cm (avg) <20

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3.3.5.5 Cooling Water

Normal Min. Design
2 2 2
kg/cm (g) °C kg/cm (g) °C kg/cm (g) °C
Supply 5(1) -- -- 32 8 60
Return 2(1) -- -- 42 8 60
TSS ppmw 20 max

Chlorides ppmw 1200
Ammonia ppmw nil
Note (1) These conditions are not necessarily the conditions

at the inlet or outlet connections of the equipment.
3.3.5.6 Instrument Air and Plant Air

Plant Air, kg/cm2(g) 5.5 5.5 6 10
2
Instrument Air, kg/cm (g) 4 7 8 10
Plant Air Dewpoint °C ---

Instrument Air Dewpoint °C -40

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3.3.5.7 Gaseous Nitrogen

Pressure, kg/cm2(g) 4 6 8 10
Composition, mole %
Nitrogen 99.5
Oxygen 20 ppmv (max)
CO 20 ppmv (max)
CO2 20 ppmv (max)
Other C Compounds 5 ppmv (max)
Chlorine 1 ppmv (max)
H2O 5 ppmv (max)
Hydrogen 20 ppmv (max)
Noble Gases Remainder
Total 100.0
3.3.6 Plant Site Conditions

3.3.6.1 Barometric Pressure: 760 mm Hg (average)
3.3.6.2 Air Temperature: 37°C (dry bulb) maximum summer design

30°C (dry bulb) for air blower design
-10°C (dry bulb) minimum winter design
-14.3°C (dry bulb) winterizing
3.3.6.3 Site Elevation: 5.6 m above mean sea level

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Table of Contents
4. POWER DISTRIBUTION .............................................................................................. 4-1
4.2 SAFETY ................................................................................................................. 4-1
4.2.1 General ........................................................................................................... 4-1
4.2.2 Hazardous (Classified) Areas ......................................................................... 4-1
4.3.1 Motors and Motor Controls ............................................................................. 4-2
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4. POWER DISTRIBUTION
4.1 Purpose of System
This utility system supplies electrical power to all users in the Amine Treating,
Amine Regeneration, Sour Water Stripping, Sulfur Recovery, Tailgas Cleanup,
Tailgas Thermal Oxidation, and Sulfur Degassing units including motors,
instruments, controls, lights, receptacles, and heat tracing.
4.2 Safety
4.2.1 General
Only authorized and qualified personnel should maintain and repair
electrical equipment. All operator controls and adjustments are accessible
without opening electrical equipment enclosures.
Maintain extreme care when operating electrical equipment and

machinery driven by electrical motors. Equipment may start without
warning.
Observe company safety rules and permit-to-work system.
If you suspect a person has been electrocuted, DO NOT approach the

victim until the source of power has been turned off or it is obvious the
victim is no longer in contact with the source. If possible, drag victim clear
of any metal or potential electrical sources using victim's clothing or by
wearing insulating gloves. If the victim is still in contact with the electrical
source and skin contact is made, you may also be electrocuted.
4.2.2 Hazardous (Classified) Areas

Most of the process areas in the Amine Treating, Amine Regeneration,
Sour Water Stripping, Sulfur Recovery, Tailgas Cleanup, Tailgas Thermal
Oxidation, and Sulfur Degassing units have been classified as Zone 2,
Gas Group IIA/IIB for electrical installation. The only exceptions to this are
any below-grade vaults which have been classified as Zone 1, Gas Group
IIA/IIB.
Locations are classified depending on the properties of the flammable

vapors, liquids, or gases which may be present and the likelihood that a
flammable or combustible concentration or quantity is present. The
electrical equipment and installation in classified areas conforms to the
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International Electrotechnical Commission (IEC) Standards. Special

precautions are required when operating electrical equipment in classified
areas. The equipment should be approved for the area classification or a
"hot-work" permit system should be followed during the period a
non-approved piece of equipment is used in the classified area.
4.3 Equipment Description

4.3.1 Motors and Motor Controls
A. In general, the electric motors are TEFC, 444 VAC, 3 Ø, 60 Hz with
the exception of:
(1) The motors on the Process Air Blower, A2-GB1530A/B, are

TEFC, 6600 VAC, 3 Ø, 60 Hz.
B. The motor control circuits for the Process Air Blower

(A2-GB1530A/B), Thermal Oxidizer Air Blower (A2-GB1570A/B), and
TGCU Start-Up Blower (A2-GB1560) include provisions that allow
the blowers to "ride-through" brief power interruptions.
Issued 30 August 2011 Power Distribution Page 4-2

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Table of Contents
5. PLANT CONTROL SYSTEMS ..................................................................................... 5-1
5.1 DISTRIBUTED CONTROL SYSTEM .................................................................... 5-1
5.2 PROGRAMMABLE LOGIC CONTROL SYSTEM ................................................. 5-2
5.3 EMERGENCY SHUTDOWN SYSTEMS ............................................................... 5-3
5.4 LOCAL CONTROL PANELS ................................................................................. 5-3
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5. PLANT CONTROL SYSTEMS

This section of the manual describes the various control systems associated with the
new Amine Treating, Amine Regeneration, Sour Water Stripping, Sulfur Recovery,
Tailgas Cleanup, Tailgas Thermal Oxidation, and Sulfur Degassing units. Most of the
process control functions are performed by a Distributed Control System (DCS). The
DCS, with its operator interface screens and keyboards, allows the control room
operator to monitor and control nearly all of the systems within the new units.
The safety system interlocks and sequential control functions are performed by a
programmable logic controller (PLC). A PLC is a solid-state microprocessor that
performs the functions of a traditional relay logic system. The PLC for the new units
will communicate with the DCS to allow the operator to monitor the PLC using the
operator interface screens of the DCS.
5.1 Distributed Control System

The Distributed Control System (DCS) provides control, monitoring, recording,
alarming, and all other functions required for dependable and effective process
control of the facility. It is a microprocessor based, fully engineered system of
hardware and software products integrated into an industrially-proven DCS
design capable of both functional and geographic distribution. A communication
system links these locations to a centralized operating center with video displays
configured as operator workstations.
The system has been designed so that control and monitoring functions are
distributed on a modular basis to minimize control and data information loss in
the event of a failure anywhere within the system. Control functionality does not
depend on a single centrally-based device or communication system to assure
that on a single failure the system will remain operative to allow continued
control and monitoring of the remainder of the process. To achieve this,
redundancy has been included for controllers, power supplies, communication
modules and cables, and operator workstations.
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5.2 Programmable Logic Control System

A Programmable Logic Control (PLC) system is used for the new Amine
Treating, Amine Regeneration, Sour Water Stripping, Sulfur Recovery, Tailgas
Cleanup, Tailgas Thermal Oxidation, and Sulfur Degassing units to perform the
functions of traditional relay logic systems. The logic control systems for each
unit are all contained in one or more PLCs. Each logic control system will be
discussed in more detail in later sections of the manual:
a. Amine Treating Unit Emergency Shutdown System (see Section 7.4.2).
b. Sour Water Stripper Unit Interlocks (see Section 8.4).
c. Sulfur Recovery Unit Emergency Shutdown System (SRU ESD) and

Burner Management System (see Sections 9.5.2 and 9.5.8).
d. Sulfur Degassing Unit Startup Interlock and Emergency Shutdown System

(SDU ESD) (see Sections 10.5.3 and 10.5.7).
e. Sulfur Loading Emergency Shutdown System (see Section 10.5.8).
f. Tailgas Cleanup Unit Emergency Shutdown System (TGCU ESD) (see

Section 11.5.5).
g. Tailgas Thermal Oxidation Emergency Shutdown System (TTO ESD) and

Burner Management System (see Sections 12.5.1 and 12.5.5).
The PLC hardware and programs are fail-safe by design. Loss of power to the
PLC will de-energize all its outputs and send devices (control valves, etc.) to
their "fail" position. The restoration of power to the PLC will restart the PLC, but
program interlocks will "lock-out" control actions until the respective ESD
systems are reset. Similarly, the PLC logic has been designed such that open
circuits in field wiring or open field contacts will de-energize their respective
outputs and render equipment and process to a "safe" status.
The PLC system is connected by both "hard-wired" cables and software "links"
that allow it to communicate with the DCS. This enables the DCS operator
interface to be used by the operators to monitor the status of the PLC and its
safety and sequential control systems.

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5.3 Emergency Shutdown Systems

The purpose of the Amine Treating Unit Emergency Shutdown (ATU ESD), Sulfur
Recovery Unit Emergency Shutdown (SRU ESD), Tailgas Cleanup Unit
Emergency Shutdown (TGCU ESD), Tailgas Thermal Oxidation Unit Emergency
Shutdown (TTO ESD), and Sulfur Degassing Unit Emergency Shutdown (SDU
ESD) systems is to shut down the appropriate equipment and divert the
appropriate streams to the flare when serious problems occur. Each of these
ESD systems can be initiated either by a system response or by an operator.
Refer to the Instrumentation and Control Systems sections of these guidelines for
complete discussions of these emergency shutdown systems.
These ESD systems are mostly independent of each other, with the exception of
the TGCU ESD system, which is activated when both of the SRU ESD systems
are activated. Except for this situation, activation of the ESD system in a
particular unit will not cause any other ESD systems to be directly activated. Of
course, depending on the particular circumstances, the effects that result when
a particular ESD system is activated may indirectly cause another ESD system
to be activated due to the process upset that occurs.
5.4 Local Control Panels

There are three local control panels that are used for startup of each Sulfur
Recovery Unit and the Tailgas Thermal Oxidation Unit. The functions of these
local panels are described in the Instrumentation and Control Systems sections
of these guidelines for the Sulfur Recovery system and the Tailgas Thermal
Oxidation system.

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Table of Contents
6. UTILITY SYSTEMS ...................................................................................................... 6-1
6.2 SYSTEM DESCRIPTION ...................................................................................... 6-1
6.2.1 Nitrogen Supply .............................................................................................. 6-1
6.2.2 C4 LPG and Treated Fuel Gas Supply .......................................................... 6-2
6.2.3 Hydrogen Supply ............................................................................................ 6-2
6.2.4 Plant Air .......................................................................................................... 6-3
6.2.5 Instrument Air ................................................................................................. 6-3
6.2.6 Sour Water Disposal....................................................................................... 6-3
6.2.7 Steam, Condensate, Boiler Feed Water, and Blowdown ............................... 6-4
6.2.7.1 Purpose of Systems ................................................................................ 6-4
6.2.7.2 Safety ...................................................................................................... 6-4
6.2.7.3 Process Description ................................................................................ 6-5
6.2.7.4 Boiler Feed Water ................................................................................... 6-5
6.2.7.5 HP Steam ................................................................................................ 6-6
6.2.7.6 LP Steam................................................................................................. 6-7
6.2.7.7 Condensate Return ................................................................................. 6-7
6.3 PRECOMMISSIONING, STARTUP, AND SHUTDOWN PROCEDURES............. 6-8
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6. UTILITY SYSTEMS
The utility headers supply the fluids necessary for plant operation and
maintenance.
6.2 System Description

The Piping and Instrument Diagrams show the utility system tie-ins for this
project. Some of the more important or complex systems are discussed in more
detail in the sections below.
6.2.1 Nitrogen Supply

The SRUs and TGCU have two sections of equipment or piping that are
stagnant during certain modes of operation. One of these, the SRU
warmup bypass line(s), would cause undesirable effects on sulfur
recovery and/or severe corrosion if leakage occurred in the line. The
other one, the TGCU Start-Up Blower, could suffer corrosion if exposed to
wet process gases when it is not running.
The most positive means of preventing these problems is to isolate the

section in question and purge it with inert gas (such as nitrogen). If the
pressure of the purge gas is higher than the process operating pressure,
then any leakage through the isolation valves will be the inert purge gas
leaking out rather than process gas leaking in. Nitrogen is used in this
manner at each of these locations within the new unit.
Nitrogen is also used for several other purposes within the new units: 1) to
purge instruments (flame scanners, pyrometers, flow meters, etc.)
exposed to process gas containing sulfur vapor or ammonia; 2) to empty
out and purge vessels before opening them for maintenance; 3) to prevent
a vacuum from forming in several overhead lines; 4) as the motive fluid for
the aspirator in the air demand analyzer; and 5) as a cool-down medium
for the SRUs and the front-end of the TGCU. A dedicated low pressure
header is used for purges permanently connected to low pressure sulfur
plant equipment; a high pressure header operating at about 7.0 kg/cm2(g)
provides nitrogen for the other users.
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6.2.2 C4 LPG and Treated Fuel Gas Supply

When the refractory in the Reactor Furnace, A2-BA1530 (A2-BA1540),
must be heated in a controlled fashion according to its cure-out schedule,
fuel is fired in the Acid Gas Burner, A2-BA1531 (A2-BA1541), on manual
control. Variable fuel gas quality could lead to temperature "run-aways" if
there is not close operator attention throughout the heating cycle. For this
reason, vaporized C4 LPG is used as the fuel gas for the Acid Gas
Burner. The heating value of vaporized LPG normally varies much less
than the heating value of a typical treated fuel gas stream, so vaporized
LPG should be much less likely to cause temperature control problems
during this manual operation.
The fuel gas to the Thermal Oxidizer Burner, A2-BA1571, is automatically

adjusted to maintain the desired temperature in the Thermal Oxidizer,
A2-BA1570. In addition, this burner normally operates with considerable
excess air, since the oxygen to oxidize the sulfur compounds entering the
Thermal Oxidizer comes from the burner combustion products. As a
result, the variable nature of treated fuel gas can be tolerated by this
burner much more easily than the Acid Gas Burner, so this burner is
designed to burn treated fuel gas.
The pilot burners for the Acid Gas Burner and the Thermal Oxidizer
Burner are not as reliable if variable quality fuel gas is used. For this
reason, vaporized LPG is used for both pilots to ensure reliable light-off
and good service life.
During normal operation, loss of the treated fuel gas supply will cause the
Thermal Oxidizer to shut down. However, the SRU should continue to
operate. The Thermal Oxidizer shutdown will be due to "flame failure" of
the Thermal Oxidizer Burner. Loss of LPG will normally not affect either
unit, but it will not be possible to restart either unit should a shutdown
occur until the LPG supply is restored.
6.2.3 Hydrogen Supply

The TGCU Unit is designed to use an external supply of reducing gas to
hydrogenate the sulfur compounds in the SRU tailgas back into H2S,
rather than generate its own reducing gas. High-purity hydrogen is
imported into the Sulfur Block, let-down to low pressure, and combined
with the SRU tailgas upstream of the TGCU Reactor Feed Mixer,
A2-ME1560. If the hydrogen supply is interrupted, it is likely that the
TGCU Unit will have to be bypassed until the hydrogen supply is restored.

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6.2.4 Plant Air

The Plant Air system provides compressed air for the utility air stations
throughout the plant. It can be used for operating pneumatic tools and
other pneumatic equipment such as air movers, spray guns, and sand
blasting apparatus. Plant air is also used in the Tailgas Cleanup Unit for
catalyst passivation.
6.2.5 Instrument Air

Dry instrument air is used to provide the motive force to operate the
control valves and shutdown valves in the Sulfur Block. Loss of the air
supply for brief periods will probably not cause any operational problems.
However, if the instrument air pressure falls below about 4.2 kg/cm2(g),
some of the large process gas valves may begin to move. If one of the
process gas valves that is in the open flowpath through the SRUs, the
TGCU, and the TTO should begin to close, the ESD system for that SRU
and/or the TGCU will be activated, resulting in an SRU and/or TGCU
shutdown.
6.2.6 Sour Water Disposal

Sour water is produced at several points in the SRU and TGCU, such as
in the Acid Gas Knock-Out Drums, A2-FA1530 (A2-FA1540), the SWS
Gas Knock-Out Drum, A2-FA1531 (A2-FA1541), and the excess water
condensed in the TGCU Quench Column, A2-DA1560. Some of this sour
water is intermittent in nature, like the knock-out drum liquids, whereas the
excess quench water will be a continuous flow. The sour water from the
Acid Gas Knock-Out Drum is pumped to the Rich Amine Flash Drum,
A2-FA1513, while the remaining sources are sent to the Sour Water Flash
Drum, A2-FA1520.
Sour water must also be drained from equipment items periodically (pump
cases, level instruments, etc.). The Closed Drain Tank, A2-FA1582, has
an underground header system to collect these liquids and hold them. As
the tank fills, the Closed Drain Pump, A2-GA1581A/B, can be used to
send the collected sour water to Sour Water Stripping Unit.

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WARNING
THE LIQUID DRAINED INTO THE CLOSED DRAIN TANK AND ITS
UNDERGROUND HEADER SYSTEM CONTAINS DISSOLVED H2S.
ALWAYS OBSERVE PROPER PROCEDURES AND PRECAUTIONS
WHEN DRAINING LIQUID FROM THESE ITEMS OR PERFORMING
MAINTENANCE ON THEM. THE "GENERAL SAFETY" SECTION
OF THIS MANUAL SHOULD BE CONSULTED IF THERE IS ANY
DOUBT ABOUT HOW TO WORK SAFELY WHEN H2S MAY BE
PRESENT.
6.2.7 Steam, Condensate, Boiler Feed Water, and Blowdown

6.2.7.1 Purpose of Systems
The Steam system provides heating media for plant systems and
equipment and motive driving power for each vent ejector. The
Condensate system is designed to collect and return the steam
which has been condensed by the users to the Steam system. The
Boiler Feed Water system provides suitably conditioned water to the
steam generators located within the Sulfur Block. The Blowdown
system collects the blowdown water from the boilers in the Sulfur
Block for safe disposal.
6.2.7.2 Safety
Use appropriate safety precautions when handling the boiler feed
water chemicals (sulfite, amine, phosphate, etc.).
The normal operating temperatures in the Steam, Condensate, and

Boiler Feed Water systems are high enough to cause burns:
Steam Pressure Steam Temperature
48.5 kg/cm2(g) 262°C

45.0 kg/cm2(g) 400°C superheated
4.2 kg/cm2(g) 153°C
Personnel should take the appropriate precautions to avoid burns

when working around open vents, open drains, steam traps, or any

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un-insulated piping in the Steam, Condensate, and Boiler Feed

Water systems. It is common for hot water to drip from steam tracing
connections, steam traps, etc. Steam leaks and steam vent streams
can cause severe burns and lacerations. Also, refer to the
discussion concerning boilers in the General Safety section of this
manual, Section 2.13.
6.2.7.3 Process Description

There are three Steam headers (saturated 48.5 kg/cm2(g),
superheated 45 kg/cm2(g) and saturated 3.5 kg/cm2(g)), a low
pressure Condensate Return header, a high pressure Condensate
Return Header, a Cold Condensate Header, a Boiler Feed Water
header, and an atmospheric pressure Blowdown header.
There are six steam generators in the Sulfur Block:
A2-BF1530 Waste Heat Boiler

(sat. 48.5 kg/cm2(g) steam)
A2-BF1540 Waste Heat Boiler

A2-EA1531 Sulfur Condenser

A2-EA1541 Sulfur Condenser

A2-EA1561 TGCU Waste Heat Reclaimer

A2-BF1570 Thermal Oxidizer Waste Heat Boiler

(superheated 45.0 kg/cm2(g) steam)
The different subsystems are described below.
6.2.7.4 Boiler Feed Water

In accordance with the ASME Section I Code for Power Boilers,
boiler feed water must be provided to the Waste Heat Boiler,
A2-BF1530 (A2-BF1540), and the Thermal Oxidizer Waste Heat
Boiler, A2-BF1570, at 58.3 kg/cm2(g) or higher (i.e., 6% above the
relief valve settings). The BFW supply header must be maintained at
or above this pressure to safely satisfy this requirement.

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In accordance with the ASME Section VIII Code for Unfired Steam
Boilers, boiler feed water must be provided to the Sulfur Condenser,
A2-EA1531 (A2-EA1541), and the TGCU Waste Heat Reclaimer,
A2-EA1561, at 5.8 kg/cm2(g)or higher (i.e., 6% above the relief valve
settings).
6.2.7.5 HP Steam
The Waste Heat Boiler, A2-BF1530 (A2-BF1540), generates
HP steam at a normal operating pressure of about 48.5 kg/cm2(g). A
small portion of this steam is consumed in the reactor feed heaters to
reheat the feed streams to the catalytic reactors in the SRUs. The
rest of the HP steam is combined with the steam from the Thermal
Oxidizer Waste Heat Boiler, A2-BF1570, enters the Steam
Knock-Out Drum, A2-FA1570, to remove any entrained water
droplets, and is then routed to the superheat passes in the Thermal
Oxidizer Waste Heat Boiler.
The Thermal Oxidizer Waste Heat Boiler includes a water-tube boiler

that uses part of the waste heat from the Thermal Oxidizer to
generate 48.5 kg/cm2(g) saturated steam. The remainder of the
waste heat is used to superheat the steam from this boiler after it
combines with the HP steam produced by the Waste Heat Boiler.
The Thermal Oxidizer Waste Heat Boiler allows a major portion of
the heat required to incinerate the sulfur compounds to SO2 to be
recovered as useful steam. The superheated steam is exported to
the refinery HP steam header at about 400°C and 45.0 kg/cm2(g).
Note that the Thermal Oxidizer Waste Heat Boiler is the only source
of superheat for the HP steam produced in the Sulfur Block. If the
Thermal Oxidizer shuts down and begins to cool, the steam will no
longer be sufficiently superheated to satisfy the requirements of the
users located outside of battery limits. Under this circumstance, the
steam from the superheat passes of the TTO Waste Heat Boiler will
instead be vented to atmosphere automatically until the Thermal
Oxidizer is restarted and the steam is once again superheated to the
proper temperature.
HP steam is used as motive fluid for the Sulfur Surge Tank Vent
Ejector, A2-EE1530 (A2-EE1540). The steam for this service is
normally supplied from the steam produced within the process train.
When the HP steam is being vented to atmosphere as described

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above, however, steam must be imported into the Sulfur Block for
this equipment item.
6.2.7.6 LP Steam
The Sulfur Condenser, A2-EA1531 (A2-EA1541), in the sulfur plant
and the TGCU Waste Heat Reclaimer, A2-EA1561, in the tailgas
cleanup unit generate LP steam at a normal operating pressure of
about 4.2 kg/cm2(g). This LP Steam is used for heating amine acid
gas in the Acid Gas Preheater, A2-EA1530 (A2-EA1540), reboiling
the solvent in the ARU Stripper Reboiler, A2-EA1512A/B, the water
in the Sour Water Stripper Reboiler, A2-EA1521, and the TGCU
solvent in the TGCU Stripper Reboiler, A2-EA1565, miscellaneous
steam tracing and steam jacketing of process gas lines, sulfur
rundown lines, sulfur vapor valves, etc., and for the heating coils in
the Sulfur Surge Tank, A2-EA1531 (A2-EA1531), and Sulfur Storage
Tank, A2-FB1550. The remaining LP Steam is exported to the
refinery.
6.2.7.7 Condensate Return

The HP condensate produced from the HP Steam used in the Sulfur
Block is collected and routed to the HP Condensate return system.
The LP condensate produced from the LP Steam used in the Sulfur

Block is collected and routed to the LP Condensate return system.

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6.3 Precommissioning, Startup, and Shutdown Procedures

The utility equipment and piping may be put into service as required by the
process systems they serve. Normal procedures should be followed after
completion of construction to ensure that the lines have been adequately blown
or flushed clean before being commissioned. Other than checking for
cleanliness and possible leaks, and following good practice in venting lines
while they are being filled, no other special procedures should be required to
commission the utility systems.

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Table of Contents
7. AMINE TREATING & AMINE REGENERATION ......................................................... 7-1
7.2 SAFETY ................................................................................................................. 7-1
7.3.1 General ........................................................................................................... 7-2
7.3.2 Water Washing ............................................................................................... 7-2
7.3.3 Sour Gas Contacting ...................................................................................... 7-3
7.3.4 Solvent Regeneration ..................................................................................... 7-3
7.4.1 Wash Water Column, A2-DA1510 .................................................................. 7-6
7.4.2 Amine Absorber, A2-DA1511 ......................................................................... 7-6
7.4.3 Flash Gas Contactor, A2-DA1512 .................................................................. 7-6
7.4.4 Stripper, A2-DA1513 ...................................................................................... 7-6
7.4.5 Wash Water Column Packing, A2-DB1510 .................................................... 7-7
7.4.6 Amine Absorber Trays, A2-DB1511 ............................................................... 7-7
7.4.8 Amine Absorber Overhead Cooler, A2-EA1510 ............................................. 7-8
7.4.9 Lean/Rich Exchanger, A2-EA1511A/B ........................................................... 7-8
7.4.10 Stripper Reboiler, A2-EA1512A/B .................................................................. 7-8
7.4.11 Stripper Reflux Condenser, A2-EC1511......................................................... 7-8
7.4.12 Lean Amine Cooler, A2-EC1510 .................................................................... 7-8
7.4.13 Wash Water Feed Knock-Out Drum, A2-FA1510 ........................................... 7-8
7.4.14 Amine Absorber Feed Knock-Out Drum, A2-FA1511 ..................................... 7-9
7.4.15 Amine Absorber Overhead Knock-Out Drum, A2-FA1512 ............................. 7-9
7.4.16 Rich Amine Flash Drum, A2-FA1513 ............................................................. 7-9
7.4.17 Stripper Reflux Accumulator, A2-FA1514..................................................... 7-10
7.4.18 Stripper Reboiler Condensate Pot, A2-FA1515A/B ...................................... 7-10
7.4.19 ATU Skim Oil Sump, A2-FA1516 ................................................................. 7-10
7.4.20 ATU Skim Oil Pump Sump, A2-FA1517A/B ................................................. 7-10
7.4.21 ATU Amine Drips Tank, A2-FA1580............................................................. 7-11
7.4.22 MDEA Storage Tank, A2-FB1580 ................................................................ 7-11
7.4.23 Wash Water Filter, A2-FD1510A/B ............................................................... 7-11
7.4.24 Rich Amine Filter, A2-FD1511A/B ................................................................ 7-11
7.4.25 Lean Amine Filter, A2-FD1512 ..................................................................... 7-11
7.4.26 Lean Amine Carbon Filter, A2-FD1513 ........................................................ 7-12
7.4.27 Lean Amine After-Filter, A2-FD1514 ............................................................ 7-12
7.4.28 ATU Amine Drips Filter, A2-FD1580 ............................................................ 7-12
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7.4.29 Wash Water Pump, A2-GA1510A/B ............................................................. 7-13

7.4.30 Lean Amine Pump, A2-GA1511A/B ............................................................. 7-13
7.4.31 ATU Skim Oil Pump, A2-GA1512A/B ........................................................... 7-13
7.4.32 Rich Amine Pump, A2-GA1513A/B .............................................................. 7-13
7.4.33 Lean Amine Booster Pump, A2-GA1514A/B ................................................ 7-13
7.4.34 Stripper Reflux Pump, A2-GA1515A/B ......................................................... 7-13
7.4.35 MDEA Transfer Pump, A2-GA1580.............................................................. 7-14
7.5.1 Treated Fuel Gas H2S Analyzer ................................................................... 7-15
7.5.2 ATU Emergency Shutdown Systems ........................................................... 7-15
7.5.2.1 Causes of ATU ESD.............................................................................. 7-15
7.5.2.2 Effects of ATU ESD ............................................................................... 7-17
7.5.2.3 Non-ESD Shutdowns and Alarms ......................................................... 7-17
7.6.1 Amine Absorber Operation ........................................................................... 7-19
7.6.1.1 Low Temperature .................................................................................. 7-19
7.6.1.2 Acid Gas Loading .................................................................................. 7-20
7.6.1.3 High Amine Concentration .................................................................... 7-20
7.6.2 Stripper Operation ........................................................................................ 7-22
7.6.3 Amine Water Balance ................................................................................... 7-24
7.6.4 Amine Loss ................................................................................................... 7-27
7.7.4 Washing the Wash Water System ................................................................ 7-33
7.7.4.1 Water Flush ........................................................................................... 7-33
7.7.4.2 Acid Wash ............................................................................................. 7-35
7.7.4.3 Alkaline Wash........................................................................................ 7-36
7.7.4.4 Initial Water Fill ...................................................................................... 7-37
7.7.5 Washing the Amine System ......................................................................... 7-38
7.7.5.1 Water Flush ........................................................................................... 7-38
7.7.5.2 Acid Wash ............................................................................................. 7-43
7.7.5.3 Weak Amine Wash ................................................................................ 7-45
7.7.5.4 Initial Solvent Fill ................................................................................... 7-46
7.7.6 Purging the Low Pressure Columns ............................................................. 7-50
7.7.6.1 Purging the Columns ............................................................................. 7-50
7.8.1 Wash Water and Amine Systems ................................................................. 7-52
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7.8.2 Sour Fuel Gas Flow to the Columns............................................................. 7-53

7.9.1 Planned Shutdown - ATU ............................................................................ 7-57
7.9.2 Planned Shutdown - ATU and ARU ............................................................. 7-60
7.9.3 Emergency Shutdown .................................................................................. 7-62
7.9.4.1 Steam System Outage .......................................................................... 7-63
7.10 ANALYTICAL PROCEDURES ............................................................................ 7-64
7.10.1 General Procedures for Analyzing ATU/ARU Solvent, ................................. 7-64
7.10.2 Determination of Amine Concentration in ATU/ARU Solvent ....................... 7-68
7.10.3 Determination of Total Acid Gas Loading in ATU/ARU Solvent ................... 7-70
7.10.4 Determination of H2S and CO2 Loading in ATU/ARU Solvent ...................... 7-72
7.10.5 Determination of Foaming Tendency of ATU/ARU Solvent .......................... 7-76
7.10.6 H2S Conc. in Amine Absorber Ovhd by the Tutweiler Method ..................... 7-78
7.10.7 H2S Conc. in Amine Absorber Ovhd Using Gas Detector Tubes ................. 7-79
7.10.7.1 Operating Principles .............................................................................. 7-79
7.10.7.2 Sampling the Amine Absorber Overhead Gas ...................................... 7-80
7.10.7.3 Calculations ........................................................................................... 7-81
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7. AMINE TREATING & AMINE REGENERATION

The purpose of the Amine Treating system is to remove essentially all the
H2S from the sour fuel gas stream using an aqueous amine solvent, MDEA
(methyldiethanolamine). The H2S is absorbed in the amine solvent and the
treated fuel gas stream, containing with less than 100 ppmv of H2S, is
returned to the complex for consumption as fuel.
The purpose of the Amine Regeneration system is to strip the H2S from the
rich amine solvent produced in the Amine Treating, LPG Treating and DHT
units. The H2S-laden acid gas is sent to the Sulfur Recovery Unit (SRU) for
disposal and the lean amine is recycled back to the upstream process units.
7.2 Safety
WARNING
ALL PIPING AND VESSELS INCLUDED IN THIS UNIT EITHER CONTAIN

OR HAVE THE POTENTIAL FOR CONTAINING HAZARDOUS GAS THAT
MAY CAUSE SERIOUS INJURY OR DEATH. THE GAS THAT IS MOST
COMMON AND HAZARDOUS IN A TOXIC WAY IS HYDROGEN SULFIDE.
CLOSE ATTENTION SHOULD BE PAID TO THE "GENERAL SAFETY"
SECTION OF THESE GUIDELINES AS TO THE NATURE AND ABILITY
OF THIS GAS 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 OF
THESE GUIDELINES 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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7.3 Process Description

7.3.1 General
The Systems Diagram, Material Balance and Process Flow Diagrams,
Dwg. Nos. 507000-7000-01, through -04, are contained in the "Process
Flow Diagrams" Section of the Basic Engineering Package. Please refer
to these drawings to follow this description of the process.
The Amine Treating Unit (ATU) uses an aqueous amine solvent, MDEA
(methyldiethanolamine), to remove essentially all the H2S from the sour
fuel gas stream. The normal solvent concentration is 45 wt % MDEA in
water. The ATU is designed to treat 10,397 Nm3/hr of sour fuel gas. The
treated gas stream is returned to the refinery for consumption as fuel, and
the acid gas (H2S, plus CO2) is routed to the Sulfur Recovery Units
(SRUs). Less than 100 PPMV of H2S remains in the treated fuel gas.
7.3.2 Water Washing

Sour fuel gas streams in chemical complexes are often contaminated with
various gaseous, liquid, and even solid substances. In order to prevent
these contaminants from causing operating problems (foaming, poor
treating, corrosion, etc.) in the amine solvent system, the sour fuel gas
streams are washed with water to remove the contaminants upstream of
the amine contactors. Some of the more common contaminants are
ammonia (NH3), hydrogen cyanide (HCN), and hydrocarbon liquids.
The sour fuel gas enters Wash Water Feed Knock-out Drum, A2-FA1510,
at 38°C [100°F] and 6.0 kg/cm2(g) [85 PSIG]. Any entrained liquids are
removed automatically on level control and routed to the sour liquids
system. The scrubbed gas enters the bottom of the Wash Water Column,
A2-DA1510, and passes upward through a packed bed where it is
countercurrently contacted with a stream of circulating water. The washed
sour gas stream leaves the top of the column and flows to Amine
Absorber Feed Knock-out Drum, A2-FA1511, to remove any wash water
that may be carried over with the gas. The scrubbed gas proceeds to the
Amine Absorber, A2-DA1511, while any wash water carry-over is routed
to the Closed Drain system on level control.
The wash water leaving the bottom of the column is pumped by the Wash
Water Pump, A2-GA1510A/B, to the Wash Water Filter, A2-FD1510A/B,
for removal of any particulates or other solid material removed from the
sour gas feed. Most of the filtered water is returned to the top of Wash

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Water Column on flow control, after being mixed with fresh makeup water.
The remainder of the filtered water is directed to the Sour Water Stripping
Unit (SWS) to purge the gaseous and liquid contaminants removed by the
wash water from the system. The makeup water rate can be adjusted as
necessary to control the contaminants (primarily ammonia in most cases)
at an acceptable concentration, and the level control on the column
bottoms will automatically adjust the purge rate to balance the water
added to the system with the makeup water flow control.
7.3.3 Sour Gas Contacting

The washed sour refinery fuel gas enters the bottom of the Amine
Absorber at 37°C [98°F] and 5.8 kg/cm2(g) [82 PSIG] and passes upward
through 30 trays to be contacted countercurrently with lean MDEA solvent.
As the sour gas is contacted by the amine, the acidic H2S (and CO2, if
present) in the gas reacts with the basic amine solution:
(1) H2S + CH3(CH2OHCH2)2N CH3(CH2OHCH2)2NH+ + HS–
(2) CO2 + CH3(CH2OHCH2)2N + H2O CH3(CH2OHCH2)2NH+ + HCO3–
This is an acid-base reaction, forming an amine "salt" that remains

dissolved in the aqueous solution. The rich amine leaves the bottom of
the column at 58°C [136°F] on level control and is routed to the Rich
Amine Flash Drum, A2-FA1513. The treated gas leaves the top of the
column and flows to the Amine Absorber Overhead Cooler, A2-EA1510,
where it is cooled to 37°C [98°F] before flowing to the Amine Absorber
Overhead Knock-out Drum, A2-FA1512, where any solvent carry-over is
recovered and returned to the rich solvent stream on level control. The
scrubbed treated gas at 37°C [98°F] and 4.5 kg/cm2(g) [64 PSIG] is then
routed to the treated fuel gas header for consumption elsewhere in the
complex.
7.3.4 Solvent Regeneration

The combined rich solvent stream from the Amine Treating Unit, the LPG
Treating Unit, and the DHT Unit enters the Rich Amine Flash Drum at
54°C [130°F]. This vessel is operated at low pressure (0.64 kg/cm2(g)
[9 PSIG]) to maximize the vaporization and removal of any light
hydrocarbons that may be entrained or dissolved in the amine solvent. A
small amount of H2S will be liberated from the rich amine by the pressure
reduction, so the resulting flash gases enter the bottom of the Flash Gas
Contactor, A2-DA1512, and flow upward through its packed bed to be

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countercurrently contacted with a small stream of lean amine. The amine

will remove most of the H2S from the flash gas, so that the treated gas
flowing to the flare will contain 200 PPMV or less of H2S. The rich amine
from the bottom of the packed bed falls into the flash drum to join the
other rich solvent.
The flash drum is large enough to provide 30-40 minutes or more of

residence time for the rich solvent. This allows time for any heavy
hydrocarbons entrained in the solvent to separate as a second liquid
phase that spills over the internal weir at the inlet end of the drum,
collecting in the ATU Skim Oil Sump, A2-FA1516. The ATU Skim Oil
Pump, A2-GA1512A/B, sends the collected hydrocarbon to the
Condensate Feed Tank on start/stop level control.
After removal of any liquid hydrocarbon, the heavier amine phase passes
under the internal weir at the outlet end of the drum to be pumped through
the Rich Amine Filter, A2-FD1511A/B, by the Rich Amine Pump,
A2-GA1513A/B, on level/flow cascade control. The filter removes
particulates from the solvent before it enters the tube side of the
Lean/Rich Amine Exchanger, A2-EA1511A/B. The Rich Amine is
preheated to 105°C [221°F] by cooling the lean solvent before flowing to
the Stripper, A2-DA1513, entering between trays #4 and #5.
The Stripper contains 30 valve trays (4 wash water trays, 26 stripping

trays) and one chimney draw tray. As the solvent flows down the column,
the absorbed H2S and CO2 are stripped from the MDEA by countercurrent
contact with stripping steam rising upward. This stripping steam is
generated in the Stripper Reboiler, A2-EA1512A/B, using LP
(3.5 kg/cm2(g) [50 PSIG]) steam as the heat input. The heat input to the
reboilers is adjusted by flow control of the steam. The steam flow
controllers can be reset by the Stripper overhead temperature, which will
maintain the desired overhead temperature of 114°C [238°F] by varying
the heat input in proportion to the amount of acid gas contained in the
Rich Amine.
The stripping steam supplies the heat of reaction required to reverse

reactions (1) and (2), and carries the H2S and CO2 stripped from the
solvent overhead to the Stripper Reflux Condenser, A2-EC1511, where
the steam is condensed as the stream is cooled to 49°C [120°F]. The
condensed water is removed by the Stripper Reflux Accumulator,
A2-FA1514, and returned as reflux to the wash water trays in the tower by
the Stripper Reflux Pump, A2-GA1515A/B. The acid gas (H2S and CO2,

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along with the uncondensed water) stripped from the solvent exits the
reflux drum at 0.85 kg/cm2(g) [12 PSIG] and flows to the SRUs.
The Lean Amine Booster Pump, A2-GA1514A/B, pumps the regenerated

lean MDEA solvent from the bottom of the Stripper through the shell side
of the Lean/Rich Amine Exchanger, cooling the lean solvent from 259°F to
78°C [172°F] by countercurrent heat exchange with the cool rich amine. A
slipstream of the lean amine then flows through the Lean Amine Filter,
A2-FD1512, to remove accumulated solids from the solvent and through
the Lean Amine Carbon Filter, A2-FD1513, where the activated carbon
adsorbs contaminants such as hydrocarbons and degradation products
from solvent. The Lean Amine After-Filter, A2-FD1514, catches any
carbon "fines" before the filtered slipstream rejoins the main solvent
stream. A portion of the lean amine flows to the DHT unit on temperature
control while the remainder flows to the Lean Amine Cooler, A2-EC1510,
where it is cooled to 50°C [122°F].
A small stream of cool lean amine is directed on flow control to the top of
the Flash Gas Contactor as described previously. A portion of the cool
lean amine flows to the LPG Treating Unit and a portion flows to the DHT
unit on temperature control. The remaining lean amine is pumped to
higher pressure by the Lean Amine Pump, A2-GA1511A/B before being
directed on flow control to the top of the Amine Absorber.

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7.4.1 Wash Water Column, A2-DA1510

The Wash Water Column contains a single bed of random packing to
provide good contact between the sour fuel gas and the circulating wash
water. The tower has a 304 S.S. woven wire mist eliminator above the
packed bed to remove entrained water droplets from the gas before it
leaves the tower.
7.4.2 Amine Absorber, A2-DA1511

The Amine Absorber contains a 30 valve trays to provide good contact
between the sour fuel gas and the amine solvent to remove H2S from the
fuel gas. The tower has a 304 S.S. woven wire mist eliminator above the
top bed to remove entrained solvent droplets from the gas before it leaves
the tower.
7.4.3 Flash Gas Contactor, A2-DA1512

As lighter hydrocarbons are allowed to disengage from the amine in the
Rich Amine Flash Tank, a small amine flow scrubs these lighter
hydrocarbons of acid gas as the amine and hydrocarbon flow counter
currently. The Flash Gas Contactor contains a single bed of random
packing which provides good contact between the light hydrocarbon gas
entering below it and the amine fed above it.
7.4.4 Stripper, A2-DA1513

The Stripper contains 28 valve trays to provide good contact between the
rich amine solvent and the reboiler vapors to strip H2S and CO2 from the
solvent. The rich amine enters on the fifth tray from the top; the four trays
above that are "water wash" trays that allow the reflux water (entering on
the top tray) to remove traces of MDEA from the overhead vapor and
minimize solvent losses.
A chimney tray is located below the bottom valve tray to gather all of the
column liquids to feed the Stripper Reboiler. The column section located
below this chimney tray serves to separate the outlet steam and lean
amine from the reboiler and to provide surge for the solvent circulating
system.

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7.4.5 Wash Water Column Packing, A2-DB1510

This bed of random packing provides good contact between the sour fuel
gas entering below it and the wash water fed above it inside the Wash
Water Column. The packing has a bed limiter above it and rests on a bed
support. The quench water is distributed over the packing by a distributor
tray. The packing is 304 S.S.; the other internals are 304 S.S.
Gaskets are installed where the bed support and distributor tray bolt to the
support ring and clips inside the Wash Water Column to prevent direct
contact between the stainless steel internals and the carbon steel vessel.
This electrically isolates the dissimilar metals from each other to prevent
direct contact that could lead to galvanic corrosion.
7.4.6 Amine Absorber Trays, A2-DB1511

These 1-pass valve trays provide good contact between the fuel gas
entering below it and lean amine fed above it inside the Amine Absorber.
The tray decks and tray downcomers are 304L S.S., and the valves are
fabricated from 304 S.S. to resist corrosion and to prevent "sticking" to the
tray decks.
7.4.7 Stripper Trays, A2-DB1513

These 1-pass valve trays provide good contact between the rich amine
solvent fed above them and the reboiler vapors fed below them inside the
Stripper. The tray decks are 304L S.S., and the valves are fabricated
from 304 S.S. to resist corrosion and to prevent "sticking" to the tray
decks. The chimney tray deck is 304L S.S. The bottom valve tray has a
seal pan for its downcomer to maintain a liquid seal and prevent gas from
blowing up the downcomer.
The chimney tray gathers the tower liquids to feed the reboiler. The outlet
from the reboiler reenters the column below the chimney tray, with the
vapor produced by the reboiler flowing upward through the chimneys in
order to reach the valve trays above.
The top four trays in the column are located above the rich amine feed
point and serve as water-wash trays to minimize the amount of amine
carried-over in the tower overhead. Since these trays have only the reflux
water flowing over them, the liquid rates for these trays are much lower
than for the trays lower in the column. For this reason, these four trays
are designed for minimum leakage (i.e., picket fence weirs, minimum
downcomer clearance, etc.).

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7.4.8 Amine Absorber Overhead Cooler, A2-EA1510

This shell and tube exchanger is used to provide the final cooling of the
treated fuel gas, with cooling water from the complex as the cooling
medium.
7.4.9 Lean/Rich Exchanger, A2-EA1511A/B

These shell and tube exchangers conserve energy by providing heat
exchange between the rich amine and the lean amine, so that the hot lean
amine leaving the Stripper can preheat the rich amine before it feeds the
Stripper. This cross exchange saves reboiler duty by preheating the rich
amine, and reduces the load on the Lean Amine Cooler by partially
cooling the hot lean amine.
7.4.10 Stripper Reboiler, A2-EA1512A/B

The Stripper Reboilers are a fixed tubesheet shell and tube heat
exchangers. The exchangers are arranged as once-through vertical
thermosiphon reboilers, mounted on the side of the Stripper. The static
head of the solvent above the inlet nozzle on the lower channel provides
the driving force to circulate the solvent through the tubes. LP steam on
the shell of the exchangers heats the solvent inside the tubes, partially
vaporizing it to create stripping steam to remove the H2S and the CO2
from the solvent flowing down the Stripper.
7.4.11 Stripper Reflux Condenser, A2-EC1511

This forced-draft aerial exchanger provides cooling to condense the
majority of the water from the acid gas stream leaving the overhead of the
Stripper. Fans are used to circulate air across the finned tubes to remove
heat from the overhead stream and condense the water to be used as
reflux for the tower.
7.4.12 Lean Amine Cooler, A2-EC1510

This forced-draft aerial exchanger provides the final cooling of the lean
amine stream returning from the regeneration section of the process.
Fans are used to circulate air across the finned tubes to remove heat from
the solvent.
7.4.13 Wash Water Feed Knock-Out Drum, A2-FA1510

This vertical vessel is installed in the inlet sour fuel gas line to remove
liquids from the gas stream before it is routed to the Wash Water Column.

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The liquid produced in this vessel is routed to the closed drain on

automatic start/stop control. The vessel is equipped with high level alarms
to warn of a rising level in the drum, and a high-high level shutdown to
activate the ATU ESD system before liquids can reach the column. The
shutdown requires that 2 out of 3 transmitters have a high-high level
indicated.
7.4.14 Amine Absorber Feed Knock-Out Drum, A2-FA1511

This vertical vessel is installed in the overhead line from the Wash Water
Column to remove liquids from the gas stream before it is routed to the
Amine Absorber. The liquid produced in this vessel is routed to the closed
drain on automatic start/stop control. The vessel is equipped with high
level alarms to warn of a rising level in the drum, and a high-high level
shutdown to activate the ATU ESD system before liquids can reach the
absorber. The shutdown requires that 2 out of 3 transmitters have a
high-high level indicated.
7.4.15 Amine Absorber Overhead Knock-Out Drum, A2-FA1512

This vertical vessel is installed in the overhead line from the Amine
Absorber to remove liquids from the treated fuel gas stream before it is
routed to the complex fuel gas system. The liquid produced in this vessel
is combined with the rich amine stream leaving the Amine Absorber on
automatic start/stop control.
7.4.16 Rich Amine Flash Drum, A2-FA1513

This horizontal vessel allows for the removal of hydrocarbons that may be
carried out of the various upstream processes with the amine. The rich
amine enters the vessel through a slotted, vertical distributor. Any
hydrocarbon that may be carried with the amine from the upstream
processes will accumulate in the center section of this vessel. When a
sufficient amount of hydrocarbon has accumulated, the hydrocarbon will
overflow the partition and flow into the hydrocarbon section. Lighter
hydrocarbons are disengaged from the amine and exit through the Flash
Gas Contactor where they are washed free of any acid gases.
Hydrocarbon-free amine then passes under another partition, at the
opposite end of the vessel, and into the amine outlet section, where the
amine is pumped to the Stripper.

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7.4.17 Stripper Reflux Accumulator, A2-FA1514

This vertical pressure vessel removes condensed water from the stream
leaving the Stripper Reflux Condenser so that the water can be used as
reflux for the Stripper. The vessel has a 304 S.S. woven wire mist
eliminator in the top to remove entrained liquid droplets from the gas
before it leaves the vessel.
7.4.18 Stripper Reboiler Condensate Pot, A2-FA1515A/B

These two vertical pressure vessels collect the condensate from the
Stripper Reboiler and return it to the condensate system on level control.
This method of removing condensate from the exchanger provides much
smoother control of the heat input to the reboiler than a conventional
steam trap could.
As stated above, this vessel is simply a very good steam trap. During
normal operation, the steam pressure required to provide the necessary
reboil heat to the Stripper may be much less than the 3.5-4.2 kg/cm2(g)
steam pressure available in the LP steam system. The normal steam
pressure in the shell of the reboiler may be such that the water level in the
condensate pot will rise upwards from the pot, perhaps even within the
shell of the reboiler. During these periods, the level valve will remain fully
open and the sight glass will indicate a full water level. This is a normal
operating condition for this vessel. The vessel will usually operate with a
visible level only when the Stripper Reboiler is operating near its
maximum capacity with full steam pressure on the shell of the exchanger.
Under these conditions, the level control and level valve will function
normally and maintain a water level in the vessel.
7.4.19 ATU Skim Oil Sump, A2-FA1516

This horizontal vessel is located in a below-ground concrete vault. It
collects the heavy hydrocarbons from the Rich Amine Flash Tank. The
collected hydrocarbon liquid is pumped back to the Condensate Feed
Tank on stop/start level control.
7.4.20 ATU Skim Oil Pump Sump, A2-FA1517A/B

These vertical vessels house the ATU Skim Oil pumps. Hydrocarbon
liquids from the ATU Skim Oil Sump flow into this vessel and are pumped
out by the ATU Skim Oil Pump.

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7.4.21 ATU Amine Drips Tank, A2-FA1580

This horizontal pressure vessel is located in a below-ground concrete
vault. It collects solvent from the ATU via headers when equipment is
drained for maintenance, etc. The vessel will normally operate with little
or no pressure so that gravity-flow is sufficient to cause solvent to drain
into the vessel. The collected solvent is pumped back to the solvent
system in the ATU for reuse when the vessel gets full.
7.4.22 MDEA Storage Tank, A2-FB1580

This vertical, cylindrical, cone roof storage tank holds fresh MDEA solvent
unloaded from transport trucks until it is needed for make-up to the ATU
solvent system.
7.4.23 Wash Water Filter, A2-FD1510A/B

These filters are designed to remove solid particles 5 microns and larger
from the circulating wash water.
7.4.24 Rich Amine Filter, A2-FD1511A/B

These full-flow filters are designed to remove solid particles 5 microns and
larger from the circulating rich solvent, which will help prevent fouling of
the downstream heat exchangers.
WARNING
THESE FILTERS HANDLE LIQUID CONTAINING H2S AND OTHER

HARMFUL SUBSTANCES. ALWAYS OBSERVE PROPER
PROCEDURES AND PRECAUTIONS WHEN PERFORMING
MAINTENANCE ON THIS FILTER. THE "GENERAL SAFETY"
SECTION OF THESE GUIDELINES SHOULD BE CONSULTED IF
THERE IS ANY DOUBT ABOUT HOW TO WORK SAFELY WHEN
H2S MAY BE PRESENT.
7.4.25 Lean Amine Filter, A2-FD1512

This full-flow filter is designed to remove solid particles 5 microns and
larger from the circulating lean solvent.

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7.4.26 Lean Amine Carbon Filter, A2-FD1513

This full-flow filter is designed to remove organic contaminants (trace
hydrocarbons, degradation products, etc.) from a slipstream of the
circulating lean solvent using a bed of activated carbon.
7.4.27 Lean Amine After-Filter, A2-FD1514

This filter is designed to remove solid particles, particularly carbon fines,
5 microns and larger from the lean solvent leaving the Lean Amine
Carbon Filter.
7.4.28 ATU Amine Drips Filter, A2-FD1580

This filter is designed to remove solid particles 5 microns and larger from
the recovered solvent drained from equipment, etc. in the ATU. The
recovered solvent is filtered as it is routed back to the ATU.
CAUTION
SINCE THE PUMPS DESCRIBED IN THE FOLLOWING SECTIONS ARE

CONSTRUCTED OF STAINLESS STEEL, DO NOT HYDROTEST THE
ASSOCIATED VESSELS OR PIPING WITH WATER CONTAINING HIGH
LEVELS OF CHLORIDES. AVOID ALLOWING WATER CONTAINING MORE
THAN 50 PPM CHLORIDES TO COME IN CONTACT WITH THESE PUMPS TO
PREVENT STRESS CORROSION CRACKING OF THE STAINLESS STEEL.
WARNING
THE LIQUID IN THESE PUMPS CONTAINS DISSOLVED H2S. THIS H2S CAN
BE RELEASED TO THE SURROUNDINGS WHEN LIQUID IS DRAINED FROM
THESE PUMPS OR FROM THE PIPING CONNECTED TO THE PUMPS.
ALWAYS OBSERVE PROPER PROCEDURES AND PRECAUTIONS WHEN
DRAINING LIQUID FROM THESE PUMPS OR PERFORMING MAINTENANCE
ON THEM. THE "GENERAL SAFETY" SECTION OF THESE GUIDELINES
SHOULD BE CONSULTED IF THERE IS ANY DOUBT ABOUT HOW TO WORK
SAFELY WHEN H2S MAY BE PRESENT.

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7.4.29 Wash Water Pump, A2-GA1510A/B

These centrifugal pumps are used to circulate wash water to which is
used to remove contaminates from the sour gas feed stream. Each pump
is designed for the total duty; the other pump is a 100% spare. These
pumps are equipped with tandem seals to reduce the likelihood of
releasing H2S to the surroundings.
7.4.30 Lean Amine Pump, A2-GA1511A/B

These centrifugal pumps are used to send the lean amine from the Amine
Regeneration Unit to the Amine Absorber. Each pump is designed for the
total duty; the other pump is a 100% spare. These pumps are equipped
with tandem seals to reduce the likelihood of releasing H2S to the
surroundings.
7.4.31 ATU Skim Oil Pump, A2-GA1512A/B

These vertical sump-type pump is mounted in the ATU Skim Oil Pump
Sump to transfer the recovered hydrocarbons back to the Condensate
Feed Tank.
7.4.32 Rich Amine Pump, A2-GA1513A/B

These centrifugal pumps are used to send the rich amine from the Rich
Amine Flash Drum to the Stripper. Each pump is designed for the total
duty; the other pump is a 100% spare. These pumps are equipped with
tandem seals to reduce the likelihood of releasing H2S to the
surroundings.
7.4.33 Lean Amine Booster Pump, A2-GA1514A/B

These centrifugal pumps are used to send the lean amine from the Amine
Regeneration Unit to the DHT Unit, the LPG Treating Unit, and to the
suction of the Lean Amine Pumps in the Amine Treating Unit. Each pump
is designed for the total duty; the other pump is a 100% spare. These
7.4.34 Stripper Reflux Pump, A2-GA1515A/B

These centrifugal pumps are used to send the reflux from the Stripper
Reflux Accumulator to the Stripper. Each pump is designed for the total

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surroundings.
7.4.35 MDEA Transfer Pump, A2-GA1580

This single-stage centrifugal pump is used to transfer amine from the
MDEA Storage Tank to the ATU solvent system. This pump does not run
continuously so no spare is provided.

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7.5 Instrumentation and Control Systems

7.5.1 Treated Fuel Gas H2S Analyzer
Analyzer A2-AE15057 measures the H2S concentration in the treated fuel
gas leaving Amine Absorber Overhead Knock-out Drum, A2-FA1512. If
the H2S concentration exceeds the specification for fuel gas (200 PPMV),
DCS relay A2-AY15057 should start ramping down the signal that
pressure controller A2-PC15057 is supplying to control valve
A2-PV15057. As this valve closes, the pressure will start to rise, until it
reaches the setpoint (6.0 kg/cm2(g)) of the over-ride pressure controller,
A2-PC15059, which will then open control valve A2-PV15059 to divert the
fuel gas to the flare header. The duration of the ramping should be about
60 seconds or so, so that the pressure in the system does not change too
rapidly.
Once the H2S concentration is back on-specification, A2-AY15057 should

start ramping up the signal from A2-PC15057 to A2-PV15057. As this
control valve opens and the pressure starts to drop back to its normal
value (5.0 kg/cm2(g)), the over-ride pressure controller will then close
A2-PV15059, so that the fuel gas is flowing to the fuel gas header once
again. The duration of this ramping should again be about 60 seconds or
so, so that the pressure in the system does not change too rapidly.
A2-HS15057 in the DCS is a bypass to disable relay A2-AY15057 and

prevent it from changing the control signal to A2-PV15057. This switch
can be used to prevent upset of process operations when calibrating or
performing maintenance on the analyzer.
7.5.2 ATU Emergency Shutdown Systems

The purpose of the ATU ESD system is to shut off the flow of sour fuel
gas to the treating system when serious problems occur. The Cause and
Effect Diagrams are contained in the Instrumentation and Controls
Drawings section of the Basic Engineering Package. These diagrams
describe the ATU ESD system in block format. For reference, the causes
and effects of the ESD system shown on these diagrams is explained
below.
7.5.2.1 Causes of ATU ESD

Any one of the devices listed below will activate the ATU ESD
system:

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a. Manual Shutdown Switch, A2-HS15022
An operator can activate the ATU ESD system using these

guidelines shutdown switch in the DCS, a "timed pulse" switch.
b. Wash Water Feed Knock-out Drum High-High Liquid Level,

A2-LT15008A/B/C.
This device prevents liquids in this vessel from entering the

wash water system for the sour refinery fuel gas and
contaminating it, since this could then lead to contamination of
the solvent system. It is set to actuate if the liquid level reaches
1,050 mm above the bottom seam of the vessel. Note that
there are three independent transmitters and 2oo3 voting logic
is used for the ESD (i.e., at least two transmitters must show
high-high level) to avoid spurious "trips" due to the malfunction
of a single transmitter.
c. Amine Absorber Feed Knock-out Drum High-High Liquid Level,

A2-LT15030A/B/C.
This device prevents liquids in this vessel from entering the

Amine Absorber and contaminating the solvent system. It is set
to actuate if the liquid level reaches 1,200 mm above the
bottom seam of the vessel. Note that there are three
independent transmitters and 2oo3 voting logic is used for the
ESD.
d. Amine Absorber Low-Low Liquid Level, A2-LT15040A/B/C.
If the solvent level drops too low in the Amine Absorber, large
amounts of high pressure gas could blow through control valve
A2-LV15040 into the Rich Solvent Flash Drum, A2-FA1513, and
other equipment and piping in the ATU/ARU with a lower design
pressure than this column. Loss of solvent in this column could
also result in the treated fuel gas going sour.
This device is set to actuate if the liquid level drops to 450 mm

above the bottom seam of the vessel. To reduce the chances
of blow-through, this device will also de-energize solenoid valve
A2-NY15040 to close the control valve. Note that there are
three independent transmitters and 2oo3 voting logic is used for
the ESD.

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7.5.2.2 Effects of ATU ESD

A shutdown of the Amine Absorber, activated either manually or
automatically, has the following effects on the ATU/ARU:
a. Closes A2-NV15002, blocking the flow of high pressure sour

fuel gas into the ATU.
b. If the ESD system is activated by low-low level in the Amine

Absorber, closes A2-LV15040 to prevent possible blow-through
of high pressure gas into the low pressure sections of the
ATU/ARU.
When S/D valve A2-NV15002 closes to stop the gas flow into the
ATU, the pressure of the incoming sour fuel gas will begin to rise.
When it reaches the setpoint (6.3 kg/cm2(g)) of over-ride pressure
controller A2-PC15001, the controller will open control valve
A2-PV15001 to divert the sour gas to the flare header.
7.5.2.3 Non-ESD Shutdowns and Alarms

In addition to the devices listed in Section 7.5.2.1 that activate the
ATU ESD system, there are several interlocks of significance that
either generate an alarm or shut down an individual piece of
equipment. These devices/interlocks and their effects are described
in this section.
a. Wash Water Column Low-Low Level, A2-LT15014A/B/C
The Wash Water Pump (A2-GA1510A/B) could be damaged if

the pump loses suction because the level in the Wash Water
Column drops too low. This device will protect the pump by
stopping it before this can occur. The setpoint is 450 mm
above the bottom seam of the column. Note that there are
three independent transmitters and 2oo3 voting logic is used for
the shutdown.
b. Treated Fuel Gas High-High H2S, A2-AE15057
This device closes pressure control valve A2-PV15057 to the

treated fuel gas header and opens pressure control valve
A2-PV15059 to the flare header when the H2S concentration for
the treated fuel gas exceeds 200 ppmv.
a. Rich Amine Flash Drum Low-Low Level, A2-LT15068A/B/C

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The Rich Amine Pump (A2-GA1513A/B) could be damaged if

the pump loses suction because the level in the Rich Amine
Flash Drum drops too low. This device will protect the pump by
stopping it and closing the downstream flow control valve
before this can occur. The setpoint is 685 mm above the
bottom of the vessel. Note that there are three independent
transmitters and 2oo3 voting logic is used for the shutdown.
c. Lean Amine Cooler Fan High Vibration, A2-WSH15080
Each fan on the Lean Amine Cooler (A2-EC1510) is provided

with its own vibration switch. If the vibration sensed by the
switch exceeds the preset level, the switch will trip to stop the
associated fan and activate an alarm in the DCS.
d. Stripper Low-Low Level, A2-LT15108A/B/C
The Lean Amine Booster Pump (A2-GA1514A/B) could be

damaged if the pump loses suction because the level in the
Stripper drops too low. Likewise, the Lean Amine Pump
(A2-GA1511A/B) could be damaged if the pump loses suction
because the Lean Amine Booster Pump has stopped. This
device will protect these pumps by stopping both pumps before
this scenario can occur. The setpoint is 450 mm above the
bottom seam line of the column. Note that there are three
shutdown.
e. Stripper Reflux Condenser Fan High Vibration, A2-WSH15118
Each fan on the Stripper Reflux Condenser (A2-EC1511) is

provided with its own vibration switch. If the vibration sensed
by the switch exceeds the preset level, the switch will trip to
stop the associated fan and activate an alarm in the DCS.

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7.6 Process Principles and Operating Techniques

The more important considerations involved in startup, operation, shutdown,
maintenance, and emergency procedures for the ATU and ARU are
discussed in the remaining sections of this portion of the operating guidelines.
The operator should also be thoroughly acquainted with the equipment and
the "Process Description" section of these guidelines 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 the "procedures" sections will be more easily
understood. In addition, the following general discussion of principles and
techniques will clarify the reasons for some of the procedures.
7.6.1 Amine Absorber Operation

The main requirement for the Amine Absorber is to consistently produce
treated fuel gas which contains a low level of residual H2S.
The absorption of H2S in the amine solution is favored by:
1. Low temperature
2. Acid gas loading
3. High amine concentration
4. High H2S partial pressure in the feed stream
5. Intimate contacting
In general practice, items 4 and 5 are not operating variables, having been
fixed by the design criteria for the unit and choice of equipment in the
absorber design.
7.6.1.1 Low Temperature

The lower the temperature of the lean amine solution, the better the
H2S removal. When treating a hydrocarbon gas, however, the lean
amine temperature is limited by the temperature of the gas being
treated. The lean amine temperature must be maintained 3-6°C
higher than that of the gas feed stream to avoid any possible
condensation of these vapors. The circulating lean amine
temperature before it enters the absorber is commonly between
27°C and 49°C.

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7.6.1.2 Acid Gas Loading

Good acid gas removal efficiency depends on good amine solution
regeneration, as will be discussed in the following sections. However,
it also depends on restricting the H2S loading in the rich amine to
favor the forward direction of reaction (1) given in section 7.3.3. The
loading of the amine solution is controlled by adjustment of the amine
circulation rate. In most cases, unless special design considerations
have been employed, the rich amine acid gas loading (H2S plus
CO2) should not exceed 0.3 to 0.4 mols total acid gas per mol of
amine present.
7.6.1.3 High Amine Concentration

The concentration of uncombined amine ion is favored by high amine
concentration in the amine solution, good regeneration, and freedom
from strong acids. Practical and economic considerations confirmed
by field experience have generally shown that the optimum amine
concentration is between 15 and 50 wt-% amine depending upon the
type of amine used. This is based on the lowest heat requirement for
the desired H2S removal, the lowest chemical losses, and the fewest
operational problems. The free amine ion concentration in the lean
amine is mainly affected by the efficiency and control of amine
regeneration. The fewer the sulfide ions in the lean amine, the
greater the free amine ion concentration available for removal of
H2S. In most cases, lean amine should not contain more than 0.03
mol H2S per mol amine nor more than 0.1 mol CO2 per mol amine.
The amine strength should be monitored and the amine content of

the circulating amine should be maintained close to the 45% (by
weight) design value. Should the amine concentration decrease
(normally due to blowdown and other amine losses), it will be
necessary to add fresh amine to compensate. Laboratory
procedures for analyzing amine are given in a later section of these
guidelines.
The amine should also be checked periodically for heat-stable salt

content. Heat-stable salts form when the amine in the amine solution
(a base) reacts with strong acids to form salts that do not decompose
at the normal amine regeneration temperature. The most common
heat-stable salts encountered in amine systems are SO2 salts,
although oxygen contamination of the amine is another common
culprit for heat-stable salts in these systems. Heat-stable salts

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increase the corrosivity of the amine (particularly at higher

temperatures, like in the Stripper Reboiler) and increase the foaming
tendencies of the amine. (Interestingly, heat-stable salts sometimes
improve the H2S-removal capability of the amine, but the higher
corrosion rate caused by the salt far outweighs this advantage.)
A heat-stable salt content of 2 wt % or lower is desirable. Salt

contents in the 5-20 wt % range can be corrosive and should be
avoided if possible. The only way to reduce the heat-stable salt
content of the amine is by dilution, blowing down some of the
circulating amine and making up with fresh amine. There is no
means for regenerating heat-stable salt from the amine while it is in
the ATU/ARU, as vacuum distillation is required. (In recent years,
however, several companies have successfully reclaimed amine
on-line using ion exchange on a slipstream of the amine.) There are
firms that specialize in reclaiming amine (usually off-site), and it may
be economical to use such a firm if a large amount of amine has
been contaminated with heat-stable salts. The best practice,
however, is to avoid forming heat-stable salt in the first place by
proper operation of the ATU, and gas-blanketing the fresh amine to
avoid oxygen contamination.

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7.6.2 Stripper Operation

The lean amine must remain comparatively free of H2S and CO2 to assure
attainment of the fuel gas specification. These acid gases are removed
from the rich amine in the Stripper by stripping them out with steam. The
stripping steam supplies heat to reverse the acid-base reaction between
the H2S/CO2 and the amine, and also reduces the H2S/CO2 partial
pressure in the vapor phase inside the column to promote mass transfer
from the liquid.
The stripping steam is produced by vaporizing some of the water in the

amine in the Stripper Reboiler, using LP (3.5-4.2 kg/cm2(g)) steam for the
heat input. The steam rate to the reboiler (and, hence, the amine stripping
rate) is controlled by A2-FC15112A. Adjust this steam rate as needed to
keep the H2S and CO2 loading in the lean amine low. See Section 7.10 in
these guidelines for appropriate laboratory procedures. For a given
column operating pressure, the overhead temperature is a direct
indication of the stripping rate: the higher the temperature, the more
stripping. Column bottoms temperature should not be used as a guideline
for degree of stripping, as it is a function only of amine concentration and
column pressure.
CAUTION
THE DESIGN STRIPPING STEAM RATE SHOWN ON THE

PROCESS FLOW DIAGRAM SHOULD BE CLOSE TO OPTIMUM.
ALTHOUGH IT MAY BE POSSIBLE TO REDUCE THIS SOMEWHAT
WITHOUT GOING OUT OF COMPLIANCE (I.E., WITH LITTLE
CHANGE IN THE H2S LOADING OF THE LEAN SOLVENT),
REDUCING THE STRIPPING STEAM RATE SIGNIFICANTLY CAN
CAUSE ACCELERATED CORROSION DUE TO HIGH CO2
LOADINGS IN THE LEAN SOLVENT. SEVERAL PLANTS HAVE
REPORTED UNEXPECTEDLY HIGH CORROSION RATES IN THE
HOT, HIGH VELOCITY AREAS OF THE LEAN SOLVENT SYSTEM,
SUCH AS THE OUTLET ENDS OF THE REBOILER TUBES AND
THE LEAN SOLVENT PUMPS, AFTER REDUCING THE REBOILER
STEAM.

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IF IT IS NECESSARY TO OPTIMIZE THE STEAM TO THE

STRIPPER REBOILER, REDUCE THE STEAM BY SMALL
INCREMENTS AND CHECK THE LEAN SOLVENT LOADINGS
(BOTH H2S AND CO2) AFTER EACH CHANGE. DO NOT REDUCE
THE STEAM FURTHER IF EITHER LOADING BEGINS TO RISE
SIGNIFICANTLY, AND BE PREPARED TO PERFORM MORE
EXTENSIVE CORROSION MONITORING WHEN OPERATING THE
STRIPPER IN THIS MANNER. REFER TO SECTION 7.10 OF
THESE GUIDELINES FOR THE PROCEDURES TO BE USED TO
DETERMINE THE LEAN SOLVENT LOADINGS.
The withdrawal of lean amine from the bottom of the Stripper is on flow
control to the Amine Absorber. As a result, the level in the bottom of the
Stripper, which serves as the "surge" for the system, will usually indicate if
adjustments of water makeup to the amine system (or water "bleed" from
the system) are required to maintain the proper water balance, as
discussed later in Section 7.6.3 Even if water must be bled from the
system by diverting some of the column reflux to Sour Water Stripping, the
amine content of that waste stream should be low and only infrequent
makeup of fresh amine should be required.
It may also be necessary to "purge" ammonia from the reflux water

periodically by routing some of the reflux water to the Sour Water
Stripping Unit. Although ammonia is usually removed by the circulating
water in the Wash Water Column, over a period of time, however, some of
the ammonia may carry over into the Amine Absorber and dissolve in the
amine.
When this ammonia-containing amine reaches the Stripper, the ammonia

becomes "trapped" because it is too light (volatile) to leave in the column
bottoms and too heavy to leave in the overhead (the acid gas). As a
result, the ammonia will become concentrated in the reflux water, to the
point where it exceeds its solubility limits and begins to cause plugging
problems. If this problem is suspected, simply "bleed" a small amount of
the reflux water to the disposal header to purge the ammonia from the
system, using the bleed water flow controller in the DCS to control the
bleed water rate while monitoring the reflux flow rate to ensure that
adequate reflux is maintained to the Stripper. Operating experience will
show how often (and how much) the reflux must be purged in this manner
to prevent excessive ammonia concentrations for a particular plant.

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There is full-flow of rich amine through the Rich Amine Filter, and full-flow
of lean amine flow through the Lean Amine Filter, the Lean Amine Carbon
Filter, and the Lean Amine After-Filter. These four filters will remove
solids and organic contaminants from the circulating amine, such as
degradation or corrosion products. The filter elements should be changed
as soon as the "change" pressure drop is reached, to remove as many
solids from the amine as possible. Finely divided solids can cause
foaming and thereby limit column capacity. While it is possible to reduce
foaming to some extent with anti-foam agents, the presence of such
agents may also reduce H2S/CO2 selectivity in the Amine Absorber, so it
is preferable that they not be used as an alternative to regular
conscientious filter maintenance
7.6.3 Amine Water Balance

The water content of the circulating amine is determined by the following
factors:
1. The water content of the feed gas to the Amine Absorber (the
overhead from the Wash Water Column).
2. The water content of the treated gas leaving the Amine

Absorber.
3. The water content of the acid gas leaving the Stripper Reflux
Accumulator.
4. The amount of water makeup to (or water "bleed" from) the

amine system.
For given operating pressures, the water content of each gas stream will
be determined by the temperature at the top of the respective vessel
(Water Wash Column, Amine Absorber, and Stripper Reflux Accumulator,
respectively), and will increase as the temperature increases. Since the
Amine Absorber inlet gas is at a slightly higher pressure than the outlet
treated gas, the inlet gas will normally contain less water than is contained
in the outlet gas (if both gas streams are at the same temperature), thus
requiring water makeup to maintain the proper water content of the amine.
This situation will be reversed if the Amine Absorber overhead
temperature is lower than the Wash Water Column overhead temperature,
requiring a "bleed" of water to maintain water balance.

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Since the lean amine to the Amine Absorber is on flow control and
withdrawal of the rich amine from the bottom of the Amine Absorber is on
level control, a net gain or loss in the amine water balance will be reflected
by an increase or decrease, respectively, of the liquid level in the bottom
of the Stripper. Observation of this liquid level can thus guide adjustment
of water makeup/bleed rate or operating conditions to maintain the desired
water concentration of the circulating amine. Since the degree of H2S
removal can depend on the amine concentration of the amine, the
concentration should be maintained close to the design value (45 wt %)
by appropriate maintenance of water concentration. It is usually possible
to control the water balance without adding fresh water or "bleeding" water
to the Sour Water Stripping Unit by adjusting the operating temperatures
in the unit, as discussed in the following paragraphs. Following the steps
outlined below will allow controlling the water balance with minimum
usage of treated makeup water and minimum impact on the sour water
system.
A persistently increasing liquid level in the bottom of the Stripper at

constant flow rates and conditions for Amine Absorber feed gas and
amine indicates a gain in the amine water content. To reduce the water
content of the amine, the preferred sequence of gradual adjustments is:
A. Reduce or terminate water makeup to the amine. Makeup water is

cold condensate.
(1) Begin "bleeding" water (or increase the "bleed" water rate) from
the amine system with the flow controller on the discharge line
of the Stripper Reflux Pump.
Be careful, however, not to starve the Stripper for reflux by

withdrawing too much water. Use the DCS flow indicator for the
reflux water to monitor the operation so that adequate reflux is
maintained to the Stripper when bleeding water from the amine
system.

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CAUTION
UNDER NORMAL CONDITIONS, THE REFLUX WATER

CONTAINS LITTLE OR NO AMINE BECAUSE OF THE "WASH
WATER" TRAYS ABOVE THE SOLVENT FEED TRAY IN THE
STRIPPER. HOWEVER, IF THE STRIPPER IS FLOODING OR
FOAMING (AS INDICATED BY HIGH OR ERRATIC COLUMN
DIFFERENTIAL PRESSURE), THE REFLUX CAN CONTAIN
LARGE AMOUNTS OF AMINE.
IF THE "BLEED" WATER LINE IS IN USE AT SUCH TIMES, A

SIGNIFICANT QUANTITY OF SOLVENT CAN BE LOST TO
THE SOUR WATER SYSTEM, AND WILL HAVE TO BE
REPLACED WITH FRESH AMINE FROM THE STORAGE
TANK. FOR THIS REASON, THE "BLEED" WATER SYSTEM
SHOULD BE BLOCKED-IN DURING UPSETS IN THE
STRIPPER.
(2) Increase the Amine Absorber overhead temperature by raising

the setpoint of the lean solvent temperature controller to
increase the lean solvent temperature.
This will increase the amount of water leaving in the fuel gas,
and it will also reduce the H2S-removal capability of the solvent.
An increase in solvent flow rate will probably be needed to
maintain the same H2S content in the vent gas, increasing the
load on the Stripper and the other process equipment
associated with the circulating solvent.
(3) Increase the acid gas temperature by increasing the

temperature setpoint of the reflux temperature controller to raise
the outlet temperature from the Stripper Reflux Condenser.
Although this will increase the water content of this stream and
reduce the water in the solvent, the effect will be small because
the quantity of acid gas is small relative to the fuel gas. This
adjustment is the least effective and would not normally be
considered during routine operations.

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(4) Should the solvent inventory be difficult to control due to

continuing problems with an excessive amount of water in the
solvent, the steam-heated Stripper Reboiler should be checked
for tube leaks.
B. Conversely, a persistently decreasing liquid level in the bottom of the

Stripper indicates a loss in the solvent water content. To increase
the water content of the solvent, the preferred sequence of gradual
adjustments is:
1. Reduce or terminate the "bleed" water from the Stripper Reflux

Accumulator.
2. Decrease the Amine Absorber overhead temperature by

lowering the lean solvent temperature with the lean solvent
temperature controller to reduce the amount of water leaving in
the fuel gas.
3. Decrease the acid gas temperature with the aerial cooling from
the Stripper Reflux Condenser to reduce the water loss in the
stream as much as possible.
4. Begin water makeup (or increase the makeup water rate) to the
solvent system using the make-up flow controller to add
condensate to the system..
7.6.4 Amine Loss

The loss of MDEA by chemical degradation in the ATU/ARU is expected
to be negligible because the upstream Wash Water Column should wash
out any acids or other contaminates that enter with the sour fuel gas.
Amine degradation can occur, however, under abnormal operating
conditions.
Amine degradation occurs via reactions with acids which can enter the
Amine Absorber when the Wash Water Column is experiencing an upset.
Any traces of acid entering the Amine Absorber will react with the MDEA
to form a thermally non-regenerable complex (i.e., heat-stable salt). If
present in sufficient quantity, this salt can alter the H2S-amine equilibrium
and prevent removal of H2S to the desired level in the Amine Absorber
overhead. Heat-stable salts also increase the corrosivity of the amine.
Amine quality can be restored by treatment with an amount of caustic
equivalent to the non-regenerable salt present but, if repeated caustic

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treatments are necessary due to repeated mal-operation, the potential for

salt deposition in the system may rise.
The equipment in the ATU/ARU, including the seals of pumps and

blowers, should be operated at positive pressure to minimize the potential
for oxygen (air) ingress into the amine. Oxygen will react with the amine
to produce carboxylic acids that cause the solution to be corrosive. For
this same reason, it is important to maintain an inert gas "blanket" on the
MDEA storage tank to prevent oxygen contamination of the fresh amine.
Amine losses due to entrainment in the treated fuel gas or the acid gas
can be minimized by proper process operation (avoidance of column
overloading, foaming, etc.) and routine inspection of the vessel internals.
Amine losses in the water "bleed" from the Stripper reflux should be
negligible if the rectifying trays (the "wash water" trays above the amine
feed point) in the Stripper are operating properly (no flooding or foaming,
no mechanical damage).
The primary source of amine loss will likely be the mechanical losses from
pump drips, cleaning of filters, etc. Good housekeeping practices,
including prompt replacement or repair of leaking pumps, together with
proper collection of amine drips for reuse (via the ATU Drips Tank,
A2-FA1580), will minimize the mechanical loss of amine.

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7.6.5 Operation at Low Flow Rates

The ATU/ARU contains four columns: the Wash Water Column and the
Flash Gas Contactor, which contain structured packing; and the Amine
Absorber and Stripper, which contain valve trays. In general, the liquid
feed rate to packed towers can decrease in proportion with the gas flow
rate down to about 50% of design gas flow rate. Below this point, the
liquid rate cannot be allowed to drop any further without risking poor
column performance due to uneven liquid distribution and wetting of the
packing. Trayed towers typically offer somewhat better turndown,
allowing the liquid rate to drop to 30-40% of design before "weeping" of
the trays begins to significantly affect performance.
In the case of the Wash Water Column, decrease the wash water rate in
proportion with the gas flow rate down to about 50% of design should
maintain adequate performance. (It should be noted, however, that there
is really no detrimental effect if the wash water circulation is simply left at
the design value at all times. The only drawback is slightly higher power
consumption by the pump and aerial cooler.)
In the packed Amine Absorber, circulating more amine relative to the gas
flow rate should maintain performance. The liquid flow rate should be
maintained at a minimum of about 50%.

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7.7 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.
7.7.1 Preliminary Check-out

Check all equipment to ensure that it is properly installed. This will
probably require consulting Manufacturer's literature as well as
construction drawings.
A. Check and lubricate all equipment, in accordance with the

Manufacturer's recommendations.
B. Check the rotation of the following pumps by "bumping" them:

(1) Wash Water Pump.
(2) Rich Amine Pump.
(3) Stripper Reflux Pump.
(4) Lean Amine Pump.
(5) Lean Amine Booster Pump
(6) ATU Skim Oil Pump
(7) MDEA Transfer Pump
C. Check the rotation of the fans on the Lean Amine Cooler and the
Stripper Reflux Condenser, by operating each fan for a short period.
D. Check all piping and equipment to be sure that all blinds have been
removed and that no valves are vented to atmosphere.
E. Place the Instrument Air System in service to all instruments and

check the action of controllers and control valves.
F. Check all relief valves to ensure that they are installed in the proper
locations, the inlet and outlet block valves (if provided) are open, the
bypass valves (if provided) are closed, and the relief valves are set
for the correct relieving pressure.

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7.7.2 Shutdown System Check-out

A. Physically check all shutdown activating devices to ensure that they
activate the ESD system.
B. Physically check all devices activated by the ESD system to ensure

that they operate properly.
C. Check all relief valves to ensure that they are installed in the proper
locations and set for the correct relieving pressures.
D. The low-low level shutdowns for the pumps in the wash water and
amine systems will be tested while washing these systems as
described in the following sections.
7.7.3 Leak Testing the Process Piping and Equipment

The process piping and equipment in the ATU can be checked for leaks
by using a temporary nitrogen “jumper” to pressurize the process side of
the equipment and piping to about 0.6-0.7 kg/cm2(g), then checking
flanges, etc. for leaks (usually by applying masking tape or "Snoop" to the
flanges, and by listening for other leaks).
This same procedure can be used to leak test the ATU following
maintenance, before restarting the unit. Whenever plant maintenance
requires opening one or more of the flanged connections in the ATU it is
good practice to leak test the unit before returning it to service. This
allows detecting any leaking connections that may have resulted from the
maintenance operations before sour fuel gas is reintroduced into the unit.
To perform leak testing in the ATU, proceed as follows:
A. Reduce the output from the sour fuel gas hand control in the DCS to
0% to close the Sour Fuel Gas inlet valve.
B. Confirm that the Wash Water Column is isolated from the wash water
circulation loop by confirming that the following valves are all closed:
(1) The bypass valve and downstream block valve at the wash
water flow control valve.
(2) The suction valves at the Wash Water Pumps.
(3) The drain valve on the suction line to the pumps.

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(4) The bypass valve and downstream block valve at the make-up
C. Confirm that the Amine Absorber is isolated from the solvent

(1) The bypass valve and downstream block valve at the lean
solvent flow control valve.
(2) The bypass valve and upstream block valve at the Absorber
level control valve.
(3) The drain valve upstream of the level control valve.
(4) The block valves in the water makeup line.
overhead pressure control valve to the SRUs.
overhead pressure control valve to the flare.
D. Use a temporary "jumper" to connect a nitrogen supply to one of the

level bridles on the Wash Water Feed Knock-out Drum and establish
a flow of nitrogen into the unit.
E. Continue adding nitrogen until the pressure reaches

0.6-0.7 kg/cm2(g).
Due to the volume inside the ATU, it will take several minutes for the
pressure to build up in the unit.
F. Once the desired pressure has been achieved close the valve where
the nitrogen "jumper" is connected to stop the flow of nitrogen. Check
all of the equipment and piping connections for visible or audible
signs of leakage.
G. Disconnect the nitrogen jumper.
H. Re-open valves as necessary to restore the wash water and solvent

circulation loops that were isolated from the columns in the previous
steps.

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7.7.4 Washing the Wash Water System

The following procedure is intended to remove grease, rust, scale, dirt,
and trash from the equipment and piping in the Wash Water system
before it is placed in operation. Washing of the system consists of three
steps: an initial water flush to remove dirt and trash from the system; an
acid wash to remove grease, rust, and scale; and a caustic wash to
acclimate the equipment and piping to alkaline pH.
Failure to clean the system properly prior to startup can lead to operating
problems (heat exchanger fouling, rapid filter plugging, etc.).
WARNING
THIS PROCEDURE REQUIRES WORKING WITH ACIDIC AND

ALKALINE CHEMICALS AND SOLUTIONS. EMPLOYEES MUST
OBSERVE ALL APPLICABLE SAFETY PROCEDURES AND
ENVIRONMENTAL REGULATIONS CONCERNING USAGE OF
PERSONAL PROTECTIVE EQUIPMENT, HANDLING OF
HAZARDOUS MATERIALS, DISPOSAL OF WASTE STREAMS, ETC.
7.7.4.1 Water Flush

A. Place the Wash Water flow controller in the DCS in "manual"
and set its output to 100% to fully open the Wash Water flow
control valve.
B. Place the Wash Water Column level controller in the DCS in

"manual" and set its output to 0% to fully close the level control
valve.
C. Confirm that the Sour Fuel Gas inlet hand control in the DCS is
set to 0% output so that the Sour Fuel Gas inlet valve is fully
closed.
D. Verify that the Wash Water flow control valve is fully open.
Open both of its isolation block valves and its bypass valve.
E. Verify that the Wash Water Column level control valve is fully
closed. Close both of its isolation block valves and its bypass
valve.

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F. Verify that the Sour Fuel Gas inlet valve is fully closed. (This
will prevent water from entering the upstream equipment if the
Wash Water Column is accidentally over-filled.)
G. The Wash Water Filters will not be used to filter solids during
this time, but the filter vessels and their piping are to be flushed
and cleaned. Remove the filter elements, then bolt-up the
filters. Open the inlet and outlet block valves on the filters, and
open the bypass valve around the filters.
H. Add water to the top of the Wash Water Column by placing the
Make-up Water flow control valve in manual and setting its
output to 100% to fully open the make-up water flow control
valve.
If make-up water is not available from the Sour Water Stripping

unit, use a temporary jumper to supply water (cold condensate)
to the Wash Water Column.
I. Once there is an adequate level in the column, all the way to

the top of its level gauge open the suction valve on a Wash
Water Pump and use its drain valve to be sure the pump is
flooded with water. Start the pump, then open its discharge
valve.
J. Watch the level in the Wash Water Column while placing the
pump in service to be sure the pump does not lose suction
while filling the downstream piping and equipment. If the level
disappears in the column, shut the pump down until enough
water (or condensate) is added to reestablish the level, then
restart the pump.
K. Once circulation is achieved and the level in the Wash Water

Column is adequate (about halfway up in the level gauge),
discontinue the addition of water (or condensate).
L. Use the low point drain valves to flush out each section of the
system. Leave the drain valves open until the water is clear.
M. Briefly open the bypass valve on the Wash Water Column level
control valve to flush this section of piping to The Sour Water
Stripping Unit. Open the upstream block valve, open the Wash
Water Column level control valve with the level controller in the

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DCS, and use the downstream drain valve to flush the control
station. Once the flush water clears up, close the Wash Water
Column level control valve and the upstream block valve.
N. Circulate the water and blow down the low point drains until all
of the drain water is clear. Add more water ( or condensate) as
necessary to maintain the level in the Wash Water Column.
At some point during the washing procedure, the standby pump

should be placed in service while the other pump is shut down.
This will ensure cleaning out both pumps and their associated
piping.
O. Once the drain water is clear, completely drain the system.

Drain the system as quickly as possible, so that the water
velocity helps to flush the solids from all parts of the system.
P. Allow the pump to continue running while the system drains, but
watch the pump closely to verify that the low-low level shutdown
shuts the pump down below the shutdown setpoint. If the level
drops completely out of the gauge glass before the pump shuts
down, stop the pump manually and correct the problem with the
low-low level shutdown before proceeding further.
7.7.4.2 Acid Wash

A weak (0.1 wt %) citric acid solution is used next to remove grease,
rust, and scale from the equipment and piping. The citric acid will
chelate with the iron in the rust and scale so that it dissolves in the
solution.
A. Reestablish a level in the Wash Water Column.
B. Once a level is established, start a Wash Water Pump to begin

circulating the water.
C. Add concentrated citric acid to the circulating water to make a

0.1 wt % citric acid solution.
D. After circulating for about 3 hours, start the other Wash Water
Pump and shut down the first one.
E. Circulate the solution for a total of about 6 hours, blowing down

the low point drains occasionally. Add more water (or

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condensate) if necessary to maintain the level in the Wash

Water Column.
F. Briefly open the bypass valve on the Wash Water Column level
control valve to flush this section of piping to The Sour Water
Stripping Unit. Then open both block valves and use the level
controller in the DCS to open the Wash Water Column level
control valve briefly and flush the control station. Close the
Wash Water Column level control valve and the block valves.
G. After 6 hours, shut down the pump and completely drain the
system. Drain the system as quickly as possible, so that the
liquid velocity will help flush any remaining solids from the
system.
7.7.4.3 Alkaline Wash

The washing operation is completed by circulating a weak alkaline
solution through the system. This will neutralize any citric acid left in
the system, and acclimate the system to high pH operation so that no
further scale is removed from the equipment and piping when the
normal Wash Water (8.0-9.5 pH) is circulated.
A. Reestablish a level in the Wash Water Column.
B. Once a level is established, start a Wash Water Pump to begin

C. Add caustic to the circulating water to make a 0.02 wt%

solution. This should give a pH in the range of 11-22.
D. Check the pH of the circulating water. If the pH is less than 11,

add more caustic until the pH is 11 or higher.
E. After circulating for about 1 hour, start the other Wash Water
Pump and shut down the first one.
F. Circulate the solution for a total of about 2 hours, blowing down

the low point drains occasionally. Add more water (or
condensate) if necessary to maintain the level in the Wash
Water Column.
G. Briefly open the bypass valve on the Wash Water Column level
control valve to flush this section of piping to the sour water
header. Then open both block valves and use the level

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controller in the DCS to open the Wash Water Column level

Wash Water Column level control valve and the block valves.
H. After 2 hours, shut down the pump and completely drain the
system.
7.7.4.4 Initial Water Fill

The Wash Water system should now be clean and ready to place in
service. All that remains is to refill the system with water and
establish the proper operating conditions.
A. Close the inlet and outlet block valves on the Wash Water
Filters (but leave the bypass valve open), then install the proper
element(s) in the filters. Leave the block valves closed for now.
B. Reestablish a level in the Wash Water Column.
C. Once a level is established, start a Wash Water Pump to begin

D. Place the Wash Water Filters in service as follows:
(1) Open the vent valves on the top of the filters.
(2) "Crack" the filter inlet block valves open slightly and allow
the filters to fill with water. When the filter is full, close the
vent valve.
(3) Open the filter inlet block valves fully and open the outlet
block valves, then close the filter bypass valve.
E. Place the Wash Water flow controller in the DCS in service and
set its setpoint to its normal value. Close the bypass valve on
the Wash Water flow control valve.
F. Confirm that the Wash Water Column level control valve is

closed, then open both of its block valves. Place the level
controller in the DCS in service and set its setpoint to its normal
value.
G. Establish cooling water flow to the Amine Absorber Overhead

Cooler.

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The Wash Water system is now ready for service. It can remain in
this operating mode indefinitely while the rest of the ATU is prepared
for startup. Check the system periodically for indications of plugging,
etc. (low flow, erratic pump discharge pressure, high filter pressure
drop), as solid materials may accumulate at various points in the
system over time.
7.7.5 Washing the Amine System

and trash from the equipment and piping in the solvent system before it is
placed in operation. Washing of the system consists of three steps: an
initial water flush to remove dirt and trash from the system; an acid wash
and rinse to remove grease, rust, and scale; and a weak amine wash and
rinse to acclimate the equipment and piping to alkaline pH.
problems (column foaming, poor treating, heat exchanger fouling, rapid
filter plugging, etc.).
WARNING

7.7.5.1 Water Flush

A. Place the following controllers in the DCS in "manual" with their
outputs set as indicated:
(1) Set the output from the lean solvent flow controller to
100% to fully open the lean solvent flow control valve.
(2) Open the manual block valve upstream of the lean solvent
filters.

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(3) Set the output from the lean solvent filter bypass flow
controller to 100% to fully open the filter bypass flow
control valve.
(4) Set the output from the Amine Absorber level controller to
100% to fully open the Amine Absorber level control valve.
(5) Set the output from the Rich Amine flow controller to 100%
to fully open the rich amine flow control valve.
(6) Set the output from the amine flow controller to the Flash
Gas Contactor to 100% to fully open the flow control valve.
(7) Set the output from the Stripper Reboiler steam flow
controller to 0% to fully close the steam flow control valve.
(8) Set the output from the Stripper Reflux Accumulator level
controller to 0% to fully close the Stripper Reflux
Accumulator level control valve.
(9) Set the output from the bleed water flow controller to 0% to
fully close the bleed water flow control valve.
(10) Set the output from the flow controller on the spill-back line
to the lean amine cooler to 0% to fully close the spill-back
flow control valve.
(11) Set the output from the makeup water flow controller to 0%
to fully close the makeup water flow control valve.
(12) Set the output from the Stripper pressure controller to 0%

to fully close the overhead pressure control valve to the
SRU.
(13) Set the outputs from the two temperature controllers to 0%

to fully close both temperature control valves to the DHT
Unit.
(14) Set the output from the lean solvent flow controller to the
LPG Treating Unit to 0% to fully close the lean solvent flow
control valve to the LPG Treating Unit.
B. Place the other Stripper pressure controller in "automatic" with a

setpoint of 0.85 kg/cm2(g). This will open the pressure control

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valve to the flare if pressure builds in the Stripper during this

procedure.
C. Verify that the following control valves are fully open. Open
both of the isolation block valves and the bypass valve (where
applicable) at each control station.
(1) The lean amine flow control.
(2) The lean amine filter bypass.
(3) The Amine Absorber level control, (the rich solvent from
the Amine Absorber).
(4) The rich solvent flow control (the rich solvent from the Rich
Amine Flash tank)
(5) The lean solvent to the Flash Gas Contactor
D. Verify that the following control valves are fully closed. Close
both of the isolation block valves and the bypass valve at each
control station.
(1) The steam flow control valve to the Stripper Reboiler.
(2) The Stripper Reflux Accumulator level control valve.
(3) The bleed water flow control valve from the Stripper reflux.
(4) The spill-back flow controller to the Lean Amine Cooler.
(5) The makeup water flow control valve.
(6) The acid gas pressure control to the SRU.
E. Verify that the bypass valve on the pressure control valve to the
flare is closed. Open both of the isolation block valves at this
control station.
F. The solvent filters will not be used to filter solids during this
time, but the filter vessels and their piping are to be flushed and
cleaned. Remove the filter elements, then bolt-up the individual
filters. Open the inlet and outlet block valves on each filter, and
open the bypass valves for the filters.
G. Verify that the valves in the amine makeup line are closed.

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H. Add water (cold condensate) to the Amine Absorber by opening

the flow control valve in the make-up water line.
I. Once there is an adequate level in the Rich Amine Flash Tank,

all the way to the top of its level gauge open the suction valve
on a Rich Amine Pump and use its drain valve to be sure the
pump is flooded with water. Start the pump, then open its
discharge valve.
Watch the level in the Amine Absorber and the Rich Amine
Flash Tank as the pump fills the downstream piping and begins
to fill the Stripper. When the level drops to the low-low level
shutdown it should shut down the pump. If it does not, stop the
pump manually before it loses suction and correct the problem
with the low level shutdown before proceeding.
J. Continue filling the Amine Absorber with condensate and

pumping the water to the Stripper periodically, until the level in
the Stripper is all the way to the top of its level gauge.
K. Once there is an adequate level in the Stripper, open the

suction valve on a Lean Amine Booster Pump and use its drain
valve to be sure the pump is flooded with water. Start the
pump, then open its discharge valve.
L. Once the downstream piping and equipment has been filled

with water, open the suction valve on a Lean Amine Pump and
use its drain valve to be sure the pump is flooded with water.
Start the pump, then open its discharge valve
M. As the pump fills the downstream piping and begins to return

water to the Amine Absorber, watch the level in the Stripper to
be sure the Lean Amine Booster Pump does not lose suction. If
the level disappears in the column, shut both pumps down, add
more condensate to the Amine Absorber and pump it to the
Stripper to reestablish the level, then restart the Lean Amine
Booster Pump and the Lean Amine Pump.
N. As the level begins to rise in the Amine Absorber, restart the

Rich Amine Pump. Watch the levels in both columns, and shut
a pump down if necessary to keep from emptying either
column.

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O. Once the levels in both columns are adequate, discontinue the

addition of condensate.
P. At this point, neither the flow into or the level of the Amine
Absorber is being controlled. Both control stations are in
"manual" with the valves fully open to flush the piping as much
as possible. Depending on the hydraulics of the system, it may
be necessary to place either or both of these controls in
"automatic" to prevent losing the level in one of the columns. If
so, leave the bypass valve on the control station "cracked" so
that the bypass piping gets flushed.
Q. Use the low point drain valves to flush out each section of the
R. Circulate the water and blow down the low point drains until all
of the drain water is clear. Add more condensate as necessary
to maintain the levels in the columns.
At some point during the washing procedure, the standby Rich

Amine Pump, standby Lean Amine Pump, and standby Lean
Amine Booster Pump should be placed in service while the
other pumps are shut down. This will ensure cleaning out both
pumps and their associated piping in each service.
At some point in the washing procedure, open the flow control

valve in the spill-back line to the Lean Amine Cooler to clean
out this section of piping. Then close the control valve again.
S. Once the drain water is clear, shut down the Rich Amine Pump
and completely drain the system. Drain the system as quickly
as possible, so that the water velocity will help flush the solids
from all parts of the system.
T. Allow the Lean Amine Pump and the Lean Amine Booster
Pump to continue running while the system drains, but watch
the pumps closely to verify that the Stripper low-low level
shutdown shuts the pumps down when the level falls to the
shutdown setpoint. If the level drops completely out of the
gauge glass before the pumps shut down, stop the pumps
manually and correct the problem with the low level shutdown
before proceeding further.

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U. Confirm that the solvent transfer line (for MDEA makeup) has
been flushed and is ready for service.
7.7.5.2 Acid Wash

solution.
A. Use the make-up water line to re-establish the levels in the

Amine Absorber, Rich Amine Flash Tank, and the Stripper as
before, and establish circulation of water in the system.
B. Add concentrated citric acid to the circulating water to make a

C. Begin steam flow to the Stripper Reboiler and gradually raise

the temperature of the circulating solution. For maximum
effectiveness, the solution should be 65-95°C throughout the
system, so adjust the steam flow accordingly. The fans on the
Lean Amine Cooler should not be operating at this time.
D. It is unlikely that any steam will leave the top of the Stripper
during this operation, so the Stripper Reflux Accumulator should
remain dry. If a level should develop in this vessel, drain the
water from the vessel using a drain valve on one of the Stripper
Reflux Pumps.
E. After circulating for about 3 hours, start the other Rich Amine
Pump and shut down the first one. Do the same with the Lean
Amine Pumps and the Lean Amine Booster Pumps.
F. Open the flow control valve in the spill-back line to the Lean
Amine Cooler and circulate through this section of piping. Then
close the control valve.
G. Circulate the hot solution for a total of about 6 hours, blowing

down the low point drains occasionally. Add more condensate
if necessary to maintain the levels in the columns.
H. After 6 hours, shut off the steam to the Stripper Reboiler, shut
down the pumps, and completely drain the system. Drain the
system as quickly as possible, so that the liquid velocity will
help flush any remaining solids from the system.

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I. Use the condensate makeup line to reestablish the levels in the

Amine Absorber and the Stripper as before, and establish
circulation of water to flush the system.
J. Switch to the other pumps for a few minutes, then shut down
the pumps and completely drain the system.
K. Once again, use the condensate makeup line to reestablish the

levels in the Amine Absorber and the Stripper as before, and
establish circulation of water in the system.
L. Reestablish steam flow to the Stripper Reboiler and gradually

raise the temperature in the column.
M. When the temperature begins to rise in the Stripper overhead

line, start a fan on the Stripper Reflux Condenser and place the
reflux temperature controller in service with a setpoint of 49°C.
N. When a level builds in the Stripper Reflux Accumulator, drain it

to the closed drain from the drain on one of the pump cases.
O. Open the downstream block valve at the Stripper Reflux

Accumulator level control valve, then use the drain valve to
blow steam from the column backwards down the reflux line to
remove any debris. Continue until the steam blows clear, then
close the drain valve and the block valve.
P. Continue to circulate water and apply heat in the Stripper

Reboiler, until the water drained from the Stripper Reflux
Accumulator is clear. During this time, blow down the low point
drains occasionally and add more condensate if necessary to
maintain the levels in the columns, and switch to the other Rich
Amine Pump, Lean Amine Booster Pump, and Lean Amine
Pump.
Q. Once the reflux loop has cleared up (the drain water is clear),
shut off the steam to the Stripper Reboiler, shut down the
pumps, and completely drain the system. Drain the system as
quickly as possible, so that the liquid velocity will help flush any
remaining solids from the system.
R. Check the pH of the water draining from the system. If

necessary, repeat Steps K through Q until the pH of the drain
water is about the same as the pH of the condensate makeup.

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7.7.5.3 Weak Amine Wash

The washing operation is completed by circulating a weak amine
the system, and acclimate the system to alkaline pH operation so
that no further scale is removed from the equipment and piping when
the normal solvent is circulated.
A. Use the condensate makeup line to reestablish the levels in the

circulation of water in the system.
B. Add enough MDEA to the circulating water to reach a

concentration of about 1 wt%.
C. Begin steam flow to the Stripper Reboiler and gradually raise

the temperature in the column.
D. When the temperature begins to rise in the Stripper overhead

line, check that at least one of the fans is running on the
Stripper Reflux Condenser.
E. When a level builds in the Stripper Reflux Accumulator, open

the suction valve on one of the Stripper Reflux Pumps and use
its drain valve to be sure the pump is flooded with water. Start
the pump, open its discharge valve, then open the bypass valve
on the Stripper Reflux Accumulator level control valve to pump
the water back into the Stripper.
Watch the level in the Stripper Reflux Accumulator while

pumping it out. Shut the pump down when the vessel is empty,
then close the suction and discharge valves on the pump and
close the bypass valve on the Stripper Reflux Accumulator level
control valve.
F. Continue to circulate the solution and apply heat to the Stripper

Reboiler, pumping out the Stripper Reflux Accumulator as
required by alternating which pump is used. During this time,
blow down the low point drains occasionally and add more
condensate if necessary to maintain the levels in the columns,
and switch to the other Rich Amine Pump, Lean Amine Booster
Pump and Lean Amine Pump.

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G. During one of the pumping cycles for the Stripper Reflux

Accumulator, flush out the minimum flow spill-back line by
opening the manual block valve to allow circulation through this
line. Then close the manual block valve.
H. During another pumping cycle, flush out the bleed water piping
by setting the output of the bleed water flow controller to 100%
to fully open the bleed water flow control valve, opening its
upstream and downstream block valves, and opening its
bypass valve. Then close the valves and set the output of the
bleed water flow control valve back to 0%.
I. Take a sample of the circulating solution and run a foam test on

it using the procedure in Section 7.10.
J. Once the solution drained from all the low point drain valves is
clear, shut off the steam to the Stripper Reboiler, shut down the
pumps, and completely drain the system. Drain the system as
quickly as possible, so that the liquid velocity will help flush any
remaining solids from the system.
K. Use the condensate makeup line to reestablish the levels in the

circulation of water to flush the system.
L. Open the control valve in the spill-back line to the Lean Amine
Cooler for a few minutes, then close the control valve.
M. Switch to the other pumps for a few minutes, then shut down
N. If the solvent sample taken in Step I was foamy, repeat Steps A

through M until the solvent is not foamy.
7.7.5.4 Initial Solvent Fill

The solvent system should now be clean, ready to place in service.
All that remains is to fill the system with the proper solvent charge
and establish the proper operating conditions.
NOTE: This procedure prepares the solvent system for operation

in the shortest possible time. However, it does allow the
MDEA to come in contact with oxygen that is in the Amine
Absorber. If a slightly longer startup schedule can be
tolerated, this deficiency can be minimized or eliminated

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by deferring the procedure in this section until nitrogen has

been used to purge the Wash Water Column and Amine
Absorber as described in the following section.
A. Close the inlet and outlet block valves (but leave the bypass
valves open) on the solvent filters, then install the proper
elements and/or carbon in the filters. Leave the block valves
closed on each filter for now.
B. Use the condensate makeup line to reestablish the levels in the

circulation of water in the system.
C. Add enough MDEA to the circulating water to reach a

D. Place in service and adjust the level controller on the Amine

Absorber to maintain its normal setpoint. Stop the condensate
and/or amine makeup when the Stripper level is about 50-60%.
E. Begin steam flow to the Stripper Reboiler and gradually raise

the temperature in the column. Place the steam flow controller
in the DCS on "automatic" with its setpoint set to its normal
value.
F. Open the high point vent valve on the Stripper overhead line
and allow the steam to purge any air from the vessel. As the
pressure builds, the vent valve can be closed.
G. Monitor the stripper pressure, and adjust the overhead pressure

controller if necessary to maintain the stripper pressure at about
0.85 kg/cm2(g) as the system is heated to operating
temperatures.
H. Ensure that the fans are running on the Lean Amine Cooler and
the Stripper Condenser.
I. Place the lean solvent temperature controllers in "automatic"

and set their setpoints to their normal values.
J. When a level builds in the Stripper Reflux Accumulator, open

the suction valve on one of the Stripper Reflux Pumps and use
its drain valve to be sure the pump is flooded with water. Open
the block valves upstream and downstream of the reflux flow

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control valve, place the reflux flow controller in "automatic" with

its setpoint set to its normal value, then start the pump and
open its discharge valve.
K. Open the block valves on the Stripper Reflux Accumulator level

control valve and place the level controller in the DCS in
"automatic" with its setpoint set to its normal value. The
Stripper Reflux Accumulator level control valve will now open as
needed to pump water back into the Stripper and maintain the
desired level in the Stripper Reflux Accumulator.
L. If the control loops on the solvent have not already been placed
in service, do so at this time. Switch the Amine Absorber level
controller, and the lean solvent flow controller in the DCS to
"automatic" with their setpoints set to their normal values.
M. Place the Amine flow controller to the Flash Gas Contactor in

“automatic” and set its setpoint to its normal value.
N. Place the level controller for the Rich Amine Flash Tank in
service as follows:
(1) Confirm that the level controller in the DCS is in

"automatic".
(2) Confirm that the remote setpoint the level controller is

supplying to the rich amine flow controller matches the
current local setpoint on the flow controller.
(3) Switch the rich amine flow controller to "cascade" mode so

that the setpoint for the rich amine flow will now be adjusted
automatically by the level controller.
(4) The setpoint of the level controller will be set at the last
reading. Adjust the setpoint to its normal value.
O. Place each of the solvent filters in service as follows:
(1) Open the vent valve on the top of the filter.
(2) "Crack" the filter inlet block valve open slightly and allow
the filter to fill with solvent. When the filter is full, close its
vent valve.
(3) Open the inlet and outlet block valves on the filter.

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(4) Slowly close the valve in the bypass line around the filter.
P. Analyze a sample of the circulating solvent using the procedure

in these guidelines to determine the amine concentration. Add
more fresh MDEA using the solvent transfer line if needed to
bring the concentration up to the design value, 45 wt %.
Q. Confirm that the bleed water flow controller is in "manual' with

its output set at 0% and that the bleed water flow control valve
is closed, then open its upstream and downstream block valves.
The solvent system is now ready for service. It can remain in this
operating mode indefinitely while the rest of the Sulfur Block is
prepared for startup. Check the system periodically for indications of
plugging, etc. (low flow, erratic pump discharge pressure, high filter
pressure drop), as solid materials may accumulate at various points
in the system over time.

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7.7.6 Purging the Low Pressure Columns

Prior to starting up the using the procedures in Section 7.8 of these
guidelines, nitrogen should be used to purge the Wash Water Column and
the Amine Absorber. This will displace the air introduced into the columns
while washing and filling them earlier.
At this point, the following conditions should exist in the ATU:
The Wash Water system and perhaps the amine system have been
cleaned and loaded with their respective initial fills of water and amine.
(The amine system may be waiting on purging of the Amine Absorber
before the system is loaded with amine.)
7.7.6.1 Purging the Columns

To establish nitrogen flow into the ATU, proceed as follows:
A. Reduce the output from the Sour Fuel Gas hand control in the
DCS to 0% to close the Sour Fuel Gas inlet valve.
B. Confirm that the Wash Water Column is isolated from the wash
water circulation loop by confirming that the following valves are
all closed:
(1) The bypass valve and downstream block valve at the

wash water flow control valve.
(2) The suction valves at the Wash Water Pumps.

make-up water flow control valve.
C. Confirm that the Amine Absorber is isolated from the solvent

circulation loop by confirming that the following valves are all
closed:
(2) The bypass valve and upstream block valve at the

Absorber level control valve.
(3) The drain valve upstream of the level control valve.
(4) The block valves in the water makeup line.

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(5) The bypass valve and upstream block valve at the

Absorber overhead pressure control valve.
D. Open all of the vent valves on the PI and PDT taps on the
Wash Water Column and the Amine Absorber, and the vent
valves at the tops of the columns.
E. Use a temporary "jumper" to connect a nitrogen supply to one

of the level bridles on the Wash Water Feed Knock-out Drum
and establish a flow of nitrogen into the unit.
F. Allow the nitrogen to continue flowing long enough to reduce

the oxygen concentration in the equipment and piping to less
than 1%. Use a portable oxygen analyzer to determine the
oxygen concentration.
G. Disconnect the nitrogen jumper.
H. Re-open valves as necessary to restore the wash water and

solvent circulation loops that were isolated from the columns in
the previous steps.
NOTE: If the initial solvent fill was not loaded into the solvent
system earlier to avoid exposing the MDEA to oxygen, this
can be accomplished now. Follow the procedure given in
the previous section to fill the solvent system with its initial
solvent charge.

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7.8 Startup Procedures

The ATU is now ready to accept sour fuel gas from the complex.
7.8.1 Wash Water and Amine Systems

Before routing sour fuel gas into the Wash Water Column and the Amine
Absorber, the wash water and amine systems should be operating and
ready to accept sour gas. The operating conditions described below
should have been established previously at the conclusion of the washing
operations but are repeated below to serve as a "checklist" before
introducing sour fuel gas to the columns as described in the sections that
follow.
A. The H2S analyzer has been calibrated.
B. The Wash Water system should be charged with its initial fill of
water, so that the level in the Wash Water Column is at the normal
setpoint for the Wash Water Column level controller.
C. Wash Water should be circulating to the Wash Water Column at the

normal setpoint for the Wash Water flow controller.
D. The Wash Water Filter should be in service.
E. The amine system should be charged with its initial fill of amine, with
the level control in the DCS controlling the level in the Amine
Absorber at its normal setpoint and the level control in the DCS
controlling the level in the Rich Amine Flash Tank at its normal
setpoint.
F. The MDEA concentration in the amine should be close to its design

value (45 wt %). Add more fresh MDEA if necessary to bring the
amine to this strength.
G. Amine should be circulating through the Stripper, the Lean/Rich

Exchanger, and the Lean Amine Cooler to the distributor tray at the
top of the Amine Absorber at the normal setpoint for the flow
controller.
H. The fans should be operating on the Lean Amine Cooler, with the
temperature controllers on the lean amine controlling at their normal
setpoints.
I. The Rich Amine Filters should be in service.

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J. The lean amine filters should be in service, with the bypass flow
controller controlling at its normal setpoint.
K. Steam should be flowing to the Stripper Reboiler at the normal

setpoint for the flow control.
L. The overhead temperature from the Stripper should be above the low
temperature alarm point for the temperature indicator.
M. The fans should be operating on the Stripper Reflux Condenser with

the temperature controller on the outlet from the Stripper Reflux
Condenser controlling at its normal setpoint or lower.
N. The Stripper pressure controller to the SRU, should be in "manual"

with its output set to 0% so that the pressure control valve is fully
closed.
O. The Stripper pressure controller to the flare should be in "automatic"

with a setpoint of 0.85 kg/cm2(g).
P. The level in the Stripper Reflux Accumulator should be at the normal

setpoint for the level control.
Q. A Stripper Reflux Pump should be operating with the minimum flow

lined up to allow reflux to spill back into the Stripper Reflux
Accumulator whenever the level valve back to the Stripper is closed.
With these operating conditions established, the ATU is ready to accept

the sour fuel gas and begin treating it.
7.8.2 Sour Fuel Gas Flow to the Columns

The last step in the startup of the ATU is to bring the sour gas from the
rest of the complex into the Wash Water Column and the Amine Absorber.
They will then remove the H2S from the gas before sending it to the
treated fuel gas system. The H2S removed will be stripped from the
amine and sent to the flare initially. Once operation of the amine system
stabilizes, this acid gas will be routed to the SRUs.
Before introducing sour fuel gas into the columns, confirm that the proper
operating conditions have been established for the Wash Water and
amine systems.

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If any of the proper conditions have not been established, do not proceed
until correcting the problem(s). Once all of the conditions are satisfied,
complete the startup of the as follows:
A. Confirm that the sour fuel gas inlet hand control in the DCS is set to
0% output with the Sour Fuel Gas Inlet Valve closed.
B. Slowly increase the output from the sour fuel gas inlet hand control
to 100%, which will open the Sour Fuel Gas Inlet Valve and admit
sour fuel gas to the Wash Water Column.
C. When the output of the sour fuel gas inlet hand control reaches
100%, the Sour Fuel Gas Inlet Valve should be fully open and the
pressure control valve to the flare should be closed to send all of the
sour fuel gas into the Wash Water Column. Visually confirm that
these valves are properly positioned.
D. Once the operation of the Stripper has stabilized, route its acid gas,
which is presently going to the flare through a pressure valve, to the
SRUs as follows:
(1) Confirm that the Stripper pressure controller to the SRUs

in the DCS is in "manual" with its output set to 0%.
(2) Confirm that the setpoint of the Stripper pressure controller

to the SRU is tracking its current reading, then place it in
"automatic".
(3) Slowly raise the setpoint of the Stripper pressure controller

to the flare to 1.0 kg/cm2(g).
(4) If, necessary, adjust the setpoint of the Stripper pressure

controller to the SRU to its normal setpoint.
The Stripper pressure controller will now take over control of the
Stripper pressure by opening the pressure valve to send the acid gas
to the Acid Gas Knock-Out Drum in the SRUs. The Stripper
pressure controller to the flare will close the acid gas pressure valve
and stop the flow of acid gas to the flare. If the SRUs shut down (or
some other upset causes the Stripper pressure to rise), the Stripper
pressure controller to the flare will act as an over-ride and divert the
acid gas to the flare.

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E. The ATU is now fully on-stream. Before directing your attention

away from the ATU, be sure that:
(1) All controllers are functioning properly.
(2) The steam heating systems are in service and the level
control on the Reboiler condensate pot is functioning
properly.

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7.9 Shutdown Procedures

The procedures to be used in performing a planned shutdown of the ATU, or the
ATU and ARU, will vary depending on the extent and type of work to be
performed in and around the units during the downtime period. If maintenance
is to be performed on the ATU, there is no need to also shut down the ARU.
This greatly simplifies and shortens the shutdown procedure. Section 7.9.1 that
follows is an example of such a procedure.
If the ARU must also be shut down, then more extensive procedures must be
followed to accomplish a satisfactory shutdown and minimize the time required
for performance of the desired maintenance work. Section 7.9.2 that follows is
an example of a procedure for this circumstance.
Section 7.9.3 is a discussion of emergency shutdown situations. A guide to

troubleshooting the causes of unplanned shutdowns is presented to assist in
quickly identifying and correcting the problem so that the ATU/ARU can be put
back on-line in a minimum amount of time.
The ATU/ARU is affected directly and indirectly by shutdowns and outages that
occur in other systems within the complex. The more important aspects of the
effects these other systems can have on the ATU/ARU are discussed in
Section 7.9.4.
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 judgment should be used to modify these
procedures as needed to serve the purpose of any given planned shutdown
situation.

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7.9.1 Planned Shutdown - ATU

Any equipment to be opened should be properly blinded and purged with
inert gas before admission of air, to avoid exposure to potentially toxic
gases or the formation of flammable vapor mixtures. Any equipment
containing amine solution that is to be opened or entered should be
drained completely, then flushed with condensate or steamed out to avoid
the possibility of skin or eye irritation.
It is generally preferable to shut down the ATU in a controlled fashion to

minimize the impact on the other process units. If time does not allow
performing a controlled shutdown, however, the unit can be shut down by
simply activating the ESD system (using the manual shutdown switch).
This will automatically block the feed into the ATU (sour fuel gas) and
divert the feed gas to the flare system.
To shut the ATU down in a controlled fashion proceed as follows:
A. Slowly reduce the output from the Sour Fuel Gas hand control in the
DCS. As the pressure in the sour fuel gas inlet line begins to
increase, the override pressure controller will open the pressure
control valve and begin diverting the sour fuel gas to the flare
system.
B. When the output of the Sour Fuel Gas hand control reaches 0%, the
pressure control valve should be open and the Sour Fuel Gas inlet
valve should be fully closed to send all of the sour fuel gas to the
flare system.
Visually confirm that these valves are properly positioned. Confirm

that the DCS indicates that the Sour Fuel Gas Inlet Valve is closed.
C. Allow the amine to continue to circulate until the all of the H2S and
CO2 have been stripped from the amine. Once the H2S/CO2 content
of the "rich" amine leaving the Absorber is essentially the same as
the "lean" amine, the ATU can be shut down and isolated from the
ARU.
D. Depending upon the type and extent of the maintenance work to be

done, the wash water can continue to circulate while maintenance is
being performed on the Amine Absorber. However, if desired, the
wash water system can be shut down as follows:
(1) Shut down the Wash Water Pump

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(2) Place the Wash Water flow controller in the DCS in

"manual" and set its output to 0% to fully close the wash
(3) Place the Wash Water Column level controller in the DCS
in "manual" and set its output to 0% to fully close the level
control valve.
(4) Place the make-up water flow controller in the DCS in

"manual" and set its output to 0% to fully close the
(5) Verify that the wash water flow control valve is fully closed.
Close both of its isolation block valves and its bypass
valve.
(6) Verify that the Wash Water Column level control valve is
fully closed. Close both of its isolation block valves and its
bypass valve.
(7) Verify that the make-up water flow control valve is fully
closed. Close both of its isolation block valves and its
bypass valve.
E. Once the H2S/CO2 content of the "rich" amine leaving the Absorber is
essentially the same as the "lean" amine, the ATU can be shut down
as follows:
(1) Shut down the Lean Amine Pump
(2) Place the lean amine flow controller in the DCS in

"manual" and set its output to 0% to fully close the lean
amine control valve.
(3) Place the amine make-up water flow controller in the DCS
in "manual" and set its output to 0% to fully close the
amine make-up water flow control valve.
(4) Place the Amine Absorber level controller in the DCS in

"manual" and set its output to 100% to fully open the level
control valve.
(5) Allow the amine to drain from the Amine Absorber until the
low-low level shutdown is activated. This should close the
level control valve. Monitor the level in the Amine Absorber

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and be prepared to close the level control valve if the

low-low level shutdown fails to activate.
(6) Monitor the level in the Rich Amine Flash Tank to ensure
that rich amine does not spill over into the hydrocarbon
section of the vessel. Be prepared to take action and close
the Amine Absorber level control valve if the amine level
gets too high in the Rich Amine Flash Tank.
(7) Drain the remaining amine from the Amine Absorber by

opening the manual block valve in the drain line upstream
of the level control valve to send the remaining amine to
the Solvent Drain System.
(8) Verify that the Amine Absorber level control valve is fully
bypass valve.
(9) Verify that the lean amine flow control valve is fully closed.
valve.
bypass valve.
(11) Verify that the spill-back flow control valve is fully closed.
valve.
F. The ATU is now ready to be isolated and made safe for entry.

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7.9.2 Planned Shutdown - ATU and ARU

gases or the formation of flammable vapor mixtures. Any equipment
containing amine solution that is to be opened or entered should be
drained completely, then flushed with condensate or steamed out to avoid
the possibility of skin or eye irritation.
To shut the ATU and ARU down in a controlled fashion proceed as

follows:
A. Shutdown and isolate the DHT Unit and the LPG Treating Unit using
the operating procedures for those units.
B. Slowly reduce the output from the Sour Fuel Gas hand control in the
DCS. As the pressure in the sour fuel gas inlet line begins to
increase, the pressure controller will open the pressure control valve
and begin diverting the sour fuel gas to the flare system.
C. When the output of the Sour Fuel Gas hand control reaches 0%, the
pressure control valve should be open and the Sour Fuel Gas inlet
valve should be fully closed to send all of the sour fuel gas to the
flare system.

that the DCS indicates that the Sour Fuel Gas Inlet Valve is closed.
D. Allow the amine to continue to circulate with steam flowing to the

Stripper Reboiler, until the all of the H2S and CO2 have been stripped
from the amine. Once the H2S/CO2 content of the "rich" amine is
essentially the same as the "lean" amine, the steam can be shut off
to the Stripper Reboiler.
E. Continue to circulate the amine and operate the Lean Amine Cooler
and the Stripper Reflux Condenser until the amine is cool.
F. Depending upon the type and extent of the maintenance work to be

done, the wash water can continue to circulate while maintenance is
being performed on the Amine Absorber or on the equipment in the
ARU. However, if desired, the wash water system can be shut down
as follows:
(1) Shut down the Wash Water Pump

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(2) Place the Wash Water flow controller in the DCS in

"manual" and set its output to 0% to fully close the wash
(3) Place the Wash Water Column level controller in the DCS
in "manual" and set its output to 0% to fully close the level
control valve.
(4) Place the make-up water flow controller in the DCS in

"manual" and set its output to 0% to fully close the
(5) Verify that the wash water flow control valve is fully closed.
valve.
(6) Verify that the Wash Water Column level control valve is
fully closed. Close both of its isolation block valves and its
bypass valve.
bypass valve.
G. Once the amine is cool (60°C or less throughout the system), shut
down the equipment in the following order:
(1) The Rich Amine Pump.
(2) The Lean Amine Booster Pump
(3) The Lean Amine Pump.
(4) The Stripper Reflux Pump.
(5) The fans on the Lean Amine Cooler and Stripper Reflux
Condenser.
H. The ATU and ARU are now ready to be isolated and made safe for
entry.

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7.9.3 Emergency Shutdown

The ATU ESD system can be initiated by any of the actuating devices
outlined in Section 7.5.2.1 of these guidelines. The operator must
determine and correct the condition causing the shutdown before the can
be restarted. The problems outlined below should be investigated first by
the operator in his troubleshooting procedure.
S/D Actuation Device Possible Causes

Wash Water Feed Knock-Out 1. Excessive liquids being received by
Drum the Knock-Out Drum.
High-High Level 2. Malfunction of level control system.
3. Level warning transmitters on the
Knock-Out Drum are plugged or
inoperable.
Amine Absorber Feed 1. Excessive liquids being received by
Knock-Out Drum the Knock-Out Drum.
inoperable.
Amine Absorber 1. Malfunction of the Lean Amine
Low-Low Level Pump
2. Malfunction of the Lean Amine
Booster Pump
3. Malfunction of the lean amine flow
control system
4. Malfunction of the level control
system.
5. Manual drain valve left open.

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7.9.4 Effects of Shutdowns and Outages in Other Systems

The ATU/ARU system is directly affected by a shutdown and/or outage in
the LP steam system for the complex. These effects are described below.
7.9.4.1 Steam System Outage

The most immediate impact on the ATU/ARU will be the loss of
LP steam to the Stripper Reboiler if the steam outage lasts long
enough. As the heat input to the reboiler declines, stripping of the
acid gas from the amine will decline and the H2S in the treated fuel
gas leaving the Amine Absorber will begin to increase. This will
cause the Treated Fuel Gas analyzer to close the pressure control
valve to the treated fuel gas system to avoid sending off-spec fuel
gas into the complex’s fuel gas system. The override pressure
control valve will then open and begin routing the sour fuel gas to the
flare system.

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7.10 Analytical Procedures

This Section contains analytical procedures for determining:
1. The concentrations of total amine in the ATU/ARU solvent (Section

7.10.2).
2. The concentrations of H2S and CO2 in the ATU/ARU solvent

(Sections 7.10.3 and 7.10.4).
3. The foaming tendency of ATU/ARU solvent (Section 7.10.5).
4. The H2S content of the ATU/ARU Amine Absorber overhead gas

(Sections 7.10.6 and 7.10.7).
7.10.1 General Procedures for Analyzing ATU/ARU Solvent1,2

An amine solution which is to be analyzed should first be inspected
visually. If conducted by an experienced person, such an inspection will
often yield important clues to the identity of a number of contaminants.
For example, a green color in an amine solution usually indicates finely
divided iron sulfide in sub-colloidal particle size (<1 micron), whereas a
finely divided black suspension indicates the presence of larger
(>3 micron) iron sulfide particles. A green or blue solution can indicate the
possibility of either copper or nickel, while an amber colored solution may
contain suspended or dissolved iron oxide. Iron may complex with the
amine an give the solution an amber or dark red color. Thermal
degradation of the amine may give the solution a dark red to brown color.
Amines sometimes display a red or dark brown color resulting from
oxidation, particularly when combined with thermal degradation. An oil
slick on the solution or an oil-like odor is indicative of hydrocarbon
contamination. The presence of these contaminants, however, must be
proven by analysis.
The next step in analyzing an amine solution is the determination of the

percent amine and the acid gas content (H2S and CO2). Both rich and
lean solutions may be analyzed for these constituents, and from the
analyses the extent of acid gas loading and efficiency of stripping can be
ascertained. Procedures for these analyses are given in Sections 7.10.2
through 7.10.4 that follow.
1
The Dow Chemical Company, Gas Conditioning Fact Book, 1962, pp. 310-311.
2
Dow Chemical U.S.A., Gas Treating from Dow, 1987, pp. 8-1-1 – 8-1-2.

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In addition to the procedure in Section 7.10.2, the amine concentration of

the solvent can be determined by performing Kjeldahl and Van Slyke
nitrogen analyses. The Kjeldahl determination indicates the total nitrogen
content of the solution, including nitrogen from the amine and from amine
degradation products. The Van Slyke method, on the other hand, shows
amine content, but does not reveal the extent to which the original amine
has been degraded or tied up as heat stable salts. The difference
between the results obtained through Kjeldahl and Van Slyke analyses
usually indicates the degree of amine degradation. As would be
expected, little difference is obtained with initial or unused solution. These
analyses are not commonly performed in plant laboratories, but are
generally left to the chemical solvent supplier.
Heat stable salts can also be determined by a total anion assay. The
amine solution is passed through an ion exchange column containing ion
exchange resin in the hydrogen form. Acid salts are thus broken down
and the acids recovered in the column effluent, while the amine is
absorbed in the column. The acid in the effluent is determined by
potentiometric titration, and from these results plus the original amine
concentration the amount of amine in the form of heat stable salts is
calculated. Again, this type of analysis is commonly left for the chemical
solvent supplier to perform.
The foaming characteristics of an amine solution are determined

empirically in a simple apparatus consisting of an air (or gas) supply,
pressure regulator or gas manometer, graduated glass cylinder, and a gas
dispersion tube. The amine solution is poured into the graduated cylinder
and air passed through at a constant rate. After five minutes, the height of
the foam is recorded, the air flow is interrupted, and the time for the foam
to break is determined. The results thus obtained will indicate whether or
not evaluation of anti-foam agents is desirable. Section 7.10.5 describes
this procedure more completely.
A water analysis can be conducted on the amine solution to obtain a

material balance and serve as an approximate check on the amine
concentration. This is typically determined using the Karl Fischer method
of analysis, but most plant laboratories leave this procedure to the
chemical solvent supplier.
Ordinarily, the above analyses will provide an accurate picture of the

condition of the amine plant solution. At times, however, unusual
operational difficulties may be encountered in amine sweetening units

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because of contaminants which are not revealed by the usual analytical

methods. When this occurs, infrared spectroscopic analysis may often be
utilized to good advantage.
Infrared spectroscopy is based on the principle that each molecule or

functional group exhibits its own particular absorption characteristics when
exposed to infrared light of a definite wavelength. A wide variety of
functional groups can be readily detected and identified by infrared
techniques. For example, it has been found that degraded or oxidized
amine solutions may contain ammonia, formic acid, a di-functional acid, a
carbonyl compound yielding a glyoxal dinitrophenylhydrazone derivative,
and a high molecular weight material that exhibits the characteristics of a
Jones polymer. Also, both mono- and di-substituted amines have been
identified. Each component exhibits its own particular effects on
corrosion, foaming, and acid gas absorption, effects which can be
determined only by the separate evaluation of each contaminant. Once
these effects are determined, a knowledge of functional groups present
and their relative concentration makes it possible to anticipate which types
of contaminants may be causing difficulties. The chemical solvent
supplier can usually perform this type of analysis more easily than the
plant laboratory.
Steps should be taken to ensure that the amine solution samples taken
are representative of the circulating solvent. Samples should be taken in
glass or plastic containers. Metal containers will cause low results for H2S
because sulfides will react with the metal walls of the container. Do not
use copper tubing to withdraw the samples; the copper will contaminate
the amine solution, and H2S will react with the copper and give low
results.
Special care should be exercised when taking samples of the rich amine
solution to avoid personnel exposure to H2S. Hot, fully loaded amine
solution can flash acid gas when released to atmospheric pressure,
causing low acid gas loading results in addition to the dispersion of H2S to
the surroundings. Take samples of the rich solution from the coolest point
in the process (the Amine Absorber outlet, usually), and cool the samples
in a stainless steel coil immersed in an ice bath or cold water to prevent
flashing. The solution should be allowed to flow to a drain in this fashion
for several minutes before taking the sample to be sure that circulating
amine is being taken.

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In the laboratory procedures that follow, several different reagents are

used that can be harmful if proper care is not exercised. Acids, bases,
and flammable substances are utilized in these procedures, so adherence
to proper laboratory safety practices is necessary to ensure the safety of
all personnel.

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7.10.2 Determination of Amine Concentration in ATU/ARU Solvent

The amine concentration in the ATU/ARU solvent can be determined by
acid titration of the lean solution. This technique is not specific for free
amine, however, as amine present in the solution as an amine-acid salt
will also react during the titration. This technique will also give erroneous
results if there are other basic materials in the solution, such as caustic or
soda ash (sometimes used to "neutralize" heat stable salts).
1. Reagents: Distilled or Deionized Water

0.5 N Hydrochloric Acid (HCl)
Bromophenol Blue Indicator
(3',3'',5',5''-tetrabromophenolsulfonephthalein)
2. Procedure:
a. Place about 95 ml of distilled or deionized water in a 250 ml

beaker or Erlenmeyer flask.
b. Add about 5 ml of lean amine solution to the water in the beaker

via pipette, recording the actual quantity.
c. Add 5 drops of Bromophenol Blue indicator to the solution in the

beaker and stir well.
d. Titrate the solution in the beaker with 0.5 N HCl to a faint yellow
color. Alternatively, if a pH meter is available, titrate to a pH of
4.5. Record the amount of HCl used in the titration.
3. Chemical reaction involved:

+ –
R2HN + HCl R2HNH + Cl
where R2HN = CH3-N-(CH2-CH2-OH)2 = MDEA

(methyldiethanolamine)
As the hydrochloric acid is added to the solution, it reacts with the

amine to form a chloride salt. Once all the amine has reacted, the
continued addition of acid causes the pH of the solution to drop, until
the Bromophenol Blue indicator changes from blue to yellow. Note
that HCl reacts with the amine on a 1:1 molar basis.

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4. Calculation of Weight Percent Amine:
ml HCl  Normality of 

 Amine   100%   Used  HCl Solution
Weight %
  Mole     
Amine  Weight  1000 ml / l   ml of    Sp. Gravity of 
  Sample  Amine Sample 
The molecular weight of MDEA is 119.17, and the specific gravity of

the solution at room temperature (20°C) is about 1.059, assuming
the solution is about 45 wt% MDEA. The equation can then be
simplified to:
ml HCl Normality of 

 Used   HCl Solution 
Weight % Amine  11.253     
 ml of 
Sample 
 

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7.10.3 Determination of Total Acid Gas Loading in ATU/ARU Solvent

The total acid gas (H2S + CO2) loading, relative to the amine
concentration, in either the lean or rich ATU/ARU solvent can be
determined by base titration of the solution. This procedure does not
distinguish between H2S and CO2. However, together with the procedure
in Section 7.10.4, the individual concentrations of H2S and CO2 can be
determined.
1. Reagents: Methanol (CH3OH), Anhydrous

0.5 N Potassium Hydroxide (KOH) Solution in Methanol
Thymolphthalein Indicator in Methanol
2. Procedure:
a. Place about 125 ml of methanol in a 250 ml beaker or

Erlenmeyer flask.
b. If a pH meter is available, insert the pH meter probe into the

methanol in the beaker and adjust the pH of the methanol to
11.2 by titrating the methanol in the beaker with the 0.5 N KOH.
c. If a pH meter is not available, add 5 drops of Thymolphthalein

indicator to the methanol in the beaker. Titrate the solution in
the beaker with 0.5 N KOH until the solution turns a faint blue
color, indicating a pH of 11.2. The change to faint blue will be
sudden, so add the KOH slowly (one drop at a time).
d. Add about 20 ml of lean amine solution to the methanol in the

beaker via pipette, recording the actual quantity. If rich amine
solution is being tested, use about 10 ml of solution instead.
e. Titrate the solution in the beaker with 0.5 N KOH back to a pH

of 11.2 (or until the solution again turns a faint blue color when
using Thymolphthalein indicator). Record the amount of KOH
used in this titration.
3. Chemical reactions involved:

+ –
H2S + KOH K + HS + H2O
+ –
CO2 + KOH K + HCO3
As the potassium hydroxide is added to the solution, it reacts with the

H2S and CO2 to form potassium hydrosulfide and potassium

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hydrogen carbonate salts. Once all of the acid gas has reacted, the
continued addition of base causes the pH of the solution to rise, until
the Thymolphthalein indicator changes from colorless to blue. Note
that KOH reacts with H2S and CO2 on a 1:1 molar basis.
4. Calculation of Acid Gas Loading (molar basis):
ml KOH   Normality of 

Moles Acid Gas  Amine   100%   Used  KOH Solution
  Mole    
Mole Amine  Weight  1000 ml / l   ml of    S.G. of    Wt % Amine
 
Sample Sample  in Solvent 
Note that "ml KOH used" refers to the amount used in the second
titration, step 2.e. The "wt % amine in solvent" can be determined
using the procedure in Section 7.10.2.

simplified to:
ml KOH  Normality of 

 Used   KOH Solution 
 11.253     
Moles Acid Gas
Mole Amine  ml of   Wt % Amine 
Sample    in Solvent 
   
5. Special Considerations:
a. Excess moisture in the equipment will give false readings.

Water may be used to clean the equipment if the equipment is
thoroughly dried prior to use with the anhydrous methanol.
b. The faint blue titration endpoint using Thymolphthalein indicator

is not definite. It may best be determined by comparing the
color of the solution against a reference prepared by titrating a
second sample of methanol-Thymolphthalein to the same color.
c. The KOH solution and Thymolphthalein indicator solution

should be kept tightly closed to prevent loss of methanol by
vaporization. Any vaporization of methanol from the KOH
solution will change the normality of the solution.
d. The Thymolphthalein indicator solution can be prepared by

dissolving 5 grams of thymolphthalein in 100 ml of anhydrous
methanol.

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7.10.4 Determination of H2S and CO2 Loading in ATU/ARU Solvent

The H2S loading, relative to the amine concentration, in either the lean or
rich ATU/ARU solvent can be determined by titration of the solution with
iodine. Since CO2 does not react with iodine, this procedure is specific for
H2S. Together with the total acid gas loading determined using the
procedure in Section 7.10.3, the individual concentrations of H2S and CO2
can be determined.

Concentrated Hydrochloric Acid (HCl) or Sulfuric Acid
(H2SO4)
Standard Starch Solution - 1%
0.1 N Iodine Solution (I2)
0.1 N Sodium Thiosulfate Solution (Na2S2O3)
2. Procedure:
a. Measure about 25 ml of chilled iodine solution and place it in a

250 ml beaker or Erlenmeyer flask. Record the amount of
iodine solution used.
b. Carefully add about 25 ml of concentrated acid to the beaker.
c. Add about 5 ml of standard starch solution to the beaker, then

re-chill the beaker in an ice batch for 2-3 minutes.
d. Slowly add 10-20 ml of lean amine solution to the solution in the

solution is being tested, use 1-2 ml of solution instead.
e. Use about 25 ml of distilled or deionized water to rinse the

inside of the beaker, then swirl the contents gently to mix the
solution without splashing it.
f. Titrate the excess iodine in the sample with the sodium

thiosulfate solution until the blue color disappears. The end
point is a pale yellow or clear color. The approach of the
endpoint is usually indicated by a milky brown tint at the top of
the liquid surface. As the endpoint nears, slow the rate of
titration and use a small amount of distilled or deionized water
to wash the flask. Record the amount of sodium thiosulfate
solution used in this titration.

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g. Check the pH of the titrated solution with pH paper to be sure

the solution is acidic. If the solution is not acidic, repeat the
procedure but use more acid in step 2.b.
H2S + I2 S + 2 HI
I2 + Na2S2O3 2 S + NaI + NaIO3
When the solvent is added to the iodine solution, the H2S in the
solvent reacts with the iodine to form hydrogen iodide and elemental
sulfur. The solution contains an excess of iodine to ensure that all of
the H2S reacts. The iodine solution is chilled prior to adding the
solvent to eliminate or minimize the evolution of H2S gas. Note that
H2S reacts with iodine on a 1:1 molar basis.
When the sodium thiosulfate solution is added to the solution, it

reacts with the remaining iodine to form sodium iodide and sodium
iodate, along with more elemental sulfur. (It is this elemental sulfur
that may cause the titrated solution to appear pale yellow.) Once the
last bit of iodine is consumed, the starch solution loses its
characteristic blue color. The amount of H2S in the solvent sample is
then calculated from the difference between the total iodine and the
iodine that reacts with the sodium thiosulfate. Note that sodium
thiosulfate reacts with iodine on a 1:1 molar basis.
The purpose of the concentrated acid is to neutralize the amine so

that it will release the H2S (a weaker acid) so it can react with the
iodine. If the titrated solution is not acidic in step 2.g, then the amine
was not fully neutralized and the H2S determination will not be
correct.
4. Calculation of H2S Loading (Molar Basis):
ml I2 Normality of   1 liter   1 g - mole 

 
g - moles
   
I2 Used  used   I2 Solution  1000 ml   2 g - equivalent 
g - moles  ml  Normality of   1 liter   1 g - mole 

Na2S2O3  Na2S2O3    Na2S2O3     
Used  used   Solution  1000 ml   2 g - equivalent 
   

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g - moles   g - moles 
 Amine   I2 Used   Na2S2O3 Used
  Mole   100 % 
Moles H2S
Mole Amine  Weight   ml of    S.G. of    Wt % Amine 
  Sample  Sample   in Solvent 
The "wt % amine in solvent" can be determined using the procedure

in Section 7.10.2.

the solution is about 45 wt% MDEA. Using these values and
substituting the first and second equations into the third, these
equations can be simplified to:
Normality  Normality of 
ml I2   of I   ml Na2S2O3   Na S O 
Used  2  Used   2 2 3
Moles H2S  Solution   Solution 
 5.626 
Mole Amine  ml of    Wt % Amine
Sample  in Solvent 
5. Calculation of CO2 Loading (Molar Basis):
Using the total acid gas loading determined with the procedure in
Section 7.10.3, the CO2 loading of the solvent is determined by
difference:
Moles CO2  Moles Acid Gas   Moles H2S 

     
Mole Amine  Mole Amine   Mole Amine 
6. Other Common Units:
The loadings calculated above can be easily converted to other units

commonly used within the industry:
Grains H2S  Moles H2S   Wt % Amine   S.G. of 

 166.7    
Gallon Solvent  Mole Amine   in Sample  Sample 
 Moles H2S 
 
Wt % Amine 
Wt % H2S  0.2858   
 Mole Amine   in Sample 

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SCF CO2  Moles CO2   Wt % Amine   S.G. of 

 0.2653    
 Moles CO2 
 
Wt % Amine 
Wt % CO2  0.3693   
Note that these conversions are specifically for MDEA. Other

amines require different conversion factors.

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7.10.5 Determination of Foaming Tendency of ATU/ARU Solvent

The procedure described in this section is an empirical method for
measuring the foaming tendency of aqueous amine solvents, universally
accepted within the industry.
1. Principle:
Air is bubbled through a solvent sample at a fixed rate for five

minutes, at which time the foam height is measured. The air flow is
stopped and the time for the foam to disappear is measured. The
foam height and "break" time are indicative of how high the foaming
tendency of the solvent is.
2. Equipment: 1000 ml Graduated Cylinder

Aquarium Air Pump (or laboratory air supply) with
Bubble Stone
Stop Watch (or regular watch with a second hand)
3. Procedure:
a. Pour about 200 ml of the sample solution into the graduated

cylinder and insert the bubble stone into the bottom of the
cylinder.
b. Record the level of sample in the cylinder (in ml).
c. Start the air pump or air supply to agitate the sample with
oil-free air at 4 liters per minute (0.2 Nm3/H).
d. After five minutes, record the height of the foam in the cylinder
(in ml). Then turn off the air supply and measure the time in
seconds for the foam to "break". For consistency, foam "break"
is defined as the first clear "fish eye" in the surface of the liquid
in the cylinder.
4. Calculation:
Foam Height = Height of Foam - Initial Height of Sample (in ml)
5. Interpretation:
Considerable experience with this test has shown that if the foam
height exceeds 200 ml or the "break" time exceeds 5 seconds, the
plant may be experiencing a foaming problem. The higher the foam

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height and/or the longer it takes to "break", the more severe the
problem.
6. Other Considerations:
a. A nitrogen cylinder with the pressure regulated to about

0.35 kg/cm2(g), equipped with a flow rotameter, may be used
instead of air. Be sure to keep the tubing and fittings oil-free.
b. This procedure can be used to evaluate the effects of anti-foam

agents on the solvent. However, care must be exercised in
cleaning the equipment between tests since a very small
quantity of residual anti-foam agent will affect the test.
c. Foaming is sometimes caused by contaminants in the solvent

that can be removed by activated carbon treatment. The effect
of activated carbon filtration can be evaluated by running foam
tests on treated and untreated samples. The sample is treated
by mixing it with a quantity of carbon (12-20 mesh) to remove
the contaminant, then filtering the mixture through Whatman
No. 41 filter paper.

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7.10.6 H2S Conc. in Amine Absorber Ovhd by the Tutweiler Method

The overhead gas from the Amine Absorber Overhead Knock-out Drum
can be sampled from the sample connection near the sample line for the
H2S analyzer.
1. Using a 500 ml Tutweiler apparatus, sample and titrate the treated

gas leaving the Amine Absorber Overhead Knock-out Drum as
outlined in Section 7.10.1 of these guidelines.
H2S + I2 2 HI + S
The hydrogen sulfide (H2S) is converted to small particles of

elemental sulfur by the iodine during the shaking. Good shaking is
required to get good contact between the hydrogen sulfide in the gas
and the iodine in the liquid. When all of the hydrogen sulfide is
converted, the excess iodine causes the characteristic blue color in
the presence of starch. This is a universal test for starch. (Iodine
causes a blue color when it contacts starchy foods, such as potato
for example.)
5. Calculation of Mole (or Volume) percent H2S (dry basis):
 ml Iodine   Normality of   273  T   760 

Mole % H2S     Iodine Solution   (11.85)    
Solution Used     289   P - V.P. 
Where T = sample temperature, °C
P = atmospheric pressure at particular location, mm Hg
V.P = vapor pressure of water at sample temperature, mm Hg
The Normality of the standard iodine solution will be 0.1 N. The last
three factors (which correct the actual H2S content to compensate for
expansion due to temperature, pressure, and water content) can be
combined and calculated as a function of temperature only. This has
been done for the 500-ml gas sample and is included as the
Tutweiler Factor Chart in Section 7.10.3 of these guidelines
(Chart 2). Therefore, the equation above can be simplified to:
ml Iodine  Normality   Factor from 

PPM H2S  10,000   Solution    of Iodine    Tutweiler 
 Used   Solution  Factor Chart 
     

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7.10.7 H2S Conc. in Amine Absorber Ovhd Using Gas Detector Tubes
As an alternative to the traditional wet-chemistry method described in the
preceding Section 7.10.6 for determining the concentration of H2S in the
Amine Absorber overhead gas, gas detector tubes can be used to quickly
and easily make this determination. Although the discussion that follows
specifically addresses using gas detector tubes manufactured by
Drägerwerk AG of West Germany, there may be suitable detector tubes
available from other manufacturers. Dräger tubes can be purchased from
most safety equipment supply companies.
The following Dräger tubes can be used with this procedure:
H2S 5/b Dräger Cat. No. CH 298 01
H2S 100/a Dräger Cat. No. CH 291 01
7.10.7.1 Operating Principles

Dräger tubes and other gas detector tubes measure gas
concentrations by using a sample pump to draw a specific volume of
the gas to be sampled into a glass tube containing a suitable
reagent. The gaseous compound of interest chemically reacts with
the reagent to produce a color change. The length of the "stain" line
is a direct function of the concentration of the compound in the
sample gas. Some detector tubes are calibrated with measured lines
to allow reading the concentration directly on the tube. Others, such
as the two listed above, have reference marks on the tube that can
be multiplied by a factor to compute the concentration.
Dräger tubes are designed to be used with a Dräger Model 31 gas

detector pump. This is a hand-operated bellows pump that will draw
a 100 cc sample volume for each pump stroke. Some tubes are
designed for a single sample stroke, while others may use 5, 10, or
even 20 strokes. In some cases, a tube may be used for measuring
different concentration ranges by using a different number of strokes.
a. Dräger Cat. No. CH 298 01, H2S 5/b
This tube will measure H2S concentrations in the range of

50 PPM to 600 PPM when one sample stroke is used. If
desired, the range can be reduced to 5 PPM to 60 PPM by
using 10 sample strokes. Each tube contains a substrate of a
white lead compound. When exposed to H2S, the lead

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compound is converted to brown lead sulfide. The H2S

concentration in PPM can be read directly from the marks on
the tube according to the length of the brown stain when using
10 sample strokes. If only one sample stroke is used, the tube
reading is multiplied by 10 to give the PPM of H2S. This lead
sulfide reaction is not affected by any of the other compounds
normally found in the overhead gas from the ATU/ARU Amine
Absorber.
b. Dräger Cat. No. CH 291 01, H2S 100/a

100 PPM to 2,000 PPM when one sample stroke is used. Each
tube contains a substrate of a white lead compound. When
exposed to H2S, the lead compound is converted to brown lead
sulfide. The H2S concentration in PPM can be read directly
from the marks on the tube according to the length of the brown
stain. This lead sulfide reaction is not affected by any of the
other compounds normally found in the overhead gas from the
ATU/ARU Amine Absorber.
7.10.7.2 Sampling the Amine Absorber Overhead Gas

The overhead gas from the Amine Absorber Overhead Knock-out
Drum can be sampled from the sample connection near the sample
line for the H2/H2S analyzer.
a. Before beginning, check the Dräger pump for leaks by inserting

an unopened tube into the pump and stroking the pump.
Confirm that the bellows does not re-expand. If it does, either
the pump or its seal around the tube is leaking, and the test
results will not be accurate.
b. Attach a short piece of rubber tubing to the process sample

valve.
c. Break off the tips at each end of a Dräger tube and insert it into
the sample pump (with the arrow on the side of the tube
pointing toward the pump).
d. Purge the rubber tubing by venting gas to the atmosphere for a

few seconds. Pinch the rubber tubing closed at the end, close
the gas sample valve, slip the end of the rubber tubing onto the
end of the Dräger tube, and reopen the sample valve.

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e. Stroke the sample pump one time (be sure to compress the
bellows until reaching the stops) and allow the pump to draw
the gas sample into the detector tube. The sample stroke is
complete when the metal chain on the bellows is taut.
f. Close the sample valve and remove the rubber tubing from the
end of the Dräger tube and from the sample valve.
g. Read the length of the brown stain using the marks on the tube
and record the reading.
7.10.7.3 Calculations
Mole (or Volume) PPM H2S (wet basis):
 
PPM H2S  
Stain 
 
Tube  1013
    
Length  Factor   Baro. Pres., mbar 
The last factor corrects the measurement for pressure effects when
samples are taken at elevations above sea level. Note that the
average barometric pressure at the compex is
14.7 PSIA = 1013 mbar.
The "Tube Factor" depends on the type of Dräger tube used and the
number of sample strokes:
Dräger Tube Catalog No. Sample Strokes Tube Factor
H2S 5/b CH 298 01 1 10

H2S 5/b CH 298 01 10 1
H2S 100/a CH 291 01 1 1

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Table of Contents
8. SOUR WATER STRIPPING ......................................................................................... 8-1
8.2 SAFETY ................................................................................................................. 8-1
8.3.1 General ........................................................................................................... 8-2
8.3.2 Sour Water Collection..................................................................................... 8-2
8.3.3 Sour Water Stripping ...................................................................................... 8-3
8.4.1 Sour Water Stripper, A2-DA1520 ................................................................... 8-5
8.4.2 Sour Water Stripper Packing and Internals, A2-DB1520 ................................ 8-5
8.4.4 SWS Cross Exchanger, A2-EA1520 .............................................................. 8-5
8.4.5 Sour Water Stripper Reboiler, A2-EA1521 ..................................................... 8-6
8.4.6 SWS Quench Water Cooler, A2-EC1520 ....................................................... 8-6
8.4.7 SWS Bottoms Cooler, A2-EC1521 ................................................................. 8-6
8.4.8 Sour Water Flash Drum, A2-FA1520.............................................................. 8-6
8.4.9 SWS Skim Oil Sump, A2-FA1522 .................................................................. 8-7
8.4.10 SWS Skim Oil Pump Sump, A2-FA1523A/B .................................................. 8-7
8.4.11 Sour Water Tank, A2-FB1520 ........................................................................ 8-7
8.4.12 Sour Water Filter, A2-FD1520A/B .................................................................. 8-7
8.4.13 Sour Water Transfer Pump, A2-GA1520A/B .................................................. 8-7
8.4.14 SWS Feed Pump, A2-GA1521A/B ................................................................. 8-8
8.4.15 SWS Quench Water Pump, A2-GA1522A/B .................................................. 8-8
8.4.16 SWS Bottoms Pump, A2-GA1523A/B ............................................................ 8-8
8.4.17 SWS Skim Oil Pump, A2-GA1524A/B ............................................................ 8-8
8.5 INSTRUMENTATION AND CONTROL SYSTEMS ............................................... 8-9
8.5.1 SWS Shutdowns and Alarms ......................................................................... 8-9
8.6.1 SWS Stripper Operation ............................................................................... 8-11
8.6.2 Quench Water Circulation ............................................................................ 8-12
8.6.3 pH Control .................................................................................................... 8-13
8.7.2 Washing the Sour Water System ................................................................. 8-15
8.8.1 Initial Startup of the SWS ............................................................................. 8-19
Issued 30 August 2011 Sour Water Stripping Page 8-i

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8.8.1.2 Exporting Treated Water ....................................................................... 8-21

8.8.2 Normal Startup of the SWS .......................................................................... 8-23
8.8.2.2 Exporting Treated Water ....................................................................... 8-26
8.9.1 Planned Shutdown ....................................................................................... 8-29
8.9.2.1 Steam System Outage .......................................................................... 8-31
Issued 30 August 2011 Sour Water Stripping Page 8-ii

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8. SOUR WATER STRIPPING

The purpose of the Sour Water Stripping (SWS) system is to remove H2S and
ammonia (NH3) from various sour water streams produced in the Sulfur Block
and elsewhere in the aromatics complex. The resulting treated water
(containing less than 20 PPMW of H2S and less than 20 PPMW of NH3) is
returned to the aromatics complex for reuse elsewhere, while the SWS off-gas
(NH3, H2S, and water vapor) is routed to the Sulfur Recovery Units (SRUs).
8.2 Safety
WARNING

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 AMMONIA. CLOSE ATTENTION SHOULD
BE PAID TO THE "GENERAL SAFETY" SECTION OF THESE
GUIDELINES AS TO THE NATURE AND ABILITY OF THESE GASES TO
CONTAMINATE OTHER ELEMENTS IN THIS UNIT.

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.
Issued 30 August 2011 Tailgas Cleanup Page 8-1

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8.3.1 General
The Systems Diagram, Material Balance and Process Flow Diagram,
Dwg. Nos. 507000-7000-01, and 507000-7000-05 through -06, are
contained in the "Process Flow Diagrams" Section of the Basic
Engineering Package. Please refer to these drawings to follow this
description of the process.
The Sour Water Stripping Unit (SWS) receives sour water streams
containing ammonia (NH3) and hydrogen sulfide (H2S) from other units in
the No. 2 Aromatics Complex. These sour water streams are combined
with sour water produced in the Sulfur Block (predominately Sour Water
from the ATU and excess quench water from the SWS) and steam
stripped to remove essentially all of the NH3 and H2S from the water. The
resulting treated water (containing less than 20 PPMW of H2S and less
than 20 PPMW of NH3) is returned to the complex for reuse elsewhere,
while the SWS off-gas (NH3, H2S, and water vapor) is routed to the SRUs.
8.3.2 Sour Water Collection

Sour water from other units within the complex is combined with the sour
water streams generated within the Sulfur Block and flows to the Sour
Water Flash Drum, A2-FA1520, at 54°C [129°F]. This vessel is operated
at low pressure (1.05 kg/cm2(g) [15 PSIG]) to maximize the vaporization
and removal of any light hydrocarbons that may be entrained or dissolved
in the sour water. Any flash gases are directed to the flare header for
disposal.
The flash drum is large enough to provide 30 minutes or more of

residence time for the sour water. This allows time for any heavy
hydrocarbons entrained in the water to separate as a second liquid phase
that spills over the internal weir at the inlet end of the drum, collecting in
the SWS Skim Oil Sump, A2-FA1522. The SWS Skim Oil,
A2-GA1524A/B, sends the collected hydrocarbon to the Condensate Feed
Tank on start/stop level control.
After removal of any liquid hydrocarbon, the heavier water phase passes
under the internal weir at the outlet end of the drum to be pumped to the
Sour Water Tank, A2-FB1520, by the Sour Water Transfer Pump,
A2-GA1520A/B, on level control. This tank is large enough to provide
3-4 days of residence time to allow "working off " an accumulation of sour

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water after an outage. The tank also provides time for mixing which
minimizes Sour Water Stripper feed composition fluctuations due to the
many sources of sour water in the complex.
8.3.3 Sour Water Stripping

After residing in the Sour Water Tank for several days, the sour water is
pumped by the SWS Feed Pump, A2-GA1521A/B, on flow control through
the tube side of the SWS Cross Exchanger, A2-EA1520. The sour water
is preheated to 100°C [211°F] by cooling the treated water before flowing
to the Sour Water Stripper, A2-DA1520, to enter the column above the
first valve tray, tray #2.
Traditional reflux systems do not work well for strippers in this service
because of the highly corrosion nature of concentrated NH3-H2S aqueous
systems. For this reason, these systems often employ a direct-contact
condenser instead, using a circulating stream of quench water to provide
cooling for the upper section of the column. The Sour Water Stripper
contains an upper section of packing to provide contact between the
quench water and the stripped gases, and a lower section of valve trays to
provide contact between the sour water and the stripping steam.
The stripping section of the column contains 30 valve trays and one
chimney draw tray. As the sour water flows down the column, the NH3
and H2S are stripped from the water by countercurrent contact with
stripping steam rising upward. This stripping steam is generated in the
Sour Water Stripper Reboiler, A2-EA1521, using LP (3.5 kg/cm2(g)
[50 PSIG]) steam on flow control as the heat input. The stripping steam
strips the NH3 and H2S from the water and carries it upward to the quench
section of the column. The SWS Bottoms Pump, A2-GA1523A/B, pumps
the treated water from the bottom of the column through the shell side of
the SWS Cross Exchanger, cooling the treated water from 123°C [254°F]
to 54°C [130°F] by countercurrent heat exchange with the cool sour
water. The SWS Bottoms Cooler, A2-EC1521, provides final cooling to
49°C [120°F] before the treated water is returned to the complex for reuse
elsewhere.
The quench section of the column contains a packed bed and a chimney
draw tray. As the stripping steam rises upward in this section, it is
countercurrently contacted by the circulating quench water, cooling the
off-gas to 85°C [185°F] as it condenses most of the steam. The chimney
tray below the packed bed that collects the quench water leaving the

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bottom of the bed has overflow pipes to direct the condensed water onto
the valve tray (tray #2) below. The quench water collecting on the
chimney tray is pumped by the SWS Quench Water Pump,
A2-GA1522A/B, to the SWS Quench Water Cooler, A2-EC1520, to cool
the water from 99°C [210°F] to 66°C [150°F] to reject the heat removed
from the stripping steam in the quench section of the column. The cooling
rate is adjusted as necessary to control the column overhead temperature
at 85°C [185°F]. This allows the NH3 and H2S stripped from the water to
leave the column at 0.85 kg/cm2(g) [12 PSIG]and flow to the SRUs.

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8.4.1 Sour Water Stripper, A2-DA1520

The upper section of the Sour Water Stripper contains a chimney draw
tray and a single bed of random packing to provide good contact between
the circulating quench water and the stripped gases. The stripping section
of the column contains 30 valve trays and one chimney draw tray. The
valve trays provide good contact between the sour water and the reboiler
vapors to strip H2S and NH3 from the water.
column liquids to feed the Sour Water Stripper Reboiler. The column
section located below this chimney tray serves to separate the outlet
steam and treated water from the reboiler.
8.4.2 Sour Water Stripper Packing and Internals, A2-DB1520

This bed of random packing provides good contact between the stripped
gases entering below it and the quench fed above it inside the Sour Water
Stripper. The packing has a bed limiter above it and rests on a bed
support. The quench water is distributed over the packing by a distributor
tray. The packing is aluminum; the other internals are 316L S.S.
8.4.3 Stripper Trays, A2-DB1521

These 1-pass valve trays provide good contact between the sour water
fed above them and the reboiler vapors fed below them inside the Sour
Water Stripper. The tray decks for Trays #1 and #2 are 316L S.S. with
316 S.S. valves and bolting. For the remaining trays, the tray decks are
carbon steel and the valves are fabricated from 316 S.S. to resist
corrosion and to prevent "sticking" to the tray decks. The bottom valve
tray has a seal pan for its downcomer to maintain a liquid seal and prevent
gas from blowing up the downcomer.
8.4.4 SWS Cross Exchanger, A2-EA1520

This shell and tube exchanger conserves energy by providing heat
exchange between the stripped sour water and the sour water feed

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stream, so that the hot water leaving the Sour Water Stripper can preheat
the sour water before it feeds the Sour Water Stripper. This cross
exchange saves reboiler duty by preheating the sour water, and reduces
the load on the SWS Bottoms Cooler by partially cooling the hot stripped
water.
8.4.5 Sour Water Stripper Reboiler, A2-EA1521

The Sour Water Stripper Reboiler is a fixed tubesheet shell and tube heat
exchanger. The exchanger is arranged as once-through vertical
thermosiphon reboiler, mounted on the side of the Sour Water Stripper.
The static head of the water above the inlet nozzle on the lower channel
provides the driving force to circulate the water through the tubes.
LP steam on the shell of the exchanger heats the water inside the tubes,
partially vaporizing it to create stripping steam to remove the H2S and the
NH3 from the sour water flowing down the Sour Water Stripper.
8.4.6 SWS Quench Water Cooler, A2-EC1520

This forced-draft aerial exchanger is used to cool a circulating stream of
quench water which enters above the packed section of the Sour Water
Stripper and provides cooling for the upper section of the column. Fans
are used to circulate air across the finned tubes to remove heat from the
circulating quench water.
8.4.7 SWS Bottoms Cooler, A2-EC1521

This forced-draft aerial exchanger provides the final cooling of the stripped
sour water stream leaving the bottom of the Sour Water Stripper. Fans
are used to circulate air across the finned tubes to remove heat from the
water.
8.4.8 Sour Water Flash Drum, A2-FA1520

This horizontal vessel allows for the removal of hydrocarbons that may be
carried out of the various upstream processes with the sour water. The
sour water enters the vessel through a slotted, vertical distributor. Any
hydrocarbon that may be carried with the sour water from the upstream
processes will accumulate in the center section of this vessel. When a
sufficient amount of hydrocarbon has accumulated, the hydrocarbon will
overflow the partition and flow into the hydrocarbon section. Lighter
hydrocarbons are disengaged from the sour water and routed to the
battery limits on pressure control. Hydrocarbon-free sour water then
passes under another partition, at the opposite end of the vessel, and into

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the sour water outlet section, where the sour water is pumped to the Sour
Water Tank.
8.4.9 SWS Skim Oil Sump, A2-FA1522

This horizontal vessel is located in a below-ground concrete vault. It
collects the heavy hydrocarbons from the Sour Water Flash Tank. The
collected hydrocarbon liquid is pumped back to the Condensate Feed
Tank on stop/start level control.
8.4.10 SWS Skim Oil Pump Sump, A2-FA1523A/B

These vertical vessels house the SWS Skim Oil pumps. Hydrocarbon
liquids from the SWS Skim Oil Sump flow into this vessel and are pumped
out by the SWS Skim Oil Pump.
8.4.11 Sour Water Tank, A2-FB1520

The Sour Water Tank is an above-ground vertical cylindrical tank with a
floating roof. This tank is large enough to provide 2-3 days of residence
time to allow "working off " an accumulation of sour water after an outage.
It has two level transmitters to indicate the sour water level, with a low
level alarm to alert the operators of a low level, and a low level shutdown
which will shut down the SWS Feed Pump if the level in the tank drops too
low. The tank also has multiple connections to the closed drain system
which can be used to route hydrocarbons to the closed drain if a layer of
hydrocarbon should form in the tank.
8.4.12 Sour Water Filter, A2-FD1520A/B

These full-flow filters are designed to remove solid particles 5 microns and
larger from the sour water, which will help prevent fouling of the
downstream heat exchangers.
8.4.13 Sour Water Transfer Pump, A2-GA1520A/B

These centrifugal pumps are used to transfer the sour water from the Sour
Water Flash Drum to the Sour Water Tank. Each pump is designed for
the total duty; the other pump is a 100% spare. These pumps are
equipped with tandem seals to reduce the likelihood of releasing H2S to
the surroundings.

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8.4.14 SWS Feed Pump, A2-GA1521A/B

These centrifugal pumps are used to send the sour water from the Sour
Water Tank to the Sour Water Stripper. Each pump is designed for the
total duty; the other pump is a 100% spare. These pumps are equipped
with tandem seals to reduce the likelihood of releasing H2S to the
surroundings.
8.4.15 SWS Quench Water Pump, A2-GA1522A/B

These centrifugal pumps are used to circulate quench water to cool the
stripped gases in the upper section of the Sour Water Stripper. Each
pump is designed for the total duty; the other pump is a 100% spare.
These pumps are equipped with tandem seals to reduce the likelihood of
8.4.16 SWS Bottoms Pump, A2-GA1523A/B

These centrifugal pumps are used to send the stripped water from the
Sour Water Stripping Unit to the battery limits for use elsewhere in the
complex. Each pump is designed for the total duty; the other pump is a
100% spare.
8.4.17 SWS Skim Oil Pump, A2-GA1524A/B

These vertical sump-type pump is mounted in the SWS Skim Oil Pump
Sump to transfer the recovered hydrocarbons back to the Condensate
Feed Tank.

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8.5.1 SWS Shutdowns and Alarms
There are several interlocks of significance in the SWS Unit that either
generate an alarm or shut down an individual piece of equipment. These
devices/interlocks and their effects are described in this section.
a. Sour Water Flash Drum Low-Low Level, A2-LT15209A/B/C
The Sour Water Transfer Pump (A2-GA1520A/B) could be damaged

if the pump loses suction because the level in the Sour Water Flash
Drum drops too low. This device will protect the pump by stopping it
before this can occur. The setpoint is 530 mm above the bottom of
the vessel. Note that there are three independent transmitters and
2oo3 voting logic is used for the shutdown.
b. Sour Water Tank Low-Low Level, A2-LT15218A/B/C
The SWS Feed Pump (A2-GA1521A/B) could be damaged if the

pump loses suction because the level in the Sour Water Tank drops
too low. This device will protect the pump by stopping it before this
can occur. The setpoint is 300 mm above the bottom of the vessel.
Note that there are three independent transmitters and 2oo3 voting
logic is used for the shutdown.
c. SWS Bottoms Cooler Fan High Vibration, A2-WSH15234
Each fan on the SWS Bottoms Cooler (A2-EC1521) is provided with

its own vibration switch. If the vibration sensed by the switch
exceeds the preset level, the switch will trip to stop the associated
fan and activate an alarm in the DCS.
d. Sour Water Stripper Low-Low Level, A2-LT15247A/B/C
The SWS Bottoms Pump (A2-GA1523A/B) could be damaged if the

pump loses suction because the level in the Sour Water Stripper
drops too low. This device will protect the pump by stopping it before
this can occur. The setpoint is 300 mm above the bottom seam of
the column. Note that there are three independent transmitters and
2oo3 voting logic is used for the shutdown.

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e. SWS Quench Water Cooler Fan High Vibration, A2-WSH15263
Each fan on the SWS Quench Water Cooler (A2-EC1520) is

provided with its own vibration switch. If the vibration sensed by the
switch exceeds the preset level, the switch will trip to stop the
associated fan and activate an alarm in the DCS.

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8.6.1 SWS Stripper Operation
The stripped water must be comparatively free of H2S and NH3 to assure
attainment of the treated water specification. These contaminates are
removed from the sour water in the Sour Water Stripper by stripping them
out with steam.
The stripping steam is produced by vaporizing some of the water in the in

the Sour Water Stripper Reboiler, using LP (3.5-4.2 kg/cm2(g)) steam for
the heat input. The steam rate to the reboiler (and, hence, the stripping
rate) is controlled by the steam flow controller. Adjust this steam rate as
needed to keep the H2S and NH3 in the treated water low, i.e., less than
20 PPMW of H2S and less than 20 PPMW of NH3.
CAUTION

WITHOUT GOING OUT OF COMPLIANCE, REDUCING THE
STRIPPING STEAM RATE SIGNIFICANTLY CAN CAUSE THE
CONCENTRATION OF H2S AND AMMONIA IN THE TREATED
WATER TO EXCEED THE ALLOWABLE CONCENTRATION IN THE
TREATED WATER SPECIFICATION.
IF IT IS NECESSARY TO OPTIMIZE THE STEAM TO THE SOUR

WATER STRIPPER REBOILER, REDUCE THE STEAM BY SMALL
INCREMENTS AND CHECK THE CONCENTRATION OF AMMONIA
AND H2S AFTER EACH CHANGE. DO NOT REDUCE THE STEAM
FURTHER IF EITHER CONCENTRATION BEGINS TO RISE
SIGNIFICANTLY.

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8.6.2 Quench Water Circulation

The operating conditions shown on the Process Flow Diagram for this
system (in terms of the quench water circulation rate and water
temperature) should generally be maintained. The quench water
circulation rate is controlled by the quench water flow controller in the
DCS, while the temperature is controlled by a temperature controller on
the Sour Water Stripper overhead gas line adjusting the speed of one of
the fans on the SWS Quench Water Cooler, A2-EC1520.
In general, decreasing the quench water circulation rate will increase the
quench water temperature upstream of the cooler (which increases the
corrosion rate) and may increase the Sour Water Stripper Overhead
temperature if the cooler cannot cool the quench water sufficiently. Care
should be taken when reducing the quench water circulation rate to
ensure that the corrosion rate in the quench water circulation loop does
not become excessive.
As the feed rate to the SWS Stripper decreases, the quench water
circulation rate can decrease in proportion with the feed flow rate down to
about 50% of design flow rate. Below this point, the quench water rate
cannot be allowed to drop any further without risking poor performance in
the packed section of the SWS Stripper due to uneven liquid distribution
and wetting of the packing. At lower feed rates (below 50%) simply setting
the quench water flow rate to the column at about 50% of design should
maintain adequate performance. (It should be noted, however, that there
is really no detrimental effect if the quench water circulation is simply left
at the design value at all times. The only drawback is slightly higher
power consumption by the pump and aerial cooler.)
Increasing the quench water temperature will increase the overhead gas
temperature and water content which increases the load on the
downstream SRUs (since water is a product of the Claus reaction, higher
water content in the SWS feed gas can negatively impact the recovery of
in the SRUs). However, decreasing the quench water temperature (and
correspondingly the overhead gas temperature) may lead operating
issues including salt deposition and plugging in the downstream piping
and equipment. Ammonium salts can form in the gas stream leaving the
top of the Sour Water Stripper if the gas temperature falls below about
70°C. These salts can plug the mist eliminator in the top of the Sour Water
Stripper as well as the downstream piping and equipment. In addition,
decreasing the overhead gas temperature below about 82°C may prevent

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the ammonia from leaving the top of the column. Instead it may become
“trapped” in the column where it will concentrate, or it may leave in the
stripped water causing the treated water to exceed the specification for
ammonia.
The flow rate and temperatures shown on the Process Flow Diagram are
usually a good compromise between minimizing corrosion, minimizing the
load on the downstream SRUs, and minimizing operating issues within the
SWS unit.
8.6.3 pH Control
High pH water tends to hold H2S in solution and aids in releasing
ammonia from sour water. Conversely, low pH water tends to hold
ammonia in solution and improves the stripping of H2S. By injecting a
small amount of caustic near the tower bottom, ammonia stripping in the
bottom of the Sour Water Stripper can be improved while the H2S is still
stripped in the upper part of the tower.
Injection points for caustic addition have been supplied in the lower
section of the Sour Water Stripper. In the event that the stripped water
cannot meet the low ammonia specification, caustic can be added to the
tower to increase the pH and improve the ammonia stripping in the tower.
If caustic is added, injection control is critical to limit the pH of the stripped
water to about 8.0.

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B. Check the rotation of the following pumps by "bumping" them:

(1) Sour Water Transfer Pump.
(2) SWS Feed Pump
(3) SWS Quench Water Pump
(4) SWS Bottoms Pump
(5) SWS Skim Oil Pump
C. Check the rotation of the fans on the SWS Quench Water Cooler and
the SWS Bottoms Cooler, by operating each fan for a short period.

locations, the inlet and outlet block valves (if provided) are open, the
bypass valves (if provided) are closed, and the relief valves are set
for the correct relieving pressure.

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8.7.2 Washing the Sour Water System

and trash from the equipment and piping in the Sour Water Stripping
system before it is placed in operation.

(1) Set the output from the Sour Water Flash Drum level controller
to 0% to fully close the Sour Water Flash Drum level control
valve.
(2) Set the output from the SWS Inlet flow controller to 100% to
fully open the SWS Inlet flow control valve.
(3) Set the output from the SWS level controller to 100% to fully
open the level control valve.
(4) Set the output from the Quench Water flow controller to 100%
to fully open the Quench Water flow control valve.
(5) Set the output from the SWS Stripper Reboiler steam flow
controller to 0% to fully close the steam flow control valve.
(6) Set the output from the SWS pressure controller to 0% to fully
close the overhead pressure control valve to the SRUs.
B. Place the other SWS pressure controller in "automatic" with a

setpoint of 0.85 kg/cm2(g). This will open the pressure control valve
to the flare if pressure builds in the Sour Water Stripper during this
procedure.
C. Verify that the bypass valve on the pressure control valve to the flare
is closed. Open both of the isolation block valves at this control
station.
D. Place the H.P. Nitrogen supply to the Stripper overhead line in

service and open the manual block valve. This will prevent a vacuum
from forming in the Sour Water Stripper during this procedure.
E. Set the Treated Water hand control in the DCS is to 0% output to

fully open the automated valve in the Startup/Re-run line to the Sour

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Water Tank, and fully close the automated valve in the Treated
Water line downstream of the SWS Bottoms Cooler. Visually confirm
that these valves are properly positioned.
F. Verify that the manual block valve at the inlet to the Sour Water Tank
is open.
G. Verify that the manual block valve in the fill line for the Quench Water
Loop is closed.
H. Verify that the SWS Inlet flow control valve is fully open. Open both
of its isolation block valves and its bypass valve.
I. Verify that the SWS level control valve is fully open. Open both of its
isolation block valves and its bypass valve.
J. Verify that the Quench Water flow control valve is fully open. Open
both of its isolation block valves and its bypass valve.
K. Verify that the Sour Water Flash Drum level control valve is fully
closed. (This will prevent water from entering the upstream
equipment if the Sour Water Tank is accidentally over-filled.)
L. The Sour Water Filters will not be used to filter solids during this
time, but the filter vessels and their piping are to be flushed and
cleaned. Remove the filter elements, then bolt-up the filters. Open
the inlet and outlet block valves on the filters, and open the bypass
valve around the filters.
M. Use a temporary “jumper” to add cold condensate to the Sour Water

Tank.
N. Once there is an adequate level in the tank, open the suction valve
on a SWS Feed Pump and use its drain valve to be sure the pump is
flooded with water. Start the pump, then open its discharge valve.
Watch the level in the Sour Water Tank as the pump fills the
downstream piping and begins to fill the Sour Water Stripper. When
the level drops to the low-low level shutdown it should shut down the
pump. If it does not, stop the pump manually before it loses suction
and correct the problem with the low level shutdown before
proceeding.

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O. Continue filling the Sour Water Tank with condensate and pumping
the water to the Sour Water Stripper periodically, until the level in the
Stripper is all the way to the top of its level gauge.
P. Once there is an adequate level in the Stripper, open the suction

valve on a SWS Bottoms Pump and use its drain valve to be sure the
pump is flooded with water. Start the pump, then open its discharge
valve.
Watch the level in the Sour Water Stripper as the pump fills the
downstream piping and begins to circulate back to the Sour Water
Tank. When the level drops to the low-low level shutdown it should
shut down the pump. If it does not, stop the pump manually before it
loses suction and correct the problem with the low level shutdown
before proceeding.
Q. Once circulation is achieved and the level in the Sour Water Stripper
is adequate (about halfway up in the level gauge), discontinue the
R. Circulate the water and blow down the low point drains until all of the
drain water is clear. Add more condensate as necessary to maintain
the level in the Sour Water Stripper.
At some point during the washing procedure, the standby SWS Feed
Pump and the standby SWS Bottoms pump should be placed in
service while the other pumps are shut down. This will ensure
cleaning out all pumps and their associated piping.
S. When the drain water begins to clear, open the manual block valve in
the Quench Water fill line, open the suction valve on a SWS Quench
Water Pump and use its drain valve to be sure the pump is flooded
with water. Start the pump, then open its discharge valve.
quench water circulation loop. Add additional condensate to the Sour
Water Tank if necessary and pump the water to the Sour Water
Stripper.
T. Once circulation is achieved in the Quench Water loop and the level
in the Sour Water Stripper is adequate (about halfway up in the level
gauge), discontinue the addition of condensate and close the manual
block valve in the Quench Water fill line.

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U. Circulate the water in the Quench Water loop and blow down the low
point drains until all of the drain water is clear.
At some point during the washing procedure, the standby SWS

Quench Water Pump should be placed in service while the other
pump is shut down. This will ensure cleaning out both pumps and
their associated piping.
V. Once the drain water is clear in the main circulation loop and Quench
Water loop, shutdown the pumps and completely drain the system.
Drain the system as quickly as possible, so that the water velocity
helps to flush the solids from all parts of the system.

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8.8.1 Initial Startup of the SWS
The SWS system should now be clean, ready to place in service. All that
remains is to fill the system with water and establish the proper operating
conditions.

A. Close the bypass valves around the following control stations:
(1) SWS Inlet flow control
(2) SWS level control
(3) Quench water flow control
B. Close the inlet and outlet block valves (but leave the bypass
valves open) on the Sour Water Filters, then install the proper
elements in the filters. Leave the block valves closed on each
filter for now.
C. Use a temporary “jumper” to add cold condensate to the Sour

Water Tank and reestablish the level in the Sour Water Stripper
as before.
D. Establish circulation of water in the system (including the

Quench Water loop) using the procedures in Section 8.7.2.
E. Start a fan on the SWS Bottoms Cooler and place the bottoms
temperature controller in service with a setpoint of 60°C.
F. Begin steam flow to the Sour Water Stripper Reboiler and

gradually raise the temperature in the column. Place the steam
flow controller in the DCS on "automatic" with its setpoint set to
its normal value.
G. Open the high point vent valve on the Stripper overhead line
and allow the steam to purge any air from the vessel. As the
pressure builds, the vent valve can be closed.
H. When the temperature begins to rise in the SWS overhead line,

start a fan on the SWS Quench Water Cooler and place the
overhead temperature controller in service with a setpoint of
85°C.

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I. Monitor the stripper pressure, and adjust the overhead pressure

temperatures.
J. Ensure that the fans are running on the SWS Bottoms Cooler
and the SWS Quench Water Cooler.
K. If the control loops for the Sour Water Stripper have not already
been placed in service, do so at this time. Switch the SWS
level controller, and the SWS Inlet flow controller in the DCS to
"automatic" with their setpoints set to their normal values.
L. Place the Quench Water flow controller in “automatic” and set

its setpoint to its normal value.
M. Place each of the sour water filters in service as follows:
the filter to fill with sour water. When the filter is full, close
its vent valve.
Note: At this point the sour water system is ready for service. It
can remain in this operating mode indefinitely while the
rest of the Complex is prepared for startup. Check the
system periodically for indications of plugging, etc. (low
flow, erratic pump discharge pressure, high filter pressure
drop), as solid materials may accumulate at various points
N. Once there is an adequate level of Sour Water in the Sour

Water Flash Drum, open the suction valve on a Sour Water
Transfer Pump and use its drain valve to be sure the pump is
flooded with water. Start the pump, then open its discharge
valve.
Watch the level in the Sour Flash Drum as the pump fills the
downstream piping and begins to flow to the Sour Water Tank.
When the level drops to the low-low level shutdown it should

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shut down the pump. If it does not, stop the pump manually
before it loses suction and correct the problem with the low
level shutdown before proceeding.
O. Place the Sour Water Flash Tank level controller in the DCS in
“automatic” and set its setpoint to its normal value.
P. Once a level of hydrocarbons has built up in the hydrocarbon

side of the Sour Water Flash Tank, the oil level controller can
also be placed “automatic” and its setpoint set to its normal
value.
The sour water will continue to circulate from the Sour Water Tank to
the Sour Water Stripper and back to the tank. The Sour Water Tank
is large enough to provide 3-4 days of residence time for the
produced sour water in the event the Sour Water System is not ready
to export treated water at this time.
8.8.1.2 Exporting Treated Water

Stripped sour water may not be routed to the complex’s treated water
system until the temperature in the bottom of the Sour Water Stripper
is high enough to satisfy the Stripped Water Low Temperature
Interlock. This interlock disables the hand control in the DCS to
prevent the operator from routing the stripped water to the complex’s
treated water system until the temperature in the bottom of the Sour
Water Stripper is sufficiently high.
Once the temperature in the bottom of the Sour Water Stripper is

high enough to satisfy the low-temperature interlock, and the
complex is producing a sufficient quantity of sour water for
processing:
A. Slowly increase the output from the Treated Water hand

control to 100%, which will open the automated valve in the
Treated Water line downstream of the SWS Bottoms Cooler
and close the automated valve in the Startup/Re-run line to the
Sour Water Tank.
B. When the output of the Treated Water hand control reaches

100%, the automated valve in the Treated Water line
downstream of the SWS Bottoms Cooler should be fully open
and the automated valve in the Startup/Re-run line fully closed
to send all of the treated water to the complex’s treated water

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system. Visually confirm that these valves are properly

positioned.
C. Once the operation of the Sour Water Stripper has stabilized,

route its acid gas, which is presently going to the flare through a
pressure valve to the SRUs as follows:
(1) Confirm that the Sour Water Stripper pressure controller to

the SRUs in the DCS is in "manual" with its output set to
0%.
(2) Confirm that the setpoint of the Sour Water Stripper

pressure controller to the SRUs is tracking its current
reading, then place it in "automatic".
(3) Slowly raise the setpoint of the Sour Water Stripper

pressure controller to the flare to 1.0 kg/cm2(g).
(4) If, necessary, adjust the setpoint of the Sour Water

Stripper pressure controller to the SRU to its normal
setpoint.
The Sour Water Stripper pressure controller will now take over
control of the Sour Water Stripper pressure by opening the
pressure valve to send the acid gas to the SWS Gas Knock-Out
Drums in the SRUs. The Sour Water Stripper pressure
controller to the flare will close the acid gas pressure valve and
stop the flow of acid gas to the flare. If the SRUs shut down (or
some other upset causes the Sour Water Stripper pressure to
rise), the Sour Water Stripper pressure controller to the flare will
act as an over-ride and divert the acid gas to the flare.
D. The SWS is now fully on-stream. Before directing your

attention away from the SWS, be sure that:
properly.

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8.8.2 Normal Startup of the SWS

The procedure for startup of the SWS after it has been shut down will be
very similar to the procedure for the initial startup, except that condensate
will not be used to fill the system. For ease of reference, the steps to be
performed are written in this Section to serve as a "check list" that can be
easily followed on subsequent startups. Refer to the previous Sections for
the reasons and details pertaining to the different steps performed.
Prior to commencing SWS startup, check for the completion of all

maintenance work (connecting lines, removing blinds, etc.) if such work
was performed.

A. Confirm that the Treated Water hand control in the DCS is to
0% output to fully open the automated valve in the Startup/Re-
run line to the Sour Water Tank, and fully close the automated
valve in the Treated Water line downstream of the SWS
Bottoms Cooler. Visually confirm that these valves are properly
positioned.
B. Place the following controllers in the DCS in "manual" with their

(1) Set the output from the SWS Inlet flow controller to 100%
to fully open the SWS Inlet flow control valve.
(2) Set the output from the SWS level controller to 100% to
fully open the level control valve.
(3) Set the output from the Quench Water flow controller to
100% to fully open the Quench Water flow control valve.
C. Confirm that the output from the SWS Stripper Reboiler steam
flow controller is set to 0% and the steam flow control valve is
fully closed.
D. Confirm that the output from the SWS pressure controller is set
to 0% and the overhead pressure control valve to the SRUs is
fully closed.
E. Place the other SWS pressure controller in "automatic" with a

setpoint of 0.85 kg/cm2(g). This will open the pressure control

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valve to the flare if pressure builds in the Sour Water Stripper

during this procedure.
F. Verify that the bypass valve on the pressure control valve to the
flare is closed and that both of the isolation block valves are
open.
G. If not already in service, place the H.P. Nitrogen supply to the

Stripper overhead line in service and open the manual block
valve.
H. Verify that the manual block valve at the inlet to the Sour Water
Tank is open.
I. Verify that the manual block valve in the fill line for the Quench
Water loop is closed.
J. If the Sour Water Flash Drum is already in service and sending

sour water to the Sour Water Tank, proceed to Step L.
Otherwise, if the Sour Water Flash Drum is not in service, open

the isolation valves upstream of the flash drum to allow sour
water to enter the flash drum from the upstream Units.
K. Once there is an adequate level of sour water in the Sour Water

Flash Drum, open the suction valve on a Sour Water Transfer
Pump and use its drain valve to be sure the pump is flooded
Watch the level in the Sour Flash Drum as the pump fills the
downstream piping and begins to send sour water to the Sour
Water Tank. When the level drops to the low-low level
shutdown it should shut down the pump. If it does not, stop the
pump manually before it loses suction and correct the problem
with the low level shutdown before proceeding.
L. Confirm that there is an adequate level of sour water in the

Sour Water Tank, then open the suction valve on a SWS Feed
Pump and use its drain valve to be sure the pump is flooded
Watch the level in the Sour Water Tank as the pump fills the
downstream piping and begins to fill the Sour Water Stripper.

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M. Continue pumping sour water to the Sour Water Stripper until

the level in the Stripper is all the way to the top of its level
gauge.
N. When there is an adequate level in the Stripper, open the

suction valve on a SWS Bottoms Pump and use its drain valve
to be sure the pump is flooded with water. Start the pump, then
open its discharge valve to begin circulating sour water back to
the Sour Water Tank.
O. Once circulation is achieved and the level in the Sour Water

Stripper is adequate, open the manual block valve in the
Quench Water fill line, open the suction valve on a SWS
Quench Water Pump and use its drain valve to be sure the
discharge valve.
quench water circulation loop. If the level in the stripper falls
below the low level alarm point, stop the SWS Quench Water
Pump and pump additional sour water to the Stripper from the
Sour Water Tank to bring the level in the level back up before
restarting the SWS Quench Water Pump.
P. Once circulation is achieved in the Quench Water loop and the

level in the Sour Water Stripper is adequate (about halfway up
in the level gauge), close the manual block valve in the Quench
Water fill line.
Q. Start a fan on the SWS Bottoms Cooler and place the bottoms
temperature controller in service with a setpoint of 60°C.
R. Begin steam flow to the Sour Water Stripper Reboiler and

gradually raise the temperature in the column. Place the steam
flow controller in the DCS on "automatic" with its setpoint set to
its normal value.
S. When the temperature begins to rise in the SWS overhead line,

start a fan on the SWS Quench Water Cooler and place the
overhead temperature controller in service with a setpoint of
85°C.

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T. Monitor the stripper pressure, and adjust the overhead pressure

temperatures.
U. Ensure that the fans are running on the SWS Bottoms Cooler
and the SWS Quench Water Cooler.
V. If the control loops for the Sour Water Stripper have not already
been placed in service, do so at this time. Switch the Sour
Water Flash Tank level controllers, the SWS level controller,
and the SWS Inlet flow controller in the DCS to "automatic" with
their setpoints set to their normal values.
W. Place the Quench Water flow controller in “automatic” and set

its setpoint to its normal value.
The sour water will continue to circulate from the Sour Water Tank to
the Sour Water Stripper and back to the tank. The Sour Water Tank
is large enough to provide 3-4 days of residence time for the
produced sour water in the event the Sour Water System is not ready
to export treated water at this time.
8.8.2.2 Exporting Treated Water

Stripped sour water may not be routed to the complex’s treated water
system until the temperature in the bottom of the Sour Water Stripper
is high enough to satisfy the Stripped Water Low Temperature
Interlock. This interlock disables the hand control in the DCS to
prevent the operator from routing the stripped water to the complex’s
treated water system until the temperature in the bottom of the Sour
Water Stripper is sufficiently high.
Once the temperature in the bottom of the Sour Water Stripper is

high enough to satisfy the low-temperature interlock, and the
complex is producing a sufficient quantity of sour water for
processing:
A. Slowly increase the output from the Treated Water hand

control to 100%, which will open the automated valve in the
Treated Water line downstream of the SWS Bottoms Cooler
and close the automated valve in the Startup/Re-run line to the
Sour Water Tank.

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B. When the output of the Treated Water hand control reaches

100%, the automated valve in the Treated Water line
downstream of the SWS Bottoms Cooler should be fully open
and the automated valve in the Startup/Re-run line fully closed
to send all of the treated water to the complex’s treated water
system. Visually confirm that these valves are properly
positioned.
C. Once the operation of the Sour Water Stripper has stabilized,

route its acid gas, which is presently going to the flare through a
pressure valve to the SRUs as follows:
(1) Confirm that the Sour Water Stripper pressure controller to

the SRUs in the DCS is in "manual" with its output set to
0%.
(2) Confirm that the setpoint of the Sour Water Stripper

pressure controller to the SRUs is tracking its current
reading, then place it in "automatic".
(3) Slowly raise the setpoint of the Sour Water Stripper

pressure controller to the flare to 1.0 kg/cm2(g).
(4) If, necessary, adjust the setpoint of the Sour Water

Stripper pressure controller to the SRU to its normal
setpoint.
The Sour Water Stripper pressure controller will now take over
control of the Sour Water Stripper pressure by opening the
pressure valve to send the acid gas to the SWS Gas Knock-Out
Drums in the SRUs. The Sour Water Stripper pressure
controller to the flare will close the acid gas pressure valve and
stop the flow of acid gas to the flare. If the SRUs shut down (or
some other upset causes the Sour Water Stripper pressure to
rise), the Sour Water Stripper pressure controller to the flare will
act as an over-ride and divert the acid gas to the flare.
D. The SWS is now fully on-stream. Before directing your

attention away from the SWS, be sure that:

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properly.

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Typical shutdown procedures for the Sour Water Stripping Unit are outlined and
discussed in the sections that follow for the more common cases. Your existing
company procedures and common sense operational judgment should be used
to modify these procedures as needed to serve the purpose of any given
planned shutdown situation.
8.9.1 Planned Shutdown

gases or the formation of flammable vapor mixtures.
To shut the SWS down in a controlled fashion proceed as follows:
A. Slowly reduce the output from the Treated Water hand control in the
DCS is to 0% output to fully open the automated valve in the
Startup/Re-run line to the Sour Water Tank, and fully close the
automated valve in the Treated Water line downstream of the SWS
Bottoms Cooler. Visually confirm that these valves are properly
positioned.
B. Place the stream flow controller in manual and set its output to 0% to
close the stream flow control valve and stop the steam flow to the
Sour Water Stripper Reboiler.
C. Continue to circulate the sour water and operate the SWS Bottoms
Cooler and the SWS Quench Water Cooler until the sour water is
cool.
D. Once the sour water is cool, shut down the SWS Feed Pump to stop
the flow of sour water to the Sour Water Stripper and close the block
valves in the pump suction lines.
E. Place the SWS flow controller in the DCS in "manual" and set its
output to 0% to fully close the sour water inlet flow control valve.
F. Shutdown the SWS Quench Water Pumps and shut down the fans
on the SWS Quench Water Cooler.
G. Place the quench water flow controller in the DCS in "manual" and
set its output to 0% to fully close the quench water flow control valve.

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H. Use the SWS Bottoms pump to pump the sour water from the Sour
Water Stripper to the Sour Water Tank until the low-low level
shutdown is activated. This should shut down the SWS Bottoms
Pump. Monitor the level in the Sour Water Stripper and be prepared
to shut down the pump if the low-low level shutdown fails to activate.
I. Place the SWS level controller in the DCS in "manual" and set its
output to 0% to fully close the SWS level control valve.
J. Shut down the fans on the SWS Bottoms Cooler
K. Drain the remaining sour water in the SWS equipment to the Closed
Drain System.
L. Verify that the SWS level control valve is fully closed. Close both of
its isolation block valves and its bypass valve.
M. Verify that the SWS flow control valve is fully closed. Close both of
its isolation block valves and its bypass valve.
N. Verify that the quench water flow control valve is fully closed. Close
both of its isolation block valves and its bypass valve.
O. The SWS is now ready to be isolated and made safe for entry.

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The SWS system is directly affected by a shutdown and/or outage in the
LP steam system for the complex. These effects are described below.

The most immediate impact on the SWS will be the loss of LP steam
to the Stripper Reboiler if the steam outage lasts long enough. As
the heat input to the reboiler declines, stripping of the acid gas from
the sour water will decline and the H2S and NH3 in the treated water
leaving the Sour Water Stripper will begin to increase. If this
happens, use the Treated Water hand control in the DCS to route the
treated water back to the Sour Water Tank until the LP steam system
can be brought back on-line.

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Table of Contents
9. SULFUR RECOVERY .................................................................................................. 9-4
9.2 SAFETY ................................................................................................................. 9-4
9.3.1 Overview......................................................................................................... 9-5
9.3.2 General ........................................................................................................... 9-6
9.3.3 Feed Gas Processing ..................................................................................... 9-6
9.3.4 Thermal Processing........................................................................................ 9-7
9.3.5 Catalytic Processing ....................................................................................... 9-8
9.3.6 Air Control System.......................................................................................... 9-9
9.3.7 Molten Sulfur Handling ................................................................................. 9-10
9.3.8 Steam Production ......................................................................................... 9-10
9.4.1 Reactor Furnace, A2-BA1530 (A2-BA1540) ................................................. 9-11
9.4.2 Acid Gas Burner Assembly, A2-BA1531 (A2-BA1541) ................................ 9-12
9.4.3 Acid Gas Knock-Out Drum, A2-FA1530 (A2-FA1540) ................................. 9-12
9.4.4 SWS Gas Knock-Out Drum, A2-FA1531 (A2-FA1541) ................................ 9-12
9.4.5 Reactor, A2-DC1530 (A2-DC1540) .............................................................. 9-13
9.4.6 Catalyst for Sulfur Plant Reactors, A2-MC1530 (A2-MC1540) ..................... 9-13
9.4.7 Acid Gas Preheater, A2-EA1530 (A2-EA1540) ............................................ 9-13
9.4.8 Sulfur Condenser, A2-EA1531 (A2-EA1541) ............................................... 9-13
9.4.12 Sulfur Surge Tank, A2-FB1530 (A2-FB1540) ............................................... 9-15
9.4.13 Acid Gas Knock-Out Drum Pump, A2-GA1530A/B (A2-GA1540A/B) .......... 9-16
9.4.14 SWS Gas Knock-Out Drum Pump, A2-GA1531A/B (A2-GA1541A/B) ......... 9-17
9.4.15 Sulfur Storage Tank Vent Ejector, A2-EE1530 (A2-EE1540) ....................... 9-17
9.4.16 Process Air Blower, A2-GB1530A/B (A2-GB1540A/B)................................. 9-18
9.4.17 Air Blower Suction Screen/Silencer, A2-FD1530A/B (A2-FD1540A/B) ........ 9-19
9.4.18 Process Air Vent Silencer, A2-FG1530A/B (A2-FG1540A/B) ....................... 9-19
9.4.19 Sulfur Drain Seal Assembly, A2-ME1530A-D (A2-ME1540A-D) .................. 9-19
9.4.20 Refractory for Reactor Furnace and Waste Heat Boiler, A2-MR1530
(A2-MR1540) .............................................................................................................. 9-20
9.4.21 Ceramic Ferrules for Waste Heat Boiler, A2-MR1532 (A2-MR1542) ........... 9-20
9.4.22 Refractory for Waste Heat Boiler, A2-MR1533 (A2-MR1543) ...................... 9-20
9.4.23 Refractory for Sulfur Condenser, A2-MR1534 (A2-MR1544) ....................... 9-20
Issued 30 August 2011 Sulfur Recovery Page 9-1

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9.4.24 Refractory for Reactor, A2-MR1535 (A2-MR1545) ...................................... 9-21

9.4.25 Rainshield for Reactor Furnace, A2-ME1531 (A2-ME1541) ........................ 9-21
9.4.26 Ceramic Ferrule for Reactor Furnace, A2-MR1531 (A2-MR1541) ............... 9-21
9.4.27 Waste Heat Boiler, A2-BF1530 (A2-BF1540) ............................................... 9-22
9.5.1 SRU Air:Acid Gas Ratio Control Loop .......................................................... 9-24
9.5.2 Acid Gas Burner Management System ........................................................ 9-30
9.5.3 Process Air Blower Controls ......................................................................... 9-34
9.5.4 Reactor Furnace Temperature Control......................................................... 9-39
9.5.5 Knock-Out Drum Pump Control .................................................................... 9-41
9.5.6 "Ride-Through" System Considerations ....................................................... 9-41
9.5.7 Boiler Low-Low Level S/D Transmitter Testing ............................................ 9-44
9.5.8 SRU Emergency Shutdown Systems ........................................................... 9-46
9.6.1 Equipment Damage ...................................................................................... 9-56
9.6.2 Cold Catalyst Bed Startup ............................................................................ 9-58
9.6.3 Sulfur Solidification ....................................................................................... 9-60
9.6.4 Ammonia Salt Formation .............................................................................. 9-61
9.6.5 Catalyst Fouling ............................................................................................ 9-62
9.6.6 Operation of SRUs in Parallel....................................................................... 9-62
9.6.7 Process air Blower Operation ....................................................................... 9-65
9.6.8 Reactor Furnace Temperature ..................................................................... 9-70
9.6.9 Ammonia Destruction Considerations .......................................................... 9-73
9.6.10 Sulfur Recovery Efficiency............................................................................ 9-76
9.6.12 Pressure Drop Surveys ................................................................................ 9-82
9.6.13 Boiler Water Treatment ................................................................................ 9-84
9.7.4 Purging the Inlet Knock-Out Drums .............................................................. 9-93
9.7.5 Commissioning Fuel Gas and Instrument Air to the Process ....................... 9-95
9.7.6 Commissioning Nitrogen to the Process ...................................................... 9-99
9.7.7 Commissioning the Sulfur Surge Tank Heating and Ventilation ................. 9-102
9.7.8 Pre-filling the Sulfur Drain Seal Assemblies ............................................... 9-104
9.8.2 Amine Acid Gas Flow ................................................................................. 9-117
9.8.3 SWS Gas Flow ........................................................................................... 9-124

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9.8.4 Routing SRU Tailgas to the TGCU ............................................................. 9-127

9.8.5 Normal Startup - Cold System .................................................................... 9-129
9.8.6 Normal Startup - Hot System...................................................................... 9-146
9.8.7 Firing Supplemental Fuel Gas .................................................................... 9-158
9.10 ANALYTICAL PROCEDURES .......................................................................... 9-187
9.10.1 Procedure for Sampling and Titrating with a Tutweiler Apparatus ............. 9-187
9.10.2 H2S Concentration in Acid Gas by the Tutweiler Method ........................... 9-189
9.10.3 H2S and SO2 Concentration in Tailgas by the Tutweiler Method ................ 9-192
9.10.4 Tailgas Analysis Table................................................................................ 9-196
9.10.5 Tailgas Analysis Operating Chart ............................................................... 9-197
9.10.6 Essential Apparatus for Tutweiler Analysis ................................................ 9-199
9.10.7 Materials for Tutweiler Analysis .................................................................. 9-200
9.10.8 H2S and SO2 Conc. in Tailgas Using Gas Detector Tubes ......................... 9-200
9.11 ADJUSTING STACKMATCH® IGNITOR/PILOTS ............................................. 9-205

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9. SULFUR RECOVERY
The purpose of the Sulfur Recovery Units (SRUs) is to dispose of H2S-laden
acid gas. This gas is produced by the new Amine Regeneration Unit and Sour
Water Stripping Unit. Acid gases of this type are not allowed into the
atmosphere, as they are highly toxic. If burned in a flare system, the pollutants
would exceed emission standards. Each Sulfur Recovery Unit can take enough
H2S out of the acid gas so that the remaining tailgas can be processed in a
Tailgas Cleanup Unit to meet the emission standards after incineration. Also,
the byproduct of pure sulfur is a marketable product.
9.2 Safety
WARNING

HYDROGEN SULFIDE AND WARNING
SULFUR DIOXIDE. CLOSE ATTENTION
SHOULD BE PAID TO THE "GENERAL SAFETY" SECTION OF THESE

WARNING
THIS PLANT.

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9.3.1 Overview
The new Sulfur Recovery Units, consisting of SRU Train 1 and

SRU Train 2, are designed to operate in parallel and recover elemental
sulfur from the off-gases produced by the new Amine Regeneration and
Sour Water Stripper Units. It is intended that the Sulfur Recovery Facility
convert and recover 99.9% or more of the hydrogen sulfide (H2S)
contained in the feed streams as elemental sulfur in compliance with
environmental requirements.
The acid gases produced by the new Amine Regeneration Unit (ARU) and
the new Sour Water Stripping Unit (SWS) are routed to two parallel Claus
Sulfur Recovery Units (SRUs) using technology licensed from BP Amoco
Corporation. The H2S is converted into molten elemental sulfur and
routed to the common Sulfur Degassing Unit (SDU) that uses technology
licensed from BP Amoco Corporation to reduce the H2S content of the
sulfur to less than 10 PPMW. The combined tailgas from the sulfur plants
is processed in a Tailgas Cleanup Unit (TGCU) using the Shell Claus
Off-gas Treating (TGCU) process licensed by Shell Global Solutions (US)
Inc. to produce an acid gas stream that is recycled back to the Claus plant
so that the overall sulfur recovery is 99.9 wt. % or better.
The effluent gas from the TGCU is thermally incinerated in a Tailgas

Thermal Oxidation Unit (TTO) to convert all of the remaining sulfur
compounds into sulfur dioxide (SO2) before dispersion of the gas to the
atmosphere. Due to the sulfur removal by the TGCU process, the
incinerated effluent gas will contain less than 200 PPMV of SO2 on a dry,
0% oxygen basis.
The two process trains are identical, so all of the information that follows
applies to both trains. Where references to equipment or instrument tag
numbers are given, the SRU Train 1 tag number is given first followed by
the SRU Train 1 tag number in parentheses.

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9.3.2 General
Each sulfur plant processes 1,181 Nm3/H of acid gas from the Amine
Regeneration Unit and 33 Nm3/H of off-gas from Sour Water Stripping
(SWS) Unit, plus 50% of the recycle acid gas from the Tailgas Cleanup
Unit. Each sulfur plant will recover 94-96% of the sulfur contained in the
total acid gas feed as elemental sulfur, producing about 34.6 MT/D of
molten sulfur product. The tailgas leaving each sulfur plant is routed to
the common TGCU.
Each sulfur plant uses the modified straight-through Claus process

licensed from BP Amoco Corporation, with a number of special design
features to accomplish the required recovery performance while providing
exceptionally good on-stream reliability and ease of operation. The Claus
process utilizes the following chemical reactions to convert hydrogen
sulfide to elemental sulfur:
(1) H2S + 3/2 O2 SO2 + H2O
(2) 2 H2S + SO2 3/n Sn + 2 H2O
The overall reaction for the process is:
(3) 3 H2S + 3/2 O2 3/n Sn + 3 H2O
The sulfur plant contains one non-catalytic conversion stage and three
catalytic conversion stages in series. The Claus reaction is highly
exothermic, releasing a great deal of heat energy that is recovered as HP
and LP steam in heat exchangers following the conversion stages.
9.3.3 Feed Gas Processing

Acid gas from the Amine Regeneration Unit is combined with the recycle
acid gas from the Tailgas Cleanup Unit and is routed to the Acid Gas
Knock-Out Drum, A2-FA1530 (A2-FA1540), at 49°C [120°F] and
0.74 kg/cm2(g) [10.5 PSIG]. Entrained liquids are separated and
automatically routed back to the Rich Amine Flash Drum by Acid Gas
Knock-Out Drum Pump, A2-GA1530A/B (A2-GA1540A/B), on start/stop
level control. The scrubbed acid gas stream flows through the Acid Gas
Preheater, A2-EA1530 (A2-EA1540), where a portion of the LP
(4.2 kg/cm2(g) [60 PSIG]) steam generated elsewhere in the SRU heats
the acid gas to 126°C [259°F]. Preheating the amine acid gas allows it to
be mixed with the SWS gas without causing ammonium salt precipitation.
The preheater is also an energy conservation device, as preheating with

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LP steam allows more HP (48.5 kg/cm2(g) [690 PSIG]) steam to be

produced in the sulfur plant.
SWS gas from the Sour Water Stripping Unit is routed to the SWS Gas
knock-Out Drum, A2-FA1531 (A2-FA1541), at 85°C [185°F] and
0.70 kg/cm2(g) [10.0 PSIG]. Entrained liquids are separated and
automatically routed back to the Sour Water Flash Drum by the SWS Gas
Knock-Out Drum Pump, A2-GA1531A/B (A2-GA1541A/B), on start/stop
level control. The scrubbed SWS gas mixes with the majority of the
preheated amine acid gas and flows to the Acid Gas Burner, A2-BA1531
(A2-BA1541). The remainder of the amine acid gas is routed into the
sides of the Reactor Furnace, A2-BA1530 (A2-BA1540), on flow ratio
control to ensure proper destruction of the ammonia in the first zone of the
furnace as described below.
9.3.4 Thermal Processing

One-third of the hydrogen sulfide in the feed stream must be converted to
sulfur dioxide before the Claus reaction (2) can be utilized to produce
elemental sulfur. Accordingly, the acid gas feed stream flows to the Acid
Gas Burner to be combusted with air provided by the Process Air Blower,
A2-GB1530A/B (A2-GB1540A/B). The amount of air is controlled to
combust one-third of the hydrogen sulfide to sulfur dioxide via reaction (1).
Sufficient air is also provided to combust the ammonia and hydrocarbons
entering with the acid gas.
The combustion products pass into the first combustion zone of the
Reactor Furnace, which provides the necessary residence time to allow
these reactions to reach equilibrium. At 1370°C [2500°F] or above (with
the proper residence time), ammonia is almost completely destructed to
nitrogen and water. The first combustion zone is controlled at or above
this temperature by adjusting the amount of amine acid gas bypassing the
burner. Combustion of the SWS gas at or above this temperature in a
reducing atmosphere is essential for destruction of the ammonia, and
avoids formation of undesirable and troublesome compounds such as
sulfur trioxide.
The first combustion zone of the Reactor Furnace is separated from the
second zone by a refractory checker wall. The amine acid gas bypassing
the burner is injected into the Reactor Furnace immediately downstream
of the checker wall, where it mixes with the burner effluent. The second
zone is large enough to provide sufficient residence time for the

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sulfur-forming and hydrocarbon-oxidizing reactions to reach equilibrium.

The Reactor Furnace functions as a non-catalytic conversion stage, as
67% of the hydrogen sulfide is converted to elemental sulfur.
The effluent from the Reactor Furnace enters the tubes in the Waste Heat
Boiler, A2-BF1530 (A2-BF1540), where the gas is cooled to 328°C
[622°F] by producing HP steam. The gas is then routed through the first
condensing pass of the Sulfur Condenser, A2-EA1531 (A2-EA1541), and
further cooled to 165°C [329°F] by producing LP steam. The outlet
channel of the Sulfur Condenser is extended and contains a compartment
that serves as a separator for the condensed sulfur that is formed as the
gases are cooled. About 65% of the sulfur entering the sulfur plant is
recovered as condensed liquid sulfur here.
9.3.5 Catalytic Processing

The vapor from the first condensing pass of the Sulfur Condenser flows to
the Reactor No. 1 Feed Heater, A2-EA1532 (A2-EA1542), and is heated
by a portion of the HP steam generated in the Waste Heat Boiler, which
circulates in a thermosiphon loop. The reheated stream then enters the
first catalyst chamber in the Reactor, A2-DC1530 (A2-DC1540), at 232°C
[450°F].
In this first catalytic conversion stage, the majority of the remaining sulfur
compounds are converted to elemental sulfur vapor by reaction (2). In
addition, much of the organic sulfur compounds formed by side reactions
in the Reactor Furnace, carbonyl sulfide (COS) and carbon disulfide
(CS2), are hydrolyzed back to H2S in this catalyst bed. Hydrolysis of the
organic sulfur compounds helps achieve high sulfur recovery by
converting the organic sulfur compounds into sulfur species that will react
via the Claus reaction to produce sulfur. Special promoted catalysts are
often employed for higher COS/CS2 conversion, and this catalytic stage is
often operated at higher temperatures since this also increases
conversion.
The sulfur vapor produced the first catalyst bed is then condensed at
about 161°C [322°F] in the second condensing pass of the Sulfur
Condenser by generating additional LP steam. About 20% of the inlet
sulfur is condensed and recovered as liquid sulfur in the separator
chamber at the outlet of this condenser pass. The vapor from the second
condensing pass is reheated to 210°C [410°F] using HP steam in the
Reactor No. 2 Feed Heater, A2-EA1533 (A2-EA1543), and is routed to the

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second catalyst chamber in the Reactor where further conversion of H2S

and SO2 occurs. The reactor effluent is then cooled to 157°C [314°F] in
the third condensing pass of the Sulfur Condenser by generating
additional LP steam. About 7% of the inlet sulfur is recovered as
condensed liquid sulfur in the separator chamber at the outlet of this
condensing pass.
The vapor leaving the third condensing pass is reheated to 204°C [400°F]
using HP steam in the Reactor No. 3 Feed Heater, A2-EA1534
(A2-EA1544), and flows to the third catalyst chamber in the Reactor, the
final conversion stage. More conversion occurs in this third catalytic stage
before the gas is cooled in the fourth pass of the Sulfur Condenser by
generating additional LP steam. An additional 2% of the total sulfur is
recovered in the separator chamber at the outlet of this fourth and final
condensing pass, bringing the total sulfur recovery to approximately 94%
in the Claus sulfur plant. The remaining vapor leaves the fourth pass of
the Sulfur Condenser at about 156°C [313°F] and flows to the TGCU.
9.3.6 Air Control System

For optimum sulfur recovery, the hydrogen sulfide:sulfur dioxide ratio of
the process gas at all points downstream of the Reactor Furnace should
be exactly 2:1. This ratio depends on the amount of air sent to the Acid
Gas Burner by the Process Air Blower. A combination of
feed-forward/feed-back control is used in the sulfur plant to control the
proper quantity of air.
The amine acid gas flow rate and SWS gas flow rate (and fuel gas flow
rate, if any) are measured, summed together, and sent to the ratio
controller which adjusts the air flow, yielding feed-forward control that
allows the sulfur plant to compensate for changes in the amine acid gas
and SWS gas flow rates (and the fuel gas flow rate, also).
The H2S:SO2 ratio of the gas from the fourth condensing pass of the
Sulfur Condenser is continuously analyzed by the air demand analyzer.
This analyzer signal is then used to change the setpoint of the flow ratio
controller, thus providing feed-back control to allow the sulfur plant to
adjust to variations in amine acid gas and/or SWS gas composition,
temperature, and pressure.

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9.3.7 Molten Sulfur Handling

Liquid sulfur from each of the four condensing passes is routed to an
individual Sulfur Drain Seal Assembly, A2-ME1530A-D (A2-ME1540A-D),
in the below-ground Sulfur Surge Tank, A2-FB1530 (A2-FB1540). Each
drain seal has a "U"-tube that uses static head from a column of liquid
sulfur to serve as a seal and prevent the process gases from escaping.
The drain seals are steam-jacketed to prevent sulfur from freezing and
have view hatches to allow verifying that each rundown line is flowing.
The Sulfur Surge Tank provides storage for about 160 metric tons of raw
sulfur production from the sulfur plant. The Sulfur Surge Tank is a
horizontal cylindrical tank resting in a concrete vault. The tank is
constructed of carbon steel and is equipped with internal steam coils. The
Sulfur Surge Tank Vent Ejector, A2-EE1530 (A2-EE1540), uses HP
motive steam to route the tank vapors to the Tailgas Thermal Oxidation
system.
9.3.8 Steam Production

The Sulfur Recovery Unit produces steam at two pressure levels. High
pressure steam is generated at 48.5 kg/cm2(g) [690 PSIG] in the Waste
Heat Boiler. A portion of this steam is used to reheat the reactor feed
streams and in the TGCU Reactor Feed Heater, A2-EA1560. The
remaining HP steam from the SRU is routed to the Tailgas Thermal
Oxidation system to be superheated in the Thermal Oxidizer Waste Heat
Boiler, A2-BF1570.
Low pressure steam at 4.2 kg/cm2(g) [60 PSIG] is produced in the Sulfur
Condenser. Part of this steam is used to preheat the amine acid gas, heat
the Sulfur Storage Tank, heat the steam-jacketed lines, and for steam
tracing services. The remainder is routed to the complex's LP steam
header.

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9.4.1 Reactor Furnace, A2-BA1530 (A2-BA1540)

The Reactor Furnace is a combustion and non-catalytic reaction chamber.
The furnace shell is internally lined with refractory insulation to protect it
against the extreme process temperatures inside. The maximum
operating temperature is about 1600°C. Although the furnace can
withstand short excursions above this temperature, prolonged operation
above this temperature will damage the refractory. The refractory is
designed to keep the furnace shell at 200-340°C to protect it from acid
corrosion on its interior. Periodic surveys of the temperature all along the
shell of the furnace should be conducted (using a hand-held infrared
pyrometer) to ensure that the shell is always in the desired temperature
range.
The furnace is divided into two combustion/reaction zones by a refractory

checker wall. In the first zone, the SWS gas and most of the amine acid
gas are combusted with process air to destroy the ammonia, oxidize the
hydrocarbons, produce sulfur dioxide, and form sulfur. The remaining
amine acid gas enters the furnace through side injection nozzles and
mixes with the combustion products flowing through the checker wall into
the second zone of the furnace. This second zone provides additional
residence time for the sulfur-forming and hydrocarbon-oxidizing reactions
to reach equilibrium.
The furnace is covered by a protective metal shroud to prevent thermal

shock to the hot metal shell by severe weather, such as heavy rains.

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9.4.2 Acid Gas Burner Assembly, A2-BA1531 (A2-BA1541)

The burner assembly is specifically designed to burn the acid gas stream
for this facility. The unit consists of an acid gas burner tip, a fuel gas
burner ring with multiple tips for combusting fuel gas during plant warmup,
a pilot gas burner with an integral ignitor, two flame scanners, two
viewports, and specially designed air distribution baffles for proper
combustion. This complete unit is installed in the front of the Reactor
Furnace
The StackMatch® ignitor/pilot assembly is designed to be retracted or

extracted after the main fuel gas burner ring or the acid gas burner tip has
been lit. If the assembly is extracted, the block valve can be closed to
isolate it from the furnace atmosphere. The assembly includes filters for
the incoming fuel gas and air, which should be checked (and cleaned, if
necessary) after each use so that there is no chance of a plugged filter
causing delays during the next startup.
9.4.3 Acid Gas Knock-Out Drum, A2-FA1530 (A2-FA1540)

This vertical vessel is installed in the inlet amine acid gas line to remove
liquids from the gas stream before it is routed to the Acid Gas Burner and
Reactor Furnace. The liquid produced in this vessel is pumped on
automatic start/stop control to the Rich Amine Flash Drum. The vessel is
equipped with high level alarms to warn of a rising level in the drum, and a
high-high level shutdown to activate the SRU ESD system before liquids
can reach the hot furnace. The shutdown requires that 2 out of 3
transmitters have a high-high level indicated.
9.4.4 SWS Gas Knock-Out Drum, A2-FA1531 (A2-FA1541)

This vertical vessel is installed in the inlet SWS gas line to remove liquids
from the gas stream before it is routed to the Acid Gas Burner. The liquid
removed in this vessel is pumped on automatic start/stop control to the
Sour Water Flash Drum. The vessel is equipped with high level alarms to
warn of a rising level in the drum, and a high-high level shutdown to
block-in the SWS gas before liquids can reach the hot furnace.

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9.4.5 Reactor, A2-DC1530 (A2-DC1540)

The Reactor is a single horizontal vessel divided by two vertical partitions
into three separate catalyst chambers. This reactor is of the axial
down-flow type, with the feed gas entering the top of each chamber (via a
standpipe from the bottom of the vessel) and proceeding vertically
downward through its catalyst bed. These standpipes discharge the feed
gases against the top of the vessel shell to distribute the gases over the
length of each chamber and prevent the inlet gas streams from impinging
directly on the catalyst beds.
A catalyst support grating is installed in each chamber to support its

catalyst bed in the center of the vessel. The support grating is covered
with a stainless steel screen to prevent the catalyst from sifting through
the grating. A small bead of castable refractory is used to seal the edges
of the support grating to prevent catalyst leaks between the grating and
the vessel shell.
9.4.6 Catalyst for Sulfur Plant Reactors, A2-MC1530 (A2-MC1540)

Refer to the Basic Engineering Package for the type of catalyst used in
the Reactor.
9.4.7 Acid Gas Preheater, A2-EA1530 (A2-EA1540)

This shell and tube exchanger uses LP steam to heat the inlet amine acid
gas stream before it mixes with the SWS gas and is combusted in the
Acid Gas Burner and the Reactor Furnace. This minimizes the possibility
of having ammonia salts precipitate when the amine acid gas mixes with
the high ammonia content SWS gas. The preheating also increases the
production of HP steam in the Waste Heat Boiler.
9.4.8 Sulfur Condenser, A2-EA1531 (A2-EA1541)

The Sulfur Condenser contains four different sets of tubes. Divider plates
in the inlet and outlet channels segregate the four different gas streams
flowing through this exchanger.
The four sets of condensing pass tubes are immersed in the water-filled
section of the shell, allowing them to cool the hot gases leaving the Waste
Heat Boiler and the three catalyst beds in the Reactor. The boiling water
in the shell of the exchanger cools the gases and condenses sulfur from
the process streams. The steam produced will be controlled at about

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4.2 kg/cm2(g). The outlet channel of the exchanger is extended to serve

as gas/liquid separators to remove entrained sulfur droplets from the gas
streams by gravity separation. The separator chambers also contain
woven wire mist eliminators to assist in removing sulfur from the gas
streams. Steam-jacketed sulfur drains are located in the bottom of each
separator chamber to remove the liquid sulfur produced.
The boiler is equipped with level transmitters that will shut down the SRU
should the water level fall to within 75 mm of the top row of condensing
tubes. The shutdown requires that 2 out of 3 transmitters have a low-low
level indicated. Operation of the boiler without a sufficient water level
could possibly damage the tubes.
9.4.9 Reactor No. 1 Feed Heater, A2-EA1532 (A2-EA1542)

This shell and tube exchanger uses HP steam to heat the process gas
stream leaving the first condensing pass of the Sulfur Condenser before it
enters the first catalyst bed in the Claus Reactor. This exchanger
operates in a thermosiphon loop with the Waste Heat Boiler using a
portion of the steam produced by the Waste Heat Boiler to provide the
heat input. The temperature of the gas leaving the exchanger is controlled
at the desired value by adjusting a control valve in the condensate outlet
line. This control valve can raise the level of condensate in the exchanger
shell to submerge some of the tubes in condensate to reduce the heat
input.

stream leaving the second condensing pass of the Sulfur
Condenser before it enters the second catalyst bed in the Claus Reactor.
This exchanger operates in a thermosiphon loop with the Waste Heat
Boiler using a portion of the steam produced by the Waste Heat Boiler to
provide the heat input. The temperature of the gas leaving the exchanger
is controlled at the desired value by adjusting a control valve in the
condensate outlet line. This control valve can raise the level of
condensate in the exchanger shell to submerge some of the tubes in
condensate to reduce the heat input.

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stream leaving the third condensing pass of the Sulfur Condenser before it
enters the third catalyst bed in the Claus Reactor. This exchanger
operates in a thermosiphon loop with the Waste Heat Boiler using a
portion of the steam produced by the Waste Heat Boiler to provide the
heat input. The temperature of the gas leaving the exchanger is controlled
at the desired value by adjusting a control valve in the condensate outlet
line. This control valve can raise the level of condensate in the exchanger
shell to submerge some of the tubes in condensate to reduce the heat
input.
9.4.12 Sulfur Surge Tank, A2-FB1530 (A2-FB1540)

This horizontal vessel is installed in a below-ground concrete vault. It
receives the produced liquid sulfur from the SRU and holds it in a molten
state for pumping to the Sulfur Degassing Unit. There are steam coils
installed in the bottom of the tank to keep the sulfur molten, each with its
own steam supply and trap. Should a steam coil develop a leak, it can be
shut off while the others keep the sulfur hot.
The tank is installed below ground to accept the sulfur production by

gravity flow. Liquid-sealed Sulfur Drain Seal Assemblies are provided to
allow draining of the produced liquid sulfur while preventing passage of
the process gases. Liquid sulfur flows through these drain seals and then
into the tank.
The primary ventilation system for the Sulfur Storage Tank is the Sulfur
Surge Tank Vent Ejector, A2-EE1530 (A2-EE1540). It uses HP steam as
the motive force to circulate air through the tank. Ambient air enters
through the breather vents at each end of the tank and is educted to the
ejector suction. The discharge from the ejector is routed to the TTO for
disposal. This air circulation dilutes the H2S that "weathers off" from the
liquid sulfur so that the concentration remains below the lower explosive
limit. The circulation also prevents accumulation of water in the tank that
could cause rapid corrosion.
In addition to the steam-powered ejector, there is a backup natural-draft

ventilation system provided for the Sulfur Storage Tank when the ejector
is out of service. The tank vapors are vented from the tank through a
heated vent stack mounted on the top of the tank. Air to displace these
vapors enters through the breather vents at each end of the tank and

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sweeps through the tank before entering the vent stack. The
steam-jacketing on the vent stack heats the air in the stack, providing the
natural-draft driving force that makes the system work.
WARNING
IT IS VERY IMPORTANT TO KEEP HEAT (STEAM) ON THE VENT

STACK TO MAINTAIN THE NATURAL DRAFT. IN ADDITION, THE
STEAM JACKET ON THE VENT STACK MUST VENTED
PERIODICALLY TO PREVENT NON-CONDENSIBLES FROM
ACCUMULATING AND "BLANKING OFF" THE STEAM HEATING
SURFACES. A VENT LINE IS PROVIDED EXPRESSLY FOR THIS
PURPOSE.
9.4.13 Acid Gas Knock-Out Drum Pump, A2-GA1530A/B

(A2-GA1540A/B)
These pumps send liquids that accumulate in the Acid Gas Knock-Out
Drum to the Rich Amine Flash Drum. The pumps are designed to start
and stop automatically when the level rises in the vessel. Level
transmitters mounted on the vessel alert the operator if the level in the
vessel exceeds the automatic start point. These pumps are equipped with
surroundings.
WARNING
THE LIQUID IN THESE PUMPS CONTAINS DISSOLVED H2S. THIS

H2S CAN BE RELEASED TO THE SURROUNDINGS WHEN LIQUID
IS DRAINED FROM THESE PUMPS OR FROM THE PIPING
CONNECTED TO THE PUMPS. ALWAYS OBSERVE PROPER
PROCEDURES AND PRECAUTIONS WHEN DRAINING LIQUID
FROM THESE PUMPS OR PERFORMING MAINTENANCE ON
THEM. THE "GENERAL SAFETY" SECTION OF THESE
GUIDELINES SHOULD BE CONSULTED IF THERE IS ANY DOUBT
ABOUT HOW TO WORK SAFELY WHEN H2S MAY BE PRESENT.

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9.4.14 SWS Gas Knock-Out Drum Pump, A2-GA1531A/B

(A2-GA1541A/B)
These pumps send liquids that accumulate in the SWS Gas Knock-Out
Drum to the Sour Water Flash Drum. The pumps are designed to start
and stop automatically when the level rises in the vessel. Level
transmitters mounted on the vessel alert the operator if the level in the
vessel exceeds the automatic start point. These pumps are equipped with
surroundings.
WARNING
THE LIQUID IN THESE PUMPS CONTAINS DISSOLVED H2S AND

NH3. THIS H2S AND/OR NH3 CAN BE RELEASED TO THE
SURROUNDINGS WHEN LIQUID IS DRAINED FROM THESE
PUMPS OR FROM THE PIPING CONNECTED TO THE PUMPS.
WHEN DRAINING LIQUID FROM THESE PUMPS OR
PERFORMING MAINTENANCE ON THEM. THE "GENERAL
SAFETY" SECTION OF THESE GUIDELINES SHOULD BE
CONSULTED IF THERE IS ANY DOUBT ABOUT HOW TO WORK
SAFELY WHEN H2S AND/OR NH3 MAY BE PRESENT.
9.4.15 Sulfur Storage Tank Vent Ejector, A2-EE1530 (A2-EE1540)

This jet ejector uses HP motive steam to circulate air through the Sulfur
Surge Tank and route it to the Thermal Oxidizer. This air dilutes the H2S
that "weathers off " from the liquid sulfur product so that the H2S
concentration in the Sulfur Surge Tank is well below the lower explosive
limit (LEL). The ejector body is steam-jacketed to prevent sulfur contained
in the circulating air from freezing and plugging the ejector.
Whenever motive steam to the ejector is not available, the ejector

discharge valve should be closed. This will prevent back-flow of Thermal
Oxidizer gases into the Sulfur Surge Tank.

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WARNING
NEVER BLOCK-IN THE EJECTOR COMPLETELY (CLOSING BOTH

THE SUCTION AND DISCHARGE VALVES) WHILE THE HP
MOTIVE STEAM IS CONNECTED TO THE EJECTOR. A LEAK IN
THE MOTIVE STEAM BLOCK VALVE COULD ALLOW THE HP
STEAM TO OVER-PRESSURE THE EJECTOR BODY.
9.4.16 Process Air Blower, A2-GB1530A/B (A2-GB1540A/B)

These multi-stage centrifugal blowers provide the combustion air required
to combust the amine acid gas and SWS gas in the Acid Gas Burner. The
air flow rate is controlled by throttling a valve in each blower suction line.
A vent valve on each blower discharge line is used to vent air to the
atmosphere when the process air flow is low so that the blower does not
go into "surge".
CAUTION
THE BOLT HOLES IN THE BLOWER/MOTOR BASEPLATES ARE

PROVIDED FOR SHIPPING AND POSITIONING PURPOSES ONLY.
DO NOT BOLT THE BASEPLATES DOWN TIGHTLY. EITHER
LEAVE THE NUTS OFF, OR HAND-TIGHTEN THEM ONLY.
EXCESSIVE TIGHTENING MAY DISTORT THE BASEPLATES AND
CAUSE MISALIGNMENT AND/OR VIBRATION DAMAGE TO THE
UNITS.
THE BASEPLATES ARE TO REST ON RESILIENT FOUNDATION

PADS. DO NOT GROUT UNDER THE BASEPLATES. RIGIDLY
CONNECTING THE BASEPLATES TO THEIR FOUNDATIONS WILL
INCREASE THE BLOWER VIBRATION LEVELS AND LEAD TO
BLOWER DAMAGE.

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9.4.17 Air Blower Suction Screen/Silencer, A2-FD1530A/B

(A2-FD1540A/B)
This filter/silencer is designed to keep rainwater and large solid particles
from entering the Process Air Blower. It also helps reduce the noise
produced by the Process Air Blowers.
9.4.18 Process Air Vent Silencer, A2-FG1530A/B (A2-FG1540A/B)

These silencers help reduce the noise produced when the blow-off valves
on the discharge of the Process Air Blowers are being used to prevent the
blowers from "surging".
9.4.19 Sulfur Drain Seal Assembly, A2-ME1530A-D (A2-ME1540A-D)

Ortloff's proprietary Sulfur Drain Seal Assemblies are designed to drain
liquid sulfur from the four outlet channels of the Sulfur Condenser. The
seals are built as "U-type" traps that use liquid sulfur to seal and prevent
process gases from flowing to the Sulfur Surge Tank along with the liquid
sulfur product. The drain seals are sized to provide a seal leg which
should not blow out at the maximum discharge pressure of the Process
Air Blower.
The seals are fully steam-jacketed and designed to be installed in the top
of the Sulfur Surge Tank. Each seal has a hinged inspection hatch to
allow observation and sampling of the flow from each condenser pass.
The liquid sulfur from the inspection basin flows down to the bottom of the
Sulfur Surge Tank through a drain pipe to prevent free-fall of the liquid
sulfur, which could cause static electricity to build up. The drain seals are
mostly carbon steel, except for the inspection hatches which are
aluminum.
Each drain seal has removable blind flanges to allow "rodding" its
rundown line and its dip leg. Before removing either flange, close the
block valve in the rundown line to prevent the escape of process gas to
the surroundings when the plugging is cleared. When the rodding
operation is complete and the flange(s) are back in place, remember to
reopen the block valve.

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9.4.20 Refractory for Reactor Furnace and Waste Heat Boiler,

A2-MR1530 (A2-MR1540)
The firing chamber of the Reactor Furnace and the transition piece on the
Waste Heat Boiler have a refractory lining consisting of alumina firebrick
backed heavy duty firebrick. The checker wall in the Reactor Furnace is
also constructed from alumina firebrick. Mortar used for installing the
brick is alumina air-setting mortar. The inlet tubesheet on the Waste Heat
Boiler is covered with a layer of alumina castable refractory.
9.4.21 Ceramic Ferrules for Waste Heat Boiler, A2-MR1532

(A2-MR1542)
The ceramic ferrules are inserted into the inlet ends of the tubes in the
Waste Heat Boiler, then a layer of castable refractory is installed over the
tubesheet. The ceramic ferrules are flush with the outside of the
refractory and extend into each tube. The ferrules and refractory protect
the tube ends from being directly exposed to the hot combustion gas and
give very long operating life to the Waste Heat Boiler.
9.4.22 Refractory for Waste Heat Boiler, A2-MR1533 (A2-MR1543)

The outlet channel of the Waste Heat Boiler is covered with a lining of
castable refractory. This refractory protects the steel surfaces of the
channel from accelerated sulfide corrosion rates due to the high process
gas temperature.
9.4.23 Refractory for Sulfur Condenser, A2-MR1534 (A2-MR1544)

The inlet channel of the first pass of the Sulfur Condenser is covered with
a lining of castable refractory. This refractory protects the steel surfaces
of the channel from accelerated sulfide corrosion rates due to the high
process gas temperature. The refractory is built up on the bottom of the
channel so that it is flush with the bottom of the inlet nozzle and with the
bottom of the tubes in the lowest row of tubes, so that the entire inlet
channel free-drains from the inlet nozzle into the tubes and liquid sulfur
cannot "puddle" in the inlet channel.

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9.4.24 Refractory for Reactor, A2-MR1535 (A2-MR1545)

A 50 mm bead of castable refractory is installed around the edges of the
catalyst bed supports inside each chamber of the Reactor. This seals the
edges of the bed supports so that the small catalyst pellets cannot escape
from the beds.
9.4.25 Rainshield for Reactor Furnace, A2-ME1531 (A2-ME1541)

The Reactor Furnace shell is internally lined with refractory insulation to
protect it against the extreme process temperatures inside. The refractory
is designed to keep the furnace shell at 200-340°C to protect it from
corrosion on its interior. Shell temperatures higher than this can result in
high temperature sulfidic corrosion of the steel shell, while temperatures
lower than this can cause the steel to drop below the acid dewpoint of the
process gas and suffer acid corrosion.
The upper 240° of the Reactor Furnace is covered by a metal rainshield to

prevent over-cooling of the furnace shell by rain and/or wind, which would
cause shorter refractory life (due to thermal cycling) and corrosion of the
furnace shell (due to acid condensation). The rainshield is mounted on
stand-off rings to protect the furnace shell from direct exposure to the
elements without restricting the free circulation of cooling air over the
furnace shell. The rainshield is formed from corrugated galvanized steel.
9.4.26 Ceramic Ferrule for Reactor Furnace, A2-MR1531 (A2-MR1541)

These ceramic ferrules are inserted into the side ports on the Reactor
Furnace where the bypassed acid gas is to be injected into the second
zone of the furnace. The ceramic ferrules extend to the outside of the
refractory lining inside the furnace so that essentially no part of the nozzle
is directly exposed to the hot furnace gases or to radiation from the hot
furnace. This will help protect the nozzles from overheating whenever the
bypass acid gas is not flowing.

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9.4.27 Waste Heat Boiler, A2-BF1530 (A2-BF1540)

The Waste Heat Boiler contains the cooling pass tubes which cool the hot
gases leaving the Reactor Furnace. The cooling pass tubes are immersed
in the water-filled section of the shell, allowing them to cool the hot gases
leaving the Reactor Furnace from by boiling water in the shell of the
exchanger. The steam produced will be controlled at about
2
48.5 kg/cm (g). Because of the high inlet temperature to these tubes, the
inlet tubesheet is refractory-lined and the inlet of each tube contains a
ceramic ferrule insert.
Most of the steam produced by the Waste Heat Boiler is routed to the
Thermal Oxidizer Waste Heat Boiler, A2-BF1570, to be superheated
before it is exported to the HP Steam header. The remaining portion of
this steam is withdrawn and directed to the three heaters for the Reactor
feeds, the Reactor No. 1 Feed Heater, the Reactor No. 2 Feed Heater,
and the Reactor No. 3 Feed Heater, which operate in a thermosiphon loop
with the Waste Heat Boiler. The steam flows over and condenses on the
outside of the tubes in these exchangers, heating the gas within the tubes
to raise the temperatures of the gas streams to the desired feed
temperatures for the catalyst beds. The condensate from these three
exchangers returns to the Waste Heat Boiler by gravity flow.
The boiler is equipped with level transmitters that will shut down the SRU
should the water level fall to within 75 mm of the top row of tubes. The
shutdown requires that 2 out of 3 transmitters have a low-low level
indicated. Operation of the boiler without a sufficient water level will result
in severe damage to the tubes and the shell.

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WARNING
AS DISCUSSED ABOVE, THE BOILING WATER IN THE SHELL

KEEPS THE COOLING PASS TUBES FROM OVERHEATING. IF
THE WATER LEVEL IN THE BOILER DROPS BELOW THESE
TUBES, THE HOT COMBUSTION GAS INSIDE WILL DESTROY
THE TUBES. ALTHOUGH LOW LEVEL SHUTDOWN SHOULD
ACTIVATE THE SRU ESD IF THE WATER LEVEL FALLS TO 75 MM
ABOVE THE COOLING PASS TUBES, THE LOW LEVEL ALARMS
IN THE DCS ARE EARLY WARNINGS OF BFW LOSS. THESE LOW
LEVEL ALARMS SHOULD RECEIVE IMMEDIATE ATTENTION TO
MINIMIZE THE POTENTIAL FOR DAMAGE TO THE BOILER. THE
LEVEL GAUGES SHOULD ALSO BE MONITORED CLOSELY BY
THE OUTSIDE OPERATOR.

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9.5.1 SRU Air:Acid Gas Ratio Control Loop
The chemistry of the Claus reaction dictates that optimum sulfur recovery
is achieved when the ratio of hydrogen sulfide (H2S) to sulfur dioxide
(SO2) in the process gases is maintained at 2:1. This ratio is determined
by the amount of H2S in the acid gas feed that is combusted to SO2 by the
oxygen in the process air stream fed to the burner. Each sulfur plant uses
a combination of feed-forward and feed-back control to adjust the ratio of
the air flow rate to the acid gas and fuel gas flow rates and maintain the
optimum 2:1 H2S:SO2 ratio. The loop diagram on page 9-29 illustrates the
components of this control scheme when implemented in a distributed
control system (DCS). (All of the instrument tag numbers used below
refer to the instruments as they are numbered in the Train 1 SRU. The
control algorithm and the relay settings for the Train 2 SRU will be
identical.)
The feed-forward portion of the control loop uses the acid gas and fuel
gas flow rates to compute the setpoint for the air flow controller,
A2-FIC15370. Since the amine acid gas, SWS gas, and fuel gas require
different amounts of air, the three flow rates are metered separately and
then summed by A2-FY15345 and A2-FY15349. The three signals are
also biased (by A2-FY15320, A2-FY15331, and A2-FY15355) to allow for
the differences in air requirements. In this manner, the setpoint for
A2-FIC15370 will be properly adjusted as the individual gas flow rates
vary.
A special photometric analyzer samples the process gas in the sulfur plant
tailgas to determine the relative amounts of H2S and SO2 in the gas. The
analyzer provides an output signal that is proportional to the amount the
air flow rate must change in order to bring the H2S:SO2 ratio to the
optimum 2:1 value. This signal is the feed-back part of the control loop,
and is used to make minor adjustments to the air:acid gas ratio and allow
the control system to respond to compositional variations in one or more
of the acid gas feeds.
The control loop is discussed in detail in the sections that follow. The
discussions are divided into five sections: air requirement computation for
the acid gas streams, air:acid gas ratio adjustment, air requirement
computation for fuel gas, air flow control, and local/remote control.

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9.5.1.1 Air Requirement Computation for the Acid Gas Streams

The purpose of the acid gas bias/summing circuit is to compute the
theoretical process air required for the acid gas streams, properly
adjusted to account for the differing amounts of oxygen that the two
streams require. The amine acid gas and SWS gas flow rate signals
are linearized and input to the DCS by A2-FT15320 and
A2-FT15331, respectively. Flow indicators A2-FI15320 and
A2-FI15331 in the DCS indicate these flow rates in engineering units.
Each flow rate is multiplied by a scale factor (relays A2-FY15320 and
A2-FY15331, respectively) to compute the process air required by
each stream, then added together by summing relay A2-FY15345 to
give the theoretical air flow requirement for the acid gas streams.
The two bias calculation blocks multiply each gas flow rate by a gain
factor equal to the process air required per unit of flow for that
stream. The appropriate gain factors are 2.563 Nm3/Nm3 for the
amine acid gas (A2-FY15320) and 2.186 Nm3/Nm3 for the SWS gas
(A2-FY15331). A2-FY15345 then sums the two outputs from the
bias relays, providing an output that (at design conditions) is equal to
the required air flow rate for the acid gas streams. This output is
then supplied to the ratio adjustment relay, A2-AY15348. These
factors can be revised periodically if changes in feedstocks, etc.
cause long-term changes in the compositions of one or both of the
acid gas streams.
Note that each bias relay has a "zero" switch (A2-HS15320 for
A2-FY15320 and A2-HS15331 for A2-FY15331). These switches
can be used to "turn off " their respective relays when there is no flow
of the corresponding gas stream. This prevents an erroneous
reading from a flow transmitter causing errors in the theoretical air
flow computations. A similar switch (A2-HS15356) is included for the
fuel gas bias relay (A2-FY15355) discussed in Section 9.5.1.3.
9.5.1.2 Air:Acid Gas Ratio Adjustment

By choosing the appropriate gain factors for A2-FY15320 and
A2-FY15331, the output from A2-FY15345 (the theoretical air flow
rate) is equal to the required process air flow rate for the acid gas
streams, assuming the composition and conditions of the amine acid
gas and SWS gas streams remain constant. This will seldom be
true, however, so there must be a means to adjust the air:acid gas
ratio for temporary changes in composition, such as increased

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hydrocarbon content. This is the reason for including the ratio

adjustment relay, A2-AY15348.
The "coarse" ratio adjustment is set manually by the DCS operator in

the range of 0.0-2.0 via A2-HIC15347. This ratio setting is then "fine
tuned" by the air demand controller, A2-AIC15347. The action of
limit relay A2-AY15347 is to allow A2-AIC15347 to vary the "coarse"
ratio setting up or down by about 10%, so that the controller acts as
a "trim" on the control loop. This is accomplished with two
calculation blocks: bias relay A2-AY15347 and summing relay
A2-HY15347.
The bias relay, A2-AY15347, reduces the magnitude of the

A2-AIC15347 output signal and centers it around zero by multiplying
the signal by a gain factor of 0.002 and adding a constant of -0.1.
Thus, as the output from A2-AIC15347 varies from 0% to 100%, the
output from A2-AY15347 will vary from -0.1 to +0.1. Summing relay
A2-HY15347 then adds this output to the output from A2-HIC15347
to yield the ratio adjustment setting that is input to A2-AY15348 and
indicated by A2-HI15347.
The ratio adjustment relay, A2-AY15348, multiplies the ratio

adjustment setting from A2-HY15347 by the theoretical air flow rate
from A2-FY15345 to produce the corrected air flow rate for the acid
gas streams. The effective ratio at A2-AY15348 will vary from 0.0 to
2.0 as the output from A2-HY15347 varies from 0.0 to 2.0. For
example, if the output from A2-HY15347 is 1.1, the effective ratio
applied to the theoretical air flow by A2-AY15348 will be 1.1, and the
corresponding corrected air flow rate will be 1.1 times the theoretical
air flow rate. The output from A2-AY15348 (the corrected air flow
rate for the acid gas streams) is then supplied to the fuel gas
summing relay, A2-FY15349. The design setting for A2-HIC15347 is
1.0 (i.e., a ratio adjustment multiplier of 1.0, which is no adjustment).
9.5.1.3 Air Requirement Computation for Fuel gas

If an SRU is operating at very low load, it may be necessary to burn
supplemental fuel gas in its Acid Gas Burner. When operating in this
mode, the air flow control scheme must also add the air required to
burn the fuel gas. Since most fuel gas has a nearly constant
composition, it is not necessary to adjust the air:fuel gas ratio like it is
with the acid gas streams. Instead, the fuel gas flow rate can simply

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be multiplied by a gain factor to compute its air requirement, then

summed together with the corrected air flow described earlier that is
computed by A2-AY15348.
The fuel gas flow rate is linearized and input to the DCS by
A2-FT15355. Flow controller A2-FIC15355 in the DCS converts this
linear signal into a flow rate in engineering units. Bias relay
A2-FY15355 then multiplies the fuel gas flow rate by the appropriate
gain factor for this fuel gas, 32.509 Nm3/Nm3 (For the C4 LPG), to
give the computed air flow for the fuel gas. This is added to the
corrected air flow for the acid gas streams by summing relay
A2-FY15349, giving the total air flow rate that is then supplied to the
air flow controller, A2-FIC15370, as a remote setpoint.
For reference, the total theoretical air flow requirement is also

computed and displayed in the DCS. This is accomplished by
summing relay A2-FY15346, which sums the theoretical air flow rate
for the acid gas streams (the output from A2-FY15345) with the
theoretical air flow rate for the fuel gas (the output from
A2-FY15355). The output from A2-FY15346 is the total theoretical
air flow requirement, which is displayed on A2-FI15346 in the DCS.
9.5.1.4 Air Flow Control

All of the complicated parts of the control loop are contained in the
calculation blocks discussed above. The resulting output from
A2-FY15349 is the required air flow rate, so it is simply supplied to
the air flow controller, A2-FIC15370, as its setpoint. A2-FIC15370 is
a standard PID controller with remote setpoint adjustment. Its output
controls the Process Air Blower suction valve, either A2-FV15333A
on A2-GB1530A or A2-FV15333B on A2-GB1530B.
Note that the signal from A2-FIC15370 actually controls

A2-FV15333A or A2-FV15333B together with the control valves on
the blower discharge lines using split ranges. This split-range action
is discussed in later sections as its details are not important to this
discussion.
9.5.1.5 Local/Remote Control

The initial startup of an Acid Gas Burner is performed by an outside
operator stationed at the local control panel near the burner. Since
the operator must be able to control the air flow rate while purging

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the furnace and lighting the burner, a hand controller (A2-HIC15370)

is mounted on the local Train 1 SRU control panel to allow manual
control of the air flow valve, A2-FV15333A or A2-FV15333B, and the
other blower control valves. After startup, control is then switched
back to the DCS.
A2-HS15370 in the DCS selects whether A2-FV15333A/B is

controlled by the local operator or by the controller in the DCS,
A2-FIC15370. During startup, when the outside operator has control,
A2-HS15370 is positioned such that the signal from A2-HIC15370 is
supplied to A2-FV15333A/B. When the DCS operator is ready to
assume control, the output of A2-FIC15370 can be matched to that
of A2-HIC15370 (as indicated by A2-HI15370 in the DCS) and
A2-HS15370 repositioned to send the output of A2-FIC15370 to
A2-FV15333A/B, resulting in a "bump-less" transfer.

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Air:Acid Gas Ratio Control Loop (SRU Train 1)

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9.5.2 Acid Gas Burner Management System

The burner management system (BMS) for the Acid Gas Burner in each
SRU is controlled by a sequential logic controller (most commonly a
programmable logic controller or PLC). The ESD reset, BMS, and
Startup/Run Logic Flowcharts for the Train 1 SRU, contained in the
Instrumentation and Controls Diagrams section of the Basic Engineering
Package, describe the sequence of steps required before permitting
ignition to ensure a safe firing order. The function of the various system
components is described below. (All of the instrument tag numbers used
below refer to the instruments as they are numbered in the Train 1 SRU.
The logic for the Train 2 SRU is identical.)
9.5.2.1 Startup/Run Interlocks

The "startup" and "run" interlock logic for the Train 1 SRU is shown
on the Startup/Run Logic Flowcharts. The purpose of this logic is to
simplify lighting the Acid Gas Burner and switching to acid gas firing
in the Train 1 SRU by automatically positioning the process gas
switching valves in the proper sequence for safe operation:
(1) Before attempting ignition of the burner, the catalyst beds

should be bypassed so that air cannot reach them and cause
sulfur fires. Setting selector switch A2-HS15314 on the local
Train 1 SRU control panel to "STARTUP" will open the two
Warmup Bypass Valves, A2-HV15441 and A2-HV15454, close
the Tailgas Valve to the TTO, A2-HV15457, and close the
Tailgas Valve to the TGCU, A2-HV15462, so that air and/or
combustion products from the Reactor Furnace are diverted
upstream of the first catalyst bed in the Reactor to flow directly
to the TTO.
(2) Once the pilot burner in the Acid Gas Burner has been lit and
the SRU is ready to accept acid gas (furnace up to temperature,
etc.), the Warmup Bypass Valves must be closed before acid
gas can be introduced into the SRU. However, in order to avoid
activating the "complete flowpath interlock" alarm and possibly
tripping the Reactor Furnace high-high pressure S/D, there
must be an open flowpath through the SRU before the bypass
valves are closed.
(3) Setting selector switch A2-HS15314 to "RUN" will automatically

open the Tailgas Valve to the TTO, prove the valve open, then

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close the two bypass valves and initiate the nitrogen purge,
A2-HV15453, between the two valves. By automating the valve
switching steps and including checks of the limits switches in
the logic, the chance of accidentally causing an SRU1 ESD due
to over-pressure during startup are greatly reduced.
While the switching valves are moving, the corresponding status

lights on the local Train 1 SRU control panel should blink to provide
feedback to the operator. If a switching valve does not move to the
proper position, its status light should continue to blink. This will alert
the operators to investigate the problem and take any required
corrective action so that the BMS then allows proceeding.
9.5.2.2 Flame Scanners

The flame scanners, A2-BE15369A and A2-BE15369B, monitor the
pilot, warmup, and acid gas burners. If a scanner detects a flame,
the associated "flame proven" signal will indicate. If neither scanner
detects a flame, the SRU1 ESD system is activated. Since a "flame
proven" signal from either scanner satisfies the ESD system,
maintenance may be performed on one flame scanner while the
other remains in service. Note that a third flame scanner,
A2-BE15368, is furnished with the pilot to detect its flame, but it is
used only to activate its status light (A2-GL15368) on the local
Train 1 SRU control panel and a status indicator (A2-BL15368) in the
DCS.
9.5.2.3 Purge Cycle

To ensure the unit is safe for firing, a purge cycle must be completed
before the pilot can be ignited. To purge the Reactor Furnace, a
Process Air Blower is used to send a high flow rate of air through the
furnace for 25 seconds to satisfy the purge timer. The air flow must
then be reduced to a low rate to allow ignition of the pilot.
9.5.2.4 Ignition Cycle

After the purge cycle is complete, pressing the "IGNITION"
push-button (A2-HPB15368) on the local Train 1 SRU control panel
causes the BMS to initiate an attempt to ignite the pilot. The BMS
closes the pilot burner purge gas valve (A2-HV15381), opens the
pilot air block valve (A2-NV15367), closes the vent valve in the fuel
gas to the pilot (A2-NV15364), opens the pilot fuel gas block valves,

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(A2-NV15363 and A2-NV15365), and energizes the ignition system,

(A2-BX15368).
After a 15 second ignition trial, the ignition system is de-energized. If

a pilot flame is established, one or both flame scanners will indicate
"flame proven" and the block valves in the air and fuel gas supplies
to the pilot will remain open. Otherwise, the air and fuel gas supplies
to the pilot are blocked-in and the purge cycle must be repeated.
9.5.2.5 Fuel gas Firing

After the pilot burner is lit, the main fuel gas supply is enabled.
Pressing push-button A2-HPB15391 on the local Train 1 SRU control
panel will close the main burner purge gas valve, (A2-HV15382),
close the vent valve in the fuel gas to the main burner (A2-NV15358),
and open the main fuel gas block valves (A2-NV15357 and
A2-NV15359). The fuel gas control valve (A2-FV15355) can then be
adjusted using either A2-HIC15355 on the local SRU control panel or
A2-FIC15355 in the DCS to manually fire fuel gas on the warmup
burner ring in the Acid Gas Burner to heat the refractory in the
Reactor Furnace and heat the water in the Waste Heat Reclaimer
and Sulfur Condenser.
9.5.2.6 Acid Gas Firing

After the pilot burner is lit, the acid gas controls can also be enabled.
Turning startup/run selector switch A2-HS15314 on the local Train 1
SRU control panel to "RUN" will open the Tailgas Valve to the TTO,
A2-HV15457, prove it open, then close the two Warmup Bypass
Valves, A2-HV15441 and A2-HV15454, and establish a nitrogen
purge between them. Turning acid gas firing selector switch
A2-HS15315 on the local Train 1 SRU control panel to "ENABLED" will
then allow using the manual acid gas controls, A2-HIC15320 and
A2-HIC15331, on the local Train 1 SRU control panel to introduce
amine acid gas and SWS gas, respectively, into the Train 1 SRU.
9.5.2.7 Pilot and Main Fuel gas On/Off Switches

Push-buttons A2-HPB15390 and A2-HPB15391 on the local Train 1
SRU control panel are used to turn the pilot burner and main fuel gas
burner, respectively, on and off. If the burner is already "on",
pressing its push-button will extinguish the burner by closing the two
block valves and opening the vent valve in its fuel gas supply, and

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then open the valve in its purge gas supply to begin purging the
burner. For the pilot burner, the block valve in its air supply is also
closed and the ignition system, A2-BX15368, is de-energized.
If the burner is "off " (and the "flame proven" is already satisfied by
one of the other burner tips), pressing its push-button will ignite the
burner by closing the valve in its purge gas supply to cease purging
the burner, and closing the vent valve and opening the two block
valves in its fuel gas supply. For the pilot burner, the block valve in
its air supply is also opened and its ignition system, A2-BX15368, is
energized for 15 seconds.

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9.5.3 Process Air Blower Controls

The depiction of the controls for the Process Air Blower (A2-GB1530A/B)
shown on P&ID 507000-7100-23 is fairly straightforward in how the control
elements are to be arranged. What may not be clear, however, is why the
controls are implemented in this manner. The discussion that follows will
describe what purposes these controls serve. (The Train 1 SRU blower
controls for A2-GB1530A are used as examples below. The concepts for
the "B" blower and for the Train 2 SRU blower controls are the same.)
In general, the process air flow to the Train 1 SRU is controlled at a

specified ratio to the acid gas and fuel gas flows by A2-FIC15370.
A2-FIC15370 is given a remote setpoint computed from the amine acid
gas flow rate, the SWS gas flow rate, the fuel gas flow rate, and the air
demand reading. A2-FIC15370 then adjusts the blower suction valve,
A2-FV15333A, to control the desired air flow rate.
9.5.3.1 Blower Operation at Low Air Flow

At low flow rates, the air flow can drop below the blower's surge line.
If this is allowed to occur, the air flow will become erratic and the
blower may be damaged. To prevent this from happening, the
blower is equipped with a blow-off valve, A2-FV15335A, on its
discharge line. When the air flow to the SRU is low, the blow-off
valve will open and allow some of the air from the blower to vent to
the atmosphere, increasing the air flow through the blower to keep it
above the surge line.
The discharge pressure from the air blower depends on the

back-pressure from the SRU, the TGCU, and the TTO, which is a
function of plant throughput. At low plant throughput, the pressure
drop through these units is low and the resulting back-pressure on
the air blower is low. If the back-pressure gets low enough, it can
limit the air flow through the blow-off valve and cause the blower to
drop below its surge line. To prevent this from happening, the air
blower discharge valve, A2-FV15334A, is designed to begin throttling
the blower discharge at very low flow rates, so that the discharge
pressure from the blower will remain high enough to allow the
blow-off valve to keep the blower from surging.
The three valves on the A2-GB1530A blower operate together over

the following controller ranges to give the response described above:

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A2-FV15333A: Fully open at 100% output from A2-FIC15370
33.3% open at 0-66.7% output from A2-FIC15370

(software "min. stop" keeps valve from closing
further)
A2-FV15334A: Fully open at 100% output from A2-FIC15370
Fully closed at 0% output from A2-FIC15370
A2-FV15335A: Fully closed at 66.7-100% output from

A2-FIC15370
Fully open at 0% output from A2-FIC15370
This results in the following actions by the blower control valves:
1. At 100% output from A2-FIC15370, the suction valve and discharge

valve will be fully open, the blow-off valve will be fully closed, and all
of the air will be flowing to the SRU.
2. As the output from A2-FIC15370 drops from 100% to 66.7%, the

suction valve will begin throttling from 100% open to 33.3% open,
the discharge valve will begin closing and going from fully open to
throttling at 66.7% open, the blow-off valve will still be fully closed,
and all of the air will still be flowing to the SRU.
3. As the output drops below 66.7%, the suction valve will not close
any further (to prevent starving the blower for air), the discharge
valve will continue to throttle, and the blow-off valve will begin to
open and vent part of the air to the atmosphere instead of flowing to
the process.
4. At 0% output, the suction valve will still be 33.3% open, the

discharge valve will be fully closed, the blow-off valve will be 100%
open, and all of the air will be venting rather than flowing to the SRU.
These split-range control actions are accomplished by the function

relays in the DCS shown on the P&ID. For the A2-GB1530A blower,
the actions of the relays are as follows:
A2-FY15333A: For an input of 66.7-100%, the output from this

relay varies linearly from 33.3-100%. For an input
below 66.7%, the output is constant at 33.3%
(minimum output limit).

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A2-FY15334A: For an input of 0-100%, the output from this relay

is direct.
A2-FY15335A: For an input of 0-66.7%, the output from this relay

varies linearly from 100% to 0%, providing reverse
action for the fail-closed control valve. For an
input above 66.7%, the output is constant at 0%.
The output signals from the DCS to each of the control valves should
be displayed on the DCS console. The I/P transducers mounted on
the valves in the field are direct (i.e., 4-20 mA to the transducer gives
an output of 0-100% from the valve positioner).
The split-range values on the P&IDs are the suggested initial settings
for the control schemes on these blowers. These values may need
adjustment once the SRUs are placed in operation, depending on
the operating characteristics of each particular air blower and its
control valves. These adjustments can be made during plant startup.
9.5.3.2 Blower "Swapping" Controls

While the SRUs are operating, it is sometimes necessary to "swap"
air blowers for maintenance purposes, etc. This means switching
from A2-GB1530A to A2-GB1530B or vice versa in the Train 1 SRU,
for instance. The DCS provides controls for slowly reducing the air
flow from the on-line blower while increasing the air flow from the
off-line blower, so that switching from one blower to the other can be
accomplished without disturbing SRU operations. (Although we have
attempted to automate this concurrent ramping operation on a couple
of past projects, we have not found this to be very satisfactory. The
way that the blower controls need to be ramped will depend on the
current plant throughput and whether or not the blower suction valve
is still in control. This is classic "fuzzy logic", something that is easy
for a human to do but very difficult for a computer.)
Bias controller A2-HIC15339A and bias relay A2-HY15339A in the

DCS adjust the controller output to the control valves on
A2-GB1530A. A setting of 1.0 on A2-HIC15339A results in
multiplying the output of A2-FIC15370 by 1.0 before sending the
signal to the valves on A2-GB1530A (i.e., no change). A setting of
0.0 on A2-HIC15339A results in multiplying by 0.0, so zero signal is
sent to the valves on A2-GB1530A (resulting in all its air venting to
atmosphere with no air flow to the process). At settings between 0.0

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and 1.0 on A2-HIC15339A, the output to the valves on A2-GB1530A

is the corresponding fraction of the output from A2-FIC15370. The
bias controllers and relays (A2-HIC15339B and A2-HY15339B) for
the other blower (A2-GB1530B) work in the same fashion.
With these controls in the DCS, it is a relatively simple matter to

swap air blowers by gradually shifting the air flow control from one
blower to the other. After the off-line blower has been started, the
DCS operator can begin to reduce the control signal to the on-line
blower while increasing the control signal to the off-line blower,
making changes as needed to maintain a stable air flow to the SRU.
Once all of the control signal is going to the off-line blower and none
is going to the on-line blower, the off-line blower has become the
on-line blower. What was the on-line blower is now the off-line
blower, and it can then be shut down without affecting the SRU.
9.5.3.3 Blower Start Interlocks and Controls

The interlocks and control actions for starting a Process Air Blower
are shown on the BMS Logic Flowchart contained in the
Instrumentation and Controls Diagrams section of the Basic
Engineering Package. These interlocks and actions ensure that
these blowers are started in a safe manner while minimizing the
starting load on the blowers and motors:
a. It is best to start a blower in an unloaded condition, with its

suction valve partially open and its blow-off valve wide open.
The "blower start permissive" relays, A2-HSL15338A/B, require
that the control signal to the blower in question be set to 0% in
order to start that blower. As described earlier in
Section 9.5.3.1, this will place the suction valve and blow-off
valve in the proper positions.
b. There is always the potential to have acid gas in the process air
piping, so having the blower suction and blow-off valves open
while its blower is not running should be minimized to reduce
the risk of releasing acid gas to the atmosphere. When the
operator presses the "permit to start" push-button,
A2-HPB15338A/B, for a blower, its suction and blow-off valves
will open for 30 seconds to allow time for the operator to start
the blower using the local start/stop control.

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If the blower is not started within this time, the suction and
blow-off valves are closed and the "permit to start" is disabled.
The operator will have to press A2-HPB15338A/B again before
the blower can be started.
c. If the operator starts the blower and the motor starter contacts
for the blower indicate that the blower is running within this
time, the solenoid valve on the blower discharge valve is then
energized so that the operator can increase the control signal to
the blower to open the discharge valve and commence air flow
to the process.
The solenoid valve for the fail-closed discharge valve on each

blower is not energized unless that blower is running. This
minimizes the potential to have acid gas "back down" the
process air line and be released to the atmosphere.

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9.5.4 Reactor Furnace Temperature Control

The temperature in the first combustion zone of each Reactor Furnace,
A2-BA1530 and A2-BA1540, must be 1370°C [2500°F] or higher to insure
maximum ammonia destruction. The temperature in each furnace can be
controlled at this value by varying the amount of amine acid gas
bypassing its Acid Gas Burner, A2-BA1531 or A2-BA1541, respectively.
Increasing the portion of bypassed acid gas increases the flame

temperature at an Acid Gas Burner, which is the opposite of what would
be expected for typical burner systems. However, remember that an Acid
Gas Burner operates at substoichiometric conditions - combustion is
limited by the amount of process air provided, not by the amount of acid
gas (i.e., the fuel) at the burner. The process air rate is determined by the
total acid gas inlet flow rate to an SRU, not by the amount of acid gas
routed to its burner.
Claus plant operation is based on converting one-third of the H2S in the

total feed gas to SO2 at the burner. Any hydrocarbons and ammonia
present are also oxidized, but the rest of the H2S passes through
un-oxidized. Bypassing some of the acid gas around the burner permits
combustion of a larger fraction of the H2S in the feed to the burner,
resulting in a higher flame temperature.
For a simplified example, consider the case where there is no SWS acid
gas flow. Without any amine acid gas bypassed, only 33% of the H2S at
the burner would be burned. If one-third of the total amine acid gas
bypasses the burner, then 50% of the H2S in the amine acid gas sent to
the burner must be burned in order to convert one-third of the total H2S to
SO2. Thus, a larger fraction of the H2S entering the burner is combusted
when part of the acid gas bypasses the burner, which raises the flame
temperature.
The furnace temperature control loop for the Train 1 SRU consists of: the
optical pyrometer, A2-TT15375; the Reactor Furnace temperature
controller, A2-TIC15375; the acid gas bypass flow ratio controller,
A2-FFIC15350; the acid gas valve to the burner, A2-FV15351, and the
acid gas bypass valve, A2-FV15350. (Note that an optical pyrometer
does not actually measure temperature. Instead, it infers the furnace
temperature by measuring the infrared radiation inside the Reactor
Furnace. Experience has shown that the temperature indicated by an

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optical pyrometer is usually 100-200°C lower than the calculated

temperature for a given set of conditions.)
The furnace temperature is not directly controlled. Instead, it is controlled

indirectly via remote setpoint adjustment of A2-FFIC15350. (Past
experience has shown that measurement of the front zone temperature
using optical pyrometers is not always consistent and/or repeatable, and
flow ratio control of the bypass amine acid gas has proven to be more
stable for control purposes.) By placing A2-FFIC15350 in "cascade",
A2-TIC15375 can adjust its ratio setpoint within the range of 0.00:1 to
0.65:1. Thus, if the temperature in the first zone of the Reactor Furnace is
too low, A2-TIC15375 will raise the ratio setpoint of A2-FFIC15350, which
will then bypass more amine acid gas around the Acid Gas Burner and
raise the furnace temperature.
The 1370°C furnace temperature for ammonia destruction discussed

earlier is a calculated temperature. As stated earlier, the temperature
indicated by an optical pyrometer is usually 100-2300°C lower than the
calculated temperature for a given set of conditions, so a normal operating
temperature of 1200°C as indicated by the pyrometer is suggested for the
first zone in the Reactor Furnace. Operating experience will dictate the
minimum indicated furnace temperature at which SWS gas can be
admitted to the furnace.
When the Train 1 SRU is operating at low flow rates, there may not be
enough pressure drop in its Acid Gas Burner to give good control of the
bypass acid gas with A2-FV15350. For this reason A2-FV15351 is
designed to work together with A2-FV15350 over split ranges of the
A2-FFIC15350 controller output. If A2-FV15350 goes fully open at lower
flow rates, the controller output will continue to increase so that
A2-FV15351 begins to "throttle" in the amine acid gas line to the burner
and force more of the acid gas to flow through A2-FV15350.
It is critical that A2-FV15351 never closes completely, as there should

always be some amine acid gas flowing to the burner to be sure that the
front zone of the Reactor Furnace does not become an oxidizing
atmosphere. The DCS limit relay, A2-FY15351, will prevent this fail-open
valve from closing completely by limiting the output to the valve to 75%
and below.

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9.5.5 Knock-Out Drum Pump Control

Under ordinary conditions, little (if any) liquid will drop out in the Acid Gas
Knock-Out Drum, A2-FA1530. During upsets, however, liquid can rapidly
accumulate in the drum. For this reason, the Acid Gas Knock-Out Drum
Pump, A2-GA1530A/B has been designed to automatically start and stop
as required by the liquid level in the drum, based on the level signal sent
to the DCS. Level signals are provided to the PLC by three LTs for use as
a 2oo3 voting shutdown if the level continues to rise.
The local H-O-A switches near the pumps allow the operator to place
these pump in "auto" start mode. The DCS should start the pump when
the liquid level reaches the "pump start" level in the drum. After the liquid
is pumped out, the DCS should stop the pump when the level reaches the
"pump stop" level. If the pump fails to start, or the liquid level is rising
faster than the pump can keep up with, the DCS should give a LAH. If the
level continues to rise, the PLC will activate the SRU ESD system when
the level reaches the LAHH setpoint to prevent carry-over of liquids into
the Acid Gas Burner and the Reactor Furnace. If the pump fails to stop,
the DCS should give a LAL.
Similarly, little (if any) liquid will drop out in the SWS Gas Knock-Out
Drum, A2-FA1531 under normal conditions. It can also have liquids
accumulate rapidly during an upset, however, so the SWS Gas Knock-Out
Drum Pump, A2-GA1531A/B has also been designed to automatically
start and stop as required by the liquid level in the drum, based on the
level signal sent to the DCS. Level signals are provided to the PLC by
three LTs for use as a 2oo3 voting shutdown.
The local H-O-A switches near the pumps allow the operator to place
these pumps in "auto" start mode. The DCS should start the pump when
the liquid level reaches the "pump start" level in the drum. After the liquid
is pumped out, the DCS should stop the pump when the level reaches the
"pump stop" level. If the pump fails to start, or the liquid level is rising
faster than the pump can keep up with, the DCS should give a LAH. If the
level continues to rise, the PLC will close the SWS gas inlet valve when
the level reaches the LAHH setpoint to prevent carry-over of liquids to the
Acid Gas Burner. If the pump fails to stop, the DCS should give a LAL.
9.5.6 "Ride-Through" System Considerations

Field experience has shown that a brief interruption in the electric power
to a typical air blower will not cause a substantial drop in the air flow as

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long as power is restored before the blower "spins down" too much. The
rotors in Process Air Blowers have relatively large moments of inertia so it
takes a relatively long time (usually many seconds) for the rotational
speed to decline to the point that the air flow drops enough to extinguish
the flame in the associated burner.
It is possible to take advantage of this phenomenon by including

provisions in the emergency shutdown (ESD) systems that will allow the
blowers in the SRUs to "ride-through" momentary power interruptions. If
power is restored quickly enough, the blower in a unit will come back up to
speed before enough air flow is lost to cause a "flame failure" shutdown,
so that the unit will not have to be restarted. If the power loss lasts long
enough, of course, the unit will shut down on "flame failure" and will have
to be restarted manually. For power "blips", however, there is a good
chance the unit will stay on-line.
In order for the blowers to "ride-through", the motor starter circuit must
include an auxiliary contact that is held-in during a power outage, so that if
power is restored the starter contactor will re-engage. The generic motor
starter schematic below shows one way of accomplishing the
"ride-through".
The key features on the schematic are:
 There is a "run permissive" contact from the PLC in the main power
supply to the starter circuit. If the unit ESD is activated for any reason
("flame failure", for instance), this contact opens so that the blower is

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stopped. If the ESD is activated during a power interruption, the blower

will not restart when power is restored because this contact will be open.
 There is a "ride-through" contact from the PLC that parallels the usual
"m" latch relay in the starter circuit. The PLC closes this contact when it
receives the "run" status from the blower. If power is restored before the
ESD is activated, this closed contact allows the starter contact to
re-engage and restore the "m" latch to keep the motor going.
 The start/stop control for the motor is interlocked, and has a

momentary "start" contact and a maintained "stop" contact. This ensures
that the blower remains off when an operator stops a blower using its local
start/stop control station, regardless of what the "ride-through" logic may
be doing at that time.
Within the PLC logic for each ESD system, the "run" status for each
blower is connected to a TDO (time delay off) timer set for 10 seconds.
Normally-open contacts from the TDO are used in the PLC logic that
determines whether a particular blower is running, as well as the logic that
determines whether any blowers are running. Thus, if power is lost to a
blower and the starter contactor disengages, the TDO contacts will
continue to maintain the "blower running" logic as "true" for up to
10 seconds. If power is restored to the blower within this time and the
starter contactor re-engages, the ESD logic will remain satisfied and the
unit will not shut down. If power is not restored to the blower within this
time, the TDO contacts will open and cause the "blower running" logic to
become "false" and activate the unit ESD.
While the TDO timer is running, all of the unit shutdowns besides "no
blower running" are still active. If any of these other shutdowns are
tripped, the ESD will be activated immediately to shut down the unit. For
example, if the flame is lost in the burner during this time, "flame failure"
will activate the ESD and the unit will shut down immediately. Among
other things, the ESD will then remove the "run permissive" from the
blowers so that the blowers cannot restart.
The logic for an air blower "run permissive" is similar to the ESD logic for
that ESD system, but there are a couple of key differences. First, each
unit ESD includes all of the shutdowns, while the "run permissive" does
not include the "no blower running" or "flame failure" S/Ds to allow starting
an air blower in the first place. Second, the unit ESD requires that the
"MANUAL RESET" push-button be pressed to reset the unit ESD, but the

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"run permissive" is auto-resetting since it must occur before the "MANUAL

RESET" push-button is pressed. The auto-resetting should be inhibited for
20 seconds after an ESD event by an internal timer in the PLC to allow
time for the 10 second blower "ride-through" relays and timers to time out,
plus other inherent time delays such as flame scanner delays and valve
travel times.
9.5.7 Boiler Low-Low Level S/D Transmitter Testing

Both of the boilers in each SRU (the Waste Heat Boiler and the Sulfur
Condenser) have three independent level transmitters connected to the
PLC that activate the SRU ESD system before the water level can get low
enough to cause tube damage. The shutdown in activated when two out
of three transmitters show a low-low level. These transmitters should be
tested periodically to determine that they are functioning properly. Since
2oo3 voting is used for the low-low level shutdowns in the SRU ESDs, the
level transmitters can be tested one at a time without having to bypass the
ESD system.
Consider A2-LT15401A on the SRU Train 1 Waste Heat Boiler, for

example. The procedure for testing A2-LT15401B and A2-LT15401C will
be similar, as will A2-LT15431A/B/C on the Sulfur Condenser. The
procedure for testing A2-LT15401A is as follows:
(1) The outside operator notifies the DCS operator that he is preparing
to test shutdown level transmitter "A" on the Waste Heat Boiler.
(2) The DCS operator confirms that A2-LI15401B and A2-LI15401C are
both indicating adequate level in the boiler, then notifies the outside
operator to proceed.

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CAUTION
DO NOT PROCEED UNLESS THE OTHER TWO LEVEL

INDICATORS SHOW ADEQUATE LEVEL IN THE BOILER.
OTHERWISE THE LOW-LOW LEVEL SHUTDOWN IN THE SRU
ESD WILL BE ACTIVATED AS SOON AS THE OUTSIDE
OPERATOR BEGINS DRAINING THE LEVEL TRANSMITTER IN
THE NEXT STEP.
(3) After being notified to proceed by the DCS operator, the outside
operator blocks-in A2-LT15401A by closing its block valves, then
opens the drain valve on the bottom of the transmitter to drain the
water from the instrument.
(4) If the transmitter is operating properly, the DCS will alarm that there
is a low level in the Waste Heat Boiler on A2-LI15401A. The DCS
operator acknowledges the alarm on the DCS and reports it to the
outside operator.
(5) After being notified of the alarm, the outside operator closes the drain
valve on A2-LT15401A, slowly opens its bottom block valve to allow
the transmitter to fill with water then opens its top block valve. This
should clear the low level alarm on A2-LI15401A in the DCS.
(6) After confirming that the low level alarm has cleared, the other level
transmitters can be tested in a similar fashion.
NOTE: The DCS operator must not begin another task until confirming
that the low level alarm has cleared. This is to guard against
having a level transmitter malfunction that causes an SRU ESD
when the other transmitters are tested.

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9.5.8 SRU Emergency Shutdown Systems

The purpose of the Sulfur Recovery Unit Emergency Shutdown systems
(Train 1 SRU ESD and Train 2 SRU ESD) is to shut off the flow of amine
acid gas, SWS gas, fuel gas, and process air to the affected SRU when
serious problems occur. The Cause and Effect Diagram for the Train 1
SRU, contained in the Instrumentation and Controls Diagrams section of
the Basic Engineering Package, describes the SRU1 ESD system in block
format. For reference, the causes and effects of the SRU1 ESD system
shown on this diagram are explained below. (All of the instrument tag
numbers used below refer to the instruments as they are numbered in the
Train 1 SRU. The logic for the Train 2 SRU is identical.)
As noted on the Cause and Effect Diagram, it is recommended that a

5 second delay be used for most of the process parameters included in
the causes of the ESD system. This is to prevent the "nuisance"
shutdowns that are sometimes caused by momentary fluctuations in the
process or the sensing elements.
9.5.8.1 Causes
Any one of the causes listed below will activate the SRU1 ESD
system:
d. Manual Shutdown Switches, A2-HS15310 and A2-HS15313
An operator can activate the SRU1 ESD system using either of

two manual shutdown switches:
(1) A2-HS15310 is a NORMAL / ESD selector switch in the

DCS.
(2) A2-HS15313 is a NORMAL / ESD selector switch mounted

on the local Train 1 SRU control panel.
(3) Acid Gas Scrubber High-High Liquid Level,

A2-LT15305A/B/C
These devices prevent liquids in the Acid Gas Scrubber from

flowing into the hot combustion chamber of the Reactor
Furnace and causing an explosion. They are set to actuate if
the liquid level reaches 1,280 mm above the bottom seam of
the vessel. Note that there are three independent transmitters
and 2oo3 voting logic is used for the ESD (i.e., at least two

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transmitters must show high-high level) to avoid spurious "trips"

due to the malfunction of a single transmitter.
e. No Process Air Blower Running, A2-GB1530A and

A2-GB1530B starter contacts
If neither Process Air Blower is sending air to the Train 1 SRU,

acid gas could flow backwards down the process air line and
escape from either the blowers or their suction screens. The
motor starter contacts on A2-GB1530A/B are used to determine
whether a blower is running, and will activate the SRU1 ESD
system if neither blower is running.
f. Acid Gas Burner Flame Failure, A2-BY15369A and

A2-BY15369B
Dual flame scanners are aimed to observe the flames from the
pilot, warmup, and main acid gas burners. If neither scanner
detects a flame (2oo2), a "flame failure" occurs and activates
the SRU1 ESD system. If only one scanner detects a flame
(1oo2), a malfunction alarm is activated in the DCS, but the
SRU1 ESD system is not activated. A third flame scanner,
A2-BY15368, is furnished with the pilot to detect its flame, but it
is used only to activate its status light (A2-GL15368) on the
local Train 1 SRU control panel and a status indicator
(A2-BL15368) in the DCS.
g. Reactor Furnace High-High Pressure, A2-PT15372A/B/C
These devices protect against over-pressuring the SRU and

blowing out its Sulfur Drain Seal Assemblies (which would emit
toxic H2S to the atmosphere) due to plugging by solid sulfur
somewhere in the plant, a surge in acid gas flow to the furnace,
etc. by activating the SRU1 ESD system before the pressure
gets too high. The sensing lines for the pressure transmitters
are mounted on the process air line to avoid corrosion and/or
plugging with sulfur. The shutdown setpoint is 0.85 kg/cm2(g).
Note that there are three independent transmitters and 2oo3
voting logic is used for the ESD.
h. Waste Heat Reclaimer Low-Low Water Level,

A2-LT15401A/B/C

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These devices activate the SRU1 ESD system to prevent the

water level from dropping below the top of the cooling pass
tubes in this boiler while hot gas is flowing through the tubes.
Hot furnace combustion gas flows inside the tubes and will
destroy these tubes if they are not cooled by water boiling
outside the tubes. These devices are set to actuate if the level
falls to within 75 mm of the top of the cooling pass tubes. Note
that there are three independent transmitters and 2oo3 voting
logic is used for the ESD.
i. Reactor 1st Bed Outlet High-High Temperature,

A2-TT15419A/B/C
These devices shut down the Train 1 SRU if a temperature of

400°C or higher is measured at the outlet from the first catalyst
bed in the Reactor. Such a temperature would indicate a sulfur
fire inside this catalyst bed, which could cause damage by
overheating the equipment if allowed to continue burning. Free
oxygen can leave the Reactor Furnace and reach this catalyst
bed if burner performance becomes poor due to burner
damage, low H2S concentration in the acid gas, etc. Note that
is used for the ESD.
j. Sulfur Condenser Low-Low Water Level, A2-LT15431A/B/C
These devices activate the SRU1 ESD system to prevent the

water level from dropping below the top of the condensing pass
tubes in this boiler while hot gas is flowing through the tubes,
thereby averting high effluent temperatures and higher than
normal tube wall temperatures. High effluent temperatures
would result in lower sulfur recovery due to insufficient
condensing of liquid sulfur, and high tube wall temperatures
could possibly damage the tubes due to differential expansion.
These devices are set to actuate if the level falls to within
75 mm of the top of the condensing pass tubes. Note that there
are three independent transmitters and 2oo3 voting logic is
used for the ESD.
k. Neither Warmup Bypass Valve Closed, A2-ZSC15441,

A2-ZSC15454

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Amine acid gas or SWS gas should not be fed to the Train 1
SRU if its warmup bypass line to the TTO is in use. Otherwise,
very high concentrations of H2S would be sent to the TTO,
possibly leading to a high-high temperature S/D of the TTO and
venting of un-combusted H2S to the atmosphere. The "closed"
limit switches on the warmup bypass valves (A2-HV15441 and
A2-HV15454) must indicate that at least one of these valves is
closed, or the SRU1 ESD system will be activated.
Note that the SRU1 ESD system is not to be activated if the

Train 1 SRU is firing supplemental fuel gas in its Acid Gas
Burner. The amine acid gas and SWS gas shutdown valves,
A2-HV15320 and A2-HV15331, respectively, are to be closed
automatically and an alarm is to be generated, but the ESD
system is not to be activated since the Train 1 SRU can
continue to fire on fuel gas through its warmup bypass line.
Example logic to accomplish this is shown below:
l. Pilot Ignition Safety Interlock Timer Expired, BMS logic
Once the pre-ignition steps have been completed and the BMS
gives a "PERMIT TO IGNITE" for the pilot burner in the Acid Gas
Burner (signaled by illuminating status indicator light
A2-AL15394 on the local Train 1 SRU control panel), an ignition
safety interlock timer is started in the BMS. If an ignition
attempt is not made within 5 minutes, the SRU1 ESD system
will be activated to shut down the sulfur plant. This prevents a
potentially unsafe condition from persisting, where a leaking
fuel gas valve could cause an explosive mixture to form in the

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Reactor Furnace, since the air flow is low at this point in the
startup procedure.
9.5.8.2 Effects
An SRU1 ESD shutdown, activated either manually or automatically,
has the following effects on the Train 1 Sulfur Recovery Unit:
a. Shuts off the amine acid gas flow to the Acid Gas Burner by
closing the acid gas shutdown valve, A2-HV15320.
b. Shuts off the SWS gas flow to the Acid Gas Burner by closing
the SWS gas shutdown valve, A2-HV15331.
c. Shuts down the Process Air Blower, A2-GB1530A/B.
d. Closes the air blower suction valves, A2-FV15333A/B, to

prevent possible venting of any hazardous gases to the
atmosphere.
e. Closes the air blower discharge valves, A2-FV15334A/B, to

prevent back-flow and possible venting of any hazardous gases
to the atmosphere.
f. Closes the air blower vent valves, A2-FV15335A/B, to prevent

possible venting of any hazardous gases to the atmosphere.
g. Initiates the Train 1 SRU Fuel Gas Burner Shutdown system,

which performs the following actions:
(1) Shuts off and depressurizes the main fuel gas supply by
closing block valves A2-NV15357 and A2-NV15359 and
opening vent valve A2-NV15358.
(2) Shuts off the pilot air supply by closing block valve
A2-NV15367.
(3) Shuts off and depressurizes the pilot fuel gas supply by
(4) De-energizes the ignition system, A2-BX15368.
(5) Begins purging the pilot burner with nitrogen by opening

block valve A2-HV15381.

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(6) Begins purging the warmup burner with nitrogen by

opening block valve A2-HV15382.
h. Sends the Train 1 SRU S/D status to the TGCU ESD system.
(The TGCU ESD system will shut down the TGCU if neither
SRU is running and the TGCU is not in "startup" mode.)
i. Cancels the "slow transfer over-ride" switch in the DCS,

A2-HS15464, for the tailgas valves.
j. Initiates purging of the Acid Gas Burner, A2-BA1531, and the

Reactor Furnace, A2-BA1530, with nitrogen by opening block
valve A2-KV15377 for 5 minutes.
When the amine acid gas flow to the Train 1 SRU is blocked, the
pressure control system on the stripper in the upstream ARU should
automatically divert acid gas to the flare as required. When the SWS
gas flow to the Train 1 SRU is blocked, the pressure control system
on the stripper in the upstream SWS should also automatically divert
SWS gas to the flare as required.

SRU1 ESD system, there are several interlocks of significance that
in this section.
a. SWS Gas Scrubber High-High Liquid Level, A2-LT15325A/B/C
These devices prevent liquids in the SWS Gas Scrubber from

flowing into the hot combustion chamber of the Reactor
Furnace and causing an explosion by closing the SWS gas
shutdown valve. They are set to actuate if the liquid level
reaches 1,490 mm above the bottom seam of the vessel. Note
that there are three independent transmitters and 2oo3 voting
logic is used for the S/D.
Unlike the level transmitters on the Acid Gas Scrubber, this

interlock does not activate the SRU1 ESD system. Instead,
it closes only the SWS gas shutdown valve, A2-HV15331, to
stop the flow of SWS gas. This valve does not re-open
automatically when the level drops down and the shutdown

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resets. The plant operators must use A2-HIC15331 on the local

control panel to open A2-HV15331 to reintroduce SWS gas into
the SRU in a controlled fashion.
b. Process Air Blower Operation while in "Startup" Mode
During normal operation, activating the SRU1 ESD system will

shut down the Process Air Blower and close the suction,
discharge, and blow-off valves on the blower. However, if the
Train 1 SRU is firing on fuel gas through its Warmup Bypass
Valves, the air blower will remain running (with its valves open)
if the "flame failure" S/D (see Section 9.5.10.1.f) is tripped or
one of the fuel gas pressures is not satisfied (see
Sections 9.5.8.3.c and 9.5.8.3.d) All other shutdown devices
(see Section 9.5.8.2) go to their shutdown positions.
By leaving the air blower running when a fuel gas flame is lost,
fewer blower restarts are necessary while re-lighting the burner,
resulting in less "wear and tear" on the large motors driving
these blowers.
c. Acid Gas Burner Fuel Gas Supply Low-Low Pressure,

A2-PT15354
During warmup while the Train 1 SRU is firing on fuel gas, loss
of the fuel gas supply would cause the fuel gas pressure to
drop. This device will shut off the fuel gas to the Acid Gas
Burner before flame instability creates the potential for an
explosion. The shutdown setpoint is 0.35 kg/cm2(g).
Note that if the Train 1 SRU is firing on acid gas, the transmitter
only activates the Train 1 SRU Fuel gas Burner Shutdown
system (pilot fuel gas and main fuel gas), so the Train 1 SRU
will continue running on acid gas. If, however, the Train 1 SRU
is firing only fuel gas (as indicated by its acid gas firing selector
switch, A2-HS15315, being set to "DISABLED"), the SRU1 ESD
system is activated and the low-low pressure is reported to the
"first out" alarm logic. Example logic to accomplish this is shown
below:

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d. Acid Gas Burner Fuel Gas High-High Burner Pressure,

A2-PT15361
During warmup while the Train 1 SRU is firing on fuel gas,

malfunction of the fuel gas pressure control could cause
excessive firing of the warmup burner in the Acid Gas Burner.
This device will prevent this unsafe condition by shutting off the
fuel gas to the Acid Gas Burner. The shutdown setpoint is
3.5 kg/cm2(g).
Note that if the Train 1 SRU is firing on acid gas, the transmitter
only activates the Train 1 SRU Fuel gas Burner Shutdown
system (pilot fuel gas and main fuel gas), so the SRU will
continue running on acid gas. If, however, the Train 1 SRU is
firing only fuel gas (as indicated by its acid gas firing selector
switch, A2-HS15315, being set to "DISABLED"), the SRU1 ESD
system is activated and the high-high pressure is reported to
the "first out" alarm logic, as shown by the example logic for the
previous item.
e. Complete Flowpath Interlock (see Logic Flow Diagrams for the

limit switch tag numbers)
In order for the Train 1 SRU to operate without over-pressuring

its drain seals, there must be a complete flowpath from the SRU
to the TTO. The ESD logic can determine whether such a
complete flowpath exists by examining the status of the limit
switches on the process gas valves. There are basically three
different paths that the Train 1 SRU can take to reach the TTO:

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(1) Both of its Warmup Bypass Valves, A2-HV15441 and

A2-HV15454, are fully open to the TTO.
(2) Its manual tailgas block valve, A2-HV15455, and its

Tailgas Valve to the TTO, A2-HV15457, are both fully
open to send the tailgas directly to the TTO.
(3) Its manual tailgas block valve and its Tailgas Valve to the
TGCU, A2-HV15462, are both fully open and the TGCU
Complete Flowpath Interlock is satisfied, allowing the
tailgas to flow through the TGCU and then to the TTO.
If the "open" limit switches do not indicate that at least one of

these flowpaths is valid, the "complete flowpath interlock" alarm
is activated. However, the SRU1 ESD system is not activated
by this interlock. Because this interlock depends on a number
of valve limit switches to determine whether a complete
flowpath exists, there is always the potential for spurious "trips"
even though all of the valves are actually in the proper
positions. Since the SRUs are already protected against
over-pressure (see Section 9.5.10.1.g), this interlock will alarm
in the DCS (A2-QA15458) but is not included in the ESD.
To prevent releasing excessive amounts of hazardous gases to

the atmosphere from the TTO and/or possibly damaging the
Thermal Oxidizer, the interlocks for the Train 1 SRU require that
at least one of its Warmup Bypass Valves be closed before
opening A2-HV15320 or A2-HV15331 and admitting amine acid
gas or SWS gas, respectively, to the Train 1 SRU. Therefore,
its Tailgas Valve to the TTO, A2-HV15457, must be open
before closing its Warmup Bypass Valves when switching from
fuel gas firing to acid gas firing.
When the TGCU is already on-line processing tailgas from one

of the SRUs, switching the tailgas from the other SRU into the
TGCU requires gradually diverting its tailgas from the TTO to
the TGCU. For the Train 1 SRU, this requires "throttling" both
tailgas valves, A2-HV15457 and A2-HV15462, at the same time
to make the switch without upsetting the TGCU.
When throttling the tailgas valves in this manner, the limit

switches on the valves will be indicating that neither of the
tailgas valves is fully open, so the Complete Flowpath Interlock

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logic will not be satisfied for the Train 1 SRU. For this reason,
there is a "slow transfer over-ride" switch in the DCS,
A2-HS15464. When this switch is toggled to "OVER-RIDE", the
limit switches on the two tailgas valves are ignored by the
Complete Flowpath Interlock logic until the DCS operator
finishes routing the Train 1 SRU tailgas into the TGCU to
deactivate the over-ride. During this time, the DCS operator is
responsible for ensuring that there is always a complete
flowpath for the Train 1 SRU.

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maintenance, and emergency procedures for the Sulfur Recovery Units are
discussed in the remaining sections of this portion of the operating guidelines.
The operator should also be thoroughly acquainted with the equipment and the
"Process Description" section in these guidelines 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 the "procedures" sections 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

The refractory installed in the Reactor Furnaces can be damaged by too
rapid heating or cooling. The Initial Cure and Normal Warmup schedules
for the refractory should be provided by the refractory vendor. These
schedules should be adhered to quite closely.
After the initial startup, the sulfur plants will contain some sulfur
throughout the system, and especially in the catalyst beds. Sulfur fires will
ignite at temperatures as low as 150°C if sufficient oxygen is available.
For this reason, it is very important to minimize the time periods when air
(or combustion gas containing oxygen) is routed through the catalyst
beds. Localized temperatures in excess of 150°C can exist in a catalyst
bed even though the temperatures measured around the Reactor are less
than 150°C. Because of this, sulfur ignition sometimes occurs in the
catalyst beds when it is not anticipated by temperatures that are readily
available for observation.
Under ordinary circumstances, the only time when oxygen-bearing gases

will be flowing through a Reactor is during the transition when switching
from firing fuel gas for warmup to firing acid gas. During this time,
observe the Reactor temperatures frequently. If the temperatures are
rising more than 5°C to 10°C in a 30 minute period after the temperatures
have reached 200°C, then there is possibly a fire present. The high
temperature shutdown on the outlet of the first catalyst bed in each SRU
will protect that SRU against excessive temperatures in its piping;
however, localized excessive temperatures can occur in the catalyst beds
prior to being indicated in the Reactor outlet lines. Steps should be taken
to prevent the temperatures rising high enough to activate the shutdown

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as it will require some time to cool down the hot spot before proceeding
with startup.
Do not use water to quickly cool a Reactor after a fire. Not only will this
damage the catalyst, the rapid cooling may cause structural damage to
the Reactor. The acidic water that forms may cause corrosion damage to
the Reactor or other equipment. Nitrogen is available in each SRU for use
in cooling a hot catalyst bed.
Explosive mixtures of air (oxygen) and gases in the equipment are a

potential danger. During an automatic shutdown all air, oxygen, fuel gas,
and acid gas flows are shut off simultaneously. Any malfunction of these
devices could leak an explosive mixture into the unit. For this reason, the
PLC requires purging of the Reactor Furnace before attempting pilot
ignition, and requires re-purging the furnace if the burner does not light but
fuel gas was admitted.

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CAUTION
NEVER "HYDROBLAST" THE TUBES (OR ANY OTHER STEEL

SURFACES) IN THE SULFUR PLANT 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 RAPIDLY CORRODE
THE STEEL.
THERE HAVE BEEN NUMEROUS INSTANCES OF SULFUR PLANT

BOILERS BEING BLASTED DURING A TURNAROUND TO CLEAN
THEM UP, THEN HAVING THE TUBES BEGIN LEAKING AS SOON
AS THE BOILER IS RETURNED TO SERVICE.
IF THE BOILER TUBES HAVE BECOME PLUGGED, THE BEST

WAY TO CLEAR THE TUBES IS TO MECHANICALLY "ROD" THEM.
IT IS OFTEN HELPFUL TO APPLY HEAT TO THE TUBES BEFORE
"RODDING", AS THIS WILL MELT ANY SULFUR THAT MAY BE
PART OF WHAT HAS PLUGGED THE TUBES. ONE WAY TO DO
THIS IS TO DRAIN THE WATER FROM THE BOILER AND PUT
STEAM ON THE SHELL, THEN DRAIN THE CONDENSATE
PERIODICALLY TO KEEP LIVE STEAM ON THE TUBES.
9.6.2 Cold Catalyst Bed Startup

Each sulfur plant is designed to be started up without first warming the
Reactor catalyst. In the cold bed startup procedure, warmup gases are
not routed through the Reactor catalyst beds. Fuel gas is burned with
excess air on the warmup burner tips of the Acid Gas Burner mounted on
each Reactor Furnace. The hot combustion products flow through the
Reactor Furnace, through the Waste Heat Boiler tubes and the first
condensing pass tubes of the Sulfur Condenser, and then to the warmup
bypass line that is upstream of the first catalyst bed. This warms the
furnace refractory lining and the process heat exchange surfaces up to
normal operating temperatures.

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The combustion gases are routed to the atmosphere via the Thermal
Oxidizer. Therefore, normal operating procedures require that the
Thermal Oxidizer also be warming up according to its refractory warmup
schedule (or already be on-line) during the period when the SRU(s) is(are)
being brought up to operating temperatures. Do not admit acid gas to an
SRU until the Thermal Oxidizer is at operating temperature and ready to
accept SRU tailgas.
The cold bed startup procedure includes the following steps:
A. Open the Warmup Bypass Valves, and close the Tailgas Valve to the
Thermal Oxidizer and the Tailgas Valve to the TGCU. Startup
cannot be attempted unless this flow path is open.
B. Ignite the warmup burner in the Acid Gas Burner and fire on fuel gas
with excess air, adjusting air and fuel gas rates to follow the
appropriate warmup schedule.
C. Once the Waste Heat Boiler and Sulfur Condenser start to make
steam, their back-pressure controllers should be placed in service.
The other tube passes in the Sulfur Condenser and the tube passes
in the reactor feed heaters will come up to temperature as these
boilers begin producing steam.
D. When the furnace and all process heat exchangers are warmed up to
normal operating temperatures and the Thermal Oxidizer is ready to
accept SRU tailgas, reduce the fuel gas and air flow rates. Open the
Tailgas Valve to the Thermal Oxidizer, then close the Warmup
Bypass Valves. Add amine acid gas and reduce fuel gas in equal
increments until the fuel gas is shut off.
E. Gradually admit the full amine acid gas flow rate. Adjust the air flow
to the proper air:amine acid gas ratio. Follow the procedures in
these guidelines for introducing SWS gas into the SRU. Gradually
admit the full SWS gas flow rate and readjust the air:acid gas ratio if
necessary.
There are several advantages to using the cold bed startup procedure.
First, the catalyst beds are not exposed to warmup gases containing free
oxygen. This reduces the chance of fires in the catalyst bed during
warmup, which can cause overheating damage to both equipment and
catalyst.

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Second, the catalyst beds are not exposed to warmup gases that contain
free carbon (soot). This reduces the chance of contaminating and
plugging the beds with soot.
Third, the cold bed startup procedure reduces catalyst sulfation and,
therefore, keeps the catalyst active longer. Deactivation has been shown
to be caused primarily by sulfate contamination of the catalyst surface.
Sulfation occurs most readily at conditions encountered during a startup
procedure which uses combusted fuel gas for catalyst heating.
An additional benefit of having the warmup bypass line is that a sulfur

plant can be kept on hot stand-by, firing on fuel gas, without exposing the
catalyst beds to overheating, carbon deposition, or sulfation damage. The
hot fuel gas combustion products will keep all process heat exchange
surfaces at normal operating temperatures. Since most corrosion damage
in sulfur plants occurs when the plants are allowed to cool down and stand
cold, using the warmup bypass can greatly extend the service life of sulfur
plants which require considerable stand-by time.
9.6.3 Sulfur Solidification

Sulfur melts at 119°C. All surfaces in the SRUs must be maintained
above this temperature during normal sulfur production operating periods.
However, temperatures around the Sulfur Surge Tanks and the Sulfur
Storage Tank should be kept below 158°C since sulfur undergoes a phase
change at this temperature that can result in a tremendous increase in
viscosity, which could overload any of the sulfur pumps. Maintaining the
steam coil pressure in the Sulfur Surge Tank and the Sulfur Storage Tank
at 5.0 kg/cm2(g) or less will ensure that the sulfur does not get too hot.
All of the piping and valves in liquid sulfur service are steam-jacketed, as
are the valves in sulfur vapor service and the vent stacks on the Sulfur
Surge Tanks. The steam traps serving these heating systems should be
checked regularly to verify proper operation. The simplest method to do
this is to verify that sulfur will melt on the steam trap inlet; if the
condensate there is hot enough to melt sulfur, then the steam in the
jackets will be hot enough, too. It is also important to periodically sweep
the non-condensibles out of the jackets and coils by giving their vent
valves a good "blow". This will prevent the accumulation of
non-condensibles that could create localized "cold" spots where sulfur can
freeze.

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9.6.4 Ammonia Salt Formation

Hydrogen sulfide reacts with ammonia at low temperature to form
ammonium hydrosulfide:
NH3 + H2S NH4HS
If the temperature is low enough, this ammonium hydrosulfide will

precipitate as a solid salt. The temperature at which the solid phase will
form is a function of the NH3 and H2S concentrations and the gas
pressure, but generally ranges from 15°C to 40°C for most acid gas
streams. It is recommended that all surfaces in contact with NH3-H2S be
maintained 20-25°C above the solid formation temperature, so all of the
equipment, piping, and instruments in the SRUs that is exposed to SWS
gas are electric traced, steam traced or steam jacketed to keep them
above 65°C.
CAUTION
TO PREVENT PLUGGING OF EQUIPMENT, PIPING, OR

INSTRUMENTS WITH AMMONIA SALTS, THE TRACING OR
STEAM JACKETING IN CERTAIN SECTIONS OF THE SRUS MUST
BE LEFT IN SERVICE YEAR ROUND. THESE ARE ANY PIPING,
EQUIPMENT AND INSTRUMENTATION IN SWS GAS SERVICE.
Essentially all of the ammonia in the SWS gas will be destroyed in the
Reactor Furnace during normal operation. If, however, amine acid gas
flow is interrupted (due to upsets in the ARU, etc.) and the SRUs are
processing only SWS gas, the ammonia may not be completely destroyed
and salts could begin to form in the downstream equipment (particularly
the Sulfur Condensers). Loss of amine acid gas flow can also cause
excessively high furnace temperatures, poor sulfur recovery, and poor
operation or equipment damage in the TGCU or the Thermal Oxidizer
downstream. For this reason, the operator must closely observe the
SRUs if their amine acid gas flow is interrupted, and be ready to activate
the SRU ESD systems if necessary to prevent equipment damage.

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9.6.5 Catalyst Fouling

The catalyst beds in the Reactors may be severely fouled by carry-over of
hydrocarbon liquids or vapors from the ARU and/or Sour Water Stripper
Units into the SRUs. This will cause permanent damage to the catalyst
and is to be avoided if at all possible, even if shutting down the SRUs for
periods is required.
The catalyst may also be fouled by passing fuel gas combustion products
through the beds when insufficient air to burn all of the fuel gas is being
supplied to the Acid Gas Burner. This causes soot (carbon) formation
which coats the catalyst and causes loss of activity. The catalyst beds in
this plant will be warmed with fuel gas combustion products only during
the initial startup. Excess air will be used during this warmup period, so
the chances of fouling the catalyst in this manner are remote.
The catalyst may also temporarily lose activity due to molten sulfur
condensing on the beds. This can be corrected by raising the Reactor
inlet temperatures by approximately 15-20°C for a few hours, then
readjusting to the normal operating range. The catalyst activity will be
completely restored in this manner by re-vaporizing the deposited sulfur.
The reactor feed temperatures can be raised by appropriate adjustment of
the temperature controllers on the gas outlet lines from the reheat
exchangers.
9.6.6 Operation of SRUs in Parallel

Train 1 SRU and Train 2 SRU are designed to operate in parallel with
each other to provide maximum acid gas processing capacity. The SRUs
are connected at their inlets, with the amine acid gas and SWS gas
feedstocks split to flow through the units in parallel. Due to the relatively
low pressure drops through the SRUs (normally 0.5-0.7 bar(g) at full rates,
when the pressure drop of the associated TGCU is included), operating
changes in one unit can significantly impact the other units because of the
flow hydraulics.
The acid gas flow controls for Train 1 SRU and Train 2 SRU are designed
to allow automatic operation of the parallel units in a fashion that
maximizes processing capacity and maximizes sulfur recovery efficiency.
There are two basic schemes for operating SRUs in parallel: "base-load"
operation of all-but-one SRU, or "cascade" operation of all SRUs. Each
scheme has advantages and disadvantages relative to the other,
depending on the operating characteristics of the particular feed units and

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SRUs, current operating conditions, and other factors. As a result, the

choice of which operating mode to use is best determined based on field
experience with the specific units.
9.6.6.1 "Base-Load" Operation on All-But-One SRU

One operating mode is to "base-load" all but one SRU, and let the
remaining SRU take the "swing." That is, the flow controllers are
used to feed a fixed quantity of amine acid gas and/or SWS gas to
one SRU, while a pressure controller is used to control the feed
valves to the remaining SRU (either directly or via setpoint
adjustment of the flow controllers). This mode allows one SRU to
operate at steady feed rates, but requires that the remaining SRU
take all of the variation in the flow of the amine acid gas and/or SWS
gas feed to the sulfur facilities.
The main advantage of this operating mode is that the "base-load"

SRU has very steady feed gas rates, which in turn allows its
air:acid gas ratio control scheme to keep the plant trimmed very
close to optimum H2S:SO2 ratio under most circumstances. This
means that the sulfur recovery efficiency of the "base-load" SRU is
generally very high.
The primary disadvantage of this operating mode is that the "swing"

SRU can see very large fluctuations in its amine acid gas and/or
SWS gas feed rates, since this unit has to take all of the flow
variation. Consequently, the sulfur recovery efficiency can be
considerably lower for this SRU than for the "base-load" unit because
the air:acid gas ratio control scheme on the "swing" unit is unable to
keep the plant as close to optimum H2S:SO2 ratio, resulting in wider
and more frequent deviations from the optimum ratio.
The impact of this disadvantage can be minimized if the total amount

of acid gas to be processed is less than the maximum capacity of the
units. By setting the "base-load" SRU to process its full capacity, a
smaller quantity of acid gas will be processed in the "swing" SRU.
This means that a larger portion of the total acid gas is processed in
the SRU operating at the higher recovery.
Depending on the quantity of SWS gas to be processed, it may be

possible to send all of the SWS gas to one of the SRUs and process
only amine acid gas in the remaining SRU. In this case, the SRU

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processing the SWS gas would be operated as the "base-load" unit

for amine acid gas. This should give steadier operating conditions
for this SRU, allowing better sulfur recovery efficiency and more
reliable ammonia destruction in the SRU. And, since the "swing"
SRU is processing only amine acid gas, its sulfur recovery efficiency
will be higher than for a "swing" SRU processing both amine acid gas
and SWS gas. The net result may be higher overall sulfur recovery
efficiency for the SRUs than if SWS gas was processed in both the
units (although this may not always be the case).
9.6.6.2 "Cascade" Operation of All SRUs

The other operating mode is to place both the SRUs in "cascade"
operation. Rather than feeding a fixed flow rate to one SRU and
forcing the remaining SRU to take all of the "swing", the acid gas can
be split in relative proportions between the SRUs. As the amount of
available acid gas changes, the feed rates to both the SRUs will be
adjusted proportionally. This mode spreads the variations in the flow
of amine acid gas and/or SWS gas feed between the SRUs so that
no unit is experiencing as much change as when operated as a
"swing" unit. However, none of the units is operating on steady flow
rates, as both the units must absorb the fluctuations in flow from the
feed units.
The primary advantage of this operating mode is that no SRU is

experiencing large variations in feed flow rates, so there is less
variation in sulfur recovery efficiency compared to operating as a
"swing" SRU. This operating mode is generally also more reliable
when the amount of SWS gas to be processed is high enough that
both the SRUs must process SWS gas.
The main disadvantage of this operating mode is that none of the

units is processing at steady feed rates, so neither SRU can maintain
its sulfur recovery efficiency as high as it can when operating as a
"base-load" SRU. If the feed units are producing acid gas at
reasonably steady rates, however, the magnitude of this loss in sulfur
recovery efficiency from operating with both the SRUs in "cascade"
mode can be relatively minor.
The overall sulfur recovery efficiency for the SRUs as a whole will depend
on how much acid gas is to be processed, the relative amounts of amine
acid gas and SWS gas to be processed, relative catalyst activities within

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the reactors of the plants, and many other factors. As a result, the choice
of which operating mode to use will often depend on the particular
circumstances at any given time. As operating experience is gained with
the units, past experience will probably serve as the best tool for choosing
the operating mode in different situations.
9.6.7 Process air Blower Operation

The Process air Blower is actually a multi-stage, low-head, centrifugal
compressor. Although this air blower is less complicated to operate than
conventional centrifugal compressors (like those used in fuel gas service,
for instance), the blower does require some special attention when
operating at low flow rates. These cases are discussed in the sections
below.
9.6.7.1 Preventing "Surge" in the Process air Blower

When centrifugal compressors are operated at low flow rates, they
may enter a range of flow instability known as "surge."
The startup air flow rate to an SRU is primarily controlled by throttling

a valve in the blower suction. This method of flow control is
preferred because suction throttling reduces the inlet air density and
maintains a higher volumetric flow rate through the blower when the
mass flow rate is lower. Because of this effect, the blower should be
able to operate down to a lower flow rate before going into surge.
Operating experience will establish what the stable operating range
is for this blower.
The primary indication of blower surge is erratic air flow rate. The
first sign of this is usually audible – the check valve in the blower
discharge line begins to "clatter." The air pressure gauge on the inlet
to the Acid Gas Burner will usually fluctuate rapidly, and the burner
flame can often be observed to "puff" back and forth, when the
blower is in surge. If the surge is severe enough, it will cause high
vibration levels on the blower. If the blower is in surge for an
extended period, the blower casing will overheat due to re-circulation
of hot air between stages of the machine. Regardless of the
symptoms, the result of allowing a blower to operate in surge for long
periods of time is physical damage to the blower, either from high
vibration or from high temperature. For this reason, do not allow an
air blower to remain in surge.

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To prevent the blower from surging at low flow rates, the discharge
piping on each blower has a "blow-off" valve installed. The action of
the blow-off valve is controlled by relays in the DCS. When the air
flow is low, the PLC will open the blow-off valve and allow some of
the air from the blower to vent to the atmosphere, increasing the air
flow through the blower to keep it above the surge line. A silencer
has been installed in the vent line to reduce the noise level around
the blower when the blow-off is used. If the blower is surging, then
adjust its blow-off valve to open more until the blower stops surging. It
does no harm to open the blow-off more than necessary, although it
does waste power by forcing the blower to compress more air than
necessary. Adjusting the amount that the blow-off opens is simply a
matter of making the appropriate configuration change in the DCS.
9.6.7.2 "Swapping" Process Air Blowers During Operation

While a sulfur plant is running, it is often 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 process by starting and stopping the blowers in
the proper manner. The procedure given below is one technique for
swapping blowers.
Since each SRU must remain on-ratio at all times for optimum sulfur
recovery, it is important that the air flow to an SRU not be disturbed
while swapping blowers. If the air flow fluctuates, the best that can
happen is a minor disturbance in air:acid gas ratio and a small drop
in sulfur recovery. At worst, the Acid Gas Burner may lose its flame,
the SRU will shut down on "flame failure", and the acid gases will be
diverted to the flare (a reportable emission episode). The "bias"
controllers in the DCS together with the bias and flow control relays
in the DCS, are designed to make swapping blowers relatively simple
and avoid these problems.
One of the complicated aspects associated with swapping blowers is

the impact that starting the off-line blower can have on air flow. Each
air blower has its own suction valve. Since the DCS will be sending
the same control signals to the valves on both blowers, there is a
potential to suddenly double the air flow when the off-line blower is
first started. This would not only disturb the process, it could
possibly blow out the flame in the burner.

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The bias relays in the DCS allow the DCS operator to slowly ramp up
the flow from the off-line blower while ramping down the flow from
the on-line blower. Although we have attempted to automate this
concurrent ramping operation on a couple of past projects, we have
not found this to be very satisfactory. The way that the blower
controls need to be ramped will depend on the current plant
throughput and whether or not the blower suction valve is still in
control of the air flow from the blower. This is classic "fuzzy logic",
something that is easy for a human to do but very difficult for a
computer.
The procedure below describes how to switch an SRU from the "A"
blower to the "B" blower. That is, the "A" blower is running to the
SRU and the "B" blower is not currently running. The procedure to
switch from the "B" blower to the "A" blower in the SRU is similar.
Make sure the SRU is operating stably before proceeding.
A. In the DCS, confirm that the “A” blower hand controller is

currently set to 100% output so the blower relay is multiplying
the signal it receives from the process air flow controller by 1.0
(i.e., no change). (If the setting is not already 100%, slowly
increase it to 100% before proceeding, allowing time for the
controls to respond.)
B. Set the “B” blower hand controller in the DCS to 0% output.
This means that its relay will be multiplying the signal it receives
from the process air flow controller by 0.0, so all of the flow
relays for the valves on the “B” blower will be receiving 0% as
their inputs. After transformation by the suction, discharge, and
vent relays in the DCS, this means that the positioners on the
suction valve, discharge valve, and vent valve will be receiving
control signals of 33%, 0%, and 100%, respectively.
C. Switch the process air flow controller to "manual".
This ensures that the input to the "bias" relays does not change
during the blower swap procedure, so that the DCS operator
can see the impact on air flow while adjusting the relays.
D. On the off-line blower (B), confirm that:
(1) Its suction valve is closed.

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(2) Its discharge valve is closed.
(3) Its blow-off valve is closed.
E. Start the off-line blower as follows:
(1) Press the local push-button to give the blower a "permit to

start" and energize the solenoid valves on its suction and
vent valves for 30 seconds.
(2) Start the blower using its local start/stop control station.
(3) Once the blower is running, the solenoid valve on its

discharge valve is also energized.
The blower suction valve will open 33%, its vent valve will open,
and its discharge valve will remain closed. The valves will all
return to being closed if the blower is not started before the
"permit to start" times out.
Since the discharge valve will still be fully closed when the
blower starts, there will be no change in the air flow to the SRU
even though air will be flowing through the blower. All of the air
will be flowing out of the blow-off valve and venting atmosphere.
F. In the DCS, begin to increase the output from the “B” blower
hand controller.
This will begin to increase the multiplier in the “B” relay from
0.0, and the output to the discharge valve will begin to increase
as the output to the vent valve begins to decrease.
G. Continue to increase the output from the “B” blower hand

controller until the “B” blower develops enough discharge
pressure to open its check valve and the air flow to the SRU
begins to increase.
Depending on current operating conditions in the SRU, this may

happen as soon as the discharge valve begins to open, or it
may not happen until the suction valve begins to open more.
Once the discharge check valve on the “B” blower opens, the
air flow to the SRU will begin to increase as the “B” blower
starts to contribute to the air flow.

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H. Begin to decrease the output from the “A” blower hand

controller.
This will begin to reduce the multiplier in “A” relay from 1.0 and
begin to reduce the flow from the “A” blower. Depending on
current operating conditions in the SRU, this may be due to
throttling the suction valve more, or may be due to closing of
the discharge valve.
I. Continue to increase the output from the “B” blower hand

controller and reduce the output from the “A” blower hand
controller as necessary to control the air flow, until the “B”
blower hand controller has 100% output and the “A” blower
hand controller has 0% output.
This will increase the air flow from the “B” blower and reduce
the air flow from the “A” blower until all the flow to the SRU is
from the “B” blower and the “A” blower is just venting air to the
atmosphere.
J. Switch the air flow controller back to "automatic".
K. Shut down the “A” blower using the local start/stop control
station.
L. The blower swap is now complete. Before leaving the area,

visually confirm that:
(1) The off-line blower is stopped.
(2) The suction, discharge, and v valves on the off-line blower

are closed.
(3) The on-line blower is running smoothly.
(4) The process has returned to steady operation.

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9.6.8 Reactor Furnace Temperature

Each Reactor Furnace is designed to destroy the ammonia contained in
the SWS gas feed by maintaining a high-temperature, reducing
atmosphere in the front zone of the furnace. In order to control the
temperature in the front zone of the furnace, a portion of the amine acid
gas bypasses the Acid Gas Burner and flows to side injection ports on the
Reactor Furnace, where the bypass gas mixes with the burner combustion
products as they enter the second zone of the furnace. If less of the
amine acid gas is routed to a burner, a greater portion of the H2S fed to
that burner is actually combusted, raising the flame temperature and
increasing the temperature in the front zone of that furnace. If more
amine acid gas is routed to a burner, a smaller fraction of the H2S entering
that burner is combusted, lowering the temperature in the front zone of
that furnace.
The amount of amine acid gas that is fed to the burner in the SRU is
controlled using the flow ratio controller in the DCS to adjust bypass gas
control valve to regulate the amine acid gas flowing to the side injection
ports on its furnace (the bypass gas flow rate). In theory, the optical
pyrometer mounted on the side of the furnace should measure the
temperature inside the first zone of the Reactor Furnace and make
appropriate adjustments to the bypass gas flow by changing the ratio
setting on the flow ratio controller to control the desired temperature.
In practice, however, the temperatures measured by optical pyrometers

on similar furnaces have often given erratic responses to process
changes. It is suspected that the cool bypass gas entering the side
injection ports is influencing the temperature measurement, either due to a
cooling effect on the refractory as the gas flows through the openings in
the lining, or due to back-mixing caused by eddies arising from the "jet"
effect of the combustion products leaving the Acid Gas Burner.
If the temperature response of the pyrometers does prove to be

unreliable, then the bypass gas ratio can be used for control purposes
instead. The graph below shows the bypass gas ratio as a function of the
ratio of SWS gas flow to amine acid gas flow. The bypass gas ratio is the
amine acid gas bypassing the burner as indicated in the DCS versus the
total amine acid gas as indicated in the DCS. Combustion of the
ammonia in the SWS gas is very exothermic, so less of the amine acid
gas must be bypassed to maintain the same front zone temperature as
the ratio of SWS gas to amine acid gas increases.

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0.215
0.214
0.213
0.212
Bypass Gas Ratio, Nm3/Nm3
0.211
Design Point (Normal Operation)

0.210
0.209
0.208
0.207
0.206
0.205
0.00 0.01 0.02 0.03 0.04 0.05
SWS Gas:Amine Acid Gas Ratio, Nm3/Nm3
The setpoint for the flow ratio controller can be set by the operator using
the graph above. When operating in this mode, the temperature indicated
on the optical pyrometer can be monitored to determine if changes to the
setpoint on the flow ratio controller are necessary. If the temperature
reading is lower than normal, raise the setpoint on the flow ratio controller
to bypass more amine acid gas around the burner and raise the
temperature. If the temperature reading is higher than normal, lower the
setpoint on the flow ratio controller to bypass less amine acid gas around
the burner and bring the temperature down.
If field experience shows that the temperature measurement of the optical

pyrometers on these SRUs will give acceptable control. Placing the flow
ratio controller in "cascade" will allow the temperature controller to adjust
its ratio setpoint, so that the amount of bypass gas is controlled
appropriately with the flow ratio controller.
Whether the bypass gas ratio is controlled directly or is set by the action of
the temperature controller adjusting the bypass gas ratio, the following
considerations apply to the bypass gas flow rate:

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(7) The total bypass acid gas flow rate should never be allowed to
exceed 67% (i.e., ⅔) of the total amine acid gas flow rate, as this will
ensure that at least ⅓ of the total acid gas feed is always flowing to
the burner regardless of the SWS gas flow rate. If less that ⅓ of the
total H2S is fed to the burner, all of the oxygen in the process air fed
to the burner may not be consumed. If this happens, free oxygen
may enter the downstream catalyst beds and catch them on fire,
leading to catalyst (and possibly equipment) damage.
(8) 65% is the recommended maximum bypass acid gas ratio to allow a
safety margin for flow measurement errors, slow control response,
plant upsets, etc.
(9) It is always desirable to minimize the bypass acid gas ratio, as

sending more of the amine acid gas feed to the burner means less
chance of contaminating the downstream catalyst beds with
hydrocarbons or carbon. Even the best-run amine systems will
always pick up small amounts of hydrocarbon, which can
subsequently contaminate the catalyst beds. Hydrocarbon fouling is
the most common cause of poor catalyst life in refinery sulfur plants.
(10) The pressure drop through the Acid Gas Burner is the driving force
that allows the bypass gas control valve to bypass part of the amine
acid gas around the burner and into middle of the furnace instead.
When the SRU is operating at low flow rates, there may not be
enough pressure drop through the burner to give good control of the
bypass acid gas. In such cases, the flow ratio controller will "pinch"
the control valve in the acid gas line to the burner, increasing the
pressure drop available for the bypass gas control valve.
The DCS relay is designed to limit the output to the control valve in
the acid gas line to the burner so that this valve is never
completely closed. There should always be at least ⅓ of the amine
acid gas flowing to the burner to be sure that the front zone of the
Reactor Furnace does not begin to operate in an oxidizing
atmosphere.
(11) When an SRU is not processing SWS gas, it is not necessary to

bypass any amine acid gas around its burner. When operating in
this mode, place the flow ratio controller in "manual" and set its
output to 0% to fully close the bypass gas control valve and send all
the amine acid gas to the burner. With all of the amine acid gas

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flowing through the burner, it is less likely that hydrocarbons in the

acid gas will leave the furnace un-combusted, so there is less
chance of fouling the downstream catalyst beds.
WARNING
IT IS POSSIBLE FOR THE SIDE INJECTION PORT NOZZLES

ON A REACTOR FURNACE TO OVERHEAT IF THERE IS NO
BYPASS ACID GAS FLOWING THROUGH THE NOZZLES.
ALTHOUGH THE HOT FURNACE GASES SHOULD NOT
"BACK" INTO THE NOZZLES, THE INTENSE RADIANT HEAT
FROM THE HOT FURNACE INTERIOR MAY CAUSE
OVERHEATING OF THE NOZZLES.
TO PREVENT ANY SUCH OVERHEATING, THE NITROGEN

PURGE FOR THE INJECTION PORTS SHOULD BE PLACED
IN SERVICE WHENEVER THERE IS NO BYPASS ACID GAS
FLOW.
9.6.9 Ammonia Destruction Considerations

It is generally accepted within the industry that sulfur plants processing
ammonia-bearing streams (sour water stripper off-gas, for instance) must
be designed to destroy essentially all of the ammonia, probably down to
PPM levels, to avoid plugging with ammonia salts in the downstream
equipment. For this reason, many sulfur plant designers impose upper
limits on the ratio of SWS gas to amine acid gas to ensure successful
operation of their SRUs. We do not believe this is necessary, however, if
the reactor furnace is designed for ammonia destruction in a reducing
atmosphere like the furnace in this SRU is.
Years ago, ammonia was destroyed in one section of a reactor furnace by

literally burning it in the presence of excess air. A notable number of
undesirable side effects result when the ammonia is destroyed in this
oxidizing atmosphere, as a significant amount of sulfur trioxide (SO3) is
formed in this oxidizing step since the ammonia-bearing feed stream also
contains sulfur compounds. This SO3 can cause significant problems
throughout the process. First, it readily reacts with any free ammonia

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throughout the process to form heat-stable salts that deposit and

accumulate. (Frequently, small amounts of ammonia enter the process in
the amine acid gas stream to participate in this salt accumulation
problem.) Second, the SO3 can react with the Claus catalyst surface to
form sulfate salts that deactivate the catalyst. Third, the SO3 can
condense on and corrode the cooler surfaces in the unit very rapidly
during upset periods. Fourth, the SO3 absorbs in the sulfur product and
causes it to be corrosive.
As these problems were diagnosed and studied, Amoco and others

discovered and demonstrated that the ammonia could be successfully
destroyed in a Claus SRU by thermal decomposition in a reducing
atmosphere. This process change essentially eliminated the formation of
SO3 in the unit. Amoco found that large quantities of ammonia could be
destroyed in a reducing atmosphere at elevated temperatures, and
obtained patents covering this mode of operation in 1973. As Amoco
licensees, our SRUs are designed for reducing-atmosphere ammonia
destruction in a two-zone reactor furnace, with careful attention to
controlling the front zone temperature at or above 1370°C to ensure near
complete ammonia destruction.
Surprisingly, though, we have found that our clients do not always operate
our SRUs in strict accordance with the published operating procedures
regarding such matters as minimum furnace temperature, feedstock
ratios, etc. In fact, some of our clients have operated their SRUs on just
sour water stripper off-gas for days at a time because of operating
problems in the amine unit. Although there was undoubtedly ammonia
escaping from the furnace when operated in this manner, there has never
been any plugging with salts during this time.
This has led us to conclude that avoiding SO3 formation, not complete
ammonia destruction, is the critical element in the reliability of our
reducing-mode SRUs. If you examine the melting points of the various
salts that can result from ammonia and the sulfur compounds that might
be found in a sulfur plant, only ammonium sulfate, (NH4)2SO4, has a
melting point that is higher than the freezing point of sulfur. Since all of
the surfaces in a sulfur plant must be maintained above the sulfur freezing
point, none of the other salts can precipitate under normal operating
temperatures. Thus, as long as the furnace is operated in a reducing
atmosphere so that there is no SO3 to combine with water and the

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residual ammonia to form ammonium sulfate, salt precipitation should not

occur in the SRU.
Since these SRUs are followed by an amine-based tailgas cleanup unit,

though, there will be cooler pieces of equipment downstream of the SRU.
However, the first cool section is the quench water system in the TGCU,
which will easily scrub the ammonia from the gas streams since ammonia
dissolves readily in water. Because this serves to raise the pH of the
quench water and counteract the drop in pH as H2S, CO2, and trace
quantities of SO2 dissolve in the water, this ammonia is actually beneficial
to the process. Depending on the amount of ammonia in the gas, some
may escape from a quench tower and dissolve in the downstream amine
solution, but periodically purging a small amount of water from the stripper
reflux system will prevent the ammonia from concentrating enough to
cause salt problems.

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9.6.10 Sulfur Recovery Efficiency

The sulfur recovery efficiency of an SRU depends on a number of factors.
These sulfur plants are designed to achieve an average sulfur recovery of
at least 94-96%, but should be capable of recoveries somewhat higher
than this. Operator attention to the following aspects of sulfur plant
operation will ensure consistently good recovery levels in these SRUs.
9.6.10.1 H2S:SO2 Ratio

Maximum sulfur recovery is obtained when the H2S to SO2 ratio in
the process gas upstream of the first catalyst bed is exactly 2:1. It is
virtually impossible to maintain this exact ratio, but efforts should be
made to control near 0% air demand on the air demand analyzer.
For instance, the changing air temperature and relative humidity
between day and night will cause some variation in the air flow rate,
resulting in variations in percent air demand (a function of the
H2S:SO2 ratio).
The air demand analyzer will continuously analyze the process gas
and calculate the percent air demand, allowing the air demand
controller to automatically trim the air:acid gas ratio to stay close to a
2:1 H2S:SO2 ratio. If the analyzer is out of service or needs to be
checked, the procedures in Section 9.10 of these guidelines can be
used to manually sample the process gas and determine the
H2S:SO2 ratio, so that the appropriate change can be made to the
air:acid gas ratio.
9.6.10.2 Reactor Feed Temperatures

The optimum feed temperature to a Claus reactor is a complex
function of several factors, which often have conflicting effects on
overall sulfur recovery. Some general guidelines used by sulfur plant
designers are:
(1) Catalytic conversion is favored by lower operating

temperatures.
(2) Hydrolysis (conversion) of organic sulfur compounds (such as

COS and CS2, which are formed by side reactions in the
Reactor Furnace) back into H2S is favored by higher operating
temperatures.

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(3) Liquid sulfur will be adsorbed in the catalyst pores (rendering

the catalyst temporarily inactive) if the reactor operating
temperature is too close to the sulfur dewpoint.
These factors were carefully considered when these SRUs were

designed and the temperatures shown on the process flow diagram
were chosen, but provisions have been included to control and/or
change these temperatures. If desired, the optimum reactor feed
temperatures can be determined for the actual operating conditions
by making changes and observing whether the amount of sulfur in
the tailgas goes up or down. The H2S and SO2 concentrations in the
SRU tailgas indicated by the air demand analyzer for the SRU in
question will give a direct indication of whether the sulfur recovery
has improved (i.e., a lower total concentration for the two) or suffered
(i.e., a higher total concentration for the two) when a change is
made.
The sulfur recovery is affected by the catalyst bed feed

temperatures. Maximum sulfur recovery is usually obtained when
the catalyst bed inlet temperatures are controlled at the lowest level
that will allow the reaction to continue. The feed temperatures must
be sufficiently high to prevent catalyst deactivation due to
condensation and deposition of liquid sulfur on the catalyst. The
catalyst bed feed temperatures should be controlled at 230°C or
higher during startup periods, and during other periods of upset or
unusual operating conditions. Calculations indicate that catalyst bed
feed temperatures may be reduced to 200-210°C or slightly lower
during periods of stable operation without causing problems,
particularly in the second and third catalyst beds.
However, lowering the feed temperature to the first catalyst bed may
not increase recovery, due to lower hydrolysis of organic sulfur
compounds in this catalyst bed. Calculations indicate that the
optimum sulfur recovery for these SRUs is obtained then the first
catalyst bed is operated at high temperature, due to the higher
conversion of the organic sulfur compounds to H2S, which is
subsequently recovered in the downstream catalyst beds. As shown
on the Process Flow Diagram, the feed temperature to the first
catalyst bed will normally be around 225-235°C. Operating
experience will show whether lower reactor outlet temperatures still

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give satisfactory performance with the catalyst used in this catalyst

bed.

Generally speaking, most sulfur plants can operate down to about 20-25%
of design throughput without much loss in recovery efficiency and without
requiring much operator attention. This is often referred to as the
turndown range or turndown ratio of the plant. Turndown to 20-25% of
design rate corresponds to a turndown ratio of 5:1 to 4:1. When an SRU
must operate at rates lower than 20-25% of design, there are several
operating problems that often occur. These problems, and ways to solve
them, are discussed below.
9.6.11.1 Loss of Sulfur Recovery Efficiency

The H2S:SO2 ratio in the process gas is the single factor that most
affects sulfur recovery. This ratio is a function of the air:acid gas flow
ratio. At low flow rates, the flow meters on the amine acid gas, SWS
gas, and process air become less accurate, due to the low
differential pressures the flow transmitters must measure. This loss
of accuracy in measuring the flows to the SRU reduces the
effectiveness of the feed-forward part of the air ratio control loop,
requiring the feed-back part of the loop (the Air Demand Analyzer) to
make bigger corrections to try to keep the H2S:SO2 ratio at 2:1. The
result is a loss in recovery because the H2S:SO2 ratio oscillates more
widely from the optimum 2:1 ratio.
This poor sulfur recovery performance due to flow meter limitations

can be corrected by adjusting the flow meters for the lower rates.
Depending on the particular circumstances, this can be
accomplished in a number of ways:
(4) If the SRU must operate at low flow rates permanently, or for
long periods of time, installing new orifice plates with smaller
bores may be an attractive solution. This will increase the
differential pressures measured by the meters to put the flow
transmitters back into good operating ranges. The
disadvantages of this technique are that a plant shutdown is
required to make the change, and that the plant cannot operate
at high flow rates again without changing orifice plates.

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(5) If the SRU must operate at low flow rates temporarily,

re-calibrating the flow transmitters to span lower differential
pressure ranges may be a better method since this change can
be made while the plant is running. In fact, with "smart"
transmitters and the required I/O modules in the DCS, this
change can be made from the control room.
(6) If the SRU must operate at variable flow rates, using dual flow
transmitters calibrated for low and high differentials can provide
accurate flow measurement over a much wider range. With
proper programming in the DCS, the dual transmitters allow
"seamless" metering of the flow.
9.6.11.2 Deactivation of Catalyst Beds by Sulfur "Fog"

As a sulfur condenser is operated at lower and lower rates, it
reaches a point where the bulk gas cooling rate caused by radiation
and conduction heat transfer exceeds the dewpoint reduction rate
caused by sulfur condensation on the tube walls. Instead of
condensing along the walls of the tubes, sulfur begins to condense
into tiny droplets out in the gas. Due to the low flow rates, there is
not enough turbulence in the gas to make the droplets coalesce
along the tube walls. The droplets come out of the tubes as a "fog"
that cannot be removed in the downstream separator section, and
are carried over into the reactor feed heaters.
The feed heaters cannot vaporize all of the carry-over liquid sulfur,
probably because the small surface area of the droplets (relative to
their volume) causes slow mass transfer of vaporized sulfur away
from the droplets that impedes heat transfer. This causes the liquid
sulfur droplets to enter the reactor catalyst beds. The liquid sulfur is
then adsorbed into the pores of the catalyst where it blocks the active
sites, rendering the catalyst inactive. The catalyst activity can be
restored by raising the reactor feed temperature and vaporizing the
liquid sulfur out of the pores, but this can be very hard to do when the
condensers are carrying over liquid sulfur.
The symptom of sulfur carry-over into the catalyst beds is a gradual

decline in the temperature rises across the beds. Since the Claus
reaction is exothermic (heat releasing), the catalyst bed T is a direct
indication of the amount of reaction occurring. As the liquid sulfur

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deactivates the catalyst, there will a gradual decrease in the reactor

bed temperatures, starting at the top and moving downward.
Experience has shown that when the condenser passes begin to fog,
the liquid sulfur will accumulate in the outlet channels of the heating
passes in this style of sulfur plant. Due to the arrangement of these
"package" sulfur plants, the heating pass outlet channels are low
spots in the flow paths from the condenser outlets to the reactor
inlets. It is believed that as the gas flowing out of the heating pass
tubes turns 90° to exit through the channel outlet nozzles, centrifugal
force causes the sulfur droplets to impinge upon the endplates of the
channels with enough force to make the small droplets coalesce into
droplets too large to leave with the gas. Over a period of time, sulfur
will accumulate to the point where it begins to cause fluctuations in
the operating pressure of the affected SRU. The pressure drop will
build up enough to "lift" some of the sulfur into the downstream
catalyst bed, at which point the pressure drop will immediately
become much lower.
These SRUs have been designed to take advantage of this

phenomenon and drain the liquid sulfur out of the reheat passes
before it builds up enough to cause pressure drop problems and be
carried into the Reactor. Each heating pass outlet channel has a
steam-jacketed sulfur drain valve on it. The drain valves are
connected together in a steam-jacketed line that is connected to the
cooling pass outlet line. At low flow rates, the pressure drop through
an SRU is very low, so the static head of the accumulated liquid
sulfur is enough to cause the sulfur to drain into the cooling pass
outlet line, where it can flow into the first condensing pass and then
drain into the Sulfur Collection Header.
If sulfur carry-over is suspected (due to a gradual decline in Reactor

bed temperatures or because of SRU pressure fluctuations), these
drain valves can be used to drain sulfur from the heating passes by
opening them periodically to allow the sulfur to drain. Open each
drain valve, one at a time, for one or two minutes, then close the
valve. Do this every 4 to 8 hours, using the Reactor bed
temperatures as an indication of whether to use the drains more or
less frequently. Do not leave the drain valves open. Once the
sulfur has drained out of the heating pass channels, hot gas from the
cooling pass outlet will flow back up the drain line and disturb the

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operation of the downstream catalyst beds if the drain valves are left
open.
9.6.11.3 Loss of Steam Pressure in Boilers

The heat released in the tubes of the Waste Heat Boiler is
proportional to the amount of feed gas processed. At very low flow
rates, generally less than 10% of the original design, the heat loss to
the surroundings can be more than this heat release, to the point
where the Waste Heat Boiler is no longer producing steam. When
this happens, the reheat exchangers will not be able to keep the
reactor feeds as hot as desired and liquid sulfur can begin to
condense on the catalyst beds and render the catalyst inactive.
The heat release in the Waste Heat Boiler can be increased by

burning supplemental fuel gas on the warmup ring of the Acid Gas
Burner. This burner is designed to burn fuel gas without forming soot
while processing acid gas. The warmup burner tips are installed in
the air plenum of the burner upstream of the acid gas tip so that the
fuel gas burns in an air-rich atmosphere, and the oxygen remaining
after combusting the fuel gas then reacts with the acid gas.
To make firing supplemental fuel gas easier, the air flow control
system is designed to automatically add air for the fuel gas like it does
for the acid gas. The air:acid gas ratio control system will
automatically add more process air for the fuel gas when firing
supplemental fuel gas. The air demand analyzer in the SRU will
continue to keep the air flow at the proper rate via the air controller.
Since the supplemental fuel gas requires an increase in the process

air flow to the sulfur plant, burning supplemental fuel gas will also
increase the mass flow rate through that plant. As a result, this
mode of operation can be used to help prevent sulfur "fog" problems
discussed earlier from occurring in a Sulfur Condenser. If the plant
throughput is near the range at which fogging occurs, firing some
supplemental fuel gas may be enough to avoid the problem.
9.6.11.4 Long Term Low-Flow Operation

Should the need arise for an SRU to operate at inlet rates below
15 to 20% for extended periods of time, consideration may be given
to plugging some of the condensing pass tubes in the Sulfur
Condenser. This will increase the flow rates through the remaining

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tubes so that they are then above the "fog" formation rate and sulfur
carry-over is eliminated. Soft iron plugs can be inserted into the inlet
ends of the tubes for this purpose. (Do not plug the outlet ends of
the tubes. Since the boiler slopes from its inlet end to its outlet end,
liquid sulfur would accumulate in the tubes and could cause localized
corrosion, plugging, etc.)
9.6.12 Pressure Drop Surveys

A commonly encountered problem in sulfur plants (and Tailgas Cleanup
Units and Thermal Oxidizers) is a flow restriction due to high pressure
drop. High pressure drop is typically caused by a restriction at one point
in the equipment or piping, due to:
5. Accumulation of liquid (sulfur, etc.) in equipment or piping
6. Partial plugging of a catalyst bed (soot, carbon, polymers, etc.)
7. Partial plugging of a mist eliminator (sulfur, soot, catalyst, etc.)
The first step in identifying the cause of the high pressure drop is to
determine which equipment pass or section of piping contains the
restriction. (It is unusual to have more than one area of high pressure
drop at any one time.) This is best accomplished by making a pressure
survey of the process side of the SRU (and Tailgas Cleanup Unit and
Thermal Oxidizer, if necessary).
Due to the low operating pressure in a sulfur plant (generally

0.7 kg/cm2(g) or less) and the low pressure drop in each equipment pass
(generally 0.00-0.04 bar per pass), a single pressure gauge must be used
to make the pressure survey in order to get meaningful results. The
gauge should be a low-pressure gauge for best results (a -1 – 0 –
+1.5 kg/cm2 gauge is recommended).
Beginning at the front end of the sulfur plant of interest, use the pressure
tap valves on the inlet and outlet lines from each equipment pass to
measure the pressure at each point in the process. Proceed toward the
back end of the process until the pass with the high pressure drop is
found. Note that some of the pressure tap valves may be plugged with
solid sulfur. Rod-out the sample valves as necessary to obtain an
accurate pressure reading.

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WARNING

WHEN USING THE PRESSURE TAP VALVES, PARTICULARLY IF
THE VALVES ARE PLUGGED AND MUST BE CLEARED.
ALTHOUGH THE VALVES ARE ORIENTED TO MINIMIZE THE
POSSIBILITY OF FILLING WITH MOLTEN SULFUR, HOT SULFUR
MAY SUDDENLY BE EXPELLED FROM A VALVE WHEN THE PLUG
IS CLEARED. RELEASE OF TOXIC GASES (H2S AND SO2, IN
PARTICULAR) IS ALSO A POSSIBILITY. THE "GENERAL SAFETY"
H2S, SO2, OR MOLTEN SULFUR MAY BE PRESENT.
When troubleshooting problems of this nature, it is very helpful to have

pressure survey information taken previously when the units were
operating properly. It is recommended that one or more pressure surveys
be performed early in the operating life of the plants, for comparison
purposes later if problems are encountered. Since the pressure drop of a
sulfur plant is a function of plant throughput (pressure drop is roughly
proportional to the square of the flow rate), it is even more helpful for
troubleshooting purposes if the early pressure surveys are performed at
different plant throughput rates. It is also important to record the gas flow
rates (amine acid gas, SWS gas, process air) during each pressure
survey, since pressure drop depends so strongly on plant throughput.

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9.6.13 Boiler Water Treatment
SAMSUNG TOTAL PETROCHEMICALS CO., LTD. IS

RESPONSIBLE FOR ESTABLISHING AND MONITORING THE
BOILER AND WATER CHEMICAL TREATMENT PROGRAM.
Proper boiler water chemical treatment is essential to achieving long

service life for the Waste Heat Boilers and Sulfur Condensers. Without
good day-to-day control of the water quality, solids buildup, corrosion, and
attack by the treating chemicals themselves can occur. It is Samsung
Total Petrochemicals Co., Ltd.’s responsibility to see that a proper
chemical treating program is initiated prior to startup and that the program
is properly monitored and refined throughout the service life of the plant.
There are many qualified boiler and water treatment companies that can
advise the owner/operator on chemical treatment testing and controls. It
is recommended that only those companies that have local technicians
with extensive experience specifically in boiler water treatment be
selected to assist with Samsung Total Petrochemicals Co., Ltd.’s program.
The design details incorporated in the boilers in these SRUs have proven
to be very reliable when combined with good operator practice regarding
water treatment. However, even properly designed equipment can be
severely damaged during a short period of operation if the water treatment
program is inadequate or improper.
The Waste Heat Boilers and the Sulfur Condensers are equipped with
continuous blowdowns to remove suspended and dissolved solids from
the water inside the boilers. In addition, these boilers are equipped with
intermittent blowdown connections on the bottom of their shells. These
intermittent blowdown valves should be used on a regular basis to give
the boilers a good "blow" to prevent sludge from accumulating in the
bottom of the shells. This is particularly important for the Waste Heat
Boiler because sludge must not be allowed to coat the tubes. The
consequence of fouling the outside of the tubes is tube failure from
overheating, as the fouling will impair the heat transfer and allow the hot
combustion gases to destroy the tubes.
Prior to using the intermittent blowdown valves, use the level controllers in
the DCS to raise the water level up to the high level alarm point. Then
open the intermittent blowdown valves, one at a time, until the level drops

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back to the normal liquid level. Watch the boiler level in the sight glasses
throughout this operation to ensure that the level is not lost (which would
activate the SRU ESD and shut down that plant). Remember to reset the
level controllers at the conclusion of this procedure.

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A. Check all equipment to ensure that it is properly installed. This will
probably require consulting the Manufacturer's literature as well as
B. Check and lubricate all equipment in accordance with the

C. Check the rotation of the Process Air Blowers, the Acid Gas
Knock-Out Drum Pumps, and the SWS Gas Knock-Out Drum
Pumps:
(1) Operate each Process Air Blower for a short period

(20 seconds or less) with its discharge valve closed.
(2) "Bump" each Acid Gas Knock-Out Drum Pump and check for
proper rotation.
(3) "Bump" each SWS Gas Knock-Out Drum Pump and check for
proper rotation.

F. Turn on the steam supplies to all of the steam-jacketed sulfur vapor

valves and use the vent valves on each jacket section to vent the air
from the jackets. "Stroke" each valve to confirm it moves freely.

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G. Fill the Waste Heat Boilers and the Sulfur Condensers with treated
boiler feed water up to the high-level alarm points. As the level is
rising, check the level transmitters and the high level alarms for
proper operation.
H. Use the quick-opening blowdown valves to lower the water levels in

the boilers and check for proper operation of the level transmitters,
the low level alarms, and the low-low level shutdowns.
I. Fill the boilers with treated boiler feed water back up to the normal
liquid levels.
J. Physically check all shutdown activating devices to ensure that they

activate the SRU ESD system.
K. Physically check all devices activated by the SRU ESD system to

ensure that they operate properly.
L. Check all relief valves to ensure that they are installed in the proper

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CAUTION
THE LOW PRESSURE PROCESS PIPING (ACID GAS, SULFUR

VAPOR, PROCESS AIR) AND LOW PRESSURE PROCESS
EQUIPMENT IN THESE SRUS ARE NOT DESIGNED TO BE FILLED
WITH WATER AFTER INSTALLATION OF REFRACTORY AND
CATALYST. ONLY THE EQUIPMENT AND PIPING UPSTREAM OF
AMINE ACID GAS AND SWS GAS SHUTDOWN VALVES CAN BE
FILLED WITH WATER AND HYDROTESTED. USE THE
FOLLOWING PROCEDURE TO LEAK-TEST THE REST OF THE
SRUS.
The process piping and equipment in each SRU can be checked for leaks
by using a Process Air Blower to pressurize the process side of the
equipment and piping to about 0.6-0.7 kg/cm2(g), then checking flanges,
etc. for leaks (usually by applying masking tape or "Snoop" to the flanges,
and by listening for other leaks). In order to develop this pressure, the
blower can be operated with the tailgas block valves and the warmup
bypass valves in the SRU closed, and the blow-off valve on the blower
"pinched". This procedure requires some special preparations to operate
the blower in this manner, as detailed below.
The Complete Flowpath Interlock must be temporarily disabled in order to

operate the SRU in this manner. The Leak Test switch on each local SRU
control panel is used to position the process gas valves as described
above and also directs the PLC to bypass most of the unit shutdowns.
This means that "jumpers" on the limits switches and "forces" in the PLC
are not necessary to perform this test. It also means that it is not
necessary to have water in the boilers (Waste Heat Boiler and Sulfur
Condenser) during the test since the low-low water level S/Ds are also
bypassed.
This same procedure can be used to leak test each SRU before restarting
it following maintenance. Whenever plant maintenance requires opening
one or more of the flanged connections in an SRU, it is good practice to
leak test that SRU before returning it to service. This allows detecting any

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leaking connections that may have resulted from the maintenance

operations before acid gas is reintroduced into that unit. Although the
SRU is pressurized with air to perform the leak test, there is no air flow
through the units during the testing procedure so there is very little
jeopardy of having sulfur fires in the catalyst beds.
Note that the SRU warmup bypass line is not leak tested during this
procedure. This line can be checked for leaks using the nitrogen purge on
the piping as described in a later section of these guidelines.
To perform leak testing in the SRU, proceed as follows:
M. Switch the process air flow hand switch in the DCS to "local" to give
control of the valves on the air blower to the air flow controller (HIC)
on the local SRU control panel.
N. Confirm that the Reactor Cool-Down switch on the local SRU control
panel is set to "NORMAL".
O. Confirm that the manual block valve in the SRU Tailgas line is open.
P. Switch the Startup/Run selector switch on the local SRU control

panel to "STARTUP".
The PLC and DCS should perform the following actions:
(1) The two Warmup Bypass Valves are opened.
(2) The nitrogen purge valve between the warmup bypass valves is
closed.
(3) The Tailgas Valve to the Thermal Oxidizer is closed.
(4) The Tailgas Valve to the TGCU is closed.
Confirm that the "WARMUP OPEN" light on the panel is illuminated, and
that the "TTO OPEN" and the "TGCU OPEN" lights on the panel are
extinguished.

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Q. Turn the Leak Test key switch on the local SRU control panel to
"TEST".
The PLC should perform the following actions:
(1) The two Warmup Bypass Valves are closed.
(2) The nitrogen purge valve is opened.
(3) All of the ESDs for that SRU are bypassed, except for the
high-high furnace pressure S/D and the manual S/D switches.
Confirm that the "WARMUP OPEN" light on the local SRU control panel
is now extinguished.
R. Set the air flow controller on the local SRU control panel to 0%
output and confirm that the suction, discharge, and blow-off valves
on the air blowers are fully closed.
S. Start a Process Air Blower:
(1) Press the local "permit to start" push-button for the selected
blower.
(2) Start the blower using its local start/stop control station.
The blower suction valve will open 33%, its vent valve will open, and
its discharge valve will remain closed when the "permit to start"
push-button is pressed. Once the blower is started and comes up to
speed, a flow of air will be established out of the blow-off valve and
its silencer.
T. Use the local air flow controller as needed to open the discharge
valve on the blower and send air to the SRU to begin pressurizing it.
Although the blower discharge valve will begin to open as the output
from the controller is increased, air will not flow through the sulfur
plant once pressure builds because the warmup bypass valves and
the tailgas valves are all closed.
At this point, two operators will be necessary to control and monitor the
Process Air Blower. One operator should be stationed at the local SRU
control panel, and one stationed near the blower area.

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CAUTION
DO NOT LET THE AIR BLOWER GO INTO SURGE. THE

OPERATOR STATIONED NEAR THE BLOWER SHOULD LOOK
AND LISTEN FOR INDICATIONS OF SURGE. IF SURGE IS
DETECTED, REDUCE THE OUTPUT ON THE AIR FLOW
CONTROLLER TO OPEN THE BLOW-OFF VALVE MORE AND
INCREASE THE AIR FLOW ENOUGH TO BRING THE BLOWER
OUT OF SURGE. IT MAY NOT BE POSSIBLE TO RAISE THE
DISCHARGE PRESSURE ALL THE WAY TO 0.6-0.7 KG/CM2(G)
WITHOUT CAUSING THE BLOWER TO SURGE.
U. Slowly increase the output from air flow controller to "pinch" the
blow-off valve on the air blower until the discharge pressure from the
blower reaches 0.6-0.7 kg/cm2(g) as measured by the pressure
gauge on the process air line to the burner.
Due to the volume inside the SRU, it will take several minutes for the
pressure to build up in the SRU.
V. Once the desired discharge pressure has been achieved, and the
blower is operating stably, check all of the equipment and piping
connections for visible or audible signs of leakage. Continue to
monitor the air blower to be sure it is operating stably.
NOTE: Do not allow the pressure to reach the high-high pressure

S/D, since this shutdown is still active and will activate the
SRU ESD system if this happens.
W. After the leak test has been completed, press the ESD push-button
on the local SRU control panel to activate the SRU ESD system and
shut down the air blower.
X. Turn the Leak Test switch on the local SRU control panel to
"NORMAL".
(2) The nitrogen purge valve is closed.

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(3) All of the ESDs for the SRU are enabled again.
Confirm that the "WARMUP OPEN" light on the local SRU control panel
is now illuminated.
Y. Confirm the following:
(1) The air blower is shut down, and its suction, discharge, and
blow-off valves are closed.
(2) The two Warmup Bypass Valves are both open.
(3) The Tailgas Valve to the Thermal Oxidizer and the Tailgas
Valve to the TGCU are both closed.

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9.7.4 Purging the Inlet Knock-Out Drums

Since inert nitrogen gas is available in the SRU area, it can be used to
purge the Acid Gas Knock-Out Drum and the SWS Gas Knock-Out Drum
prior to removing the blinds in their inlet lines. One procedure for doing so
is as follows.
WARNING
UNTIL THE AIR IS PURGED FROM THE KNOCK-OUT DRUMS,

THERE MAY BE FLAMMABLE GAS MIXTURES PRESENT IN THE
VESSELS AND THEIR PIPING. ENSURE THAT ALL IGNITION
SOURCES, INTERNAL AND EXTERNAL TO THE VESSELS, HAVE
BEEN REMOVED BEFORE PROCEEDING.
A. Verify that the blinds are in place in the inlet amine acid gas line and
the inlet SWS gas line. Do not attempt this procedure if these lines
are not blinded from their respective acid gas sources.
B. The sulfur plant downstream of the drums does not need to be

purged with nitrogen. Verify that the amine acid gas and SWS gas
flow controllers on the local SRU panel are set to 0% output and that
the inlet amine acid gas valve and the inlet SWS gas valve are
closed.
C. Open the suction valve and close the discharge valve on each Acid
Gas Knock-Out Drum Pump.
D. Open all of the vent and drain valves on the level and pressure
instruments on the Acid Gas Knock-Out Drum and each Acid Gas
Knock-Out Drum Pump, and the vent and drain valves on each Acid
Gas Knock-Out Drum Pump.
E. Remove the blind from the drain valve on the pump suction line and
use a hose or other means to temporarily connect nitrogen to the
valve. Commence the flow of nitrogen into the Acid Gas Knock-Out
Drum and each Acid Gas Knock-Out Drum Pump, so that nitrogen is
flowing out of all of the open valves. Be sure to include the acid gas
inlet line from the Amine Regeneration Unit.

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F. 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.
G. When the oxygen concentration is below 1%, begin closing the vent
and drain valves. Close the valves on each Acid Gas Knock-Out
Drum Pump first, then the valves on the Acid Gas Knock-Out Drum
level instruments. Leave the sample connection valve open on the
outlet line from the Acid Gas Knock-Out Drum.
H. Close the valve where the nitrogen hose is connected to stop the
flow of nitrogen, then close the sample connection valve.
I. Repeat Steps C through H for the SWS Gas Knock-Out Drum and
the SWS Gas Knock-Out Drum Pump. The sample connection valve
on the outlet line from the SWS Knock-Out Drum should be the last
valve closed, after stopping the flow of nitrogen.
Leave each system blocked-in like this until ready to bring acid gas into
the SRU.

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9.7.5 Commissioning Fuel Gas and Instrument Air to the Process

The fuel gas and instrument air supplies to the process side of an SRU
must be made ready for use prior to starting up the SRU using the
procedures in Section 9.8 of these guidelines. This requires blowing down
each section of piping to ensure that there are no liquids and/or
construction debris in the headers and supply lines. The procedure below
can be used to make sure that these gas utility systems are ready for
service.
A. Select local manual control for the main fuel gas control valve by
switching the fuel gas hand switch in the DCS to "local".
B. Set the fuel gas controller on the local SRU control panel to 0%
output.
C. Confirm that the following fuel gas and instrument air valves are
closed:
(7) The manual block valve in the main fuel gas supply line.
(8) The two automated block valves and the flow control valve
downstream of the manual block valve in the main fuel gas line
to the Acid Gas Burner.
(9) The upstream manual block valve, the two automated block
valves, and the downstream manual block valve in the fuel gas
supply line to the pilot.
(10) The manual block valve(s), and the automated block valve in
the air supply line to the pilot.
(11) The manual block valve in the instrument air supply line to the
Air Demand Analyzer.
(12) The block valves in the instrument air supplies to the level
transmitters, on the Sulfur Surge Tank.
D. Confirm that all of the manual vent/drain valves in the main fuel gas,
pilot fuel gas, and pilot air piping are closed.
E. If the orifice plate has already been installed in the fuel gas flow
meter remove it for now.
F. Disconnect the fuel gas and instrument air from the burner systems
by performing the following steps:

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(1) Unbolt the flanged connection at the burner in the main fuel gas
supply line.
(2) Disconnect the fuel gas supply tubing where it connects to the
pilot.
(3) Disconnect the instrument air supply tubing where it connects to

the pilot.
(4) Cover the open ends of these connections on the burner and
pilot to prevent debris from entering when the upstream piping
is blown down.
G. Remove the following pressure regulators, then cover the

downstream piping to prevent debris from entering when the
upstream piping is blown down:
(1) The main fuel gas supply regulator.
(2) The pilot instrument air supply regulator.
(3) The pilot fuel gas supply regulator.
H. "Force" the PLC to open the following valves:
(1) The automated block valves in the main fuel gas supply line.
(2) The automated block valves in the fuel gas supply line to the
pilot.
(3) The automated block valve in the instrument air supply line to
the pilot.
I. Confirm that these automated valves have moved to the proper

positions.
J. "Crack" the manual block valve in the main fuel gas supply line and
allow fuel gas to blow through the piping until it is clear. Then close
the gate valve, reinstall the main fuel gas pressure regulator, and
K. Using the pressure gauge and the vent valve downstream of the
main fuel gas pressure regulator, adjust the main fuel gas regulator
to its specified setpoint.
L. Use the main fuel gas flow controller on the local control panel to
fully open the fuel gas flow control valve in the main fuel gas line,

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then use the downstream vent valve to blow out this section of
piping. Close the vent valve when the piping is clear.
M. "Crack" the manual block valve downstream of the fuel gas flow
control valve and allow fuel gas to blow through the piping until it is
clear. Then close the manual block valve and the control valve.
N. "Crack" the upstream manual block valve in the fuel gas supply line
to the pilot and allow fuel gas to blow through the piping until it is
clear. Then close the ball valve, reinstall the pilot fuel gas pressure
regulator and reopen the block valve.
O. Using the pressure gauge and the vent valve downstream of the pilot
fuel gas pressure regulator, adjust the pilot fuel gas regulator to its
specified setpoint.
P. "Crack" the manual block valve downstream of pilot fuel gas

automated block valves and allow fuel gas to blow through the piping
until it is clear. Then close the manual block valve.
Q. "Crack" the upstream manual block valve in the instrument air supply
line to blow air through the piping until it is clear. Then close the
block valve, reinstall pressure regulator the instrument air pressure
regulator and reopen the block valves.
R. Using the pressure gauge and the vent valve downstream of the
instrument air pressure regulator, adjust the pilot instrument air
regulator to its specified setpoint.
S. "Crack" the manual block valve downstream of automated instrument

air block valve and allow instrument air to blow through the piping
until it is clear. Then close the manual block valve.
T. Disconnect the air supply line at the Air Demand Analyzer, cover the
open end of the downstream piping, and "crack" the manual block
valve to blow air through the piping until it is clear. Then close the
manual block valve, reconnect the piping, and reopen the block
valve.
U. Disconnect the upstream fitting in the air supply to purge the

rotameter for the bubbler-type level transmitter on the Sulfur Surge
Tank, then open the block valve in the air supply line briefly to blow
any liquids or debris from the purge line. Reconnect the FI,
disconnect the fitting where the purge enters the bubbler tube, and

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cover the opening. Open the block valve briefly to blow any liquids
or debris from the purge line, then reconnect the purge to the bubbler
tube. Reopen the block valve and adjust the FI to a small air flow
(0.8-1.6 Nm3/Hr). Place the other level transmitters in service in the
same manner.
V. Remove the "forces" from the PLC and confirm that all of the
automated block valves close and all of the automated vent valves
open.
W. Close the manual block valve in the main fuel gas supply line and the
manual block valve in the instrument air line supply until the SRU is
ready for startup.
X. Reconnect the fuel gas and instrument air to the burner systems by
performing the following steps:
(1) Bolt the flanged connection at the burner in the main fuel gas
supply line back together.
(2) Reinstall the fuel gas supply tubing where it connects to the
pilot.
(3) Reinstall the instrument air supply tubing where it connects to

the pilot.
(4) Reinstall the orifice plate in the fuel gas flow meter.

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9.7.6 Commissioning Nitrogen to the Process

The nitrogen supplies to the process side of each SRU must be made
ready for use prior to starting up the SRUs using the procedures in
Section 9.8 of this manual. This requires blowing down each section of
piping to ensure that there are no liquids and/or construction debris in the
headers and supply lines. The procedure below can be used to make
sure that this gas utility system is ready for service.
A. Confirm that the following nitrogen valves are closed:
(1) The manual block valves in the N2 purge line to the bypass acid
gas injection nozzles on the Reactor Furnace.
(2) The ball valves in the purge lines to the burner instruments.
(3) The block valves in the purge lines to the optical pyrometer.
(4) The gate valves in the nitrogen supply lines located near the
Reactor and the nitrogen supply line located near the Acid Gas
Burner.
(5) The ball valves in the purge lines to the SWS gas flow
transmitter and pressure gauge.
(6) The gate valve in the nitrogen supply line to the Air Demand
Analyzer.
(7) The gate valve upstream and the ball valve downstream of the
rotometer in the purge line on the SRU warmup bypass line.
B. Confirm that the H.P. nitrogen and L.P. nitrogen supply headers have
been placed in service, with the pressure regulator(s) set at the
values specified on the P&IDs and safety relief valves in service, and
that the main supply header piping has been blown down and
drained.
C. Open the gate valve in each of the three nitrogen supply lines
located near the Reactor and the nitrogen supply line near the Acid
Gas Burner until each line is clear.
D. Remove pressure regulator in the purge line for the optical pyrometer
viewport and nozzle, cover the open end of the downstream piping,
open the gate valve, and "crack" the ball valve in the supply line to
blow nitrogen through the piping until it is clear. Then close the gate
valve and the ball valve and reinstall the regulator.

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E. Disconnect the purge tubing from the viewports on the optical

pyrometer and cover the opening.
F. Open the gate valve and the ball valve in the nitrogen supply. Using
the pressure gauge, adjust the regulator to its specified setpoint.
Allow nitrogen to blow through the tubing until it is clear. Reinstall
the purge tubing to the pyrometer. Leave the gate valve and the ball
valve in the supply line open.
G. Remove the plug and use the drain valve at the end of the supply
line to the purges for the burner instruments to blow out this section
of piping until it is clear, then close the drain valve and reinstall the
plug.
H. Each of the low pressure purges for the burner instruments and for
the bypass acid gas nozzles has a rotameter (FI) near where it
connects to the process. Disconnect the upstream fitting at each FI
and cover the opening, then open its upstream ball valve briefly to
blow any liquids or debris from the purge line. Reconnect each FI,
disconnect the fitting where each purge enters the process and cover
the opening, open its upstream ball valve, then open its downstream
valve briefly to blow any liquids or debris from the purge line. Then
reconnect each purge to the process and open its downstream valve
to place it in service.
I. The SWS gas flow transmitter has low pressure purges for both of its
sensing lines, each with a rotameter near where it connects to the
sensing line. Disconnect the upstream fitting at each FI and cover
the opening, then open its upstream ball valve briefly to blow any
liquids or debris from the purge line. Reconnect each FI, disconnect
the fitting where each purge connects to the sensing line and cover
the opening, open its upstream ball valve, then open its downstream
ball valve briefly to blow any liquids or debris from the purge line.
Then reconnect each purge to the sensing line and open its
downstream ball valve to place it in service.
NOTE: The two rotameters must be adjusted to the same flow rate
so that the pressure drop of the purge gas in the sensing
lines does not affect the reading of the flow transmitter.
One way to do this is to confirm that the equalizing valve on
the flow transmitter manifold is closed, set the rotameter on
the upstream sensing line to a small flow rate

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(~0.8-1.6 Nm3/Hr), and then adjust the flow rate of the other
rotameter until the flow meter reads zero.
J. The SWS gas pressure gauge also has a low pressure purge for its
sensing line with a rotameter near where it connects to the sensing
line. Disconnect the upstream fitting at the FI and cover the opening,
then open its upstream ball valve briefly to blow any liquids or debris
from the purge line. Reconnect the FI, disconnect the fitting where
the purge connects to the sensing line and cover the opening, open
its upstream ball valve, then open its downstream ball valve briefly to
blow any liquids or debris from the purge line. Then reconnect the
purge to the sensing line and open its downstream ball valve to place
it in service.
K. Disconnect the nitrogen supply line at the Air Demand Analyzer,

cover the open end of the downstream piping, and "crack" the gate
valve to blow nitrogen through the piping until it is clear. Then close
the gate valve, reconnect the piping, and reopen the gate valve.
L. If necessary, "force" the PLC to close the two Warmup Bypass

Valves and open the N2 purge valve. Disconnect the upstream fitting
at the rotometer (FI) and cover the opening, then open its upstream
gate valve briefly to blow any liquids or debris from the purge line.
Reconnect the FI, then disconnect the fitting where the purge enters
the process and cover the opening. Open the upstream gate valve,
open the downstream manual block valve briefly to blow any liquids
or debris from the purge line, then reconnect the purge to the
process.
M. Open the manual block valve downstream of the FI and allow the
nitrogen to pressurize the piping between the two Warmup Bypass
Valves. Check all of the piping connections for visible or audible
signs of leakage (by applying masking tape or "Snoop" to the
flanges, listening for other leaks, etc.). When this leak checking
complete, if the PLC was "forced" in the previous step, remove the
"force" and confirm that the Warmup Bypass Valves open and the
purge valve closes. Leave the manual block valve downstream of
the FI open.

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9.7.7 Commissioning the Sulfur Surge Tank Heating and Ventilation

The heating and ventilation systems for each Sulfur Surge Tank can be
placed in service at any time prior to the beginning of sulfur production
from the associated SRU. It is advantageous to place these systems in
service prior to startup of the SRU so that any problems can be corrected
without impacting the schedule for commissioning the SRU.
To place the heating and ventilation systems in service, proceed as

follows:
A. Confirm that the steam supply valves to the steam coils in the Sulfur
Surge Tank are all closed, and that the steam trap stations on each
of the coils are all blocked in.
B. Open the vent valves on each of the steam coils.
C. Establish steam flow into each of the coils by opening the steam
supply valves to each coil.
D. Allow air (and any liquids or debris) to purge from the vent valves.
Close each vent valve as it begins to blow steam.
E. Open the upstream block valve of the steam trap on each coil and
use the bleeder on each trap to drain water (and any other liquids)
from each coil. Close the bleeder on each trap once hot condensate
begins flowing through the trap.
F. 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.
G. Repeat Steps A through F to commission the heating systems on

each of the four sulfur rundown lines from the Sulfur Condenser and
their associated Sulfur Drain Seal Assemblies. Open all of the vent
valves on the steam jackets long enough to vent the air from the
jackets.

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H. Repeat Steps A through F to commission the heating systems on the

air sweep vent stack, the Sulfur Surge Tank Vent Ejector,
A2-EE1530 (A2-EE1540), the ejector suction line, and the ejector
discharge line. Open all of the vent valves on the steam jackets long
enough to vent the air from the jackets. In particular, use the vent
line on the air sweep vent stack to vent the air from its steam jacket.
I. Make sure that the breather vents at each end of the Sulfur Surge
Tank are unobstructed and that the air sweep vent stack has begun
to draft air into the tank through the breather vents.
J. Check that the suction valve on the Sulfur Surge Tank Vent Ejector is
closed and the discharge valve is open.
K. Confirm that the globe valve in the motive steam line to the Sulfur
Surge Tank Vent Ejector is closed, then open the upstream manual
block valve in the line.
L. Slowly open the globe valve to establish motive steam flow to the
ejector. Verify that the steam is flowing at the proper rate (about
500 kg/H) on the steam flow meter in the DCS.
M. Open the ejector suction valve. The ejector should now begin to
overcome the natural-draft driving force of the air sweep vent and
route the ventilation air from the pit to the Thermal Oxidizer.
N. Confirm that all steam traps are functioning properly and that steam
is flowing to the ejector before directing your attention away from the
Sulfur Surge Tank.

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9.7.8 Pre-filling the Sulfur Drain Seal Assemblies

The Sulfur Drain Seal Assemblies, A2-ME1530A-D (A2-ME1540A-D),
must be filled with molten sulfur in order to seal the pressurized process
gases inside the SRU. The initial sulfur production when the SRU is first
started up can be used to accomplish this as described in Section 9.8.2 of
these guidelines. It is often convenient, however, to pre-fill the seals with
sulfur prior to starting up the SRU. The blind flange on the top of each
assembly can be removed to allow pouring sulfur into the drain seal to fill
it.
Pre-filling of the seals can be accomplished at any time after the steam
heating for the sulfur rundown lines and Drain Seal Assemblies has been
placed in service as described in the preceding section. Both molten
sulfur and solid sulfur prills have been used for this purpose. If sulfur prills
are used, proceed slowly enough so that the steam jackets on the seals
can melt the sulfur. Continue to add sulfur to each seal until molten sulfur
pours from its spill-over spout into its collection basin. Then bolt the blind
flange back on the top of each seal assembly.
If the drain seals are pre-filled in this fashion, the block valves in the sulfur
rundown lines can be left open during the initial plant startup. Otherwise,
these block valves must be closed when acid gas is first introduced to
prevent hazardous process gases from escaping from the SRU.
Section 9.8.2 of this manual describes how to use the sulfur produced
during startup to fill the drain seals if they are not pre-filled.

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The procedure used to start up an SRU depends on whether the Reactor
catalyst contains sulfur, and whether the refractory in the Reactor Furnace is up
to operating temperature. This first section describes the procedure for the
initial startup of a new plant. Subsequent startups will require a different
procedure, and are discussed later (Sections 9.8.5 and 9.8.6 of this manual).
9.8.1 Initial Firing / Refractory Cure-out

Only during the initial startup of an SRU can the warmup gases be routed
through the entire sulfur plant. After a sulfur plant has been operated to
produce sulfur, residual sulfur will always be present in the catalyst beds.
If warmup gases containing free oxygen are routed through the catalyst
beds during subsequent warmup periods, this residual sulfur will ignite,
resulting in excessive temperatures which can cause equipment and/or
catalyst damage. It should be noted that the auto-ignition temperature of
sulfur on catalyst beds can be as low as 150°C when sufficient oxygen is
present.
During the initial startup, the Reactor Furnace and downstream equipment
will be warmed up to operating conditions following the refractory vendor's
cure-out schedule for the Reactor Furnace.
CAUTION
IT IS CRITICAL THAT THE WARMUP PROCEDURES BE

FOLLOWED VERY CLOSELY. THE REFRACTORY MATERIAL
MUST BE HEATED SLOWLY TO ALLOW THE CONTAINED WATER
TO VAPORIZE AND ESCAPE FROM THE REFRACTORY LINING,
WITHOUT EXERTING EXCESSIVE INTERNAL PRESSURE AND
CAUSING LINING DAMAGE.

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9.8.1.1 Initial Preparations

A. Check that all devices in the SRU ESD have been satisfied,
except for the following:
(1) Neither blower running.
(2) Flame failure.
The PLC logic provides bypasses for these two conditions so

that the system can be started up.
B. Confirm that the manual block valve in the SRU tailgas line is
open.
C. Confirm that the amine acid gas flow on/off switch, is set to "on"
so that this flow will be included in the air:acid gas ratio control
system.
D. Select local manual control for the control valves on the

Process Air Blower by switching process air hand switch (HS) in
the DCS to "local".
E. Place the air flow controller in "cascade".
F. Place the air demand controller in "manual" and set its output to
50%.
G. Confirm that the manual signal bias control for the blower to be
used is set to 100% so that the control signals to the blower
valves are not modified.
H. Select local manual control for the fuel gas flow control valve,
by switching the main fuel gas hand switch (HS) in the DCS to
"local".
I. Place the fuel gas flow controller in "automatic".
J. Confirm that the fuel gas flow on/off switch is set to "on" so that
this flow will be included in the air:acid gas ratio control system.
K. Place the Reactor Furnace front zone temperature controller in

the DCS in "automatic".
L. Place the bypass acid gas flow ratio controller in "manual" and
set its output to 0% so that control valve the bypass acid gas
control valve will be fully closed.

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M. Confirm that both boilers (Waste Heat Boiler and Sulfur

Condenser) are filled with water up to their normal liquid levels.
N. Verify that the four block valves in the sulfur rundown lines from
the Sulfur Condenser are closed (unless the Sulfur Drain Seal
Assemblies have been pre-filled with sulfur as described in
Section 9.7.8 of this manual).
O. During the early part of refractory cure-out, the startup

thermocouple assembly furnished with the optical pyrometer,
will be used to measure the furnace temperature, using their
furnished hand-held digital display units. (Optical pyrometers
are unreliable at temperatures below 200°C.) The
thermocouple will be used until the third "hold" point (about
500°C) in the warmup schedule is reached.
Loosen the wing nut on the hinged pyrometer fixture and swing
the pyrometer out of the way. Unscrew the viewport len and
remove it (be careful with the rubber o-ring gasket). Store the
viewport lens in a safe place. Screw the thermocouple adapter
housing onto the pyrometer mounting plate (with the o-ring in
place). Open the pyrometer block valve, slide the thermocouple
into the furnace, and tighten the packing gland on the end of the
adapter housing.
P. Confirm that the Acid Gas Firing switch on the local SRU
control panel is set to "DISABLED".
Q. Confirm that the Leak Test switch on the local SRU control
R. Confirm that the Reactor Cool-Down switch on the local SRU

control panel is set to "NORMAL".
S. Set the manual amine acid gas control (HIC) on the local SRU
control panel to 0% output.
Visually confirm that the amine acid gas inlet valve is closed.
T. Set the manual SWS gas control (HIC) on the local SRU control
panel to 0% output.
Visually confirm that the SWS gas inlet valve is closed.
U. Set the manual fuel gas control (HIC) on the local SRU control

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panel to 0% output.
Visually confirm that the main fuel gas valve and the two
automated shutdown valves are closed.
V. Set the manual air control on the local SRU control panel to 0%
output.
W. Verify that the acid gas control valve in the amine acid gas line
to the burner is fully open.
X. Verify that the bypass acid gas control valve in the bypass acid
gas line is fully closed.
Y. Verify that the pilot burner mounting nozzle is being purged with
nitrogen as indicated by its rotameter.
9.8.1.2 Igniting the Pilot Burner

A. Switch the Startup/Run selector switch on the local SRU control
panel to "STARTUP".
The "WARMUP OPEN" status light on the local SRU control

panel will flash until these valves have moved to the
proper position, then remain steadily illuminated.
(3) The Tailgas Valve to the TTO is closed.
The "TTO OPEN" status light will flash until this valve has
moved to the proper position, then will be extinguished.
The " TGCU OPEN" status light will flash until this valve has
NOTE: If a status light continues to flash, it means that the

limit switches on the associated valve(s) never
confirmed that the valve(s) moved to the proper
position. If this occurs, the startup sequence will not

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be allowed to proceed until the problem is corrected

and the valve(s) move to the proper position.
Note that the valve may have actually moved to the

proper position, but a faulty limit switch may not be
detecting that the valve is in the proper position.
Confirm that these valves have moved to the proper positions.

Confirm that the "WARMUP OPEN" light on the panel is
illuminated, and that the "TTO OPEN" and the "TGCU OPEN" lights
on the panel are extinguished.
B. Verify that the local start/stop controls for the Process Air
Blowers have their selector switches turned to the "STOP"
position.
C. Verify that the suction, discharge, and blow-off valves on both

blowers are all closed.
D. Start a Process Air Blower:
(1) Press the local push-button to give a “permit to start” for

the desired blower.
This will energize the solenoid valves on the blower

suction and vent valves. The blower suction valve will
open 33% and the blow-off valve will open 100%, but the
discharge valve will remain closed. These valves will
close again if the blower is not started within 30 seconds
when the "permit to start" times out.
(2) Start the blower using the local start/stop control station for
that blower.
When the blower starts, the solenoid valve on the blower

discharge valve is also energized, but the valve will remain
closed because the local process air flow controller (HIC)
is set to 0% output.
Once the blower is started and comes up to speed, a flow of air

will be established out of the blow-off valve and its silencer.
Starting the blower with its suction throttling valve "pinched"
allows the blower to start in an unloaded condition, which
imposes less of a load on the blower and its motor.

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E. Confirm that the air blower is running, then press the "ESD
RESET" push-buttonon the local SRU control panel to reset the
SRU ESD and extinguish the "RESET REQUIRED" light. This will
illuminate the "PURGE REQUIRED" light.
F. Verify that the "LIMITS SATISFIED" light is glowing steadily (not

flashing) on the local SRU control panel.
NOTE: If the "LIMITS SATISFIED" light is flashing, this means

that either a limit switch or a pressure transmitter is
not satisfied. The limit switches on the amine acid
gas valve, the SWS gas valve and the main fuel gas
valves must all indicate that their respective valves
are closed. The low-low pressure setpoint on the fuel
gas supply and the high-high pressure setpoint on
the fuel gas to the burner must both be satisfied.
For safety reasons, the PLC will not allow the light-off
sequence to proceed until all these conditions are
satisfied. Once the problem with the valves, their
limit switches, or the pressure transmitters has been
corrected, the "LIMITS SATISFIED" light will stop
flashing and glow steadily, and the light-off sequence
can proceed.
G. Adjust the output of the air flow control (HIC) on the local SRU
panel to open the blower control valves and allow a large air
flow, 80% or more on the flow indicator on the local SRU control
panel, to purge the entire system for about 5 minutes. The
"PURGE REQUIRED" light will be extinguished and the "PURGE
COMPLETE" light will be illuminated after about 30 seconds, but
continue to purge the system for a full 5 minutes prior to this
first time ignition attempt.
H. Open the following manual block valves:
(1) The manual block valve(s) in the main fuel gas supply line.
(2) The manual block valve(s) in the fuel gas supply line to the
burner.
(3) The manual block valve(s) in the fuel gas supply to the
pilot.

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(4) The manual block valve(s) in the instrument air supply to

the pilot.

the pilot.
I. Adjust the output of the air flow control (HIC) on the local SRU
panel to reduce the air flow to 10-20%. This will extinguish the
"PURGE COMPLETE" light and illuminate the "PERMIT TO IGNITE"
light and the PLC will "enable" the ignition circuit.
NOTE: Once the "PERMIT TO IGNITE" light is illuminated, an

ignition safety interlock timer starts. If an ignition
attempt is not made within 5 minutes, the SRU ESD
system will be activated to shut down the sulfur plant.
This prevents a potentially unsafe condition from
persisting, where a leaking fuel gas valve could
cause an explosive mixture to form in the Reactor
Furnace, since the air flow is low at this point in the
startup procedure.
If either flame scanner detects a flame before the

"IGNITION" push-button is pressed, this will activate
the SRU ESD system and the "flame scanner
malfunction" alarm in the DCS. This will stop the air
blower and extinguish the flame (unless of course, a
flame scanner is giving a false indication). A flame
prior to ignition usually indicates a leaking fuel gas or
acid gas valve. If this occurs, check these valves
before proceeding with startup, as a leaking valve
can allow an explosive mixture to form in the Reactor
Furnace without warning.
J. Press the "IGNITION" push-button on the local SRU control panel

to initiate an ignition attempt. The PLC will do the following:
(1) The nitrogen purge valve for the pilot burner is closed.
(2) The pilot air automated block valve is opened.
(3) The pilot gas automated vent valve is closed and the
automated block valves are opened.
(4) The ignition system is energized to begin sparking the

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ignitor inside the pilot.
(5) The "PILOT ON" light is illuminated.
K. The air and fuel gas pressure regulators for the pilot may
require some adjustment when first put in service before the
pilot will light. However, once set properly, the pilot should
ignite readily on subsequent startups. Refer to Section 9.11 of
these guidelines for a suggested procedure to adjust these
regulators.
L. If neither flame scanner detects a flame after 15 seconds of

sparking the ignitor, the ignition try is aborted, the SRU Burner
Shutdown system is activated, and the PLC causes the
sequence to return to Step G.
M. When either flame scanner detects a flame from the pilot

burner, the appropriate "MAIN FLAME ON" light(s) are illuminated.
The pilot air and fuel gas valves will remain open after the
ignition trial, and the PLC will perform the following activities:
(1) The "LIMITS SATISFIED" and "PERMIT TO IGNITE" lights are

extinguished.
(2) The "PILOT ON" light remains illuminated.
(3) The ignition system is de-energized.
(4) The startup bypass in the PLC for the "flame failure" S/D is
disabled.
(5) The "MAIN FUEL START" push-button on the local SRU

control panel is enabled.
(6) The "RUN" position on the Startup/Run selector switch on

the local SRU control panel is enabled.
N. After the pilot is lit, use the air flow control (HIC) on the local
SRU panel to increase the air flow rate to about 50% of scale,
or as high a rate as can be maintained without blowing the pilot
out. When curing refractory, it is best to keep the air flow as
high as possible to help distribute the heat more evenly and to
heat the downstream equipment more quickly.

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9.8.1.3 Routing Warmup Gases Through the Entire SRU

At this point, the warmup gases from the Acid Gas Burner are only
flowing through the Reactor Furnace, the Waste Heat Boiler, and the
first pass of the Sulfur Condenser. The Warmup Bypass Valves
divert the gases from the first pass outlet of the Sulfur Condenser to
the Thermal Oxidizer (the normal "startup" mode). For the initial
firing of the SRU, the warmup gases are to be routed through the
entire SRU as follows to cure-out the refractory in Reactor and to
heat up all of the unit.

panel to "RUN".
The PLC will perform the following actions:
(1) The Tailgas Valve to the TTO is opened.
The "TTO OPEN" status light will flash until this valve has
moved to the proper position, then remain steadily
illuminated.
(2) After the limit switches prove this valve open, the two
Warmup Bypass Valves are closed.
The "WARMUP OPEN" status light will flash until these valves
have moved to the proper position, then will be
extinguished.
(3) After the limit switches prove that at least one of these
valves is closed, the nitrogen purge valve to the Warmup
Bypass Line is opened.
NOTE: If a valve status light continues to flash, it means that

the limit switches on the associated valve(s) never
position. If this occurs, the startup sequence cannot
proceed until the problem is corrected and the
valve(s) move to the proper position.

Confirm that the "WARMUP OPEN" light on the panel is
extinguished, the "TTO OPEN" light on the panel is illuminated,
and the "TGCU OPEN" light on the panel remains extinguished.

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B. Open the vent valves on each of the two boilers to vent air from
the steam sections.
C. Confirm that the BFW level controllers and control valves to the
Waste Heat Boiler and Sulfur Condenser are in service and
functioning properly.
D. The heat input from the pilot should be sufficient to reach the
first "hold" point in the refractory warmup schedule, 100-150°C.
If the temperature is too high, increase the air flow rate. If the
temperature is too low, decrease the air flow rate.
9.8.1.4 Igniting the Main Warmup Burner

When the firing rate needs to be increased to raise the furnace
temperature, the main warmup burner can be placed in service. The
control valve in the main fuel gas line will be used to control the fuel
gas flow rate.
A. Confirm that the flow control valve in the main fuel gas line is
fully closed.
B. Confirm that the manual block valve(s) in the main fuel gas line
to the burner is (are) open.
C. If the air flow rate is not at 50% of scale, use the air flow control
(HIC) on the local SRU panel to set the air flow at about 50% of
scale.
D. Press the "MAIN FUEL START" push-button on the local SRU

control panel to commission the main fuel gas. The PLC
performs the following actions:
(1) The nitrogen purge valve for the main warmup burner is
closed.
(2) The main fuel gas automated vent valve is closed.
(3) The main fuel gas automated block valves are opened.
(4) The "MAIN FUEL ON" light on the local control panel is
illuminated.
E. Adjust the output of the main fuel gas flow control (HIC) on the
local SRU control panel to slowly open the control valve to
commence fuel gas flow to the warmup burner ring. Adjust the

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fuel gas flow rate until a stable flame can be maintained.
Note that the fuel gas flow rate will be indicated on the local
panel and in the DCS.
9.8.1.5 Refractory Cure-out and Warmup

With the main fuel gas ring on the Acid Gas Burner in service, its
firing rate can now be adjusted to control the refractory cure-out of
the Reactor Furnace.
A. Adjust the fuel gas flow rate with the main fuel gas flow control
(HIC) on the local control panel as necessary to cause the
furnace temperature to follow the refractory cure-out schedule
for the initial cure supplied by the refractory vendor.
It is often helpful to maintain a log of the air flow, the fuel gas
flow, and the furnace temperature during the cure-out for future
reference.
B. Frequently confirm that the proper water levels are maintained

in the Waste Heat Boiler and the Sulfur Condenser. Confirm
that the level control systems are functioning properly.
C. As the steam pressure starts to build in the Waste Heat Boiler,

put the Waste Heat Boiler Steam pressure controller in the DCS
in "automatic" with a setpoint of 48.5 kg/cm2(g).
D. Place the three temperature controllers for the Reactor feeds in

"manual" and set their outputs to 100% to fully open the valves
in the condensate outlet lines from the reheat exchangers. This
will ensure that the feeds are as hot as possible for curing the
refractory in the three chambers of the Reactor.
E. As the steam pressure starts to build in the Sulfur Condenser,

put the Sulfur Condenser steam pressure controller in the DCS
F. Once the third "hold" point in the cure-out schedule has been
reached (about 500°C), the optical pyrometer can be placed in
service. After the furnace temperature has stabilized, loosen
the packing gland on the thermocouple adapter housing and
slide the thermocouple out until the "keeper" stops it. Close the
pyrometer block valve then unscrew the adapter housing and

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store it in a safe place.
CAUTION: THE THERMOCOUPLES WILL BE VERY

HOT. HANDLE THEM CAREFULLY TO
AVOID BURNS AND TO AVOID DAMAGING
THE THERMOCOUPLES.
Screw the viewport lens back onto the pyrometer mounting

plate (with the o-ring in place), swing the pyrometer back into
place, tighten the wing nut, and open the pyrometer block valve.
Open the block valve in the pyrometer purge system to begin
purging the viewport lens and nozzle with nitrogen. Verify that
the purge to the pyrometer viewport is operating properly.
The furnace temperature will now be indicated over the full

range of the pyrometer on the local digital indicators mounted
near the pyrometer. The controller in the DCS will also indicate
the furnace temperature.
G. Commission all steam heating systems on the sulfur rundown

lines, sulfur drain seals, sulfur surge tank, sulfur pumps, and
valve jackets if these are not already in service. Check all
steam traps for proper operation, and use the vent valves to
sweep non-condensibles out of the steam spaces.
H. As the equipment and piping heat up, inspect all of the

equipment and piping for the effects of thermal expansion.
I. As the steam pressures build in the boilers, the vent valves on

the steam spaces may be closed.
At the conclusion of this procedure, the SRU is ready to process acid

gas. However, if the acid gas feed from the Amine Regeneration
Unit is not yet available, the SRU can run indefinitely in this mode
until the other systems are ready. Monitor the Reactor Furnace
temperature and make adjustments to the fuel gas flow as needed to
control this temperature around 1200°C.

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9.8.2 Amine Acid Gas Flow

At the end of the refractory cure-out schedule, the SRU is firing on fuel
gas and is ready to accept acid gas. The switch to acid gas firing is
accomplished by gradually swapping acid gas for fuel gas.
A. Before commencing acid gas flow, confirm that the following

conditions are all true:
(1) The feed temperatures to all three chambers of the Reactor are
205°C or higher.
(2) The steam pressure in the Sulfur Condenser is 4.2 kg/cm2(g) or

higher.
(3) The Thermal Oxidizer is ready to accept SRU tailgas.
(4) All vent and drain valves on the Acid Gas Knock-Out Drum, its
piping, and the Acid Gas Knock-Out Drum Pump are closed
and plugged.
(5) Any blinds installed in the amine acid gas line have been
removed.
(6) The block valves are lined up to place an Acid Gas Knock-Out
Drum Pump in service, the selector switch on that pump is set
to "AUTO", and the pump level control transmitter is in service.
B. Confirm that the bypass acid gas flow ratio controller in the DCS is
still in "manual" with its output set to 0%. This ensures that the
bypass acid gas control valve will remain closed so that all of the
amine acid gas will flow to the Acid Gas Burner.
C. Adjust the process air flow rate to 50% of scale on the local indicator
using the air flow control (HIC) on the local SRU panel. Reduce the
fuel gas flow rate to 50% of scale on the local indicator using the
main fuel gas flow control (HIC) on the local panel.
D. Because of the procedure used for this initial firing, the Warmup
Bypass Valves are already closed and the Tailgas Valve to the
Thermal Oxidizer is already opened. Thus, the flowpath through the
SRU is already set correctly for introducing acid gas.
E. Switch the Acid Gas Firing selector switch on the local SRU control
panel to "ENABLED".

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F. Slowly increase the output from the amine acid gas flow control (HIC)
on the local SRU control panel to begin opening the amine acid gas
inlet valve until the acid gas flow rate is approximately 10% on the
indicator on the local SRU control panel.
G. As soon as the acid gas flow rate reaches 10%, use the main fuel
gas flow control (HIC) to reduce the fuel gas flow rate from 50% to
40% on the local indicator.
H. Continue to add amine acid gas in 10% increments and reduce the
fuel gas in 10% increments until the fuel gas control valve is
completely closed.
I. Press the “FUEL GAS OFF” push-button on the local SRU control panel.
The PLC performs the following actions to "double block and bleed"
the main fuel gas:
(1) The main fuel gas automated block valves are closed.
(2) The main fuel gas automated vent valve is opened.
(3) The nitrogen purge valve for the main burner is opened.
(4) The “FUEL GAS ON” light is extinguished.
Verify that the that the fuel gas valves have moved to their proper
positions and that the main fuel gas burner ring is being purged with
nitrogen as indicated by the associated rotometer.
J. Press the "PILOT OFF" push-button on the local SRU control panel.
The PLC performs the following actions to block the pilot air and
"double block and bleed" the pilot fuel gas:
(1) The aitmated block valve in the air supply to the pilot is closed.
(2) The pilot fuel gas automated block valves are closed.
(3) The pilot fuel gas automated vent valve is opened.
(4) The automated nitrogen purge valve for the pilot burner is
opened.
(5) The "PILOT ON" light is extinguished.

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Verify that the air and fuel gas valves have moved to their proper
positions and that the pilot burner is being purged with nitrogen as
indicated by the associated rotameter.
K. Continue to slowly increase the output from the amine acid gas flow
control (HIC) to 100% so that the amine acid gas inlet valve is fully
open.
L. If the amine acid gas flow rate (in percent) displayed on the local
control panel is significantly different from the air flow rate (in
percent) displayed on the local control panel, use the air flow control
(HIC) on the local SRU panel to adjust the air flow until the
percentages are about the same. This should put the air:acid gas
ratio reasonably close to where it should be.
M. Close the following manual block valves:
(1) The two manual block valve(s) in the main fuel gas line.
(2) The manual block valve(s) in the fuel gas to the pilot.
(3) The manual block valve(s) in the instrument air to the pilot.
N. Loosen the packing gland on the pilot and retract or extract the pilot
assembly:
(1) If the pilot is just to be retracted:
(a) Retract it until it reaches the limit of the retraction bar.
(b) Tighten the packing gland on the pilot.
(c) Verify that the pilot burner is still being purged with
nitrogen as indicated by the associated rotameter.
(2) If the pilot is to be completely extracted:
(a) Retract it until the retaining chain is taut.
(b) Close the block valve to isolate the pilot from the furnace.
(c) Close the block valve in the nitrogen purge to the pilot
burner.

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(d) Disconnect the chain and remove the pilot assembly and
store it in a safe place.
CAUTION: THE PILOT ASSEMBLY WILL BE VERY

HOT. HANDLE IT CAREFULLY TO
AVOID BURNS AND TO AVOID
DAMAGING IT.
(3) Verify that the pilot burner mounting nozzle is still being purged
with nitrogen as indicated by the associated rotometer.
O. Place the air:acid gas ratio control loop in service as follows:
(1) Confirm that the air demand controller in the DCS is in "manual"
and its output is set at 50%.
(2) Confirm that the process air flow controller in the DCS is in
"cascade".
(3) Confirm that the output of the process air flow controller is
tracking the output of the manual air control on the local SRU
control panel.
(4) Confirm that the setpoint of the process air flow controller is
tracking its current reading.
(5) Confirm that the "coarse" setting of the air:acid gas manual ratio
set (HIC) is being back-calculated so that the remote setpoint it
supplies to the process air flow controller matches the current
"local" air flow setpoint on the controller.
(6) Switch the process air hand switch (HS) from "local" to
"remote".
The DCS process air flow controller now has control of the control
valves on the Process Air Blower, so that the process air flow rate
will be ratio-controlled automatically with the amine acid gas flow
rate. The output from the manual ratio set (HIC) will remain fixed at
its last value.
P. Observe the temperatures in the catalyst beds and in the Reactor

outlet lines. These temperatures should begin to rise as the Claus
reaction is initiated. Watch the steam pressures and water levels in
the boilers to confirm that the control systems are functioning

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properly.
Q. If the Sulfur Drain Seals were not pre-filled with liquid sulfur to seal
them prior to startup, the block valves in the rundown lines will all be
closed at this time. After operating on acid gas for about 30 minutes,
open the block valve on the first condenser pass drain line.
Sufficient sulfur should have been produced by then to seal this drain
seal. If the drain seal does not seal within 30 seconds, close the
valve and try it again every 30 minutes or so until it seals.
R. After the first drain seals, open the block valve to the second drain
seal at approximately one hour intervals until it seals. Repeat this
with the third and fourth drain seals.
WARNING
MAKE SURE EACH DRAIN SEAL HAS SEALED BEFORE

LEAVING ITS BLOCK VALVE OPEN. IF THE BLOCK VALVE TO
AN UNSEALED DRAIN SEAL REMAINS OPEN, PROCESS GAS
CONTAINING POISONOUS H2S AND SO2 WILL ENTER THE
SULFUR SURGE TANK AND BE RELEASED TO THE
SURROUNDING AREA.
S. After operating for a few hours on acid gas, the process

temperatures can be lowered somewhat from the levels established
during startup.
(1) Confirm that the Waste Heat Boiler steam pressure controller is
set at 48.5 kg/cm2(g) and is controlling.
(2) The three reactor feed temperature controllers are in "manual"

at this time. Confirm that their setpoints are tracking their
current readings then switch the controllers to "automatic".
Slowly reduce the temperature setpoints to their normal values.
(3) Adjust the setpoint of the Sulfur Condenser steam pressure

controller to 1.75 kg/cm2(g).
This will cause the steam back-pressure control valve on the

Sulfur Condenser to remain wide open under normal

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circumstances, allowing the steam pressure to remain as low as

possible by "floating" on the LP steam header. Keeping the
steam pressure as low as possible in the Sulfur Condenser
allows it to remove the maximum amount of sulfur from the
process streams and reduces the load on the downstream
TGCU. Giving the Sulfur Condenser steam pressure controller
a setpoint of 1.75 kg/cm2(g) will ensure that the water in the
Sulfur Condenser shell stays safely above the freezing
temperature of sulfur by causing the steam pressure control
valve to maintain back-pressure in the shell of the Sulfur
Condenser if the pressure in the steam header should drop
below this value for any reason.
T. If the air demand analyzer is not in service and operating properly

after the SRU has been on-stream for 24 hours, manually analyze a
sample of the process gas leaving the fourth pass of the Sulfur
Condenser to determine the H2S:SO2 ratio, using one of the
laboratory procedures in Section 9.10 of this manual. As discussed
earlier, maximum sulfur recovery is obtained when the H2S:SO2 ratio
is 2:1.
If the H2S:SO2 ratio is higher than 2:1, the SRU is running with less
than optimum air (i.e., "air deficient"). Increase the setting on the
air:acid gas manual ratio set (HIC) to raise the air:acid gas ratio and
reduce the H2S:SO2 ratio in the process gas.
If the H2S:SO2 ratio is lower than 2:1, the SRU is running with more
than optimum air (i.e., "excess air"). Reduce the setting on the
air:acid gas manual ratio set (HIC) to lower the air:acid gas ratio and
increase the H2S:SO2 ratio in the process gas.
U. If the air demand analyzer is in service, adjust the air:acid gas ratio
as necessary with the air:acid gas manual ratio set (HIC) to bring the
air demand displayed on the air demand controller "on-scale"
(between -10.0% and +10.0%).
If the air demand is high (0.0% to +10.0%), the air:acid gas ratio is
too high (i.e., "excess air"). Reduce the setting on the air:acid gas
manual ratio set (HIC) to lower the air:acid gas ratio and reduce the
air demand.
If the air demand is low (-10.0% to 0.0%), the air:acid gas ratio is too
low (i.e., "air deficient"). Increase the setting on the air:acid gas

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manual ratio set (HIC) to raise the air:acid gas ratio and increase the
air demand.
Once the air demand is "on-scale", switch the air demand controller
to "automatic" and adjust its setpoint to 0.0% air demand. the air
demand controller will now adjust the ratio setting from the air:acid
gas manual ratio set (HIC) via relays to keep a 2:1 H2S:SO2 ratio in
the tailgas leaving the SRU.
V. The sulfur plant is now on-stream, firing on amine acid gas. Before
bringing in SWS gas or directing your attention away from the SRU,
be sure that:
(2) Sulfur is draining freely from each rundown line.
(3) All steam heating systems are in service and the steam traps
are functioning properly.
(4) The Warmup Bypass Valves are fully closed.
(5) The Thermal Oxidizer is functioning properly.

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9.8.3 SWS Gas Flow

Once the SRU is operating stably on amine acid gas, the SWS gas stream
can be introduced into the SRU. Do not attempt to bring in the SWS gas if
the SRU is not running smoothly on amine acid gas, as this will make it
that much harder to stabilize the unit. Instead, focus your attention on
stabilizing the operation of the SRU first (usually by correcting a problem
in the upstream Amine Regeneration Unit), and then use the procedure
below to establish SWS gas flow into the SRU.
Before commencing SWS gas flow, it will be necessary to raise and

control the temperature in the front combustion zone of the Reactor
Furnace to prepare it for ammonia destruction.
A. Before beginning, confirm that the following conditions are all true:
(1) SWS gas flow on/off switch in the DCS is set to "on" so that this
flow will be included in the air:acid gas ratio control system.
(2) All vent and drain valves on the SWS Gas Knock-Out Drum, its
piping, and the SWS Gas Knock-Out Drum Pump are closed
and plugged.
(3) Any blinds installed in the inlet SWS gas line have been
removed.
(4) The block valves are lined up to place a SWS Gas Knock-Out
Drum Pump in service, the H-O-A selector switch on that pump
is set to "AUTO", and the pump level control transmitter is in
service.
B. At this time, the bypass amine acid gas flow ratio controller in the
DCS is in "manual" with its output set to 0%. As a result, the bypass
acid gas control valve is closed, forcing all of the amine acid gas to
flow to the Acid Gas Burner.
C. Confirm that the Reactor Furnace front zone temperature controller is

in "automatic".
D. Confirm that the setpoint of the bypass acid gas flow ratio controller
is tracking its current reading (which should be zero), then switch it to
"automatic".
E. Slowly raise the ratio setpoint on the bypass acid gas flow ratio
controller to begin opening the bypass acid gas control valve and

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bypassing some of the amine acid gas to the side injection ports on
the furnace.
This should begin to raise the temperature in the front zone of the
furnace.
F. Continue to raise the ratio setpoint on the bypass acid gas flow ratio
controller until the temperature indicated on the front zone
temperature controller is approximately 1200°C.
NOTE: The 1370°C temperature for ammonia destruction

discussed in earlier sections is a calculated temperature.
The temperature indicated by an optical pyrometer is
usually 100-200°C lower than the calculated temperature
for a given set of conditions, so a normal operating
temperature of 1200°C is suggested for the front zone of
the furnace.
Operating experience will dictate the minimum indicated

temperature at which SWS gas can be admitted to the
furnace.
G. It may become necessary for the bypass acid gas flow ratio controller
to "pinch" flow control valve on the amine acid gas to the acid gas
burner in order to obtain enough bypass acid gas flow through the
bypass acid gas control valve.
After the bypass acid gas flow ratio controller is controlling the
bypass acid gas flow and the furnace temperature is up to about
1200°C, the furnace is ready to accept SWS gas.
H. Slowly increase the output from the SWS gas flow control (HIC) on
the local SRU control panel to begin opening the SWS gas inlet valve
using the flow indicator on the local SRU control panel to monitor the
SWS gas flow rate.
I. As SWS gas begins flowing to the Acid Gas Burner, the air:acid gas
ratio control system will begin sending additional process air to the
burner to combust the SWS gas. Increase the SWS gas flow slowly
to allow time for the ratio control system to adjust to the increasing
SWS gas flow.
J. Continue to slowly increase the output from the SWS gas flow control
(HIC) to 100% so that the SWS gas inlet valve is fully open.

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K. Monitor the bypass acid gas flow ratio controller to verify that it
maintains control of the bypass acid gas flow and that the front zone
temperature in the Reactor Furnace remains about 1200°C.
L. Observe the air demand controller and adjust the air:acid gas ratio
with the air:acid gas manual ratio set (HIC) if necessary to help keep
the air demand "on-scale".
If the air demand is high (0.0% to +10.0%), reduce the output from
the air:acid gas manual ratio set (HIC) to lower the ratio and reduce
the air demand.
If the air demand is low (-10.0% to 0.0%), increase the output from
the air:acid gas manual ratio set (HIC) to raise the ratio and increase
the air demand.
M. If the optical pyrometer on the Reactor Furnace is giving reliable

indication of the front zone temperature in the furnace the
temperature cascade control can be placed in service as follows:
(1) Confirm that the remote ratio setpoint that the front zone
temperature controller is supplying to the bypass ratio controller
matches the current setting on the ratio controller.
(2) Confirm that the front zone temperature controller is in

"automatic" and its setpoint is tracking its current reading.
(3) Switch the bypass acid gas flow ratio controller to "cascade" so
that the temperature controller can now adjust the ratio setpoint
on the ratio controller.
(4) If necessary, slowly adjust the setpoint of the front zone

temperature controller to its normal setpoint of 1200°C.
(5) Verify that the bypass acid gas flow ratio controller is adjusting
the bypass gas flow rate as needed to control the desired
temperature setting on the front zone temperature controller.
N. The sulfur plant is now fully on-stream, firing on both amine acid gas
and SWS gas. Before switching the SRU tailgas to the TGCU or
directing your attention away from the SRU, be sure that:

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9.8.4 Routing SRU Tailgas to the TGCU

Before switching the SRU tailgas from the Thermal Oxidizer to the TGCU
Tailgas Cleanup Unit, be sure all of the following conditions are true:
(1) The SRU is operating stably on amine acid gas, or on amine

acid gas and SWS gas.
(2) The air demand indicated on the air demand controller is +2.0%
or lower.
If the air demand is higher than this, the SRU tailgas contains
excessive amounts of SO2 and could cause overheating of the
TGCU Reactor in the TGCU.
(3) The TGCU has been warmed up to operating temperature and

is ready to accept SRU tailgas.
If any of these conditions are not true, do not attempt to bring SRU tailgas
into the TGCU. In particular, do not attempt switching tailgas to the TGCU
when the sulfur plant is upset. The result will be two upset units to deal
with. Instead, focus your attention on stabilizing the operation of the SRU
first (usually by correcting a problem in the upstream Amine Regeneration
Unit and/or Sour Water Stripper Unit). Then use the operating procedures
for the TGCU in Section 11 of these guidelines to switch the SRU tailgas
from flowing to the Thermal Oxidizer to flowing into the TGCU.
Once the sulfur plant tailgas is flowing to the TGCU, be sure of the
following before directing your attention away from the SRU:
(1) The Tailgas Valve to the TTO and the TGCU Warmup/Bypass
Valve are fully closed.
(2) This is necessary to prevent leakage of SRU tailgas to the TTO

that would cause high SO2 emissions and the resulting permit
violation.

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(6) The TGCU and the Thermal Oxidizer are functioning properly.

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9.8.5 Normal Startup - Cold System

The procedure for startup of an SRU after it has been shut down long
enough to get cold (less than about 750°C in the Reactor Furnace) will be
very similar to the procedure for the initial startup, Sections 9.8.1 through
9.8.4 of this manual. However, the steps to be performed are written in
this section to serve as a "check list" that can be easily followed on
subsequent startups. Refer to the previous sections for the reasons and
details pertaining to the different steps performed.
NOTE
THIS PROCEDURE USES THE WARMUP BYPASS VALVES TO

ROUTE THE FUEL GAS COMBUSTION PRODUCTS DIRECTLY TO
THE THERMAL OXIDIZER WHILE WARMING UP THE SRU. (THIS
PREVENTS OXYGEN-BEARING GASES FROM REACHING THE
REACTOR BEDS AND CAUSING SULFUR FIRES IN THE
CATALYST.)
IT IS NORMAL TO PRODUCE A SMALL SO2 PLUME FROM THE

THERMAL OXIDIZER WHEN USING THE WARMUP BYPASS LINE
AS THE OXYGEN IN THE COMBUSTION GAS REACTS WITH THE
SULFUR COATING THE WALLS OF THE PIPING AND EQUIPMENT
TO FORM SO2.
HOWEVER, IF A LARGE AMOUNT OF SO2 IS BEING RELEASED

FROM THE STACK, THIS MAY BE AN INDICATION THAT SULFUR
HAS ACCUMULATED INSIDE THE SRU FOR SOME REASON. TO
PREVENT DAMAGE TO THE EQUIPMENT, SHUT DOWN THE SRU
AND VERIFY THAT THE FIRST PASS OF THE SULFUR
CONDENSER IS NOT FILLED WITH SULFUR BEFORE
CONTINUING.

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Prior to commencing SRU startup:
(1) Check for the completion of all maintenance work (connecting

lines, removing blinds, etc.) if such work was performed.
(2) If any of the flanged connections in the SRU were opened for
maintenance or other purposes while the SRU was off-line, it is
good practice to leak test the SRU before returning it to service.
Refer to Section 9.7.3 of this manual for a suggested procedure
to accomplish this.
(3) 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.
(4) Physically check all shutdown activating devices to ensure that

they activate the SRU ESD system.
(5) Check all devices activated by the SRU ESD system to ensure
that they operate properly.
(6) Confirm that both boilers (Waste Heat Boiler and Sulfur
Condenser) are filled with water up to their normal liquid levels.
(7) If the furnace temperature is less than 250°C, insert the startup
thermocouple assembly furnished with the optical pyrometer by
swinging the pyrometer out of the way, removing the viewport,
and attaching the thermocouple adapter to the mounting plate.

A. Check that all devices in the SRU ESD have been satisfied,
(2) Flame failure.
B. Confirm that the manual block valve in the SRU tailgas line is
open.
C. Confirm that the amine acid gas flow on/off switch is set to "on".
D. Select local manual control for the control valves on the

Process Air Blower by switching the process air hand switch
(HS) in the DCS to "local".

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E. Place the process air flow controller in "cascade".
F. Place the air demand controller in "manual" and set its output to
50%.
G. Confirm that the manual signal bias control for the blower to be
used is set to 100%.
H. Select local manual control for the fuel gas flow control valve by
switching the main fuel gas hand switch (HS) in the DCS to
"local".
I. Place the fuel gas flow controller in "automatic".
J. Confirm that the fuel gas flow on/off switch is set to "on".
K. Place the Reactor Furnace front zone temperature controller in

"automatic".
L. Place the bypass acid gas flow controller in "manual" and set its
output to 0%.
M. Confirm that Acid Gas Firing switch on the local SRU control
panel is set to "DISABLED".
N. Confirm that Leak Test key switch on the local SRU control
O. Confirm that Reactor Cool-Down key switch on the local SRU

control panel is set to "NORMAL".
P. Set the amine acid gas flow control (HIC) and the SWS gas flow
control (HIC) on the local SRU control panel to 0% output.
Visually confirm that the amine acid gas inlet valve and the
SWS gas inlet valve are closed. If either of these valves is not
closed, H2S will be routed directly to the Thermal Oxidizer when
the Warmup Bypass Valves are opened. This could cause
overheating of the Thermal Oxidizer.
Q. Set the manual fuel gas control on the local SRU control panel
to 0% output.
shutdown valves are closed.

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R. Set the air flow control (HIC) on the local SRU panel to 0%
output.
S. Verify that the acid gas control valve in the amine acid gas line
T. Verify that the bypass acid gas control valve in the bypass acid
U. Loosen the packing gland on the pilot mounting nozzle. If the

pilot was extracted previously, insert the pilot assembly,
connect its retaining chain, and open the block valve. Slide the
pilot all the way in then tighten the packing gland. Open the
block valve in the purge nitrogen to the pilot and confirm that
the pilot and the pilot mounting nozzle are both being purged
with nitrogen.

panel to "STARTUP".
The PLC will open the two Warmup Bypass Valves and close
the Tailgas Valve to the TTO and the Tailgas Valve to the
TGCU. Verify that the "WARMUP OPEN" light on the panel is now
illuminated and the "TTO OPEN" and "TGCU OPEN" lights on the
panel are extinguished.

position.


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the desired blower.
that blower.
RESET" push-button on the local SRU control panel to reset the


gas, SWS gas, and fuel gas valves must all indicate
that their respective valves are closed, and the two
pressure transmitters on the main fuel gas must be
satisfied.
For safety reasons, the BMS will not allow the

light-off sequence to proceed until all these
conditions are satisfied. Once the problem with the
valves, their limit switches, or the pressure
transmitters has been corrected, the "LIMITS
SATISFIED" light will stop flashing and glow steadily,
and the light-off sequence can proceed.
G. Open the following manual block valves:
burner.
pilot.

the pilot.

the pilot.

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H. Adjust the output of the air flow control (HIC) on the local SRU
flow, 80% or more the flow indicator, to purge the furnace for 30
seconds and extinguish the "PURGE REQUIRED" light. The
"PURGE COMPLETE" light will then be illuminated.
panel to reduce the air flow to 10-20%, extinguishing the
"PURGE COMPLETE" light and illuminating the "PERMIT TO IGNITE"
light.
NOTE: Remember that the ignition safety timer will shut

down the SRU if an ignition attempt is not made
within 5 minutes of receiving the "PERMIT TO IGNITE".
J. Press the "IGNITION" push-button to initiate an ignition attempt.
K. If neither flame scanner detects a flame after 15 seconds of

L. When either flame scanner detects a flame from the pilot

burner, the pilot air and fuel gas valves remain open, the "PILOT
ON" light remains illuminated, and the PLC enables the "FUEL
GAS ON" push-button and the "RUN" position on the Startup/Run
selector switch.
M. After the pilot is lit, use the air flow control (HIC) on the local
SRU panel to increase the air flow rate to about 50% of scale,
or as high a rate as can be maintained without blowing the pilot
out.
N. Open the vent valves on each of the two boilers to vent air from
the steam sections.
O. The heat input from the pilot will be sufficient during the early
part of the refractory warmup schedule. If the temperature is
rising too quickly, increase the air flow rate. If the temperature
is rising too slowly, decrease the air flow rate.
NOTE: The refractory warmup schedule for normal warmup,

(supplied by the refractory vendor), should be used
for normal startup with a cold system.

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9.8.5.3 Igniting the Main Warmup Burner / Refractory Warmup

temperature, the main warmup burner should be placed in service.
A. Confirm that in the main fuel gas line is fully closed.
B. Confirm that the manual block valve(s) in the main fuel gas line
to the burner is open.
C. If the air flow rate is not at 50% of scale, use the air flow control
(HIC) on the local SRU panel to set the air flow at about 50% of
scale.
D. Press the "FUEL GAS ON" push-button on the local SRU control
panel to open the main fuel gas block valves and illuminate the
“FUEL GAS ON” light.
E. Adjust the output of the main fuel gas flow control (HIC) on the
local control panel to slowly open the control valve to
commence fuel gas flow to the warmup burner ring. Adjust the
fuel gas flow rate until a stable flame can be maintained.
F. Adjust the fuel gas flow rate with the main fuel gas flow control
(HIC) as necessary to cause the furnace temperature to follow
the refractory warmup schedule for normal warmup.
G. Frequently confirm that the proper water levels are maintained

in the Waste Heat Boiler and the Sulfur Condenser. Confirm
that the level control systems are functioning properly.
H. As the steam pressure starts to build in the Waste Heat Boiler,

put the Waste Heat Boiler Steam pressure controller in the DCS
I. Place the three temperature controllers for the Reactor feeds, in

"manual" and set their outputs to 100%.
This will fully open the valves in the condensate outlet lines
from the reheat exchangers and ensure that the Reactor feeds
are as hot as possible when the switch to acid gas firing is
made.

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J. As the steam pressure starts to build in the Sulfur Condenser,

put the Sulfur Condenser steam pressure controller in the DCS
K. During the early part of warmup, monitor the furnace

temperature using the startup thermocouple assembly and the
hand-held digital display unit. The thermocouple will be used
until the first "hold" point (about 250°C) in the warmup schedule
is reached.
Once the first "hold" point in the warmup schedule has been
reached, the optical pyrometer can be placed in service. After
the furnace temperature has stabilized, slide the thermocouple
out until the "keepers" stop them, close the pyrometer block
valve, then unscrew the adapter housing and store them in a
safe place.
CAUTION: THE THERMOCOUPLES WILL BE VERY

HOT. HANDLE THEM CAREFULLY TO
AVOID BURNS AND TO AVOID DAMAGING
THE THERMOCOUPLES.
Replace the viewport lens on the pyrometer mounting plate

(with the o-ring in place) and put the pyrometer back in service
so that the furnace temperature is indicated on the local
indicator and the controller in the DCS. Confirm that the purge
system for the pyrometer viewport lens is operating.
L. Confirm that all steam heating systems on the sulfur rundown

lines, sulfur drain seals, sulfur collection header, sulfur pump,
and valve jackets are in service. Check all steam traps for
proper operation, and use the vent valves to sweep
M. As the steam pressures build in the boilers, the vent valves on

the steam spaces may be closed.
At the conclusion of this procedure, the SRU is ready to process acid

gas. However, the SRU can run indefinitely in this mode until the
other systems are ready. Monitor the Reactor Furnace temperature
on the furnace temperature controller and make adjustments to the
fuel gas flow as needed to control this temperature around 1200°C.

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9.8.5.4 Amine Acid Gas Flow

At the end of the refractory warmup schedule, the SRU is firing on
fuel gas (using the warmup bypass line to divert the combustion
products to the Thermal Oxidizer) and is ready to accept acid gas.
The switch to acid gas firing is accomplished by routing the
combustion products through SRU, then rapidly swapping acid gas
for fuel gas.
A. Before commencing acid gas flow, confirm that the following

conditions are all true:
(1) The steam pressure in the Waste Heat Boiler is

48.5 kg/cm2(g) or higher.
(2) The steam pressure in the Sulfur Condenser is

4.2 kg/cm2(g) or higher.
(3) The Thermal Oxidizer is ready to accept SRU tailgas.
(4) All vent and drain valves on the Acid Gas Knock-Out
Drum, its piping, and the Acid Gas Knock-Out Drum Pump
are closed and plugged.
(5) The block valves are lined up to place an Acid Gas

Knock-Out Drum Pump in service, the H-O-A selector
switch on that pump is set to "AUTO", and the pump level
control transmitter is in service.
B. Confirm that the bypass acid gas flow ratio controller in the
DCS is still in "manual" with its output set to 0%.
C. Verify that the bypass acid gas control valve is fully closed.
D. Verify that the acid gas control valve in the amine acid gas line to
the Acid Gas Burner is fully open.
E. Adjust the process air flow rate to 50% of scale on the local
indicator using the air flow control (HIC) on the local SRU panel.
Reduce the fuel gas flow rate to 50% of scale on the local
indicator using the main fuel gas flow control (HIC) on the local
panel.

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WARNING
AS SOON AS THE TAILGAS VALVE IS OPENED IN THE NEXT

STEP, OXYGEN-BEARING GASES WILL BEGIN FLOWING
THROUGH THE CATALYST BEDS. IF THE CATALYST IS
HOTTER THAN THE AUTO-IGNITION TEMPERATURE OF
SULFUR ON CLAUS CATALYST (150°C), THE SULFUR
CONTAINED IN THE CATALYST WILL BEGIN TO BURN. FOR
THIS REASON, IT IS IMPORTANT THAT THE SWITCH FROM
FIRING FUEL GAS TO FIRING ACID GAS BE MADE AS
QUICKLY AS POSSIBLE.
IF ANY DELAYS IN INTRODUCING ACID GAS ARE

ENCOUNTERED, IMMEDIATELY SWITCH THE
STARTUP/RUN SELECTOR SWITCH BACK TO "STARTUP" TO
OPEN THE WARMUP BYPASS VALVES AND CLOSE THE
TAILGAS VALVE SO THAT THE CATALYST BEDS DO NOT
CONTINUE TO BURN.
F. Switch the Startup/Run selector switch on the local SRU control

panel to "RUN" to route the combustion gases through the SRU.
The PLC will open the Tailgas Valve to the Thermal Oxidizer
then close the Warmup Bypass Valves. The "TTO OPEN" light will
be illuminated, then the "WARMUP OPEN" light will be extinguished
as the valves move to their new positions.

Should this occur, switch the Startup/Run

selector switch back to "STARTUP" so that the
catalyst beds do not continue to burn.

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G. Switch the Acid Gas Firing selector switch on the local SRU
control panel to "ENABLED".
H. Increase the output from the amine acid gas flow control (HIC)
on the local SRU control panel to begin opening the amine acid
gas inlet valve until the acid gas flow rate is approximately 10%
on the local indicator.
I. As soon as the acid gas flow rate reaches 10%, use the main
fuel gas flow control (HIC) to reduce the fuel gas flow rate from
50% to 40% on the local indicator.
J. Continue to add amine acid gas in 10% increments and reduce

the fuel gas in 10% increments until the fuel gas control valve is
completely closed.
K. Press the “FUEL GAS OFF” push-button to "double block and

bleed" the main fuel gas and the "PILOT OFF" push-button to
"double block and bleed" the pilot fuel gas. Verify that the “fuel
gas on” and the "PILOT ON" lights are both extinguished, and that
the warmup burner and pilot burner are being purged with
nitrogen.
L. Continue to slowly increase the output from the amine acid gas
flow control (HIC) to 100% so that the amine acid gas inlet
valve is fully open.
M. If the amine acid gas flow rate (in percent) displayed on the
local control panel is significantly different from the air flow rate
(in percent) displayed on the local control panel, use the air flow
control (HIC) on the local SRU panel to adjust the air flow until
the percentages are about the same.
N. Close the following manual block valves:
(3) The manual block valve(s) and manual block valve(s) in

the instrument air to the pilot.
O. Loosen the packing gland on the pilot and retract or extract the
pilot assembly:

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nitrogen.
(b) Close the block valve to isolate the pilot from the
furnace.
(c) Close the block valve in the nitrogen purge to the

pilot burner.
(d) Disconnect the chain and remove the pilot assembly

and store it in a safe place.
CAUTION: THE PILOT ASSEMBLY WILL BE

VERY HOT. HANDLE IT
CAREFULLY TO AVOID BURNS
AND TO AVOID DAMAGING IT.
(3) Verify that the pilot burner mounting nozzle is still being
purged with nitrogen.
P. Place the air:acid gas ratio control loop in service as follows:
(1) Confirm that the air demand controller in the DCS is in

"manual" and its output is set at 50%.
"cascade", its output is tracking the output of the air flow
control (HIC) on the local SRU control panel, and its
setpoint is tracking its current reading.
(3) Confirm that the "coarse" setting on the air:acid gas

manual ratio set (HIC) is being back-calculated so that the
remote setpoint it supplies to the air flow controller
matches the current "local" setpoint on the controller.

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"remote" to give the process air flow controller in the DCS
control of the Process Air Blower, so that the process air
flow rate will be ratio-controlled automatically. The output
from the air:acid gas manual ratio set (HIC) will remain fixed
at its last value.
Q. Adjust the air:acid gas ratio as necessary with the air:acid gas
manual ratio set (HIC) to bring the air demand displayed on the
air demand controller "on-scale" (between -10.0% and +10.0%).
If the air demand is high (0.0% to +10.0%), the air:acid gas ratio
is too high (i.e., "excess air"). Reduce the setting on the air:acid
gas manual ratio set (HIC) to lower the air:acid gas ratio and
reduce the air demand.
If the air demand is low (-10.0% to 0.0%), the air:acid gas ratio
is too low (i.e., "air deficient"). Increase the setting on the
air:acid gas manual ratio set (HIC) to raise the air:acid gas ratio
and increase the air demand.
Once the air demand is "on-scale", switch the air demand

controller to "automatic" and adjust its setpoint to 0.0% air
demand.
R. Observe the temperatures in the catalyst beds and in the

Reactor outlet lines. These temperatures should begin to rise
as the Claus reaction is initiated. Watch the steam pressures
and water levels in the boilers to confirm that the control
systems are functioning properly.
S. After operating for a few hours on acid gas, the process

temperatures can be lowered somewhat from the levels
established during startup.
(1) Confirm that the Waste Heat Boiler steam pressure

controller is set at 48.5 kg/cm2(g) and is controlling.
(2) Confirm that the three temperature controllers for the

Reactor feeds, are tracking their current readings then
switch the controllers to "automatic". Slowly reduce the
temperature setpoints to their normal values.

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(3) Adjust the setpoint of the Sulfur Condenser steam

pressure controller, the Sulfur Condenser steam pressure
controller, to 1.75 kg/cm2(g).
T. The sulfur plant is now on-stream, firing on amine acid gas.

Before bringing in SWS gas or directing your attention away
from the SRU, be sure that:
(3) All steam heating systems are in service and the steam
traps are functioning properly.

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9.8.5.5 SWS Gas Flow

Once the SRU is operating stably on amine acid gas, the SWS gas
stream can be introduced into the SRU. Do not attempt to bring in
the SWS gas if the SRU is not running smoothly on amine acid gas,
as this will make it that much harder to stabilize the unit. Instead,
focus your attention on stabilizing the operation of the SRU first
(usually by correcting a problem in the upstream Amine
Regeneration Units), and then use the procedure below to establish
SWS gas flow into the SRU.
A. Check that all vent and drain valves on the SWS Gas
Knock-Out Drum, its piping, and the SWS Gas Knock-Out Drum
Pump are closed and plugged.
B. Line up the block valves to place a SWS Gas Knock-Out Drum

Pump in service, set the H-O-A selector switch on that pump to
"AUTO", and verify that the pump level control transmitter is in
service.
C. Confirm that the SWS gas flow on/off switch in the DCS is set to
"on".
D. Confirm that the Reactor Furnace front zone temperature

controller is in "automatic".
E. Confirm that the setpoint of the bypass acid gas flow ratio
controller is tracking the current reading (which should be zero),
then switch it to "automatic".
F. Slowly raise the ratio setpoint on the bypass acid gas flow ratio
controller to begin opening the bypass acid gas control valve
and bypassing some of the amine acid gas to the side injection
ports on the furnace.
G. Continue to raise the ratio setpoint on the bypass acid gas flow
ratio controller until the front zone temperature indicated on the
front zone temperature controller is approximately 1200°C.
bypass acid gas flow and the furnace temperature is up to
about 1200°C, the furnace is ready to accept SWS gas.

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H. Slowly increase the output from the SWS gas flow control (HIC)
on the local SRU control panel to begin opening the SWS gas
inlet valve.
I. As SWS gas begins flowing to the Acid Gas Burner, the air:acid
gas ratio control system will begin sending additional process
air to the burner to combust the SWS gas. Increase the SWS
gas flow slowly to allow time for the ratio control system to
adjust to the increasing SWS gas flow.
J. Continue to slowly increase the output from the SWS gas flow
control (HIC) to 100% so that the SWS gas inlet valve is fully
open.
K. Monitor the bypass acid gas flow ratio controller to verify that it
maintains control of the bypass acid gas flow and that the front
zone temperature in the Reactor Furnace remains about
1200°C.
L. Observe the air demand controller and adjust the air:acid gas
ratio with the air:acid gas manual ratio set (HIC) if necessary to
help keep the air demand "on-scale".
If the air demand is high (0.0% to +10.0%), reduce the setting

on the air:acid gas manual ratio set (HIC) to lower the ratio and
If the air demand is low (-10.0% to 0.0%), increase the setting

on the air:acid gas manual ratio set (HIC) to raise the ratio and
increase the air demand.
M. If the optical pyrometeris giving reliable indication of the front

zone temperature in the furnace, place the temperature
cascade control in service as follows:
(1) Confirm that the remote ratio setpoint that the temperature
controller is supplying to the bypass acid gas flow ratio
controller matches the current setting on the ratio
controller.
(2) Confirm that the temperature controller is in "automatic"

and its setpoint is tracking its current reading.

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(3) Switch the bypass acid gas flow ratio controller to

"cascade". If necessary, slowly adjust the setpoint of the
temperature controller to its normal setpoint of 1200°C.
(4) Verify that the controllers are adjusting the bypass gas
flow rate as needed to control the desired temperature in
the front zone of the Reactor Furnace.
N. The sulfur plant is now fully on-stream, firing on both amine acid
gas and SWS gas. Before switching the SRU tailgas to the
TGCU or directing your attention away from the SRU, be sure
that:

(3) All steam heating systems are in service and functioning
properly.
9.8.5.6 Routing SRU Tailgas to the TGCU

Before switching the SRU tailgas from the Thermal Oxidizer to the
TGCU Tailgas Cleanup Unit, be sure all of the following conditions
are true:

or lower.

If any of these conditions are not true, do not attempt to bring SRU
tailgas into the TGCU. In particular, do not attempt switching tailgas
to the TGCU when the sulfur plant is upset. The result will be two
upset units to deal with. Instead, focus your attention on stabilizing
the operation of the SRU first (usually by correcting a problem in the
upstream Amine Regeneration Unit and/or Sour Water Stripper Unit),
and then use the operating procedures for the TGCU in the TGCU
Section of these guidelines to switch the SRU tailgas from flowing to
the Thermal Oxidizer to flowing into the TGCU.

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(1) The Tailgas Valve to the Thermal Oxidizer and the TGCU
Warmup/Bypass Valve are fully closed.
9.8.6 Normal Startup - Hot System

When an SRU shutdown occurs due to some minor malfunction which can
be corrected quickly, it is desirable to restart the plant in a minimum amount
of time. The following procedure should be followed to accomplish a rapid
restart of the SRU when it is already hot (750°C or higher in the Reactor
Furnace). Refer to the previous sections for the reasons and details
pertaining to the different steps performed.

A. Check that all SRU ESD devices have been satisfied, except for
the following:
(2) Flame failure.
B. Confirm that the amine acid gas flow on/off switch is set to "on".
C. Select local manual control for the control valves on the

Process Air Blower by switching the process air hand switch
(HS) in the DCS to "local".
D. Place the process air flow controller in "cascade".
E. Place the air demand controller in "manual" and set its output to
50%.
F. Confirm that the manual signal bias control for the blower to be
used is set to 100%.
G. Select local manual control for the fuel gas flow control valve by

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"local".
H. Place the fuel gas flow controller in "automatic".
I. Confirm that the fuel gas flow on/off switch is set to "on".
J. Place the Reactor Furnace front zone temperature controller in

"automatic".
K. Place the bypass acid gas flow controller in "manual" and set its
output to 0%.
L. Confirm that Acid Gas Firing switch on the local SRU control
panel is set to "DISABLED".
M. Confirm that Leak Test switch on the local SRU control panel is
set to "NORMAL".
N. Confirm that Reactor Cool-Down switch on the back of the local

SRU control panel is set to "NORMAL".
O. Set the amine acid gas flow control (HIC) and the SWS gas flow
control (HIC) on the local SRU control panel to 0% output.
Visually confirm that the amine acid gas inlet valve and the
SWS gas inlet valve are closed.
P. Set the manual fuel gas control on the local SRU control panel
to 0% output.
shutdown valves are closed.
Q. Set the air flow control (HIC) on the local SRU panel to 0%
output.
R. Verify that the acid gas control valve in the amine acid gas line
S. Verify that the bypass acid gas control valve in the bypass acid
T. Loosen the packing gland on the pilot mounting nozzle. If the

pilot was extracted previously, insert the pilot assembly,
connect its retaining chain, and open the block valve. Slide the
pilot all the way in then tighten the packing gland. Open the

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block valve in the purge nitrogen and confirm that the pilot
burner and pilot mounting nozzle are both being purged with
nitrogen.

panel to "STARTUP".
the Tailgas Valve to the TTO and the Tailgas Valve to the
TGCU. Verify that the "WARMUP OPEN" light on the panel is now

position.


the desired blower.
that blower.
RESET" push-button on the local SRU control panel to reset the

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gas, SWS gas, and fuel gas valves must all indicate
that their respective valves are closed, and the two
pressure transmitters on the main fuel gas must be
satisfied.
For safety reasons, the BMS will not allow the

light-off sequence to proceed until all these
conditions are satisfied. Once the problem with the
valves, their limit switches, or the pressure
transmitters has been corrected, the "LIMITS
burner.
pilot.

the pilot.
H. Adjust the output of the air flow control (HIC) on the local SRU
flow, 80% or more to purge the furnace for 30 seconds and
extinguish the "PURGE REQUIRED" light. The "PURGE COMPLETE"
light will then be illuminated.
panel to reduce the air flow to 10-20%, extinguishing the
"PURGE COMPLETE" light and illuminating the "PERMIT TO IGNITE"
light.

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NOTE: Remember that the ignition safety timer will shut

down the SRU if an ignition attempt is not made
J. Press the "IGNITION" push-button to initiate an ignition attempt.

sequence to return to Step H.
L. When either flame scanner detects a flame from the pilot

burner, the pilot air and fuel gas valves remain open, the "PILOT
ON" light remains illuminated, and the PLC enables the "MAIN
FUEL START" push-button and the "RUN" position on the
Startup/Run selector switch.

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9.8.6.3 Amine Acid Gas Flow

Since the SRU is already hot, there is no need to place the main fuel
gas and the warmup burner ring in service. The acid gas can be
ignited with the pilot burner flame. All that is required is to route the
combustion products through the SRU, then bring in the acid gas and
shut off the pilot.
WARNING
AS SOON AS THE TAILGAS VALVE IS OPENED IN THE NEXT

STEP, OXYGEN-BEARING GASES WILL BEGIN FLOWING
THROUGH THE CATALYST BEDS. IF THE CATALYST IS
HOTTER THAN THE AUTO-IGNITION TEMPERATURE OF
SULFUR ON CLAUS CATALYST (150°C), THE SULFUR
CONTAINED IN THE CATALYST WILL BEGIN TO BURN. FOR
THIS REASON, IT IS IMPORTANT THAT ACID GAS FIRING
COMMENCE AS QUICKLY AS POSSIBLE.
IF ANY DELAYS IN INTRODUCING ACID GAS ARE

ENCOUNTERED, IMMEDIATELY SWITCH THE
STARTUP/RUN SELECTOR SWITCH BACK TO "STARTUP" TO
OPEN THE WARMUP BYPASS VALVES AND CLOSE THE
TAILGAS VALVE SO THAT THE CATALYST BEDS DO NOT
CONTINUE TO BURN.

panel to "RUN" to route the combustion gases through the SRU.
The PLC will open the Tailgas Valve to the Thermal Oxidizer
then close the Warmup Bypass Valves. The "TTO OPEN" light will
be illuminated, then the "WARMUP OPEN" light will be extinguished
as the valves move to their new positions.


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Should this occur, switch the Startup/Run

selector switch back to "STARTUP" so that the
catalyst beds do not continue to burn.
B. As soon as the "WARMUP OPEN" light is extinguished, switch the

Acid Gas Firing selector switch on the local SRU control panel
to "ENABLED".
C. Immediately increase the output from the amine acid gas flow
control (HIC) on the local SRU control panel to begin opening
the amine acid gas inlet valve. Establish an amine acid gas
flow rate of approximately 10% and observe if ignition of the
acid gas is accomplished.
If not, reduce the amine acid gas flow control (HIC) to 0%

output to shut off the amine acid gas, open the manual block
valve(s) in the main fuel gas supply to the burner, press the
"FUEL GAS ON" push-button to open the main fuel gas valves,
and use the main fuel gas flow control (HIC) to ignite the fuel
gas warmup ring just long enough to ignite the acid gas burner.
After establishing an acid gas flame, shut off the main fuel gas
by pressing the “FUEL GAS OFF” push-button.
D. Increase the air flow on by 10% using the air flow control (HIC)
on the local SRU panel, then increase the amine acid gas flow
by 10%. Continue to make incremental increases in air and
amine acid gas flow, keeping about a 1:1 ratio of air to amine
acid gas (as measured by the percentages displayed on the
local indicators), until the amine acid gas inlet valve is fully
open.
E. Press the "PILOT STOP" push-button to "double block and bleed"

the pilot fuel gas. Verify that the “FUEL GAS ON” and the "PILOT
ON" lights are both extinguished, and that the warmup burner
and pilot burner are being purged with nitrogen.
F. Close the following manual block valves:

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(3) The manual block valve(s) and manual block valve(s) in

the instrument air to the pilot.
G. Loosen the packing gland on the pilot and retract or extract the
pilot assembly:
nitrogen.
(b) Close the block valve to isolate the pilot from the
furnace.
(c) Close the block valve in the nitrogen purge to the

pilot burner.


VERY HOT. HANDLE IT
purged with nitrogen.
H. Place the air:acid gas ratio control loop in service as follows:
(1) Confirm that the air demand controller in the DCS is in

"manual" and its output is set at 50%.
"cascade", its output is tracking the output of the air flow
control (HIC) on the local SRU panel and its setpoint is
tracking its current reading.

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(3) Confirm that the "coarse" setting on the air:acid gas

manual ratio set (HIC) is being back-calculated so that the
remote setpoint it supplies to the air flow controller
matches the current "local" setpoint on the controller.
"remote" to give the process air flow controller in the DCS
control of the Process Air Blower, so that the process air
flow rate will be ratio-controlled automatically. The output
from the air:acid gas manual ratio set (HIC) will remain fixed
at its last value.
I. Adjust the air:acid gas ratio as necessary with the air:acid gas
manual ratio set (HIC) to bring the air demand displayed on the
air demand controller "on-scale" (between -10.0% and +10.0%).
If the air demand is high (0.0% to +10.0%), the air:acid gas ratio
is too high (i.e., "excess air"). Reduce the setting on the air:acid
gas manual ratio set (HIC) to lower the air:acid gas ratio and
If the air demand is low (-10.0% to 0.0%), the air:acid gas ratio
is too low (i.e., "air deficient"). Increase the setting on the
air:acid gas manual ratio set (HIC) to raise the air:acid gas ratio
and increase the air demand.
Once the air demand is "on-scale", switch the air demand

controller to "automatic" and adjust its setpoint to 0.0% air
demand.
J. Observe the temperatures in the catalyst beds. The first bed

may show a temporary increase in temperature due to the
oxygen that was flowing through the bed, but its temperatures
should quickly return to normal now that acid gas flow has been
established.
K. The sulfur plant is now on-stream, firing on amine acid gas.

Before bringing in SWS gas or directing your attention away
from the SRU, be sure that:

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9.8.6.4 SWS Gas Flow

Once the SRU is operating stably on amine acid gas, the SWS gas
stream can be introduced into the SRU. Do not attempt to bring in
the SWS gas if the SRU is not running smoothly on amine acid gas,
as this will make it that much harder to stabilize the unit. Instead,
focus your attention on stabilizing the operation of the SRU first
Regeneration Units), and then use the procedure below to establish
SWS gas flow into the SRU.
A. Confirm that the SWS gas flow on/off switch in the DCS is set to
"on".
B. Confirm that the bypass acid gas flow ratio controller is in

"manual" and that the front zone temperature controller is in
"automatic".
C. Confirm that the setpoint of the bypass acid gas flow ratio
controller is tracking its current reading (which should be zero),
then switch it to "automatic".
D. Slowly raise the ratio setpoint on the bypass acid gas flow ratio
controller to begin opening the bypass acid gas control valve
and bypassing some of the amine acid gas to the side injection
ports on the furnace.
E. Continue to raise the ratio setpoint on the bypass acid gas flow
ratio controller until the front zone temperature indicated on the
front zone temperature controller is approximately 1200°C.
bypass acid gas flow and the furnace temperature is up to
about 1200°C, the furnace is ready to accept SWS gas.
F. Slowly increase the output from the SWS gas flow control (HIC)
on the local SRU control panel to begin opening the SWS gas
inlet valve.

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G. As SWS gas begins flowing to the Acid Gas Burner, the air:acid
gas ratio control system will begin sending additional process
air to the burner to combust the SWS gas. Increase the SWS
gas flow slowly to allow time for the air flow control system to
adjust to the increasing SWS gas flow.
H. Continue to slowly increase the output from the SWS gas flow
control (HIC) to 100% so that the SWS gas inlet valve is fully
open.
I. Monitor the bypass acid gas flow ratio controller to verify that it
maintains control of the bypass acid gas flow and that the front
zone temperature in the Reactor Furnace remains about
1200°C.
J. Observe the air demand controller and adjust the air:acid gas
ratio with the air:acid gas manual ratio set (HIC) if necessary to
help keep the air demand "on-scale".
If the air demand is high (0.0% to +10.0%), reduce the setting

on the air:acid gas manual ratio set (HIC) to lower the ratio and
If the air demand is low (-10.0% to 0.0%), increase the setting

on the air:acid gas manual ratio set (HIC) to raise the ratio and
increase the air demand.
K. If the optical pyrometer is giving reliable indication of the front

zone temperature in the furnace, place the temperature
cascade control in service as follows:
(1) Confirm that the remote ratio setpoint that the front zone
temperature controller is supplying to the bypass acid gas
flow ratio controller matches the current setting on the ratio
controller.
(2) Confirm that the front zone temperature controller is in

(3) Switch the bypass acid gas flow ratio controller to

"cascade". If necessary, slowly adjust the setpoint of the
front zone temperature controller to its normal setpoint of
1200°C.

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(4) Verify that the controllers are adjusting the bypass gas
flow rate as needed to control the desired temperature in
the front zone of the Reactor Furnace.
L. The sulfur plant is now fully on-stream, firing on both amine acid
gas and SWS gas. Before switching the SRU tailgas to the
TGCU or directing your attention away from the SRU, be sure
that:

Before switching the SRU tailgas from the Thermal Oxidizer to the
TGCU Tailgas Cleanup Unit, be sure all of the following conditions
are true:

or lower.

tailgas into the TGCU. In particular, do not attempt switching tailgas
to the TGCU when the sulfur plant is upset. The result will be two
upset units to deal with. Instead, focus your attention on stabilizing
the operation of the SRU first (usually by correcting a problem in the
upstream Amine Regeneration Unit and/or Sour Water Stripper Unit),
and then use the operating procedures for the TGCU in the TGCU
section of these guidelines to switch the SRU tailgas from flowing to
the Thermal Oxidizer to flowing into the TGCU.

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(1) The Tailgas Valve to the Thermal Oxidizer and the TGCU
Warmup/Bypass Valve are fully closed.
9.8.7 Firing Supplemental Fuel Gas

As discussed in Section 9.6.11 of these guidelines, when a sulfur
condenser is operated at lower and lower rates, it reaches a point where
the bulk gas cooling rate caused by radiation and conduction heat transfer
exceeds the dewpoint reduction rate caused by sulfur condensation on the
tube walls. Instead of condensing along the walls of the tubes, sulfur
begins to condense into tiny droplets out in the gas. Due to the low flow
rates, there is not enough turbulence in the gas to make the droplets
coalesce along the tube walls. The droplets come out of the tubes as a
"fog" that cannot be removed in the downstream separator section, and
are carried over into the reactor feed heaters
Another one of the symptoms of low flow operating problems is a loss in

temperature rise across the catalyst beds in the Reactor. This
observation is not always an accurate indication that problems are
occurring, however, because the process temperatures are influenced by
other operating conditions, such as poor ratio control in the SRU as an
example. Instead, it is simpler to use the process air flow rate to the SRU
as the main process parameter to monitor.
It turns out that the process air flow rate to the SRU is actually a very good
indicator of the mass flow rate through the SRU, because the process air
flow rate is a function of the amount of combustible compounds in the
incoming feed streams. As a result, regardless of whether or not
supplemental fuel gas is being fired in the SRU, the mass flow rate
through the plant is about the same per unit of air flow. So, if action is
taken to keep the process air flow rate high, sulfur "fog" formation should
not be a problem. The action to take if the air flow drops below this point
is to begin firing supplemental fuel gas. Since burning fuel gas in the Acid
Gas Burner will require more process air to combust the fuel gas, the fuel

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gas flow rate can be adjusted to maintain a minimum process air flow
(determined from experience).
As discussed in previous sections, the air:acid gas ratio control system in

the SRU is designed to automatically add the proper amount of air when
burning supplemental fuel gas, so initiating supplemental firing is as
simple as opening the control valve in the main fuel gas line to send fuel
gas to the Acid Gas Burner. It is important, however, to increase or
decrease the fuel gas flow rate slowly so that the control system has time
to respond.
The required fuel gas flow rate can be estimated from operating
experience. Once the fuel gas flow has been set using the flow control in
the DCS, observe the process air flow rate on the process air flow
controller in the DCS and adjust the fuel gas flow rate as needed to keep
the process air flow rate at the minimum flow rate. If the process air flow
is too low, raise the setpoint on the fuel gas flow controller to increase the
firing rate, which will increase the process air flow rate. If the process air
flow rate is higher than the minimum, reduce the setpoint on the fuel gas
flow controller to reduce the firing rate and reduce the process air flow.
While firing supplemental fuel gas, observe the Reactor Furnace

temperature closely on the temperature controllers in the DCS. As the
supplemental firing rate is increased, the furnace temperature will begin to
rise and the ratio setting on the bypass acid gas ratio controller may have
to be adjusted. (If the temperature control cascade for the front zone
temperature is in service, the front zone temperature controller should
adjust the ratio setting automatically.) Do not allow the furnace
temperature to exceed 1,500°C, however, as operation at temperatures
above this may cause the refractory lining to fail. Do not increase the
firing rate even if it means the process air flow drops below the minimum
flow rate. The unit will just have to suffer the low-flow operating problems
if the feed rate drops to this point, in order to avoid damaging the Reactor
Furnace.
The bypass acid gas flow ratio controller, will initially be able to maintain
the desired furnace temperature by reducing the bypass gas flow rate to
send more of the amine acid gas to the burner, which will lower the
temperature in the front zone of the Reactor Furnace. In fact, if enough
supplemental fuel gas is fired at the burner, all of the amine acid gas can
be routed to the burner due to the increase in furnace temperature caused
by the heat release from the fuel gas combustion. However, once the

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bypass acid gas flow ratio controller has routed all of the amine gas to the
burner, it will no longer be able to control the front zone temperature, and
this temperature may begin to rise. If so, reduce the supplemental fuel
gas flow rate as needed to keep the furnace temperature below 1,500°C
(preferably, below 1370°C).
9.8.7.1 Initiating Supplemental Firing

Supplemental fuel gas firing is accomplished by relighting the
warmup burner in the Acid Gas Burner. The procedure below
assumes that the SRU is on-line and processing acid gas.
A. Select local manual control for the fuel gas flow control valve by
"local".
B. Place the fuel gas flow controller in "automatic".
C. If necessary, "toggle" the fuel gas flow on/off switch in the DCS
to "ON" so that the fuel gas flow will be included in the
air:acid gas ratio control system.
D. Set the manual fuel gas control on the local SRU control panel
to 0% output and visually confirm that the main fuel gas valve
and the two shutdown valves are closed.
E. Open the following manual block valves:
(1) The upstream manual block valve(s) in the main fuel gas
supply line.
(2) The downstream manual block valve(s) in the main fuel

gas line to the burner.
F. Press the "FUEL GAS ON" push-button on the local SRU control
panel to open the main fuel gas block valves and illuminate the
“FUEL GAS ON” light.
G. Adjust the output of the main fuel gas flow control (HIC) on the
local SRU control panel to slowly open the control valve and
commence fuel gas flow to the warmup burner ring. Look
through the viewports on the Acid Gas Burner and adjust the
fuel gas flow rate until a stable flame can be maintained on the
burner tips.

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H. Observe the air flow on the process air flow controller and
confirm that the air:acid gas ratio control system has added the
air needed to combust the fuel gas.
I. Switch the fuel gas flow rate to automatic control as follows:
(1) Confirm that the fuel gas flow controller in the DCS is in
"automatic", its output is tracking the output of the main
fuel gas flow control (HIC) on the local SRU control as
indicated in the DCS, and its setpoint is tracking its current
reading.
(2) Switch the main fuel gas hand switch (HS) from "local" to
"remote". The DCS controller now has control of the fuel
gas control valve and will be controlling a fixed fuel gas
flow rate, with its setpoint equal to the last reading
J. If the process air flow indicated on the process air flow

controller is already at the minimum flow rate or higher, do not
lower the fuel gas flow. Leave the fuel gas flow controller
setpoint where it is, as this is the minimum fuel gas flow for a
stable flame on the warmup burner ring at the current operating
conditions. Lowering the fuel gas flow could create an unstable
fuel gas flame and lead to operating problems.
There is no harm in firing more supplemental fuel gas than is

necessary as long as the furnace temperature does not exceed
the maximum operating temperature of the refractory, 1,500°C.
The only disadvantages are the higher fuel gas cost and a slight
reduction in the sulfur recovery. (Since water is a product of the
Claus reaction, the water vapor in the fuel gas combustion
products tends to inhibit the Claus reaction to a degree.)
K. If the process air flow indicated on the process air flow

controller is less than the minimum flow rate, slowly raise the
setpoint on the fuel gas flow controller to increase the
supplemental fuel gas firing rate. The air:acid gas ratio control
system will in turn raise the setpoint of the process air flow
controller and increase the air flow rate. Adjust the fuel gas
flow rate as needed to maintain the air flow at the minimum flow
rate or above on the process air flow controller.

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L. Monitor the furnace temperature closely and make appropriate

adjustments to the ratio setting on the bypass acid gas ratio
controller. If the temperature control cascade for the front zone
temperature is in service, the front zone temperature controller
should adjust the ratio setting automatically.
If necessary, lower the fuel gas flow rate to keep the furnace
temperature at 1,500°C or below. Once the output from the
bypass acid gas flow ratio controller reaches 0% and the
bypass acid gas control valve is fully closed, the bypass gas
ratio controller will no longer be able to control the furnace
temperature.
M. Monitor the air demand on the air demand controller closely and
be prepared to adjust the air:acid gas ratio as necessary with
the air:acid gas manual ratio set (HIC) to help the air demand
controller keep the plant "on-ratio".
N. If the warmup burner does not light or will not maintain a stable
flame:
(1) Press the “FUEL GAS OFF” push button to block-in the main
fuel gas.
(2) Verify that the main fuel gas automated block valves have
closed, the main fuel gas automated vent valve has
opened, and the “FUEL GAS ON” light has been
extinguished.
(3) Close the manual block valve(s) in the main fuel gas
supply line.
(4) Close the downstream manual block valve(s) in the main

fuel gas line to the burner.
The most likely reason for failure of the burner to light is

physical damage to the burner (plugging of the tips with scale,
carbon, sulfur, or corrosion products, melting of the tips, etc.).
In such cases, the nitrogen purge flow to the warmup burner will
usually be low or nonexistent. Supplemental fuel gas firing (as
well as warmup of the SRU during a "cold" startup) will not be
possible until the SRU is shut down so that the burner can be
repaired.

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9.8.7.2 Discontinuing Supplemental Firing

When the acid gas feed rate increases again and supplemental fuel
gas firing is no longer needed to keep the process air flow above the
minimum rate, the supplemental firing can be discontinued as
described below.
A. Place the fuel gas flow controller in "manual".
B. Slowly reduce the output from the fuel gas flow controller to 0%
to close the control valve in the main fuel gas line and reduce
the fuel gas flow to zero. Lower the fuel gas flow rate slowly to
allow the air:acid gas ratio control system to adjust the air flow
properly.
C. Press the “FUEL GAS OFF” push-button on the local SRU control
panel to "double block and bleed" the main fuel gas.
D. Verify that the main fuel gas block valves have closed, the
“FUEL GAS ON” light has been extinguished, and the warmup
burner is being purged with nitrogen.
E. Close the two manual block valve(s) in the main fuel gas line.
F. "Toggle" the fuel gas flow on/off switch in the DCS to "OFF" so
that the fuel gas flow rate will no longer be included in the
air:acid gas ratio control system (in case the meter does not
read exactly zero when there is no flow).

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The procedures to be used in performing a planned shutdown of a sulfur plant
will vary depending on the extent and type of work to be performed in and
around that SRU during the downtime period. If there are no plans for opening
the SRU such that air would be allowed entry to the catalyst beds in the
Reactor, few special procedures are required in performing the shutdown. In
general, unless there is a suspected problem in the Reactor or the catalyst is to
be replaced, there is no benefit to be gained from opening up the Reactor
vessel. If the Reactor vessel does not need to be opened (or exposed to
significant air entry during some other maintenance procedure), there is no need
to cool the catalyst beds. This greatly simplifies and shortens the shutdown
procedure. Section 9.9.1 that follows is an example of such a procedure.
Also, Section 9.9.1.K (1) briefly addresses keeping a sulfur plant on hot
stand-by to minimize corrosion due to water condensation in the boiler and
exchanger tubes. Since each SRU has a warmup bypass line to the Thermal
Oxidizer, they can be kept on hot stand-by indefinitely by firing on fuel gas and
venting the combustion products to the Thermal Oxidizer. This allows
maintaining the furnace refractory and heat exchanger surfaces at their normal
operating temperatures, ready to accept acid gas, without exposing the catalyst
beds to overheating, carbon deposition, or sulfation damage. (Refer to the
description of cold catalyst bed startup in these guidelines.)
If the catalyst is to be replaced, if the Reactor must be entered, or if

maintenance on some other portion of the plant will allow a significant amount of
air to enter the Reactor vessel, then more extensive and lengthy procedures
must be followed to accomplish a satisfactory shutdown and minimize the time
required for performance of the desired maintenance work. Section 9.9.2 that
follows is an example of a procedure for this circumstance.
One special circumstance that may exist during a shutdown is to have tube
leaks in either the Waste Heat Boiler or the Sulfur Condenser. This special
case is discussed in Section 9.9.3.

quickly identifying and correcting the problem so the SRU(s) can be put back
on-line in a minimum amount of time.

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Each SRU is affected directly and indirectly by shutdowns and outages that
occur in other systems. The more important aspects of the effects these other
systems can have on the SRUs are discussed in Section 9.9.5.
situation.
9.9.1 Planned Shutdown - No Reactor Entry

When there are no plans to open up the Reactor, there is no need to cool
the catalyst beds during the shutdown procedure. Even when entry to
other parts of an SRU is planned, this can normally be accomplished
without exposing the catalyst beds to significant amounts of air by using
slip-blinds to isolate the Reactor prior to purging, etc. Under these
circumstances, the shutdown procedure given in this section may be used
as a guide.
All of the equipment and process piping in each SRU is designed to be

free-draining so that there should be very little accumulation of liquid sulfur
within the unit during normal operation. For this reason, there is usually no
need to perform a "sulfur strip" when shutting down an SRU, as there is
generally very little residual sulfur contained in the catalyst beds and
separation chambers when the sulfur plant is shut down. Experience has
shown that plugging of the piping or equipment with solid sulfur during the
subsequent restart is normally not a problem. If, however, there is reason
to believe that there has been significant accumulation of sulfur within the
unit, the "sulfur strip" procedure described in Section 9.9.2 can be
performed at the conclusion of this procedure.
It is generally preferable to shut down the SRU in a controlled fashion to

minimize the impact on the other process units. If time does not allow
performing a controlled shutdown, however, the unit can be shut down by
simply activating the SRU ESD system (using either the local push-button
or the DCS "toggle" switch). This will automatically block the feeds into
the SRU (amine acid gas, SWS gas, fuel gas, and combustion air).
To shut the SRU down in a controlled fashion, follow the procedure below.
A. If both SRUs are to be shut-down, the Tailgas Cleanup Unit should

be shut down first using one of the procedures in these guidelines.

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However if one SRU remains on-line, the TGCU can remain online
as well.
B. Discontinue SWS gas flow to the SRU by slowly reducing the output
from the manual control hand controller on the local SRU control
panel to begin closing the SWS gas shutdown valve. Allow time for
the air flow controller to reduce the air flow to the SRU accordingly.
C. Continue to reduce the output from the manual controller to 0% until

the SWS gas inlet valve is completely closed.
The pressure control system(s) on the Sour Water Stripper(s) should

begin to divert the SWS gas flow to the flare as the feed rate to the
SRU is reduced.
D. Begin to "back out" the amine acid gas flow to the SRU by slowly
reducing the output from the manual control hand controller on the
local SRU control panel to begin closing the amine acid gas
shutdown valve. Allow time for the air flow controller to reduce the
air flow to the SRU accordingly.
E. Observe the amine acid gas flow rate the flow indicator on the local
SRU control panel and continue reducing the output on the manual
controller until the flow rate drops to 20-30%.
The pressure control system on the stripper in the ARU should begin
to divert the amine acid gas flow to the flare as the feed rate to the
SRU is reduced.
F. Once the amine acid gas flow rate is down to 20-30%, the SRU can
be shut down with minimal impact on the other process units. The
simplest way to do so is to activate the SRU ESD system, using
either the push-button in the DCS or the push-button on the local
SRU control panel.
G. Visually confirm that:
(1) The amine acid gas shutdown valve is closed.
(2) The SWS gas shutdown valve is closed.
(3) The fuel gas to the Acid Gas Burner is blocked-in and bled.
(4) The Process air Blower is shut down and the suction, blow-off,
and discharge valves are closed.

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(5) All steam heating services are still functioning and the steam
traps are operating properly.
H. If the TGCU was shut down in Step A, the Tailgas Valve to the TTO
should have been opened and the Tailgas Valve to the TGCU should
have been closed automatically. Visually confirm the positions of
these valves.
If this is not the case, proceed as follows:
(1) Switch the Startup/Run selector switch on the local SRU control
panel to "STARTUP".
the Tailgas Valve to the TGCU. Verify that the "WARMUP OPEN"
light on the panel is now illuminated and the "TGCU OPEN" light
is extinguished.
(2) Switch the Startup/Run selector switch back to "RUN".
The PLC will open the Tailgas Valve to the TTO, then close the
Warmup Bypass Valves. Verify that the "TTO OPEN" light on the
panel is illuminated, and that the "WARMUP OPEN" and "TGCU
OPEN" lights are extinguished.
I. If the other SRU and the TGCU are to remain online, isolate the
off-line SRU from the TGCU and the Thermal Oxidizer:
(6) Switch the Startup/Run selector switch on the local SRU control
panel to "STARTUP".
(7) The PLC will open the two Warmup Bypass Valves and close
the Tailgas Valve to the TGCU or the Tailgas Valve to the TTO.
Verify that the "WARMUP OPEN" light on the panel is now
(8) Turn the Leak Test key switch on the local SRU control panel to
"TEST".
(9) The PLC will close the two Warmup Bypass Valves and start the
nitrogen purge between the valves. Verify that the "WARMUP
OPEN" light on the panel is now extinguished, and that nitrogen is
flowing into the piping by observing the FI.

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(10) If desired, close the manual block valve in the SRU tailgas line.
J. All temperatures in the sulfur plant should be monitored to confirm

that no air leaks into the system (due to "drafting" from the Thermal
Oxidizer, for instance) and causes sulfur fires in the catalyst beds. If
possible, establish a small flow of inert gas into the SRU inlet to
purge the SRU to the Thermal Oxidizer using the nitrogen connection
on the air line to the Acid Gas Burner.
WARNING
STEPS MUST BE TAKEN TO ENSURE THAT THE SRU IS NOT

COMPLETELY BLOCKED-IN.
FOR INSTANCE, IT IS POSSIBLE TO BLOCK-IN THE SRU BY

CLOSING THE BLOCK VALVES IN THE WARMUP BYPASS LINE
AND IN THE TAILGAS LINES TO THE THERMAL OXIDIZER AND
THE TGCU. BEFORE DOING SO, ANOTHER OPENING FROM THE
SRU TO THE ATMOSPHERE MUST BE CREATED SO THAT THE
SRU CANNOT BE OVER-PRESSURED.
K. If the SRU will be down for an extended period, special precautions

should be taken to prevent the boiler and exchanger tubes from
cooling to the point where water can condense inside them. Most of
the corrosion that occurs in sulfur plants is due to the acidic water
that can form if the plant is allowed to get cold.
(1) The Waste Heat Boiler, the reheat exchangers and the Sulfur
Condenser can be kept hot by firing the warmup burner in the
Acid Gas Burner with fuel gas, using the Warmup Bypass
Valves to divert the combustion gases to the Thermal Oxidizer.
Use the procedures in these guidelines to fire the SRU in hot
standby mode on fuel gas.
(2) If this is not possible, allow the two boilers to cool enough to
reduce the steam pressure to about 1 kg/cm2(g). Then
de-pressure the boilers and drain the water from them. Use a
temporary "jumper" to supply LP steam to the Waste Heat

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Boiler, open the sulfur condenser pressure control valve to

"back" LP steam into Sulfur Condenser, and drain the
condensate from them occasionally. (Make sure the valves are
open in the condensate outlet lines from the reactor feed
heaters.) This will keep the tubes in the boilers and reheat
exchangers safely above the water condensation temperature
(100-110°C).

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9.9.2 Planned Shutdown for Reactor Entry

It is always best, but not absolutely necessary, to reduce the amount of
residual sulfur contained in the catalyst beds and separation chambers to a
minimum before opening the sulfur plant equipment for maintenance or
catalyst change-out. This minimizes the purging and cleaning required prior
to vessel entry. This "sulfur strip" can be accomplished most effectively by
raising temperatures throughout the plant and routing inert gas through the
plant.
In this procedure, where complete cooling of the plant and air purging are
required, the time-controlling step will be the period of time required to
cool the catalyst beds below 150°C. Also, attention should be given to the
cooling of the Reactor Furnace refractory; it should be limited to
100-150°C per hour. The catalyst beds must be cooled to 150°C or below
before air flow can be established to purge the plant and cool it rapidly
from that temperature. If the catalyst beds are not cooled to this level
before beginning the air purge, sulfur fires can occur in the beds, the
sulfur separators and mist eliminators, and the other parts of the plant
where elemental sulfur is present.
9.9.2.1 Cooling Gas for the Catalyst Beds

There will always be enough sulfur in a used catalyst bed to burn and
generate sufficient heat to damage equipment if enough air is routed
to the bed to supply the oxygen required for combustion. Therefore,
gases which contain essentially no oxygen must be routed through
the catalyst beds until the outlet temperature from each bed is below
150°C. Otherwise, the plant would have to be blocked-in for days to
obtain the necessary ambient heat loss cooling of the catalyst beds.
The following gases can be considered for catalyst bed cooling:
A. Inert gases such as nitrogen, carbon dioxide, or a mixture of

nitrogen and carbon dioxide like that produced by a
combustion-type inert gas generator.
We recommend cooling the SRU with LP nitrogen from the from

the hard-piped nitrogen connection on the Process Air line to
the burner. However, if sufficient nitrogen is not available from
the nitrogen header in the plant or some other source, inert
combustion gases may be generated by firing the warmup fuel
gas burner inside the Acid Gas Burner near stoichiometric

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air:gas ratio (little or no excess air), or slightly below

stoichiometric. There are a few disadvantages with this
technique:
(1) Careful control of the air:gas ratio is required to keep it

near stoichiometric. Too much air will allow free oxygen to
reach the catalyst beds, causing sulfur fires. Too little air
can cause the warmup burner to produce soot. However,
the only real damage the soot will cause is to settle out on
the first catalyst bed. If the catalyst is being replaced, this
will be of no consequence.
(2) The flame temperature when burning fuel gas with

stoichiometric air is generally in excess of 1600°C. Steam
or nitrogen (or some other inert gas) will probably have to
be added to the Reactor Furnace to keep the furnace
temperature below 1500°C as measured on the
pyrometers so that there is no damage to the refractory.
B. Steam is a good catalyst bed cooling gas. The only negative

factor is that pure steam may damage the activity of some
sulfur plant catalysts. If the catalyst is being replaced, then
steam is a good choice. If the catalyst is not being replaced,
the catalyst manufacturer should be contacted to determine the
extent of damage, if any, that would result from cooling the
catalyst with steam to the 150°C temperature level. It is likely
that little catalyst damage will occur unless the temperature is
allowed to fall below about 110°C where water could condense.
If steam is to be used for cooling, it may be necessary to take

steps to maintain at least 0.7 kg/cm2(g) steam pressure on the
shell sides of the Waste Heat Boiler and the Sulfur Condenser
in order to prevent water condensation in the plant.
Temperatures should be monitored closely and steam
pressures controlled if necessary. If these two boilers cool
enough to reduce the steam pressure to about 1 kg/cm2(g),
de-pressure the boilers and drain the water from them. Use a
temporary "jumper" to supply LP steam to the Waste Heat
Boiler , open the sulfur condenser pressure control valve to
"back" LP steam into Sulfur Condenser, and drain the
condensate from them occasionally. (Make sure the valves are
open in the condensate outlet lines from the reactor feed

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heaters.) This will keep the tubes in the boilers and reheat
exchangers safely above the water condensation temperature
(100-110°C).
9.9.2.2 "Sulfur Strip" Procedure Using Inert Gas

Before cooling down the catalyst beds, the amount of residual sulfur
in the SRU should be reduced as much as possible by performing a
"sulfur strip" on the plant. This can be accomplished by flowing hot
inert gas through the catalyst beds to vaporize any residual sulfur,
which is subsequently condensed and removed in the downstream
passes of the Sulfur Condenser.
The preferred source of inert gas is nitrogen from the plant header. If
nitrogen (or some other type of inert gas from an external source) is
available in sufficient quantity, follow the procedure given in this
section to use nitrogen or inert gas as the stripping media.
If nitrogen or inert gas is not available in sufficient quantity, follow the

procedure given in this section using either steam or inert gas
generated with the Acid Gas Burner as the stripping media.
A. Follow the procedure given in the preceding Section 9.9.1 to

"back out" the SWS gas and amine acid gas feeds to the SRU
and shut it down.
B. Visually confirm that:
(1) The amine acid gas shutdown valve is closed.
(2) The SWS gas shutdown valve is closed.
(3) The fuel gas to the Acid Gas Burner is blocked-in and
bled.
(4) The Process air Blower is shut down and the suction,
blow-off, and discharge valves are closed.
(6) The Tailgas Valve to the TTO is open.
(7) The manual block valve in the SRU tailgas line is open.
(8) All steam heating services are still functioning and the
steam traps are operating properly.

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C. Begin the flow of inert gas through the plant.
(1) If using nitrogen from the plant header, the nitrogen can be
introduced through the hard-piped connection on the
process air line near the Acid Gas Burner.
(2) If using inert gas from another source, it can be introduced

through the bleed valve on the hard-piped LP nitrogen
connection near the Acid Gas Burner.
(3) If using the warmup burner in the Acid Gas Burner to

generate inert gas, take care to keep the Reactor Furnace
temperature below 1500°C on the pyrometers. Admit
nitrogen or LP steam (using the hard-piped LP nitrogen
connection on the process air line near the burner) to the
furnace as necessary to moderate the furnace temperature.
Use an oxygen analyzer to measure the oxygen content of
the combustion gas flowing to the first catalyst bed in the
Reactor, and adjust the air:gas ratio as necessary to keep
the oxygen concentration between 0.5% and 2.0%. If
steam is being used to moderate the furnace temperature,
make sure that there is no liquid in the steam supply before
introducing it into the furnace to avoid an explosion from
water entering the hot furnace.
D. Adjust the temperatures throughout the plant by making

changes as follows:
(1) Place the steam pressure controller on the Waste Heat

Boiler in "manual" and adjust its output to 100% to fully
open the steam valve. This will allow steam from the
HP steam header to "back" into the boiler (if using nitrogen
or inert gas).
(2) Place the temperature controllers for the Reactor feeds in

"manual" and set their outputs to 100% to fully open the
valves in the condensate outlet lines from the exchangers
and supply maximum heating to each catalyst bed.
(3) Lower the steam pressure in the Sulfur Condenser if

possible by adjusting the setpoint of the pressure
controller to 1 kg/cm2(g). This will condense as much
sulfur as possible as it is "stripped" from the three catalyst

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beds. (It should be noted that the back-pressure from the

LP steam header will probably not allow operating the
Sulfur Condenser any lower than about 3.5 kg/cm2(g).)
The hot inert gas flowing through the Reactor should vaporize
most of the residual sulfur contained in the catalyst beds so that
it can be condensed and removed in the downstream
condensing passes of the Sulfur Condenser.
E. Continue to purge the sulfur plant with this inert gas stream until
sulfur is no longer running from any of the Sulfur Drain Seal
Assemblies.
Once sulfur stops running from all of the Sulfur Drain Seal
Assemblies, cool-down of the catalyst beds can commence
using the procedure given in Section 9.9.2.3 that follows.
9.9.2.3 Cool-down Procedure

Once the "sulfur strip" procedure is complete, cool-down of the
catalyst beds can begin. The cool-down gas will normally be the
same inert gas that was used for the "sulfur strip" operation.
However, if inert gas is being generated using the warmup burner in
the Acid Gas Burner as described in Section 9.9.2.2, it may be
desirable to switch to a once-through flow of inert gas (nitrogen, for
example) instead to cool the catalyst beds.
A. Begin reducing the steam pressures in the Waste Heat Boiler

and the Sulfur Condenser to 0.7-1.0 kg/cm2(g) by placing their
steam pressure controllers in "manual" and adjusting the
outputs to 0% to close the valves, then venting the boiler shells
to atmosphere. This steam pressure will keep the tubes in the
boilers safely above the water condensation temperature
(100-110°C).
(1) If dry inert gas (nitrogen) is being used for the cooling gas,
the steam pressures in both boilers can be allowed to fall
to 0 kg/cm2(g), since there is no risk of water condensation
in the tubes.
(2) If the warmup burner in the Acid Gas Burner is being used
to generate the inert gas, it may not be possible to reduce
the Waste Heat Boiler steam pressure to

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0.7-1.0 kg/cm2(g), since the combustion products will

provide considerable heat to the boiler.
B. Confirm that the temperature controllers for the Reactor feeds,

are in "manual" and set their outputs to 0% to fully close the
valves in the condensate outlet lines from the exchangers and
supply minimum heating to the catalyst beds.
C. Monitor the water levels in the Waste Heat Boiler and the Sulfur
Condenser and confirm that the level controls continue to
function properly to maintain normal levels in the boilers
throughout the cool-down procedure.
D. Continue to route inert gas through the catalyst beds, with

maximum cooling in the Sulfur Condenser and minimum
heating in the reheat exchangers, until the outlet temperatures
from all catalyst beds are below 150°C.
If using the warmup burner in the Acid Gas Burner to generate

inert gas, it may not be possible to cool the first catalyst bed
below 150°C. After extinguishing the burner, one of the
following intermediate steps may be necessary to cool this
catalyst bed below 150°C:
(1) Route nitrogen, steam, or some other inert gas through the
reactor.
(2) Allow the reactor to cool by ambient heat loss.
E. When all catalyst beds are below 150°C, stop the flow of
cooling gas. Switch the Startup/Run selector switch on the
local SRU control panel to "STARTUP".
the Tailgas Valve to the TTO Unit. Verify that the "WARMUP
OPEN" light on the panel is now illuminated and the "TTO OPEN"
light is extinguished.
F. Start a Process Air Blower:
(1) Switch blower hand swtich in the DCS to "local".
(2) Set air blower flow controller (HIC) on the local SRU
control panel to 0% output.

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(3) Press the local push-button to give a "permit to start" for

the desired blower.
that blower.
The next step would normally be to press the "ESD RESET"

push-button. Do not press it, however.
G. Turn the Reactor Cool-Down switch on the local SRU control

panel to "COOL-DOWN".
H. Switch the Startup/Run selector switch back to "RUN".
The PLC will open the Tailgas Valve to the TTO, then close the
Warmup Bypass Valves. Verify that the "TTO OPEN" light on the
panel is illuminated, and that the "WARMUP OPEN" and "TGCU
OPEN" lights are extinguished.
I. Increase the output from the local air flow controller (HIC) to
begin a rapid air purge of the entire sulfur plant.

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CAUTION
WATCH THE TEMPERATURES IN EACH CATALYST BED

AND OUTLET LINE VERY CLOSELY AFTER STARTING
THE AIR PURGE, UNTIL ALL ARE WELL BELOW 120°C.
SULFUR FIRES CAN IGNITE IN THE PLANT AFTER
STARTING THE AIR PURGE EVEN THOUGH ALL THE
TEMPERATURE INDICATORS REGISTERED 150°C OR
LESS. IT IS POSSIBLE, FOR INSTANCE, TO HAVE
LOCALIZED "HOT" SPOTS IN A CATALYST BED THAT
CAN START A SULFUR FIRE.
THE AIR PURGE SHOULD BE STOPPED IMMEDIATELY

UPON OBSERVING A SIGNIFICANT TEMPERATURE
RISE IN ANY TEMPERATURE INSIDE THE PLANT. THE
INERT GAS FLOW SHOULD THEN BE RE-ESTABLISHED
UNTIL ALL AREAS ARE COOLED BACK TO THE
DESIRED 150°C LEVEL, BEFORE REATTEMPTING THE
AIR PURGE.
J. Continue the rapid air purge of the entire sulfur plant until all
temperatures are approximately equal to the discharge air
temperature from the blower.
K. Isolate the plant from all potential contaminating gases (acid

gas, fuel gas, etc.), using slip-blinds or by disconnecting the
piping, before stopping the air purge.
L. Once the plant is isolated from the feed gases, discontinue the
air purge by shutting down the Process Air Blower.
M. Turn the Reactor Cool-Down switch on the local SRU control

panel back to "NORMAL".
N. Isolate the SRU from the TGCU and the Thermal Oxidizer:
(1) Switch the Startup/Run selector switch on the local SRU

control panel to "STARTUP".
The PLC will open the two Warmup Bypass Valves and
close the Tailgas Valve to the TTO. Verify that the

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"WARMUP OPEN" light on the panel is now illuminated and

the "TTO OPEN" and "TGCU OPEN" lights on the panel are
extinguished.
(2) Turn the Leak Test key switch on the local SRU control
panel to "TEST".
The PLC will close the two Warmup Bypass Valves and
start the nitrogen purge between the valves. Verify that the
"WARMUP OPEN" light on the panel is now extinguished, and
that nitrogen is flowing into the piping by observing the FI.
(3) If desired, close the manual block valve in the SRU tailgas
line.
O. Visually confirm that:
(1) The SRU is isolated from the amine acid gas source, the
SWS gas source, the fuel gas header, the instrument air
header, the nitrogen header, the TGCU, and the Thermal
Oxidizer.
(2) The Process Air Blowers are shut down and their suction,
blow-off, and discharge valves are closed.
(3) All steam heating services are still functioning and the
steam traps are operating properly. If possible, the
LP steam and condensate system should remain in
service, with selected branches taken out of service as
required for maintenance.
P. The plant can now be opened for entry. Refer to the "General
Safety" section of these procedures for important
considerations when performing maintenance work on this
plant.
WARNING
THE OVER-PRESSURE PROTECTION FOR THE SRU IS THE

SULFUR DRAIN SEALS, A2-ME1530A-D(A2-ME1540A-D),
WHICH WILL RELEASE THE GAS INSIDE THE SRU IF THE

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PRESSURE EVER EXCEEDS 0.88 KG/CM2(G). HOWEVER, IF

THE BLOCK VALVES IN THE RUNDOWN LINES TO THE
SULFUR DRAIN SEALS ARE CLOSED WHILE THE SRU IS
SHUT DOWN, STEPS MUST BE TAKEN TO ENSURE THAT
THE SRU IS NOT COMPLETELY BLOCKED-IN BY CREATING
ANOTHER OPENING FROM THE SRU TO THE ATMOSPHERE
SO THAT THE SRU CANNOT BE OVER-PRESSURED.
Q. If the SRU will be down for an extended period, special

precautions should be taken to prevent the boiler and
exchanger tubes from cooling to the point where water can
condense inside them. Most of the corrosion that occurs in
sulfur plants is due to the acidic water that can form if the plant
is allowed to get cold.
The Waste Heat Boiler, reheat exchangers and the Sulfur

Condenser can be kept hot using LP steam. De-pressure the
boilers and drain the water from them. Use a temporary
"jumper" to supply LP steam to the Waste Heat Boiler, open the
sulfur condenser pressure control valve to "back" LP steam into
Sulfur Condenser, and drain the condensate from them
occasionally. (Make sure the valves are open in the
condensate outlet lines from the reactor feed heaters.) This will
keep all the tubes safely above the water condensation
temperature (100-110°C).

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9.9.3 Shutting Down When Boiler Tubes Are Leaking

One special circumstance that merits discussion is shutting down the SRU
when there are tube leaks in the Waste Heat Boiler or Sulfur Condenser.
While the plant is running, minor tube leaks usually cause little damage
because the hot process gas vaporizes the boiler feed water before it has
a chance to form acid and cause rapid corrosion. When the SRU is shut
down, however, several problems can develop:
1. Liquid water may accumulate in the equipment or piping and form a

variety of acids (sulfurous, polythionic, etc.) that will rapidly corrode
the steel.
2. Liquid water may reach the refractory linings in the equipment and
damage the linings.
3. Water and/or steam may reach the catalyst in the Reactor and
weaken or damage it.
4. If there is a large tube leak in the Waste Heat Boiler, water may
back-flow into the hot Reactor Furnace and rapidly vaporize, possibly
violently enough to damage its refractory lining or create high
pressure in the SRU.
If a boiler tube leak is suspected, a shutdown procedure similar to the

following may be appropriate:
A. Shut down the SRU using the procedures given in Section 9.9.1.
B. Commence a flow of nitrogen as soon as the Acid Gas Burner is shut

down to purge any steam from tube leaks to the Thermal Oxidizer.
C. De-pressure the boiler having the suspected tube leak, taking care to
reduce the pressure slowly enough to avoid over-stressing the boiler.
D. Maintain a visible water level in the boiler. Water must remain in the
boiler until it is de-pressured to prevent overheating damage to the
tubes.
E. Once the boiler is fully de-pressured, drain the water from the boiler
to prevent any further leakage into the process side of the
equipment.
F. The SRU is now ready to be isolated and made safe for entry.

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The SRU ESD system can be initiated by any of the actuating devices
outlined in these guidelines, or by a power failure. The operator must
determine and correct the condition causing the shutdown before the
sulfur plant can be restarted. The problems outlined below should be
investigated first by the operator in his troubleshooting procedure.
If the malfunction causing the emergency shutdown can be determined

and corrected in a short period of time, the SRU can be put back on-line
using the rapid restart procedure outlined in these guidelines.
Acid Gas Knock-Out 1. Excessive liquids being received by the

Drum Knock-Out Drum.
inoperable.
4. Knock-Out Drum Pump malfunction.
5. Pump suction or discharge line plugged,
strainer plugged, or block valve closed.
6. Malfunction of the stripper reflux pumps in
the upstream system.
Process Air Blower 1. Equipment damage has caused the blower

Not Running to quit running.
2. A failure in the starter contacts is causing a
false indication that the blower is not
running.
Reactor Furnace 1. Warmup bypass valve or tailgas block

High-High Pressure valve not open.
2. A sulfur condenser separator chamber is
filled with molten sulfur due to plugging of a
sulfur rundown line or a drain seal.
3. Steam pressure is too low in the Sulfur
Condenser, causing tubes to be plugged
with solid sulfur.
4. Soot or carbon buildup in a catalyst bed or
a sulfur condenser mist eliminator is
restricting flow.
5. Malfunction of the air pressure sensing
system.

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Acid Gas Burner 1. Failure of a component in the flame sensor

Flame Failure circuit.
2. Condensation of sulfur or water vapor on
the lens of the flame scanner.
3. Low acid gas (or fuel gas) flow.
4. Low process air flow due to:
a. Malfunction of the blower suction valve
or the flow control system.
b. Blower discharge valve is not fully
open.
c. Blower blow-off valve is open
excessively.
d. Blower shutdown due to mechanical
problems with the blower, the motor, or
the switchgear.
e. High pressure drop due to plugging or
blockage downstream.
Waste Heat Boiler 1. Loss of make-up water supply pressure.

Low-Low Level 2. Make-up water line plugged, or manual
block valve closed or pinched.
3. Malfunction of the level control system.
4. Manual blowdown valve left open.
Reactor 1st Bed Outlet 1. Malfunction of the air:acid gas ratio control
High-High Temperature system, allowing excess air to enter the
system.
2. Malfunction of the control system has
caused less than 1/3 of the acid gas to be
routed to the burner, allowing free oxygen
to reach the catalyst bed.
3. Low H2S concentration in the inlet acid gas
is causing incomplete combustion in the
Reactor Furnace, allowing free oxygen to
reach the catalyst bed.
4. Damaged acid gas burner tip causing
incomplete mixing and combustion of air
and acid gas, allowing free oxygen to reach
the catalyst bed.
5. Malfunction of the control system has
caused a high reactor inlet temperature.

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Sulfur Condenser 1. Loss of make-up water supply pressure.

Low-Low Level 2. Make-up water line plugged, or manual
block valve closed or pinched.
Neither Warmup Bypass 1. Neither warmup bypass valve is fully

Valve Closed Interlock closed.
2. Malfunction of a limit switch is causing a
false indication that a valve is not closed.

The Sulfur Recovery system is directly or indirectly affected by shutdowns
and/or outages in five other systems in the plant. These effects are
described below.
9.9.5.1 ATU / ARU Outages

Acid gas flow from the ARU can be interrupted for a variety of
reasons. For instance, the gas flow to the absorber in the ATU in the
plant can be blocked manually or automatically, the solvent flow from
the flash tank to the stripper can be interrupted, etc. When these
events occur, the acid gas flow will not cease immediately due to the
residence time in the solvent distribution piping, the flash tank, and
the stripper. If processing in the affected ARU is restarted within the
time frame of this system residence time, the amine acid gas flow to
the SRU will probably dip, but should not stop completely.
If the interruption in the ARU is long enough, though, the amine acid
gas flow can fall far enough to cause the acid gas flame in the SRU
to become unstable, at which point the SRU ESD system will be
activated by "flame failure". If this happens, the SRU can be
restarted on fuel gas and run in hot stand-by using the Warmup
Bypass Valves, then brought back on-line once amine acid gas flow
resumes. If the SRU is currently processing SWS gas, it is possible
that the acid gas flame may remain stable enough for continued
operation on just SWS gas. If the SRU is processing only SWS gas,
note the cautions in these guidelines regarding this mode of
operation.

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9.9.5.2 Sour Water Stripper Outages

SWS gas flow from the Sour Water Stripper can also be interrupted
for a variety of reasons. However, since the loss of SWS gas flow to
the SRU generally has minimal impact, outages in this system are
usually of little consequence.
9.9.5.3 TGCU ESD System

When the TGCU ESD system is activated, its warmup/bypass valve
opens immediately to divert the tailgas from the upstream SRUs to
the Thermal Oxidizer. At the same time, the PLC opens the Tailgas
Valve to the TTO proves the valve open, then closes the Tailgas
Valve to the TGCU. Once this switch is complete, the SRU tailgas
stream is blocked off from the TGCU and flows directly to the
Thermal Oxidizer.
When the TGCU warmup/bypass valve first opens, the pressure drop
through the TGCU will no longer be imposing back-pressure on the
SRUs. Depending on the magnitude of this change in back-pressure
(which is mainly determined by the unit throughput), there may be a
temporary "bobble" in the feed and air flow rates to the SRUs.
Although this will probably cause brief deviations from the proper
air:acid gas ratio in the SRUs, the "bobble" should not be large
enough to cause a "flame failure" shutdown in the SRU. If so, the
SRU will remain on-line with its tailgas flowing to its Thermal
Oxidizer, so that there is no need to restart the SRUs. Once the
TGCU has been restarted, the SRU tailgas streams can be
reintroduced into the TGCU to resume processing with as little
interruption as possible.
9.9.5.4 Thermal Oxidizer ESD System

A TTO ESD has no direct effect on the upstream SRUs, as the flow
of SRU tailgas and/or TGCU effluent to the Thermal Oxidizer will not
be interrupted. However, when the TTO ESD shuts down the
Thermal Oxidizer Burner, the sulfur compounds in the Thermal
Oxidizer feed gas will no longer be oxidized to sulfur dioxide. This
means that hydrogen sulfide will be vented to the atmosphere from
the top of its Thermal Oxidizer Vent Stack. Under normal
circumstances, this is not a cause for concern because the TGCU is
on-line processing the SRU tailgas. Since the H2S content of the

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TGCU effluent is low and the stack is tall, dangerous ground level
concentrations of H2S should not develop.
However, if the SRU is running directly to the TTO while

operating off-ratio on the "air deficient" side (negative air
demand), high concentrations of H2S could be vented from the
stack when the TTO is shut down. For this reason, pay very
close attention to the air demand controller and the air:acid gas
ratio control system in the SRU when the TTO is off-line, and be
prepared to shut down the SRU if it is not operating properly.
In particular, note the warnings in the TTO Sections of these

guidelines regarding high temperature in the Thermal Oxidizer if the
SRU tailgas contains excessive amounts of H2S. Also, note that the
operating permit for this plant may not allow venting un-incinerated
gases for extended periods. Review the permit before operating in
this mode for a lengthy period.
If the H2S concentration in the TTO feed gas is high (above 3.0%),
do not attempt to restart the Thermal Oxidizer. Instead, direct your
attention to the amine or SWS unit(s) upstream of the SRUs that are
probably causing the problem and bring the SRUs back on-ratio, so
that the H2S concentration in the Thermal Oxidizer feed gas is
reduced to an acceptable level and restart of the Thermal Oxidizer
can proceed smoothly.
Failure to correct the upstream problem(s) first will likely lead to

the TTO shutting down again, requiring another restart of the
TTO. If the H2S concentration is high enough, there is also a
possibility of causing an explosion in the Thermal Oxidizer.

There are two impacts on the SRU if the complex steam system is
shut down. One of these will only create problems if the steam
supply to the SRUs is unavailable for a long period of time. The
heating steam for the sulfur vapor switching valves, the sulfur
rundown lines, the Sulfur Surge Tanks and the Sulfur Storage Tank
will be lost, leading to solid sulfur freezing in these locations.
The more immediate impact on the SRU will be the loss of LP steam
to the stripper reboiler in the upstream Amine Regeneration Unit if
the steam outage lasts long enough. As the heat input to the reboiler

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declines, stripping of the acid gas from the solvent will decline and
the amine acid gas flow rate to the SRU will gradually diminish. If the
amine acid gas flow falls far enough to cause the acid gas flame to
become unstable, the SRU ESD system will be activated by "flame
failure" as described previously in the discussion about Amine
Regeneration Unit outages.

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This section contains analytical procedures for determining:
1. The H2S concentration in the inlet amine acid gas using Tutweiler analysis
(Sections 9.10.1, 9.10.2, 9.10.6, and 9.10.7).
2. The H2S and SO2 concentrations in the SRU tailgas using Tutweiler
analysis (Sections 9.10.1 and 9.10.3 through 9.10.7).
3. The H2S and SO2 concentrations in the SRU tailgas using gas detector
tubes (Section 9.10.8).
9.10.1 Procedure for Sampling and Titrating with a Tutweiler

Apparatus
The procedure given below is specifically written for a 100 ml Tutweiler
apparatus, commonly used when analyzing streams with high H2S
concentrations (amine acid gas, for instance). The same procedure can
be used with the 500 ml Tutweiler apparatus, commonly used for
analyzing dilute streams (SRU tailgas, for instance), by substituting a
reference to the 500 ml apparatus for all the references to the 100 ml
apparatus. With this in mind, the few differences in the procedure have
been noted by enclosing specific directions for the 500 ml apparatus in
parenthesis.
1. Using a 100 ml (500 ml) Tutweiler apparatus, fill the 10 ml titrating

burette on top of the Tutweiler apparatus with 0.1 N iodine solution
to some level below 10 ml. Carefully read and record this reading.
2. Fill a leveling bottle with fresh starch solution.
3. Attach a short piece of rubber tubing to the process sample valve.
4. Attach the leveling bottle filled with starch solution to the lower
stopcock of the Tutweiler burette.
5. Use the starch solution to purge the Tutweiler burette:
Raise the leveling bottle, open the lower stopcock, open the upper
stopcock to the inlet tube connection and completely fill the burette.
Close the upper stopcock when a few drops of the starch solution
flow out of the inlet tube connection. Close the lower stopcock.

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6. Purge the rubber tubing by venting acid gas (tailgas) to the

atmosphere a few seconds. Pinch the rubber tubing closed at the
end, close the gas sample valve, and slip the end of the rubber
tubing onto the inlet tube connection of the Tutweiler burette's upper
stopcock.
7. Crack the gas sample valve open and draw gas into the burette by
lowering the leveling bottle and opening the stopcocks. When the
liquid level is several milliliters below the 100-ml mark (500-ml mark),
close the lower stopcock, upper stopcock, and gas sample valve.
8. Remove the sample gas rubber tubing from the Tutweiler burette.
9. Open the lower stopcock and bring the starch solution to the
100-ml mark (500-ml mark) by raising the leveling bottle; then close
the lower stopcock. Open the upper stopcock long enough to
equalize the pressure inside the burette with the atmosphere, then
close the top stopcock. There is now exactly 100 ml (500 ml) of gas
at atmospheric pressure and ambient temperature in the Tutweiler
burette.
10. Open the lower stopcock and lower the leveling bottle. Lower the
level of the starch solution in the burette to the 110-ml mark
(550-ml mark) to pull a partial vacuum. Close the lower stopcock.
11. Place a tubing clamp on the rubber hose to the leveling bottle and
remove the hose from the Tutweiler burette lower stopcock.
12. Carefully crack the stopcock on the iodine burette and allow a small
amount of iodine solution to be sucked into the large burette. Close
the stopcock.
NOTE: Experience will soon allow the operator to know

approximately how much iodine will be needed. It is good
procedure to admit 75% of this "estimate" the first time.
13. Shake the burette vigorously, carefully holding the glass cap in place
on top of the iodine burette with one finger. As soon as all traces of
blue are gone, repeat the addition of iodine solution, adding smaller
and smaller amounts as the "anticipated" volume is approached.
NOTE: For best accuracy, the entire titration procedure explained

above should be done smoothly and quickly without

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interruption or delays. A yellow or red color may develop

during the titration, but it is of no significance.
14. Continue the titration until the starch solution turns a definite blue
color and holds the color without fading during shaking for
approximately one minute. Carefully read the final iodine burette
level.
15. Record the temperature of the air around the sampling point.
9.10.2 H2S Concentration in Acid Gas by the Tutweiler Method

The inlet amine acid gas can be sampled from the sample connection on
the outlet of the Acid Gas Knock-Out Drum.
1. Using a 100 ml Tutweiler apparatus, sample and titrate the acid gas
feed to the SRU as outlined in Section 9.10.1.
H2S + I2 2 HI + S

for example.)

Mole % H2S      (11.85)    
Solution Used Iodine Solution   289   P - V.P. 
three factors (which correct the actual acid gas content to
compensate for expansion due to temperature, pressure, and water
content) can be combined and calculated as a function of
temperature only. This has been done for the 100-ml gas sample

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and is included as the Tutweiler Factor Chart in this section

(Chart 1). Therefore, the equation above is simplified to:
 ml Iodine   Normality of   Factor from 

Mole % H2S     
Solution Used Iodine Solution   Tutweiler Factor Chart 

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16.0
Chart 1
15.5
Tutweiler Factor
vs.
Air Temperature
15.0
Sample Volume: 100 ml
Baro. Pressure: 1.033 kg/cm2(a)
14.5
14.0
13.5
13.0
Tutweiler Factor
12.5
12.0
11.5
11.0
10.5
10.0
9.5
9.0
-30 -20 -10 0 10 20 30 40 50

Air Temperature, °C

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9.10.3 H2S and SO2 Concentration in Tailgas by the Tutweiler Method

The sulfur plant tailgas can be sampled from the sample valve on the
outlet line from the fourth pass of the Sulfur Condenser.
1. Using a 500 ml Tutweiler apparatus, sample and titrate the SRU

tailgas as outlined in Section 9.10.1.
H2S + I2 S + 2 HI
SO2 + I2 + 2 H2O H2SO4 + 2 HI
The hydrogen sulfide (H2S) and sulfur dioxide (SO2) are converted by
the iodine during the shaking. When both gases are completely
converted, the slightest excess of free iodine causes the
characteristic blue color with the starch solution. Although the
relative amount of each gas cannot be determined from the Tutweiler
titration alone, only sulfur dioxide is converted to sulfuric acid
(H2SO4). Therefore, a further step can be used to determine the
amount of sulfuric acid formed in order to calculate the amount of
sulfur dioxide originally present in the gas sample.
NOTE: Sulfur dioxide and hydrogen sulfide react in the presence

of water to form sulfur:
2 H2S + SO2 3 S + 2 H2O
This side reaction (the Claus reaction) causes the iodine

titration to give a low answer. This can be minimized by
rapid titration.
3. Carefully drain the blue starch solution into a clean

250 ml Erlenmeyer flask. Rinse the inside of the Tutweiler burette
with distilled water and add this washing water to the flask with the
blue starch solution.
4. Using an eyedropper, add one drop of 0.1 N sodium thiosulfate

(Na2S2O3) and swirl the flask. This drop should use up the excess
iodine and the starch solution should lose its blue color. If more than
one drop is required, too much iodine was added.
5. Add five drops of methyl purple indicator to the flask and swirl gently.

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6. Titrate carefully to a definite green end point with 0.1 N sodium

hydroxide (NaOH).
7. Chemical reactions in this titration:
H2SO4 + 2 NaOH 2 H2O + Na2SO4
HI + NaOH H2O + NaI
8. Calculations:
a. For a 500-ml gas sample, Mole (or Vol) percent H2S + SO2 (dry
basis):
Mole %  ml Iodine   Normality of   273  T   760 

    Iodine Solution  (2.369)    
(H2S  SO2) Solution Used    289   P - V.P. 

The Normality of the standard iodine solution will be 0.1 N. The

last three factors (which correct the actual gas content to
compensate for expansion due to temperature, pressure, and
water content) can be combined and calculated as a function of
temperature only. This has been done for the 500-ml gas
sample and is included as the Tutweiler Factor Chart in this
section (Chart 2). Therefore, the equation above is simplified
to:
Mole %  ml Iodine   Normality of   Factor from 

    
(H2S  SO2) Solution Used  Iodine Solution   Tutweiler Factor Chart 
b. Mole (or Volume) percent SO2 (dry basis):
 ml NaOH  Normality of  

   
 Mole %    Used  NaOH Solution 
Mole % SO2   
   1
H2 S  SO 2   ml Iodine   Normality of  
 
   
  Used  Iodine Solution  
c. Mole (or Volume) percent H2S (dry basis):
Mole % H2S = Mole % ( H2S + SO2 ) – Mole % SO2
d. Molar (or Volume) Ratio of H2S to SO2 in tailgas:

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Mole % H2S
H2S : SO2 Ratio 
Mole % SO2
Calculate each quantity as shown above and divide to obtain the

H2S:SO2 ratio, or consult the Process Gas Analysis Table or the
Process Gas Analysis Operating Chart that follows the Tutweiler
Factor Chart.

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3.2
Chart 2
3.1
Tutweiler Factor
vs.
Air Temperature
3.0
Sample Volume: 500 ml
Baro. Pressure: 1.033 kg/cm2(a)
2.9
2.8
2.7
2.6
Tutweiler Factor
2.5
2.4
2.3
2.2
2.1
2.0
1.9
1.8
-30 -20 -10 0 10 20 30 40 50

Air Temperature, °C

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9.10.4 Tailgas Analysis Table

After completion of the Tutweiler iodine and sodium hydroxide titrations
(see Section 1 on the preceding pages) the Molar (or Volume) ratio of
hydrogen sulfide to sulfur dioxide in the SRU tailgas can be read directly
from this table. If the readings fall off the table, divide (or multiply) both
titration volumes by the same number in order to get within the range of
the table. Note, however, that the iodine and sodium hydroxide solutions
must be of the same Normality for the tabulated values to be correct.
Examples:
If 1.3 ml of 0.1 N iodine is used and 1.8 ml of 0.1 N sodium hydroxide

is used, the molar ratio of H2S:SO2 = 1.60.
If 3.0 ml I2 and 4.6 ml NaOH are used (these are off the table), divide
by 2 to get 1.5 ml I2 and 2.3 ml NaOH, for a molar ratio of
H2S:SO2 = 0.88.
If 0.8 ml I2 and 1.1 ml NaOH are used, multiply by 2 to get 1.6 ml I2

and 2.2 ml NaOH, for a molar ratio of H2S:SO2 = 1.67.
The values in the table below are the ratio of H2S:SO2 for the quantities of
iodine and sodium hydroxide used in the titrations.
NOTE: This table is valid only when the Normalities of the iodine and
sodium hydroxide solutions are the same.
ml
I2 ml of NaOH
1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
0.9 8.00 3.50 2.00 1.25 0.80 0.50 0.28 0.12 0.00 * *
1.0 * 9.00 4.00 2.33 1.50 1.00 0.67 0.43 0.25 0.11 0.00
1.1 * * 10.00 4.50 2.67 1.75 1.20 0.84 0.58 0.38
1.2 * * * 11.00 5.00 3.00 2.00 1.40 1.01 0.73 0.51
1.3 * * * * 12.00 5.50 3.33 2.25 1.60 1.18 0.88
1.4 * * * * * 13.00 6.00 3.67 2.50 1.80 1.35
1.5 * * * * * * 14.00 6.50 4.00 2.75 2.00
1.6 * * * * * * * 15.00 7.00 4.33 3.00
1.7 * * * * * * * * 16.00 7.50 4.67
1.8 * * * * * * * * * 17.00 8.00
1.9 * * * * * * * * * * 18.00
2.0 * * * * * * * * * * *
* Erroneous Test

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ml
I2 ml of NaOH
2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1
1.2 0.51 0.33 0.20 0.09 0.00 * * * * * * *

1.3 0.88 0.63 0.44 0.30 0.18 0.08 0.00 * * * * *
1.4 1.35 1.00 0.75 0.56 0.40 0.27 0.17 0.08 0.00 * * *
1.5 2.00 1.50 1.14 0.88 0.67 0.50 0.36 0.25 0.15 0.07 0.00 *
1.6 3.00 2.20 1.67 1.29 1.00 0.78 0.60 0.45 0.33 0.23 0.14 0.07
1.7 4.67 3.25 2.40 1.83 1.43 1.13 0.89 0.70 0.55 0.42 0.31 0.21
1.8 8.00 5.00 3.50 2.60 2.00 1.57 1.25 1.00 0.80 0.64 0.50 0.38
1.9 18.00 8.50 5.33 3.75 2.80 2.17 1.71 1.38 1.11 0.90 0.73 0.58
2.0 * 19.00 9.00 5.67 4.00 3.00 2.33 1.86 1.50 1.22 1.00 0.82
2.1 * * 20.00 9.50 6.00 4.25 3.20 2.50 2.00 1.63 1.33 1.10
2.2 * * * 21.00 10.00 6.33 4.50 3.40 2.67 2.14 1.75 1.44
2.3 * * * * 22.00 10.50 6.67 4.75 3.60 2.83 2.29 1.88
2.4 * * * * * 23.00 11.00 7.00 5.00 3.80 3.00 2.43
2.5 * * * * * * 24.00 11.50 7.33 5.33 5.25 4.00
2.6 * * * * * * * 25.00 12.00 7.67 5.50 4.20
* Erroneous Test
9.10.5 Tailgas Analysis Operating Chart

The titration volumes can also be used with the following Tailgas Analysis
Operating Chart for a quick check to see how close to optimum ratio the
sulfur plant is currently running.

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6.0
Chart 3
5.5
Tailgas Analysis
Operating Chart
H2S:SO2 = 2.3
5.0 (Both solutions must be
the same normality)
H2S:SO2 = 1.7
4.5
4.0
DEFICIENT AIR
ml of Iodine Solution
3.5 EXCESS AIR
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5
ml of Sodium Hydroxide Solution
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9.10.6 Essential Apparatus for Tutweiler Analysis

1. Tutweiler apparatus, complete, two 100 milliliter size and one
500 milliliter size.
2. Burette clamps, single, two.
3. Graduated cylinders, 100 milliliter and 50 milliliter, one each.
4. Automatic burettes with Teflon stopcocks, 50 milliliter, two.
5. Erlenmeyer flasks, 250 milliliter, four.
6. Ring stands, two.
7. Avery labels, approximately 7/8" x 1¼", one package.
8. Thermometers, 0°C - 400°C and -30°C - 120°C ranges, three each.
9. Volumetric flasks with glass stoppers, 1000 milliliter, two.
10. Volumetric flask with glass stopper, 2000 milliliter, one.
11. Dropper bottles, PE (polyethylene), 4 ounce (approx. 125 ml), two.
12. Rubber tubing, ¼" I.D.
13. Tubing clamps, six.
14. Tube fittings, ¼" pipe to ¼" rubber tubing, six.
15. Wash bottle, PE, 1 liter, one.
16. Reagent bottles, plain narrow mouth, with flat head stopper, Pyrex,
1 liter capacity, three.
17. Amber bottles with Bakline screw caps, 5 pint capacity (approx.
2.5 liters), two.
18. Aspirator bottle, 125 milliliter capacity, two.

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9.10.7 Materials for Tutweiler Analysis

1. Acculutes, sodium thiosulfate, 0.1 normal, two.
2. Acculutes, sodium hydroxide, 0.1 normal, four.
3. Acculutes, iodine, 0.1 normal, six.
4. Methyl purple indicator in dropper bottle, 4 ounce (approx. 125 ml),

one.
5. Starch solution, stabilized, 1 quart (approx. 1 liter), one.
6. Distilled water, 5 gallon, (approx. 20 liters), one.
7. Stopcock grease, silicone, one tube.
9.10.8 H2S and SO2 Conc. in Tailgas Using Gas Detector Tubes
As an alternative to the traditional wet-chemistry methods described in the
preceding Section 1 for determining the concentrations of H2S and SO2 in
the sulfur plant tailgas, gas detector tubes can be used to quickly and
easily make this determination. Although the discussion that follows
The following Dräger tubes are needed for this procedure:
H2S 0.2% Dräger Cat. No. CH 281 01
(H2S + SO2) 0.2% Dräger Cat. No. CH 282 01


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a. Dräger Cat. No. CH 281 01, H2S 0.2%
This tube will measure H2S concentrations in the range of 0.2%

to 7% when one sample stroke is used. If desired, the range
can be reduced to 0.02% to 0.7% by using 10 sample strokes.
Each tube contains a substrate of a pale blue copper
compound. When exposed to H2S, the copper compound is
converted to black copper sulfide. The length of the black stain,
marked in cm on the tube, is multiplied by a factor stamped on
the box to give the H2S concentration in percent.
This copper sulfide reaction is not affected by any of the other

compounds normally found in sulfur plant tailgas. SO2 in the
tailgas may turn the indicating layer somewhat yellow (due to
precipitation of elemental sulfur), but does not affect the H2S
measurement.
b. Dräger Cat. No. CH 282 01, (H2S + SO2) 0.2%
This tube will measure the combined concentration of H2S and

SO2 in the range of 0.2% to 7% if one sample stroke is used. If
desired, the range can be reduced to 0.02% to 0.7% by using
10 sample strokes. Each tube contains a substrate of brown
iodine. When exposed to H2S and/or SO2, the iodine reacts to
form hydroiodic acid (a gas) and the brown color disappears.
Since H2S reacts with iodine to form elemental sulfur, the brown
will become pale yellow. The length of the yellow stain, marked
in cm on the tube, is multiplied by a factor stamped on the box
to give the H2S+SO2 concentration in percent.

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9.10.8.2 Sampling the Tailgas

The sulfur plant tailgas can be sampled from the sample valve on the
outlet line from the fourth pass of the Sulfur Condenser.
a. Before beginning, check the Dräger pump for leaks by inserting

b. Attach a short piece of rubber tubing to the process sample

valve.
c. Break off the tips at each end of an H2S Dräger tube and insert
it into the sample pump (with the arrow on the side of the tube
pointing toward the pump).
d. Purge the rubber tubing by venting tailgas to the atmosphere for

a few seconds. Pinch the rubber tubing closed at the end,
close the gas sample valve, slip the end of the rubber tubing
onto the end of the Dräger tube, and reopen the sample valve.
e. Stroke the sample pump one time (be sure to compress the
bellows until reaching the stops) and allow the pump to draw
the gas sample into the detector tube. The sample stroke is
f. Close the sample valve, remove the rubber tubing from the end
of the Dräger tube, and use the pump to draw two strokes of
fresh air through the detector tube to complete the reactions.
g. Read the length of the black stain using the cm marks on the
tube and record the reading.
h. Break off the tips at each end of an H2S+SO2 Dräger tube and
insert it into the sample pump (with the arrow on the side of the
tube pointing toward the pump).
i. Repeat steps d through f.
j. Read the length of the yellow stain using the cm marks on the
tube and record the reading.

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k. Check that the sample valve is closed, then remove the rubber
tubing.
a. Mole (or Volume) percent H2S (wet basis):
 Stain   Factor   1013 

Mole % H2S     
Length, cm on Box   Baro. Pres., mbar 
The last factor corrects the measurement for pressure effects

when samples are taken at elevations above sea level. Note
that the average barometric pressure at the complex is
14.7 PSIA = 1013 mbar.
b. Mole (or Volume) percent H2S+SO2 (wet basis):
 Stain   Factor   1013 

Mole % ( H2S  SO2 )     
Length, cm  on Box   Baro. Pres., mbar 
c. Mole (or Volume) percent SO2 (wet basis):
Mole % SO2 = Mole % ( H2S + SO2 ) – Mole % H2S
d. Molar (or Volume) Ratio of H2S to SO2 in the tailgas:
Mole % H2S
H2S : SO2 Ratio 
Mole % SO2
9.10.8.4 Example
Suppose, for example, that the following measurements are taken:
Stain Length Factor on Box
H2S Tube 1.5 cm 0.44
H2S+SO2 Tube 2.1 cm 0.51
= (1.5 cm)  (0.44)  

1013 
a. Mole % H2S = 0.66%
1013 
 
= (2.1 cm)  (0.51)  

1013 
b. Mole % (H2S +SO2)  = 1.07%
1013 
c. Mole % SO2 = 1.07% - 0.66% = 0.41%

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0.66%
d. H2S : SO2 Ratio = = 1.61
0.41%
This indicates that the H2S:SO2 ratio is a little low (less than 2.0), so
the air:acid gas ratio is on the high side. The output from the air
demand hand control should be lowered slightly, and the
measurements repeated after the SRU reaches a steady state again.
If the H2S:SO2 ratio had been high (greater than 2.0), that would
have meant that the air:acid gas ratio was on the low side. In that
case, the output from thr air demand hand control would need to be
raised slightly to increase the air flow and bring the H2S:SO2 ratio
down.

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9.11 Adjusting StackMatch® Ignitor/Pilots

The pilots for the burners are StackMatch® DRAM (Dual Range Air Mixed)
ignitor/pilot assemblies. The ignitor inside each pilot burner is a flame front
generator (FFG). It works by taking part of the air and fuel gas mixture that is
flowing to the primary pilot, igniting the mixture with a high-energy plasma spark,
and allowing the flame "front" to travel down a flame delivery tube to the primary
pilot tip, lighting the primary pilot. The small primary flame then ignites the much
larger secondary pilot flame. Flame front generator ignitors are preferred for
burners in sour service because the electrical parts are not exposed to the
corrosive process atmosphere, giving the ignitor better long-term reliability.
In order for a flame front generator to work properly, two conditions must be
satisfied. First, the air:gas mixture must be within the flammability limits (neither
too lean nor too rich). Second, the flowing velocity of the mixture must be higher
than the flame speed so that the "fireball" will travel to the pilot. The ignitor has
orifices to regulate the air and fuel gas, sized by the manufacturer to provide the
proper quantities of air and fuel gas when both streams are at the manufacturer’s
specified pressure as indicated on the pressure gauges for both air and fuel gas
supplied on the pilot assembly.
In theory, adjusting the pilot air and fuel gas regulators to the manufacturer’s
specified pressure should be all that is needed to make the ignitor work. In
practice, a certain amount of adjustment of the pressures is sometimes required
before the ignitor works reliably, especially if the fuel gas composition is variable.
However, once the proper pressures are determined, the ignitor can usually be
made to work easily by making sure that the regulators are set to these pressures
before attempting to ignite the pilot.
If the pilot does not light with the regulators set at the design pressures,
trial-and-error can be used to determine the proper regulator pressures. One
technique that has worked well is described below. It requires two operators:
one to adjust the regulators, one to control the ignition cycle and observe the pilot.
1. Adjust the pilot air regulator to the manufacturer’s specified pressure.
2. Unscrew the adjustment screw on the pilot fuel gas regulator so that the
pilot fuel gas is at minimum pressure.
3. Follow the procedures given in these guidelines to start the air blower and
reset the shutdown system.

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4. The first operator raises the air flow (using the hand indicator controller) to
satisfy the "PURGE REQUIRED" light, lowers the air flow to get the "PERMIT
TO IGNITE", then pushes the "IGNITION" push-button to begin an ignition
attempt.
5. Once the ignition cycle starts, the second operator begins gradually
increasing the pilot fuel gas pressure from the pressure control valve
(observing the pressure on the local pressure gauge) while the first
operator observes the operation of the pilot through one of the viewports
on the burner.
6. As the pilot fuel gas pressure increases, a flame will be observed on the
pilot. When the flame is observed, the second operator should stop
increasing the pilot fuel gas pressure.
7. If the pilot does not ignite, repeat the sequence beginning at Step 4,
starting with the pilot fuel gas regulator set where it was at the end of the
previous ignition attempt, or a little lower.
8. If repeated attempts at adjusting the fuel gas pressure are unsuccessful,

changing the pilot air pressure regulator setting may be required. Try
adjusting the air pressure 0.05-0.10 bar one way or the other.
9. Once a flame is observed on the pilot, the pilot fuel gas pressure can then
be adjusted to produce a good stoichiometric pilot flame. While the first
operator continues to observe the pilot flame through the burner viewport,
the second operator can raise or lower the pilot fuel gas pressure slightly
until the pilot flame is dark blue:
a. If the flame is yellow, the air:natural mixture is too "rich". Lower the
fuel gas pressure with the pressure control valve to reduce the
amount of fuel gas flowing to the pilot.
b. If the flame is light blue, the air:natural mixture is too "lean". Raise
the fuel gas pressure with the pressure control valve to increase the
amount of fuel gas flowing to the pilot.
10. Once the pilot has ignited, make note of the pilot air and fuel gas
pressures for future reference. The pilot regulators should be adjusted to
these settings prior to subsequent startups.

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Table of Contents
10. SULFUR DEGASSING, STORAGE & LOADING .................................................. 10-3
10.2 SAFETY ............................................................................................................... 10-4
10.4.1 Sulfur Degassing Reactor, A2-DC1550 ........................................................ 10-7
10.4.2 Sulfur Storage Tank, A2-FB1550 ................................................................. 10-7
10.4.3 Sulfur Feed Pump, A2-GA1532A/B (A2-GA1542A/B) .................................. 10-8
10.4.4 Sulfur Loading Pump, A2-GA1550A/B ......................................................... 10-8
10.4.5 Degassing Air Blower, A2-GB1550A/B ......................................................... 10-9
10.4.6 Bed Support and Limiter for Sulfur Degassing Reactor, A2-DC1551 ........... 10-9
10.4.7 Degassed Sulfur Drain Seal Assembly, A2-ME1550.................................... 10-9
10.5.1 Sulfur Feed Rate Control ............................................................................ 10-11
10.5.2 Degassing Air Flow..................................................................................... 10-12
10.5.3 Sulfur Degassing Unit Startup Interlock ...................................................... 10-13
10.5.4 Snuffing Steam ........................................................................................... 10-13
10.5.5 Sulfur Loading ............................................................................................ 10-14
10.5.6 Sulfur Loading Pump Local Stop Switches................................................. 10-17
10.5.7 Sulfur Degassing Shutdown System .......................................................... 10-18
10.5.8 Sulfur Loading ESD System ....................................................................... 10-21
10.6.2 Degassing Air Blower Operation ................................................................ 10-26
10.6.3 Sulfur Solidification ..................................................................................... 10-29
10.6.4 Sulfur Pumping ........................................................................................... 10-29
10.7.2 Commissioning the Heating and Ventilation Systems ................................ 10-32
10.7.3 Purging the Sulfur Degassing Reactor ....................................................... 10-37
10.8.1 Initial Startup of the Sulfur Degassing Unit ................................................. 10-40
10.8.2 Normal Startup of the Sulfur Degassing System ........................................ 10-46
10.8.3 Initial Sulfur Loading Operation .................................................................. 10-51
10.8.4 Normal Sulfur Loading Operation ............................................................... 10-53
Issued 30 August 2011 Sulfur Degassing Page 10-1

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10.9.3 Shutdown for Tank Entry ............................................................................ 10-57

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10. SULFUR DEGASSING, STORAGE & LOADING

The purpose of the Sulfur Degassing Unit (SDU) is to reduce the H2S content of
the molten sulfur product to 10 PPMW or less, then transport the sulfur to the
Sulfur Storage Tank. 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 meet the 10 PPMW specification for the
sulfur product, the SDU provides additional degassing that will ensure that the
H2S content is sufficiently low before the sulfur is transferred to the storage tank.
The purpose of the Sulfur Storage & Loading system is to collect the degassed
sulfur, hold it in a molten state, and then load it into trucks as a product for sale.

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10.2 Safety
WARNING
ALL PIPING AND VESSELS INCLUDED IN THESE SYSTEMS CONTAIN

MOLTEN SULFUR, WHICH IS A BURN HAZARD FOR PERSONNEL.
CLOSE ATTENTION SHOULD BE PAID TO THE "GENERAL SAFETY"
SECTION OF THESE GUIDELINES REGARDING THE HAZARDS POSED
BY MOLTEN SULFUR. IN ADDITION, 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 THESE GUIDELINES AS TO THE
NATURE AND ABILITY OF THESE GASES TO CONTAMINATE OTHER
ELEMENTS IN THIS UNIT.

THIS PLANT.

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The Systems Diagram, Material Balance and Process Flow Diagram, Dwg. Nos.
507000-7000-01, and 507000-7000-07 through -08, are contained in the
"Process Flow Diagrams" Section of the Basic Engineering Package. 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 fresh 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 + (x-1) S H2SX
While the liquid sulfur is stored in the Sulfur Surge Tank, 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 tank. 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 10 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 10 PPMW. The Sulfur Feed Pumps,
A2-GA1532A/B and A2-GA1542A/B pump the fresh liquid sulfur from the Sulfur
Surge Tanks, A2-FB1530 and A2-FB1540 to the Sulfur Degassing Reactor,
A2-DC1550. Compressed air from the Degassing Air Blower, A2-GB1550A/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

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the polysulfide.
The degassed sulfur, containing less that 10 PPMW hydrogen sulfide,

gravity-drains from the top of the reactor into the Sulfur Storage Tank,
A2-FB1550, through the Degassed Sulfur Drain Seal Assembly, A2-ME1550.
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 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 TTO for
incineration.
The Sulfur Storage Tank is sized to hold about two week of production from the
two SRUs, or about 500 MT when completely full. The tank is constructed of
carbon steel and is equipped with internal steam coils and a ventilation system.
The steam-jacketed Sulfur Loading Pump, A2-GA1550A/B, mounted beside the

tank is used to load molten sulfur into trucks at two loading spots.

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10.4.1 Sulfur Degassing Reactor, A2-DC1550

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 Tank. 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.
10.4.2 Sulfur Storage Tank, A2-FB1550

The Sulfur Storage Tank is an above-ground vertical cylindrical tank. It
has serpentine steam coils in the bottom and circumferential steam coils
on the sides to keep the sulfur molten, each with its own steam supply and
trap. Should a steam coil develop a leak, it can be shut off while the
others keep the sulfur hot. It has a level transmitter to indicate the sulfur
level, with a high level alarm to alert the operators of a high level. There is
a snuffing steam line entering the top of the tank in case of fire.
The primary ventilation system for the Sulfur Storage Tank is a

natural-draft ventilation system. Ambient air enters through the four
breather vents placed around the top of the tank and sweeps through the
tank. This air circulation dilutes the H2S that may "weathers off" from the
liquid sulfur so that the concentration remains below the lower explosive
limit. The air circulation also prevents accumulation of water in the tank
that could cause rapid corrosion. The vapors are vented from the vessel

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through a 3 m tall heated vent stack, mounted on top of the tank. The
steam-jacketing on the vent stack heats the air in the stack, providing the
natural-draft driving force that draws ambient air into the tank to sweep the
vapor space.
WARNING
IT IS VERY IMPORTANT TO KEEP HEAT (STEAM) ON THE VENT

STACK TO MAINTAIN THE NATURAL DRAFT. IN ADDITION, THE
STEAM SPACE IN THE VENT STACK JACKET MUST VENTED
PERIODICALLY TO PREVENT NON-CONDENSIBLES FROM
ACCUMULATING AND "BLANKING OFF" THE STEAM HEATING
SURFACES. A VENT LINE IS PROVIDED EXPRESSLY FOR THIS
PURPOSE.
10.4.3 Sulfur Feed Pump, A2-GA1532A/B (A2-GA1542A/B)

These special steam-jacketed sump-type pumps are used to transfer the
molten sulfur product from the Sulfur Surge Tanks to the Sulfur Degassing
Reactor. 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.
10.4.4 Sulfur Loading Pump, A2-GA1550A/B

These pumps are horizontal centrifugal pumps. They are steam-jacketed
to keep the sulfur in the molten state and send it to the loading stations for
sulfur trucks. Start and stop push-buttons are located at the loadings
station for ease of loading. Stop switches are also located at the pumps
for emergency use.

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10.4.5 Degassing Air Blower, A2-GB1550A/B

These single-stage 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.
10.4.6 Bed Support and Limiter for Sulfur Degassing Reactor,

A2-DC1551
A bed support and a bed limiter fabricated from grid-type 304 S.S. 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.
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 and the vessel shell.
10.4.7 Degassed Sulfur Drain Seal Assembly, A2-ME1550

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 Tank 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 Tank. 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

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Sulfur Tank 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 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.

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10.5.1 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 Surge Tanks from the SRUs reasonably closely, or else the
Surge Tanks will eventually run dry. 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 Surge Tank and extended nearly to
the bottom of the tank. 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 tank, 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 tank. This
type of level measuring device is used for A2-LT15450 and A2-LT15449.
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 Sulfur Surge Tanks
into the Sulfur Degassing Reactor by the Sulfur Feed Pumps. The flow
meter, A2-FT15450, is located downstream of the take-off for the
spill-back line so that the sulfur feed rate from SRU 1 into the reactor can
be adjusted by varying the amount of sulfur spilling back into the tank.
The level in the tank is controlled by A2-LIC15450, which supplies a

cascade setpoint to the sulfur feed rate controller, A2-FIC15450. If the
level is rising in the tank, the feed rate from SRU1 to the Sulfur Degassing
Reactor will be slowly increased by raising the setpoint of A2-FIC15450. If
the level is falling, the setpoint will be lowered to slowly reduce the feed
rate. In this manner, the level in the Sulfur Surge Tank can be maintained

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at the desired value while avoiding sudden changes in the feed rate to the
Sulfur Degassing Reactor.
10.5.2 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 (45 Nm3/MT) 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 Pumps 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

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flow alarm on A2-FI15702) 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.
10.5.3 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 SDU "start" permissives is contained in the
Instrumentation and Controls Diagrams section of the Basic Engineering
Package. These permissives are (in order):
(1) Start a Sulfur Feed Pump.
(1) Allow the pump to fill the Sulfur Degassing Reactor to satisfy its
low-low level shutdown.
(2) Start a Degassing Air Blower and press its "reset" push-button to
open its discharge valve.
Failure to satisfy a permissive 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.)
10.5.4 Snuffing Steam

There are snuffing steam lines entering the top of each Sulfur Surge Tank
to flood the vapor space with LP steam in case a fire develops inside a
tank. The snuffing steam supply valves are operated by either a remote
switch in the DCS or a local switch that is located at least 50 feet from the
tank. Opening this valve for a few minutes will fill the vapor space of the
tank with steam and displace all of the air, quickly extinguishing the fire.
There is a snuffing steam line entering the top of the Sulfur Storage Tank
to flood the tank vapor space with LP steam in case a fire develops inside
the tank. The snuffing steam supply valve is operated by either a remote
switch in the DCS or a local switch that is located at least 50 feet from the
tank. Opening this valve for a few minutes will fill the vapor space of the

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tank with steam and displace all of the air, quickly extinguishing the fire.
The logic for the snuffing steam valves is contained in the Instrumentation
and Controls Diagrams section of the Basic Engineering Package. They
can be opened by "toggling" the switch in the DCS to "on" or by pressing
the local push-button. The valve can be closed later by "toggling" the
switch in the DCS to "off" or by pressing the local push-button again.
10.5.5 Sulfur Loading

The Sulfur Loading system is designed to load molten sulfur from the
Sulfur Storage Tank into sulfur trucks, or both simultaneously. The
loading operations are controlled by a programmable logic controller
(PLC) housed in a local control panel located inside the loading building in
the sulfur loading area. Status indicator lights are mounted on the front of
this panel to allow monitoring operation of the system and to assist with
troubleshooting.
The logic for sulfur loading operations is shown on the Logic Flow
Diagrams contained in the Instrumentation and Controls Diagrams section
of the Basic Engineering Package. Note that only one Sulfur Loading
Pump at a time is used for loading, regardless of whether one or both
loading spots are being used. Selector switch A2-HS15716 is used to
select which Sulfur Loading Pump is active.
10.5.5.1 Starting Sulfur Loading
The sequence of events when beginning sulfur loading can be

summarized as follows.
(1) The truck driver spots his truck and connects the grounding
cable.
(2) The truck driver presses the "START" push-button on the

applicable start/stop station. The associated status light at that
loading spot begins flashing and a timer for that loading spot is
started.
(3) The discharge valve on the Sulfur Loading Vent Ejector

(A2-EE1550A or A2-EE1550B) at that loading spot is opened

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and proven open.
(4) The motive steam valve on the Sulfur Loading Vent Ejector at
that loading spot is opened and proven open.
(5) The sulfur loading valve at that loading spot is opened and
proven open.
(6) A Sulfur Loading Pump (A2-GA1550A or A2-GA1550B) is

started, a timer for that pump is started, and the associated
status light for that pump on the local loading control panel
begins flashing.
If the other loading spot is not currently active, the "lead" pump
is started. If the other loading spot is active, the "lag" pump is
started. When selector switch A2-HS15716 is set to "NORMAL",
the "A" and "B" pumps will alternate in the "lead" position after
each loading operation. If A2-HS15716 is set to either "A" or "B",
only that pump is to be started even when both loading spots
are active.
(7) When its motor starter contacts show that the pump is running,
the discharge valve for that pump is opened and proven open.
(8) If the pump discharge valve is proven open before the timer on
that pump times out, the pump status light stops flashing and
remains steadily illuminated.
If the timer times out before the pump discharge valve is proven
open, the pump is stopped, its discharge valve is closed, its
status light is extinguished, and the corresponding "pump start
failure" alarm is activated.
If it was the "lead" pump that failed to start, then an attempt is

made to start the "lag" pump beginning at step (6). If the timer
for the "lag" pump times out before its discharge valve is proven
open, the "lag" pump is stopped, its discharge valve is closed,
its status light is extinguished, the corresponding "pump start
failure" alarm is activated, and the "PUMP START FAILURE" status

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light on the local loading control panel is illuminated. The Sulfur

Loading ESD is also activated to stop both pumps and close all
of the valves (pump discharge, sulfur loading, motive steam,
and ejector discharge).
(9) If one of the pumps is successfully started before the timer on

that loading spot times out, the status light for that loading spot
stops flashing and remains steadily illuminated, and sulfur will
begin flowing into the truck.
10.5.5.2 Stopping Sulfur Loading
The sequence of events when ending sulfur loading can be

summarized as follows.
(1) The truck driver presses the "STOP" push-button on the

applicable start/stop station. The associated status light at the
loading spot begins flashing.
(2) If the other loading spot is not currently active, stopping of the
"lead" pump is initiated. If the other loading spot is active,
stopping of the "lag" pump is initiated. The applicable pump
status light on the local loading control panel begins flashing.
(3) The applicable pump (A2-GA1550A or A2-GA1550B) is

stopped.
(4) The applicable discharge valve is closed and proven closed.
(5) When its motor starter contacts show that the pump is stopped
and the limit switches show the pump discharge valve is closed,
the pump status light on the local loading control panel is
extinguished.
(6) The sulfur loading valve at that loading spot is closed and
proven closed.
(7) The motive steam valve on the Sulfur Loading Vent Ejector at
that loading spot is closed and proven closed.
(8) The discharge valve on the Sulfur Loading Vent Ejector at that

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loading spot is closed and proven closed.
(9) The status light for that loading spot is extinguished.
10.5.6 Sulfur Loading Pump Local Stop Switches

Section 10.5.5 describes how the pump start and stop push-buttons
located at the truck loading stations are used to transfer sulfur from the
Sulfur Storage Tank to the loading spots. Local pump "stop" switches are
located at each pump for maintenance or emergency use. Setting one of
these switches to the "STOP" position will remove the power from the
corresponding pump motor to prevent that pump from running.

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10.5.7 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, A2-DC1550, when serious problems occur. The
Cause and Effect Diagram, contained in the Instrumentation and Controls
Diagrams section of the Basic Engineering Package, describes the
SDU ESD system in block format. For reference, the causes and effects
of the ESD system shown on this diagram are explained below.
10.5.7.1 Causes
Any one of the devices listed below will activate the SDU ESD:
a. No Sulfur Feed Pump Running, A2-GA1532A&B and
A2-GA1542A&B starter contacts
If no 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.
a. Sulfur Degassing Reactor High-High Temperature,
A2-TT15703A/B/C
There is always a potential for a fire in the Sulfur Degassing Reactor

since sulfur is flammable at elevated temperatures (generally above
237°C) and it is in contact with air. The heat from a sulfur fire would
damage the equipment if allowed to continue burning. If this device
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
205°C.
b. No Degassing Air Blower Running, A2-GB1550A and A2-GB1550B
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

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running, and activate the SDU ESD if neither of the blowers is

running.
c. Sulfur Degassing Reactor High-High Level, A2-LT15704A
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 setpoint for this device is 5,300 mm above
the bottom seam of the reactor vessel.
d. Sulfur Degassing Reactor Low-Low Level, A2-LT15704B
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 3,850 mm above the bottom seam of the reactor vessel.
10.5.7.2 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, A2-GA1532A/B and
A2-GA1542A/B, to stop the flow of sulfur into the Sulfur
Degassing Reactor.
b. Shuts down the Degassing Air Blower, A2-GB1550A/B, to stop

the flow of air into the Sulfur Degassing Reactor.
c. Closes the Sulfur Feed Pump discharge valves to prevent

draining all of the sulfur out of the Sulfur Degassing Reactor.
d. Closes the Degassing Air Blower discharge valves,

A2-NV15701A and A2-NV15701B, to prevent back-flow and
possible venting of any hazardous gases to the atmosphere.
e. Places each sulfur feed controller in "manual" and sets its

output to 0% to close the control valve in each spill-back line
and prevent draining all of the sulfur out of the Sulfur Degassing
Reactor. (The normal control action would close these valves
when the associated pump stops and the sulfur quits flowing,
but it may not do so quickly enough to prevent much of the

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sulfur from draining out of the reactor.)

a. Sulfur Surge Tank Low-Low Level, A2-LT15449 and A2-LT649
Each Sulfur Feed Pump is based on a unique design that uses

the molten sulfur to lubricate the shaft bearings. It requires a
minimum submergence above the impeller to ensure steady
flow so that the bearings remain lubricated; otherwise, the
pump could be damaged. This transmitter will activate the
SDU ESD to shut down the pump if the level in the raw
production section of the Sulfur Tank gets too low. It is set to
actuate if the liquid level drops to 450 mm above the tank floor,
however this value should be confirmed once a specific pump
has been selected.

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10.5.8 Sulfur Loading ESD System

The purpose of the Sulfur Loading Emergency Shutdown (ESD) system is
to stop all the sulfur loading equipment when serious problems occur.
The Cause and Effect Diagrams, contained in the Instrumentation and
Controls Diagrams section of the Basic Engineering Package, describes
the Sulfur Loading ESD system in block format. For reference, the causes
and effects of the ESD system shown on this diagram are explained
below.
10.5.8.1 Causes
Any one of the causes listed below will activate the Sulfur Loading
ESD system:
a. Manual Shutdown Switches, A2-HS15727 and A2-HS15728
An operator can activate the Sulfur Loading ESD system using

either of two manual shutdown switches:
(1) A2-HS15727 is a NORMAL / ESD selector switch mounted in
the truck loading area.
on the local loading control panel.
b. Sulfur Storage Tank Low-Low Level, A2-LT711A
The Sulfur Loading Pump (A2-GA1550A/B) could be damaged

if the pump loses suction because the level in the Sulfur
Storage Tank drops too low. These devices will protect the
pump by stopping it before this can occur. The shutdown
setpoint is 600 mm above the bottom of the tank.
c. Both Sulfur Loading Pumps Fail to Start, PLC logic
If neither the "lead" nor the "lag" Sulfur Loading Pump starts,
the Sulfur Loading ESD system is activated to shut down the
system and direct operator attention to the loading system.

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10.5.8.2 Effects
A Sulfur Loading Shutdown, activated by any one of the devices

listed above, has the following effects on the Sulfur Loading system:
a. Shuts down the Sulfur Loading Pump (A2-GA1550A&B) to stop
the flow of sulfur to the loading arms.
b. Closes the Sulfur Loading Pump discharge valves.
c. Closes the sulfur loading valves to stop the flow of sulfur from
the loading arms.
d. Once the sulfur loading valves are closed, closes the motive
steam valves on the Sulfur Loading Vent Ejector
(A2-EE1550A&B).
e. Once the motive steam valves are closed, closes the discharge
valves on the Sulfur Loading Vent Ejector.
10.5.8.3 Non-ESD Shutdowns

Sulfur Loading ESD system, there is one additional interlock of
significance that shuts down individual pieces of equipment.
a. Loading Spot Ground Disconnected, A2-CS15721A&B
If continuity is lost for the ground connection at a loading spot,

that loading spot is shut down, and the applicable Sulfur
Loading Pump is stopped.

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maintenance, and emergency procedures of the Sulfur Degassing and Sulfur
Storage & Loading systems are discussed in the remaining sections of this
portion of the operating guidelines. The operator should also be thoroughly
acquainted with the equipment and the "Process Description" section in these
guidelines 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 the "procedures"
sections will be more easily understood. In addition, the following general
discussion of principles and techniques will clarify the reasons for some of the
procedures.

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 both Sulfur Feed Pumps are 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.

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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.
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 DOWNSTREAM OF THE RUNNING PUMP INDICATES
SULFUR IS FLOWING.
3. THE UPSTREAM SRU(S) IS OPERATING SMOOTHLY IF

IT(THEY) IS ON-LINE.
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.

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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.
After the initial startup, the Sulfur Storage & Loading system will also
contain sulfur throughout the system. Even when the sulfur is pumped out
of the Sulfur Storage Tank, the interior of the tank will still be coated with
residual sulfur. Elemental sulfur and/or iron sulfide in the Sulfur Storage
Tank may ignite when ventilating the tank with air prior to maintenance
operations. The heat from the fire can damage the tank if allowed to
continue burning, so use the snuffing steam to extinguish the fire should
this occur.
The walls of the tank above the liquid level are exposed to an oxygen-rich
atmosphere (due to the ventilation system sweeping air through the vapor
space of the tank), so little iron sulfide should form above the highest
air-liquid interface level in the tank. The middle region of the tank walls
should not have much iron sulfide, either, since the oxygen in the sweep
air will oxidize the iron sulfide as soon as the level is pumped back down.
However, the "heel" region of the tank may build up a considerable
quantity of iron sulfide, so auto-ignition of this iron sulfide is always a
potential problem when preparing the tank for maintenance.

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10.6.2 Degassing Air Blower Operation

The Degassing Air Blowers, A2-GB1550A/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.
10.6.2.1 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 blow-off valve in 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. 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
"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

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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 it's "reset" push-button is pressed, the PLC will
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 these guidelines
includes the following steps:
(1) Fully open the blow-off valve on the blower.
(2) Start the blower and let it come up to speed.
(3) Slowly "pinch" the blow-off valve until the discharge pressure
increases to 0.07-0.15 kg/cm2(g).
(4) Press the "reset" push-button to open the blower discharge

valve.
(5) Slowly close the blow-off valve the rest of the way to establish
air flow into the Sulfur Degassing Reactor.
10.6.2.2 "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

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simple and avoid any problems.

A. On the on-line blower:
(1) Confirm that the valve in its blow-off line is fully closed.
B. On the off-line blower:
(1) Confirm that its discharge valve is closed.
(2) Fully open its blow-off valve.
C. Start the off-line blower using its local start/stop control station.
D. After the off-line blower comes up to speed, press its "reset"

push-button 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.
E. 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.
F. Slowly open the blow-off valve on the on-line blower to begin

venting some of its air to atmosphere.
G. 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 the
degassing air flow transmitter and proceed slowly enough to
keep the degassing air flow rate stable.
H. 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.
I. The blower swap is now complete. Before leaving the area,

visually confirm that:

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(2) The discharge and blow-off valves on the off-line blower

are closed.
(4) The Sulfur Degassing Unit has returned to steady
operation.
10.6.3 Sulfur Solidification

Sulfur melts at 119°C [246°F]. All surfaces in these systems must be
maintained above this temperature while the system contains sulfur to
avoid plugging the piping or damaging rotating equipment due to
formation of solid sulfur. For this reason, there are steam coils along the
bottom inside of the Sulfur Surge Tanks, and along the walls and bottom
inside the Sulfur Storage Tank. The Sulfur Feed Pumps and Sulfur
Loading Pump are steam-jacketed. All of the piping and valves in liquid
sulfur service are steam-jacketed, as are the ventilation systems on the
Sulfur Surge Tanks and Sulfur Storage Tank.
The steam traps serving these heating systems should be checked

regularly to verify proper operation. The simplest method to do this is to
verify that sulfur will melt on the steam trap inlet; if the condensate there is
hot enough to melt sulfur, then the steam in the jackets will be hot enough,
too. It is also important to periodically sweep the non-condensibles out of
the jackets and coils by giving their vent valves a good "blow". This will
prevent the accumulation of non-condensibles that could create localized
"cold" spots where sulfur can freeze.
10.6.4 Sulfur Pumping

Pure sulfur undergoes a phase change at about 158°C [317°F] that
causes a tremendous increase in its viscosity. Although dissolved H2S
reduces the magnitude of the increase, and sulfur produced in Claus
SRUs always contains some H2S, this temperature region must be
avoided to prevent problems in handling the molten sulfur. This is
particularly important for the sulfur in the Sulfur Storage Tank, since
degassing significantly reduces the H2S content of the sulfur.
Accordingly, the temperature inside the Sulfur Storage Tank and the

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Sulfur Loading Pump should be kept below 158°C [317°F] to avoid

overloading the pump due to high liquid viscosity. Note that the tank is
equipped with a local temperature indicator to allow easy monitoring of
this temperature. Maintaining the steam coil pressure in the tank at
2
5.0 kg/cm (g) or less should ensure that the sulfur does not get too hot.
Note that the sulfur experiences a small temperature rise inside the Sulfur
Loading Pump due to the pumping energy, so it may be necessary to
maintain the tank temperature slightly lower than 158°C [317°F] so that
the pumped sulfur does not get too hot.

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B. Check and lubricate all equipment, in accordance with the

C. Check the rotation of the Degassing Air Blower and Sulfur Feed
Pumps:
(1) Operate each Degassing Air Blower for a short period

(20 seconds or less) with its discharge valve closed and its
blow-off valves open.
(2) The Sulfur Feed Pumps depend on molten sulfur to lubricate

their bearings, and should not be operated dry. Remove the
coupling between each pump and its motor while checking the
rotation of the motor.
D. Check the rotation of the Sulfur Loading Pump by "bumping" each

pump.
E. Check all piping and equipment to be sure that all blinds have been
F. Place the Instrument Air System in service to all instruments and

G. Place the instrument air in service to the bubbler-type level

transmitters on the two Sulfur Surge Tanks and the Sulfur Storage
Tank.
H. Once the heating systems have been placed in service (see

Section 10.7.2), manually "stroke" each steam-jacketed liquid sulfur
valve and confirm that each valve still moves freely.

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10.7.2 Commissioning the Heating and Ventilation Systems

The heating and ventilation systems for the two Sulfur Surge Tanks and
the Sulfur Storage Tank, 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 an 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:
A. Commission the steam supply to the Sulfur Storage Tank,
A2-FB1550, and place its ventilation system in service as follows:
(1) Confirm that the steam supply valves to the steam coils in the
Sulfur Storage Tank are all closed, and that the steam trap
stations on each of the coils are all blocked-in.
(2) Establish steam flow into each of the coils by opening the
steam supply valves to each coil.
(3) Open the upstream block valve of the steam trap on each coil
and use the bleeder on each trap to vent air (and any liquids or
debris) from each coil. Close the bleeder on each trap once hot
condensate begins flowing through the trap.
(4) Open the test valve on each trap and confirm that each trap is
downstream block valve on each trap to place the traps in
service to the condensate header.
(5) Repeat Steps 1 through 4 to commission the heating system on

the air sweep vent stack. Open the vent valves on the steam
jackets long enough to vent the air from the jackets. In
particular, use the vent line on the air sweep vent stack to vent
the air from its steam jacket.
(6) Make sure that the breather vents at each quadrant of the top of
the Sulfur Storage Tank are unobstructed and that the air

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sweep vent stack has begun to draft air into the tank through
the breather vents.
(7) Confirm that the block valve in the snuffing steam supply line for
the Sulfur Storage Tank is closed, and that the steam trap
station for the steam jackets on the snuffing steam shutdown
valve and the tank nozzle is blocked-in.
(8) Open the block valve in the snuffing steam supply line, then
open the upstream block valve of the steam trap and use its
bleeder to vent air (and any liquids or debris) from the piping
and jackets. Close the bleeder on the trap once hot
(9) Open the test valve on the trap and confirm that the trap is
downstream block valve to place the trap in service to the
condensate header.
(10) Press the local push-button to open the automated snuffing

steam valve. Leave the valve open long enough to confirm that
steam is blowing into the tank, then press the push-button again
to close the valve. Visually confirm that the valve has closed
and that steam has stopped flowing into the tank.
(11) Confirm that the steam supply valves to the jacketed suction
and discharge piping on the Sulfur Loading Pump are all
closed, and that the steam trap stations on each pump's steam
jacket and the steam-jacketed piping are all blocked in.
(12) Open all of the vent valves on the steam-jacketed piping.
(13) Establish steam flow into the jacketed piping and the steam
jackets on each pump by opening the steam supply valves.
(14) Allow air (and any liquids or debris) to purge from the vent
valves. Close each vent valve as it begins to blow steam.
(15) Open the upstream block valve of each steam trap on the
jacketed piping and the steam jackets on each pump, and use
the bleeder on each trap to drain water (and any other liquids)
from the pump and piping. Close the bleeder on each trap once
hot condensate begins flowing through the trap.

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B. Commission the steam supply to the Train 1 Sulfur Surge Tank,

A2-FB1530 and place its ventilation system in service as follows:
(1) Confirm that the steam supply valves to the steam coils in the
Sulfur Surge Tank are all closed, and that the steam trap
stations on each of the coils are all blocked-in.
(2) Establish steam flow into each of the coils by opening the
steam supply valves to each coil.
(3) Open the upstream block valve of the steam trap on each coil
and use the bleeder on each trap to vent air (and any liquids or
debris) from each coil. Close the bleeder on each trap once hot
(5) Repeat Steps 1 through 4 to commission the heating systems

on the air sweep vent stack the Sulfur Surge Tank Vent Ejector,
the ejector suction line, and the ejector discharge line. Open all
of the vent valves on the steam jackets long enough to vent the
air from the jackets. In particular, use the vent line on the air
sweep vent stack to vent the air from its steam jacket.
(6) Make sure that the breather vents at the top of the Sulfur Surge
Tank are unobstructed and that the air sweep vent stack has
begun to draft air into the tank through the breather vents.
(7) Confirm that the ejector discharge valve is closed and the
ejector suction valve is open. Confirm that the motive steam
supply to the ejector is blocked-in. The ejector cannot be
placed in service until a TTO is operating.
(8) Confirm that the block valves in both of the snuffing steam
supply lines for the Sulfur Surge Tank are closed, and that the

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steam trap stations for the steam jackets on both snuffing

steam shut-down valves and the tank nozzles are blocked-in.
(9) For each snuffing steam supply line, open the block valve in the
supply line, then open the upstream block valve of the steam
trap and use its bleeder to vent air (and any liquids or debris)
from the piping and jackets. Close the bleeder on the trap once
hot condensate begins flowing through the trap.
(10) Open the test valve on each trap and confirm that the traps are
operating properly. Then close the test valves and open the
downstream block valves to place the traps in service to the
condensate header.
(11) For each snuffing steam supply line, press the local push-button
to open the automated snuffing steam valve. Leave the valve
open long enough to confirm that steam is blowing into the tank,
then press the push-button again to close the valve. Visually
confirm that the valve has closed and that steam has stopped
flowing into the tank.
C. Commission the steam supply to the Train 2 Sulfur Surge Tank,

A2-FB1540 and place its ventilation system in service in the same
manner.
D. Confirm that the steam supply valve(s) to the jacketed discharge

piping on the Train 1 Sulfur Feed Pump, A2-GA1532A/B, are all
closed, and that the steam trap stations on each pump are all
blocked in.
E. Open all of the vent valves on the jacketed discharge piping.
F. Establish steam flow into the jacketed pipe and the pumps by
opening the steam supply valve(s).
G. Allow air (and any liquids) to purge from the vent valves. Close each
vent valve as it begins to blow steam.
H. 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

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I. Open the test valve on each trap and confirm that each trap is
downstream block valve on each trap to place the traps in service to
the LP Condensate header.
J. Repeat Steps D through I 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 Train 1 sulfur spill-back line, and control valve.
(2) The Train 2 Sulfur Feed Pump, A2-GA1542A/B.
(3) The Train 2 sulfur spill-back line, and control valve.
(4) The bubbler tubes for all of the level transmitters in the two
Sulfur Surge Tanks and the Sulfur Storage Tank.
(5) The sulfur drain line, from the Sulfur Degassing Reactor, the
strainer, and the associated Degassed Sulfur Drain Seal
Assembly, A2-ME1550.
(6) The jacket on the Sulfur Degassing Reactor, A2-DC1550.
(7) The degassing air line feeding the Sulfur Degassing Reactor.
(8) The spent degassing air line from the Sulfur Degassing
Reactor.
Confirm that all steam traps are functioning properly before directing your
attention away from these heating systems.

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10.7.3 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 the Train 1 sulfur feed rate controller in the DCS in "manual"
and set its output to 0%.
B. Verify that the control valve in the associated Train 1 sulfur spill-back
line is fully closed.
C. Place Train 2 sulfur feed rate controller in the DCS in "manual" and
set its output to 0%.
D. Verify that the control valve in the Train 2 sulfur spill-back line is fully
closed.
E. Verify that the discharge valves on the Sulfur Feed Pumps for both
SRU trains are closed.
F. Close the block valve in the spent degassing air line.
G. Open the block valve upstream of the strainer in the rundown line to
the Degassed Sulfur Drain Seal Assembly.

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H. Confirm that the steam-out valve on the degassing air line is closed
and remove its blind flange.
I. Use a temporary hose to connect nitrogen to the steam-out valve

then open the valve to commence the flow of nitrogen into the Sulfur
Degassing Reactor and out the open path through the Degassed
Sulfur Drain Seal Assembly.
J. 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.
K. When the oxygen concentration is below 1%, set the output of the
Train 1 sulfur feed rate controller to 100%
L. Verify that the control valve in the Train 1 spill-back line is fully open.
M. "Force" the PLC to open the Train 1 Sulfur Feed Pump

(A2-GA1532A/B) discharge valves.
N. Close the block valve in the rundown line to the Degassed Sulfur
Drain Seal Assembly.
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.
P. When the oxygen concentration is below 1%, open the block valve in
the spent degassing air line to the Thermal Oxidizer.
Q. Close the following valves:
(1) Adjust the output of the Train 1 sulfur feed rate controller in the
DCS to 0% to close the spill-back valve.
(2) Remove the "forces" from the PLC and confirm that the
automated discharge block valves on the Train 1 Sulfur Feed
Pumps close.
R. Set the output of the Train 2 sulfur feed rate controller to 100%
S. Verify that the control valve in the Train 2 spill-back line is fully open.
T. "Force" the PLC to open the Train 2 Sulfur Feed Pump

(A2-GA1542A/B) discharge valves.

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U. Close the block valve in the spent degassing air line to the Thermal
Oxidizer.
V. Allow the nitrogen to continue flowing long enough to reduce the

W. When the oxygen concentration is below 1%, open the block valve in
the spent degassing air line to the Thermal Oxidizer.
X. Close the following valves:
(1) Adjust the output of the Train 2 sulfur feed rate controller in the
DCS to 0% to close the spill-back valve.
(2) Remove the "forces" from the PLC and confirm that the
automated discharge block valves on the Train 2 Sulfur Feed
Pumps close.
Y. Allow the nitrogen to continue flowing long enough to reduce the

Z. Close the steam-out valve where the nitrogen "jumper" is connected

to stop the flow of nitrogen, and disconnect the nitrogen hose.
Replace the blind flange on the steam-out valve.
AA. Open the block valve in the rundown line to the Degassed Sulfur
Drain Seal Assembly.
BB. Close the block valve in the spent degassing air line to the Thermal
Oxidizer.
The Sulfur Degassing System is now ready for service. Once an SRU has
been started up and there has been sufficient sulfur production into a
Sulfur Surge Tank to commence operation of a Sulfur Feed Pump, sulfur
degassing can begin.

SULFUR BLOCK

This section describes the procedures for the initial startup of the Sulfur
Degassing Unit, subsequent startups of the Sulfur Degassing Unit, and
operation of the Sulfur Loading system.
10.8.1 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.
The following steps are based on placing the Train 1 Sulfur Feed Pump in
service first. The same procedures can be used for the Train 2 Sulfur
Feed Pump.
10.8.1.1 Filling the Sulfur Drain Seal in the Sulfur Outlet Line
CAUTION
THE SHAFT BEARINGS ON THE SULFUR FEED PUMPS ARE

LUBRICATED BY SOME OF THE LIQUID SULFUR BEING
PUMPED. TO ENSURE AN ADEQUATE SUPPLY OF SULFUR
FOR THE BEARINGS, THE PUMP MANUFACTURER
TYPICALLY RECOMMENDS MAINTAINING A MINIMUM OF
450 mm OF SULFUR LEVEL ABOVE THE PUMP SUCTION
WHEN OPERATING ONE OF THESE PUMPS.
CHECK THE SULFUR LEVEL IN THE SULFUR SURGE

TANK(S) BEFORE STARTING UP THE SULFUR DEGASSING
UNIT. DO NOT PROCEED UNTIL THE LEVEL MEASURES AT
LEAST 450 MM ABOVE THE BOTTOM OF THE TANK(S).

SULFUR BLOCK
A. Place the Train 1 sulfur feed rate controller in the DCS in

"manual" and set its output to 0%.
B. Verify that the control valve in the Train 1 spill-back line is

closed.
C. Verify that the block valve in the Sulfur Degassing Reactor

overhead line is closed.
D. Verify that the block valve in the sulfur rundown line, is open.
E. Verify that the shutdown valves in the discharge lines from the
Train 1 Sulfur Feed Pumps are closed.
F. Start a Sulfur Feed Pump, A2-GA1532A or A2-GA1532B, using

its local start/stop control push-button and verify that its
discharge valve is open.
G. The Train 1 sulfur flow meter should begin to indicate that sulfur
is flowing into the Sulfur Degassing Reactor.
H. It will take the Sulfur Feed Pump about 3-5 hours 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, A2-ME1550, and begin flowing into the Sulfur
Storage Tank. Open the view hatch on the Sulfur Drain Seal
and confirm that sulfur is now flowing into the tank.
I. Open the block valve in the Sulfur Degassing Reactor overhead

line and lock it open.

SULFUR BLOCK
10.8.1.2 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 Sulfur Surge
Tank, and degassing air flow can be established to bring the system
on-line.
WARNING
NEVER START A DEGASSING BLOWER UNLESS EACH OF

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

ASSOCIATED SULFUR FLOW METER INDICATES
SULFUR IS FLOWING.


SMOOTHLY.
FAILURE TO OBSERVE THESE PRECAUTIONS COULD

CAUSE A FIRE AND/OR EXPLOSION IN THE SULFUR
DEGASSING REACTOR.
A. Confirm that the setpoint of the Train 1 sulfur feed rate flow
controller is tracking its current reading, then switch it to
"automatic" (not "cascade"). Slowly adjust the setpoint as

SULFUR BLOCK
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

B. Confirm that the block valve in the spent degassing air line is
open.
C. Confirm that both the Degassing Air Blower discharge valves

are fully closed.
D. Start a Degassing Air Blower:
(1) Open the valve in its blow-off line.
(2) Start the blower using its local start/stop control

push-button.
(3) Once the blower comes up to speed, slowly "pinch" the

valve in the blow-off line until the discharge pressure
(4) Press the "reset" push-button on the blower to open its

discharge valve.
(5) Slowly close the valve in the blow-off line.
NOTE: Do not allow the pressure to exceed 3.5 kg/cm2(g),

as this will cause the relief valves on the blower
discharge lines to open in order to relieve the
excessive pressure.
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
the sulfur feed rate flow controller in the DCS if necessary to
stabilize the sulfur feed rate.
F. Confirm that the degassing air flow rate indicated in the DCS is
200 Nm3/H or higher.
G. Place the level controller for the Train 1 Sulfur Surge Tank in
service as follows:

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"automatic".

supplying to the sulfur feed rate controller matches the
current local sulfur feed rate setpoint on the controller.
(3) Switch the sulfur feed rate controller to "cascade" mode so

that the setpoint for the sulfur feed rate will now be adjusted
H. Once SRU Train 2 has been started up and there is sufficient

sulfur production into the Train 2 Sulfur Surge Tank, the Train 2
Sulfur Feed Pump can be placed in service as follows:
(1) Place the Train 2 sulfur feed rate controller in the DCS in
(2) Verify that the control valve in the Train 2 spill-back line is
closed.
(3) Verify that the shutdown valves in the discharge lines from
the Train 2 Sulfur Feed Pumps are closed.
(4) Start a Sulfur Feed Pump, A2-GA1542A or A2-GA1542B,

using its local start/stop control push-button and verify that
its discharge valve is open.
(5) The Train 2 sulfur flow meter should begin to indicate that
sulfur is flowing to the Sulfur Degassing Reactor.
(6) Confirm that the setpoint of the Train 2 sulfur feed rate
flow controller 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.
(7) Place the level controller for the Train 2 Sulfur Surge Tank
in service.

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I. The Sulfur Degassing Unit is now in operation. Before directing

your attention away from this system make sure that:
(1) The Train 1 sulfur feed rate controller is functioning

properly.
(2) The level in the Train 1 Sulfur Surge Tank is under control.

properly.
(5) The degassing air flow rate is at its normal value or above.
(6) Sulfur is draining freely from the Degassed Sulfur Drain

Seal Assembly.

properly.
(8) The TTO is operating smoothly.

SULFUR BLOCK
10.8.2 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.
2. Place all steam heating systems in service. Check all steam traps
for proper operation, and use the vent valves to sweep
The following steps are based on placing the Train 1 Sulfur Feed Pump in
service first. The same procedures can be used for the Train 2 Sulfur
Feed Pump.
10.8.2.1 Filling the Sulfur Degassing Reactor
CAUTION
CHECK THE SULFUR LEVEL IN THE SULFUR SURGE TANK

BEFORE STARTING UP THE SULFUR DEGASSING UNIT. DO
NOT PROCEED UNTIL THE LEVEL MEASURES AT LEAST
450 mm ABOVE THE BOTTOM OF THE TANK.
A. Place the Train 1 sulfur feed rate controller in the DCS in

B. Verify that the control valve in the Train 1 spill-back line is

closed.
C. Verify that the block valve in the Sulfur Degassing Reactor

overhead line is open.
D. Verify that the block valve in the sulfur rundown line is open.
E. Verify that the shutdown valves in the discharge lines from the
Train 1 Sulfur Feed Pumps are closed.

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F. Start a Sulfur Feed Pump, A2-GA1532A or A2-GA153/B, using

its local start/stop control push-button and verify that its
discharge valve is open.
G. The Train 1 sulfur flow meter should begin to indicate that sulfur
is flowing into the Sulfur Degassing Reactor.
H. It will take the Sulfur Feed Pump about 3-5 hours 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, A2-ME1550, and begin flowing into the Sulfur
Storage Tank.
I. Open the view hatch on the Degassed Sulfur Drain Seal

Assembly and observe when sulfur begins to flow into the tank.
When sulfur begins to flow out of the Degassed Sulfur Drain
Seal Assembly, proceed to the next section to complete the
startup of the Sulfur Degassing Unit.

SULFUR BLOCK
10.8.2.2 Placing the Sulfur Degassing Reactor in Operation
WARNING
NEVER START A DEGASSING BLOWER UNLESS EACH OF

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

ASSOCIATED SULFUR FLOW METER INDICATES
SULFUR IS FLOWING.


SMOOTHLY.
FAILURE TO OBSERVE THESE PRECAUTIONS COULD

CAUSE A FIRE AND/OR EXPLOSION IN THE SULFUR
DEGASSING REACTOR.
A. Confirm that the setpoint of the Train 1 sulfur feed rate flow
controller 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

SULFUR BLOCK
B. Confirm that both the Degassing Air Blower discharge valves

are fully closed.
C. Start a Degassing Air Blower:
(1) Open the valve in its blow-off line.
(2) Start the blower using its local start/stop control

push-button.
(3) Once the blower comes up to speed, slowly "pinch" the

valve in the blow-off line until the discharge pressure
(4) Press the "reset" push-button on the blower to open its

discharge valve.
(5) Slowly close the valve in the blow-off line.
NOTE: Do not allow the pressure to exceed 3.5 kg/cm2(g),

as this will cause the relief valves on the blower
discharge lines to open in order to relieve the
excessive pressure.
D. Be prepared to take control of the sulfur feed rate flow controller
in the DCS if necessary to stabilize the sulfur feed rate.
E. Confirm that the degassing air flow rate indicated in the DCS is
200 Nm3/H or higher.
F. Place the level controller for the Train 1 Sulfur Surge Tank in
service as follows:

"automatic".

supplying to the sulfur feed rate controller matches the
current local sulfur feed rate setpoint on the controller.
(3) Switch the sulfur feed rate controller to "cascade" mode so

that the setpoint for the sulfur feed rate will now be adjusted

SULFUR BLOCK
G. Once SRU Train 2 has been started up and there is sufficient

sulfur production into the Train 2 Sulfur Surge Tank, the Train 2
Sulfur Feed Pump can be placed in service as follows:
(1) Place the Train 2 sulfur feed rate controller in the DCS in
(2) Verify that the control valve in the Train 2 spill-back line is
closed.
(3) Verify that the shutdown valves in the discharge lines from
the Train 2 Sulfur Feed Pumps are closed.
(4) Start a Sulfur Feed Pump, A2-GA1542A or A2-GA1542B,

using its local start/stop control push-button and verify that
its discharge valve is open.
(5) The Train 2 sulfur flow meter should begin to indicate that
sulfur is flowing to the Sulfur Degassing Reactor.
(6) Confirm that the setpoint of the Train 2 sulfur feed rate
flow controller 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.
(7) Place the level controller for the Train 2 Sulfur Surge Tank
in service.
H. The Sulfur Degassing Unit is now in operation. Before directing

your attention away from this system make sure that:

properly.

properly.
(5) The degassing air flow rate is at its normal value or above.

SULFUR BLOCK
(6) Sulfur is draining freely from the Degassed Sulfur Drain

Seal Assembly.

properly.
(8) The TTO is operating smoothly.
10.8.3 Initial Sulfur Loading Operation

Once a level of liquid sulfur has been established in the Sulfur Storage
Tank, loading of sulfur trucks can commence.
A. Confirm that the steam-jacket heating systems are operating properly
on each Sulfur Loading Pump, their seals, their suction piping and
valves, their discharge piping and valves, and the sulfur loading arm
at each loading spot.
B. Confirm that there is sufficient sulfur in the Sulfur Storage Tank to
load a truck.
C. Select a Sulfur Loading Pump for service by turning the selector

switch to that pump.
D. Position a truck under a sulfur loading arm, and connect the

grounding cable to it.
E. Confirm that the applicable grounding status light is illuminated on

the loading control panel, then lower the loading arm into the tank
hatch.
F. Start the selected Sulfur Loading Pump by pressing the applicable

start/stop push-button mounted at the sulfur loading platform.
G. If sulfur does not begin flowing into the truck within 60 seconds, stop
the Sulfur Loading Pump by pressing the start/stop push-button. The
following items should be investigated to determine why sulfur is not
being pumped:
(1) Confirm that selector switch is set to the correct Sulfur Loading
Pump.
(2) Confirm that the "stop" switch for that pump, either is in the
"run" position.

SULFUR BLOCK
(3) Confirm that the steam-jacketed heating systems, steam traps,

etc. on the pumps, piping, and loading arms are functioning
properly.
(4) Confirm that there is adequate level in the tank.
Once the problem has been corrected, station an observer by the

Sulfur Loading Pump, return to Step F to commence loading again,
and have the observer confirm that the pump suction valve opens,
the pump starts, and then the discharge valve opens.
H. Once the sulfur truck is full, stop the Sulfur Loading Pump by
pressing the start/stop push-button at the loading spot.
I. Confirm that the Sulfur Loading Pump has stopped and its suction
and discharge valves are now closed.
CAUTION
ALWAYS CONFIRM THAT THE BLOCK VALVE AT THE LOADING

SPOT CLOSES AFTER STOPPING THE SULFUR LOADING PUMP.
THE SULFUR LOADING ARMS ARE LOWER THAN THE TOP OF
THE SULFUR STORAGE TANK, SO THE TANK CAN PARTIALLY
EMPTY THROUGH THE LOADING LINE, EVEN WHEN A PUMP IS
NOT RUNNING, IF THE LEVEL IN THE TANK IS HIGH ENOUGH
AND THE BLOCK VALVE REMAINS OPEN.

SULFUR BLOCK
10.8.4 Normal Sulfur Loading Operation

A. Position a truck under a sulfur loading arm, and connect the
grounding cable to it.
B. Confirm that the applicable grounding status light is illuminated on
the loading control panel, then lower the loading arm into the tank
hatch.
C. Commence sulfur loading by pressing the applicable start/stop

push-button mounted at the sulfur loading platform.
D. If sulfur does not begin flowing into the truck within 60 seconds, stop
the Sulfur Loading Pump by pressing the start/stop push-button.
Investigate the items listed above to determine why sulfur is not
being pumped.
E. Once the sulfur truck is full, stop the sulfur loading operation by
pressing the start/stop push-button at the loading spot.
CAUTION
ALWAYS CONFIRM THAT THE BLOCK VALVE AT THE LOADING

SPOT CLOSES WHEN LOADING IS STOPPED. THIS WILL
PREVENT THE SULFUR STORAGE TANK FROM PARTIALLY
EMPTYING ITSELF DUE TO GRAVITY-FLOW THROUGH THE
LOADING LINE IF THE LEVEL IN THE TANK IS HIGH.

SULFUR BLOCK

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 for
Planned Shutdown with Entry should be followed to accomplish a satisfactory
shutdown and minimize the time required for performance of the desired
maintenance work.
situation.

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 filling the vessel with sulfur.
A. Stop the Sulfur Feed Pump, A2-GA1532A/B using its local start/stop
control push-button.
Stop the Sulfur Feed Pump, A2-GA1542A/B using its local start/stop
This should activate the SDU ESD system to shut down the
Degassing Air Blower.
B. Place the Train 1 sulfur feed rate controller in the DCS, in "manual"
and set its output to 0% to close the control valve in the spill-back
line.

SULFUR BLOCK
Place the Train 2 sulfur feed rate controller in the DCS, in "manual"
and set its output to 0% to close the control valve in the spill-back
line.
This will prevent sulfur from draining out of the Sulfur Degassing
Reactor.
C. Visually confirm that:
(1) All Sulfur Feed Pumps are stopped, and that their discharge
valves are closed.
(2) Both Degassing Air Blowers are stopped and their discharge
valves are closed.
(3) The control valves in both spill-back lines are closed.
D. Confirm that all steam heating services are still functioning and the
steam traps are operating properly.
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.

Use the following steps to shut down the Sulfur Degassing Unit for
maintenance or inspection.
A. Stop the Sulfur Feed Pump, A2-GA1532A/B using its local start/stop
Stop the Sulfur Feed Pump, A2-GA1542A/B using its local start/stop
This should activate the SDU ESD system to shut down the
Degassing Air Blower.
B. Visually confirm that:
(1) All Sulfur Feed Pumps are stopped, and that their discharge
valves are closed.
(2) Both Degassing Air Blowers are stopped and their discharge
valves are closed.

SULFUR BLOCK
C. Confirm that the 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 Surge Tank(s).
Note: The sulfur from the Sulfur Degassing Reactor may be drained into
the surge tank for either SRU. Unless noted otherwise, the following
procedure applies to both Train 1 and Train 2.
D. Place the sulfur feed rate controller in the DCS, in "manual" and set
its output to 100%.
This will fully open the control valve in the spill-back line and allow all
of the liquid sulfur to empty from the Sulfur Degassing Reactor back
into the Sulfur Surge Tank.
E. Once the Sulfur Degassing Reactor is empty, set the output from the
flow controller to 0%.
Confirm that the control valve in the spill-back line is fully closed.
F. Remove the blind flange then open the steam-out valve on the
degassing air line and use LP steam to purge the gases in the Sulfur
Degassing Reactor out to the TTO.
G. Discontinue steam-out of the vessel and re-install the blind flange.
H. 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.
I. Close the block valve in the sulfur drain line to isolate the Sulfur
Degassing Reactor from the drain trap and the Sulfur Storage Tank.
Once the Sulfur Degassing Reactor is isolated, it can be opened for

entry. Refer to the "General Safety" section of these guidelines for
procedures to be followed when performing maintenance work on
this plant.

SULFUR BLOCK
10.9.3 Shutdown for Tank Entry

If the Sulfur Storage Tank is to be entered, it should be isolated, emptied,
purged, and ventilated using normal procedures. This should include at
least the following:
A. Close the block valves in the sulfur inlet lines to the Sulfur Storage
Tank and install slip blinds at the tank flanges.
B. Use the Sulfur Loading Pump to empty the Sulfur Storage Tank as
completely as possible. Since the pump suction lines inside the tank
extend to near the bottoms of recessed sumps in the tank bottom, it
should be possible to remove all of the molten sulfur covering the
tank floor before the pump loses suction.
C. Briefly operate the other Sulfur Loading Pump until it loses suction to
remove as much sulfur as possible from the other suction sump.
D. Install slip blinds in the pump suction lines at the tank flanges.
E. Close the block valves in the steam and condensate lines for the
steam coils inside the tank, then de-pressure the coils.
F. Remove the covers from the roof and shell manholes, then use fans
or other means to sweep air through the tank and displace all of the
tank vapors.
G. If desired, the steam supply to the steam jacket on the air sweep
vent stack can be left in service so that the stack will help ventilate
the tank.
H. Monitor the air inside the tank and continue to sweep the tank with
air until no H2S is detected.
I. Once these steps have been completed, entry into the tank following
your company's policies for "confined space entry" should be
possible.

SULFUR BLOCK
WARNING
THE SULFUR STORAGE TANK ALWAYS HAS THE POTENTIAL TO

CONTAIN H2S AND/OR SO2. ALL SAFETY PRECAUTIONS
OUTLINED IN THE GENERAL SAFETY SECTION OF THIS
GUIDELINES REGARDING WORKING SAFELY WHEN H2S AND/OR
SO2 MAY BE PRESENT SHOULD BE FOLLOWED.
MOLTEN SULFUR MAY ALSO BE PRESENT INSIDE THE TANK,

INCLUDING UNDERNEATH WHAT OTHERWISE APPEARS TO BE
SOLID SULFUR. MOLTEN SULFUR CAN CAUSE SEVERE BURNS,
SO ALWAYS USE APPROPRIATE PERSONAL PROTECTION
EQUIPMENT.

SULFUR BLOCK
Table of Contents
11. TAILGAS CLEANUP .............................................................................................. 11-1
11.2 SAFETY ............................................................................................................... 11-2
11.3.1 General ......................................................................................................... 11-3
11.3.2 Tailgas Hydrogenation/Hydrolysis ................................................................ 11-3
11.3.3 Process Gas Cooling .................................................................................... 11-4
11.3.4 Gas Contacting ............................................................................................. 11-5
11.3.5 Solvent Regeneration Section ...................................................................... 11-6
11.3.6 Steam Production/Consumption ................................................................... 11-7
11.4.1 TGCU Quench Column, A2-DA1560 ............................................................ 11-8
11.4.2 TGCU Quench Column Packing, A2-DB1560 .............................................. 11-8
11.4.3 TGCU Contactor, A2-DA1561 ...................................................................... 11-8
11.4.4 TGCU Contactor Packing & Internals, A2-DB1561 ...................................... 11-8
11.4.5 TGCU Stripper, A2-DA1562 ......................................................................... 11-9
11.4.6 TGCU Stripper Trays, A2-DB1562 ............................................................... 11-9
11.4.7 TGCU Reactor, A2-DC1560 ....................................................................... 11-10
11.4.8 TGCU Stripper Reflux Accumulator, A2-FA1560 ....................................... 11-10
11.4.9 Catalyst for TGCU Reactor, A2-MC1560 ................................................... 11-10
11.4.10 TGCU Stripper Reboiler Condensate Pot, A2-FA1562 ........................... 11-10
11.4.11 TGCU Reactor Feed Heater, A2-EA1560 ............................................... 11-11
11.4.12 TGCU Waste Heat Reclaimer, A2-EA1561 ............................................ 11-11
11.4.13 TGCU Quench Water Trim Cooler, A2-EA1562A/B ................................ 11-11
11.4.14 TGCU Lean/Rich Exchanger, A2-EA1564 .............................................. 11-11
11.4.15 TGCU Stripper Reboiler, A2-EA1565 ..................................................... 11-12
11.4.16 TGCU Lean Amine Trim Cooler, A2-EA1563 ......................................... 11-12
11.4.17 TGCU Quench Water Cooler, A2-EC1560 ............................................. 11-12
11.4.18 TGCU Stripper Reflux Condenser, A2-EC1562 ...................................... 11-12
11.4.19 TGCU Lean Amine Cooler, A2-EC1561 ................................................. 11-12
11.4.20 TGCU Quench Water Pump, A2-GA1560A/B......................................... 11-13
11.4.21 TGCU Rich Amine Pump, A2-GA1561A/B ............................................. 11-14
11.4.22 TGCU Stripper Reflux Pump, A2-GA1563A/B ........................................ 11-14
11.4.23 TGCU Lean Amine Pump, A2-GA1562A/B ............................................. 11-14
11.4.24 TGCU Start-Up Blower, A2-GB1560 ....................................................... 11-14
11.4.25 Refractory for TGCU Reactor, A2-MR1560 ............................................ 11-15
11.4.26 TGCU Reactor Feed Mixer, A2-ME1560 ................................................ 11-16
Issued 30 August 2011 Tailgas Cleanup Page 11-i

SULFUR BLOCK
11.4.27 TGCU Quench Water Filter, A2-FD1560A/B .......................................... 11-16

11.4.28 TGCU Rich Amine Filter, A2-FD1562A/B ............................................... 11-16
11.4.29 TGCU Lean Amine Filter, A2-FD1563 .................................................... 11-17
11.4.30 TGCU Amine Carbon Filter, A2-FD1564 ................................................ 11-17
11.4.31 TGCU Amine After-Filter, A2-FD1565 .................................................... 11-17
11.4.32 pH Meter Sample Filter, A2-FD1561A/B ................................................. 11-17
11.5.1 TGCU Reactor Feed Control Loops ........................................................... 11-18
11.5.1.1 Reactor Feed Temperature Control .................................................... 11-18
11.5.1.2 Hydrogen Concentration Control ......................................................... 11-19
11.5.1.3 Controls for Startup and Shutdown ..................................................... 11-20
11.5.2 Hydrogen and Hydrogen Sulfide Analyzer, A2-AE15858/A2-AE15859 ...... 11-23
11.5.4 Tailgas Switching Valve Controls ............................................................... 11-26
11.5.4.1 Repositioning the Tailgas Valves Following a TGCU ESD ................. 11-26
11.5.4.2 Introducing SRU Tailgas into the TGCU — Scenario 1 ....................... 11-27
11.5.4.3 Introducing SRU Tailgas into the TGCU — Scenario 2 ....................... 11-29
11.5.5 TGCU Shutdown System ........................................................................... 11-33
11.5.5.1 Causes ................................................................................................ 11-33
11.5.5.2 Effects ................................................................................................. 11-36
11.5.5.3 Non-ESD Shutdowns .......................................................................... 11-37
11.6.2 Catalyst Fouling .......................................................................................... 11-40
11.6.3 TGCU Reactor Operation ........................................................................... 11-41
11.6.4 TGCU Catalyst ........................................................................................... 11-43
11.6.5 TGCU Start-Up Blower Operation .............................................................. 11-44
11.6.6 TGCU Quench Column Operation.............................................................. 11-45
11.6.7 TGCU Contactor Operation ........................................................................ 11-48
11.6.8 TGCU Stripper Operation ........................................................................... 11-52
11.6.9 TGCU Amine Water Balance...................................................................... 11-55
11.6.10 TGCU Amine Loss .................................................................................. 11-59
11.6.11 Operation at Low Flow Rates.................................................................. 11-60
11.6.12 Pressure Drop Surveys ........................................................................... 11-61
11.6.13 Boiler Water Treatment ........................................................................... 11-63
11.7.3 Commissioning Nitrogen and Utility Air to the Process .............................. 11-66
11.7.4 Commissioning Hydrogen to the Process .................................................. 11-72
Issued 30 August 2011 Tailgas Cleanup Page 11-ii

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11.7.5 Leak Testing the Process Piping and Equipment ....................................... 11-75
11.7.6 Washing the Quench Water System .......................................................... 11-79
11.7.6.1 Water Flush ......................................................................................... 11-79
11.7.6.2 Acid Wash ........................................................................................... 11-82
11.7.6.3 Alkaline Wash...................................................................................... 11-82
11.7.6.4 Initial Water Fill .................................................................................... 11-84
11.7.7 Washing the Amine System ....................................................................... 11-85
11.7.7.1 Water Flush ......................................................................................... 11-86
11.7.7.2 Acid Wash ........................................................................................... 11-89
11.7.7.3 Weak Amine Wash .............................................................................. 11-91
11.7.7.4 Initial Solvent Fill ................................................................................. 11-93
11.7.8 Purging the Low Pressure TGCU Columns ................................................ 11-97
11.7.8.1 Establishing Nitrogen Flow .................................................................. 11-97
11.7.8.2 Purging the TGCU Start-Up Blower .................................................... 11-99
11.7.8.3 Purging the Columns ......................................................................... 11-100
11.8 STARTUP PROCEDURES.............................................................................. 11-102
11.8.1 Initial Startup of the TGCU ....................................................................... 11-102
11.8.1.1 Initial Preparations............................................................................. 11-102
11.8.1.2 Establishing Nitrogen Flow ................................................................ 11-103
11.8.1.3 Establishing Re-circulation Flow ....................................................... 11-104
11.8.2 Pre-Sulfiding the TGCU Catalyst .............................................................. 11-107
11.8.2.1 Establishing Reducing Gas Flow....................................................... 11-108
11.8.2.2 Pre-Sulfiding the Catalyst .................................................................. 11-111
11.8.3 Routing SRU Tailgas to the TGCU ........................................................... 11-115
11.8.3.1 Introducing SRU Tailgas into the TGCU — Scenario 1 ..................... 11-116
11.8.3.2 Introducing SRU Tailgas into the TGCU — Scenario 2 ..................... 11-119
11.8.4 Quench Water and Amine Systems ......................................................... 11-122
11.8.5 Process Gas Flow to the TGCU Columns ................................................ 11-124
11.8.6 Normal Startup of the TGCU .................................................................... 11-128
11.8.6.1 Initial Preparations............................................................................. 11-128
11.8.6.2 Purging the Low Pressure TGCU Columns....................................... 11-130
11.8.6.3 Establishing Nitrogen Flow ................................................................ 11-130
11.8.6.4 Establishing Re-circulation Flow ....................................................... 11-131
11.8.6.5 Establishing Reducing Gas Flow....................................................... 11-133
11.8.6.6 Routing SRU Tailgas to the TGCU.................................................... 11-134
11.8.6.7 Quench Water and Amine Systems .................................................. 11-138
11.8.6.8 Process Gas Flow to the TGCU Columns ......................................... 11-140
11.9 SHUTDOWN PROCEDURES ......................................................................... 11-144
11.9.1 Planned Shutdown - No Reactor Entry..................................................... 11-145
11.9.2 Planned Shutdown for Reactor Entry ....................................................... 11-151
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11.9.3 Shutting Down When Boiler Tubes Are Leaking ...................................... 11-158
11.9.4 Special Precaution During Shutdowns ..................................................... 11-159
11.9.5 Emergency Shutdown .............................................................................. 11-163
11.9.6 Effects of Shutdowns and Outages in Other Systems.............................. 11-164
11.9.6.1 Amine Regeneration Unit Outages.................................................... 11-164
11.9.6.2 Sour Water Stripper Outages ............................................................ 11-164
11.9.6.3 Sulfur Recovery Unit ESD System .................................................... 11-164
11.9.6.4 Thermal Oxidizer ESD System.......................................................... 11-165
11.9.6.5 Steam System Outage ...................................................................... 11-166
11.10 ANALYTICAL PROCEDURES ..................................................................... 11-167
11.10.1 General Procedures for Analyzing TGCU Solvent, ............................... 11-167
11.10.2 Determination of Amine Concentration in TGCU Solvent ..................... 11-171
11.10.3 Determination of Total Acid Gas Loading in TGCU Solvent ................. 11-173
11.10.4 Determination of H2S and CO2 Loading in TGCU Solvent .................... 11-175
11.10.5 Determination of Foaming Tendency of TGCU Solvent ........................ 11-179
11.10.6 H2S Conc. in TGCU Contactor Ovhd by the Tutweiler Method ............. 11-181
11.10.7 H2S Conc. in TGCU Contactor Ovhd Using Gas Detector Tubes ......... 11-182
11.10.7.1 Operating Principles.......................................................................... 11-182
11.10.7.2 Sampling the TGCU Contactor Overhead Gas ................................. 11-183
11.10.7.3 Calculations ...................................................................................... 11-184
11.10.8 Monitoring the Performance Level of TGCU Catalyst ........................... 11-185
Issued 30 August 2011 Tailgas Cleanup Page 11-iv

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11. TAILGAS CLEANUP

The purpose of the Tailgas Cleanup system is to remove objectionable
components from the sulfur plant tailgas, thereby allowing the treated effluent to
be incinerated and safely discharged to the atmosphere. The Shell Claus
Off-gas Treating (SCOT) process licensed by Shell Global Solutions (US) Inc.
processes the tailgas from the SRU, converting sulfur compounds present in the
tailgas back into H2S. The H2S is then absorbed in a selective solvent, stripped
from the solvent, and recycled back to the SRU, allowing an overall sulfur
recovery in excess of 99.9%.
Treated vent gas from the Tailgas Cleanup Unit (TGCU) is routed to the Tailgas
Thermal Oxidation system and afterwards dispersed to the atmosphere. Due to
the sulfur removal by the TGCU process, the incinerated effluent gas will
normally contain less than 200 PPMV of SO2 on a dry, 0% oxygen basis.

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11.2 Safety
WARNING

HYDROGEN SULFIDE AND SULFUR DIOXIDE. CLOSE ATTENTION

THIS PLANT.

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11.3.1 General
The Tailgas Cleanup Unit (TGCU) receives tailgas from the two Sulfur
Recovery Units and uses the Shell Claus Off-gas Treating (SCOT)
process licensed by Shell Global Solutions (US) Inc. for sulfur removal.
The TGCU Unit has been designed to process the 7,655 Nm3/H of sulfur
plant tailgas that results when each SRU receives a total fresh acid gas
feed containing 34.6 MT/D of sulfur. The TGCU process reduces all of the
sulfur compounds in the sulfur plant tailgas to H2S, then uses selective
amine absorption to recover H2S from the tailgas while allowing most of
the CO2 to "slip" by. The H2S and CO2 removed by the amine are stripped
from the amine and recycled to the two SRUs, allowing an overall sulfur
recovery in excess of 99.9 wt. %.
Less than 220 PPMV of sulfur (wet basis, expressed as H2S) remains in
the treated effluent flowing to the Tailgas Thermal Oxidation Unit. This
sulfur content is low enough to keep the SO2 content of the incinerated
effluent below 200 PPMV (on a dry, 0% oxygen basis) when the H2S and
sulfur in the spent degassing air from the Sulfur Degassing Unit and the
sweep air from the Sulfur Surge Tanks are included, due to the dilution
effect of the thermal incineration process.
11.3.2 Tailgas Hydrogenation/Hydrolysis

The tailgas stream from the fourth pass of the Sulfur Condenser in each
SRU is combined and heated using HP steam in the TGCU Reactor Feed
Heater, A2-EA1560. The heated gas is then mixed with hydrogen-rich
reducing gas by the TGCU Reactor Feed Mixer, A2-ME1560, (a static
mixer) before the mixture flows to the TGCU Reactor, A2-DC1560, at
240°C [464°F]. As the gas flows through the bed of Criterion 234
cobalt-molybdenum catalyst, the reducing atmosphere hydrogenates or
hydrolyzes most of the sulfur compounds to H2S:
(1) SO2 + 3 H2 H2S + 2 H2O

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(2) S + H2 H2S
(3) COS + H2O H2S + CO2
(4) CS2 + 2 H2O 2 H2S + CO2
Carbon monoxide in the tailgas also reacts with the water vapor in the gas
to form hydrogen, the classic "water gas shift" reaction:
(5) CO + H2O H2 + CO2
These reactions are all exothermic, causing the gas temperature to

increase to 291°C [556°F] at the outlet of the TGCU Reactor.
11.3.3 Process Gas Cooling

Before the amine solvent can be used to remove the H2S from the
process gas, the gas must be cooled to an acceptable contact
temperature. The first stage of cooling occurs in the TGCU Waste Heat
Reclaimer, A2-EA1561, where the effluent from the TGCU Reactor is
cooled to 166°C [331°F] by generating LP steam.
During the course of starting up the TGCU, the equipment must be

brought up to operating temperature before the sulfur plant tailgas is
introduced. The TGCU Start-Up Blower, A2-GB1560, accomplishes this
by re-circulating gas from the outlet of the TGCU Waste Heat Reclaimer
back to the TGCU Reactor Feed Heater. This gas is circulated through
the system and heated with the TGCU Reactor Feed Heater until the
sulfur plant tailgas is ready to be routed to the TGCU, at which time the
TGCU Start-Up Blower can be shut down.
The partially cooled gas from the TGCU Waste Heat Reclaimer enters the
bottom of the TGCU Quench Column, A2-DA1560, for the second stage of
cooling. As the gas passes upward through the packed bed in this tower,
it is further cooled by direct contact with a circulating stream of quench
water. As the gas is cooled, most of the water vapor produced by the
upstream reactions (Claus, combustion, and hydrogenation) is condensed
and removed from the gas stream. In addition to cooling the gas, direct
contact with the quench water serves to absorb trace quantities of SO2
that may "break through" the TGCU Reactor periodically. Since SO2 will
react with amines to form heat-stable salts, the "washing" action of the
quench water helps minimize degradation of the MDEA solvent.

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The cooled gas stream leaves the top of the TGCU Quench Column at
39°C [102°F] and flows to the TGCU Contactor, A2-DA1561, while the
quench water exits the bottom of the tower at 67°C [153°F]. The TGCU
Quench Water Pump, A2-GA1560A/B, circulates the water stream to the
TGCU Quench Water Cooler, A2-EC1560, and the TGCU Quench Water
Trim Cooler, A2-EA1562A/B, to reject the heat removed in the TGCU
Quench Column. This cools the quench water to 38°C [104°F] before it is
returned to the top of the tower.
A sidestream of the quench water flows through the TGCU Quench Water
Filter, A2-FD1560A/B, to remove solids from the quench water system. A
portion of the filtrate is routed to the Sour Water Stripping Unit to balance
the water condensed from the gas in the TGCU Quench Column, on level
control from the tower. The remainder of the filtrate returns to the suction
of the circulating pump.
11.3.4 Gas Contacting

The cooled gas from the TGCU Quench Column enters the bottom of the
TGCU Contactor at 39°C [102°F] and 0.06 kg/cm2(g) [0.9 PSIG]. As the
gas flows upward through the packed bed in this tower, it is contacted with
an aqueous solution of methyldiethanolamine, MDEA. The MDEA solvent
(45 wt% MDEA) absorbs the H2S in the gas stream to reduce the total
sulfur content below 220 PPMV on a wet basis while allowing the majority
of the CO2 to "slip" overhead. The treated gas exits the top of the TGCU
Contactor at 39°C [102°F] and flows to the Tailgas Thermal Oxidation
Unit.
The reactions between the acidic gases and the basic amine solution can
be represented by:
(6) H2S + CH3(CH2OHCH2)2N CH3(CH2OHCH2)2NH+ + HS–
(7) CO2 + CH3(CH2OHCH2)2N + H2O CH3(CH2OHCH2)2NH+ + HCO3–
The selectivity of the solvent for H2S over CO2 is important since the
absorbed gases are recycled to the SRUs. Minimizing CO2 pickup
reduces the amount of gas recycling to the sulfur plants, and allows the
equipment in the Sulfur Recovery and Tailgas Cleanup Units to be
smaller.
The selectivity of tertiary amines like MDEA for H2S is a result of the
indirect reaction that must occur between the amine and CO2. Unlike

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primary amines (such as MEA) and secondary amines (such as DEA),

tertiary amines do not react directly with CO2. Instead, the CO2 must first
be ionized into a bicarbonate ion (a slow reaction) before it will react with
the amine. Since MDEA reacts directly (and quickly) with H2S, proper
selection of the contact time between the amine and the process gas
allows preferential removal of the H2S. The selectivity of MDEA for H2S
over CO2 is enhanced by lower contact temperatures, hence the use of
the trim cooler to reduce the solvent temperature before it enters the
TGCU Contactor.
The rich amine leaves the bottom of the tower at 42°C [108°F] and is
pumped by the TGCU Rich Amine Pump, A2-GA1561A/B, through the
TGCU Rich Amine Filter, A2-FD1562A/B, to remove accumulated solids.
The rich amine then flows on level control through the tube side of the
TGCU Lean/Rich Exchanger, A2-EA1564A/B/C, and is preheated to
105°C [221°F] by cooling the lean amine before flowing to the TGCU
Stripper, A2-DA1562, entering between trays #4 and #5.
11.3.5 Solvent Regeneration Section

The TGCU Stripper contains 28 valve trays (4 wash water trays, 24
stripping trays) and one chimney draw tray. As the solvent flows down the
column, the absorbed H2S and CO2 are stripped from the MDEA by
countercurrent contact with stripping steam rising upward. This stripping
steam is generated in the TGCU Stripper Reboiler, A2-EA1565, using
LP steam as the heat input. The heat input to the reboiler is adjusted by
flow control of the steam. The steam flow controller can optionally be
reset by the TGCU Stripper overhead temperature, which will maintain the
desired overhead temperature of 118°C [244°F] by varying the heat input
in proportion to the amount of acid gas contained in the rich amine.
The stripping steam supplies the heat of reaction required to reverse

reactions (6) and (7), and carries the H2S and CO2 stripped from the
solvent overhead to the TGCU Stripper Reflux Condenser, A2-EC1562,
where the steam is condensed as the stream is cooled to 49°C [120°F].
The condensed water is removed by the TGCU Stripper Reflux
Accumulator, A2-FA1560, and returned as reflux to the wash water trays
in the tower by the TGCU Stripper Reflux Pump, A2-GA1563A/B. The
acid gas (H2S and CO2, along with the uncondensed water) stripped from
the solvent exits the reflux drum at 0.85 kg/cm2(g) [12.1 PSIG] and flows
to the two Sulfur Recovery Units.

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The TGCU Lean amine Pump, A2-GA1562A/B, pumps the regenerated

lean MDEA solvent from the bottom of the TGCU Stripper through the
shell side of the TGCU Lean/Rich Exchanger, cooling the lean amine from
127°C [261°F] to 66°C [152°F] by countercurrent heat exchange with the
cool rich amine. A slipstream of the lean amine then flows through the
TGCU Lean Amine Filter, A2-FD1563, to remove accumulated solids from
the solvent and through the TGCU Amine Carbon Filter, A2-FD1564,
where the activated carbon adsorbs contaminants such as degradation
products from solvent. The TGCU Amine After-Filter, A2-FD1565,
catches any carbon "fines" before the filtered slipstream rejoins the main
solvent stream and flows to the TGCU Lean Amine Cooler, A2-EC1561,
and the TGCU Lean Amine Trim Cooler, A2-EA1563A/B, which cool the
solvent to 38°C [100°F] before it returns to the top of the TGCU Contactor
on flow control.
11.3.6 Steam Production/Consumption

The TGCU consumes steam at two pressure levels, and produces steam
at one pressure level. Saturated HP steam from the SRUs is used to heat
the TGCU Reactor feed stream, and LP steam is used to reboil solvent in
the TGCU Stripper Reboiler. LP steam is produced in the TGCU Waste
Heat Reclaimer, supplying a portion of the steam consumed in reboiling
the TGCU solvent.

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11.4.1 TGCU Quench Column, A2-DA1560
The TGCU Quench Column contains a single bed of random packing to
provide good contact between the hot process gas and the quench water
that is to cool it. The tower has a 304 S.S. woven wire mist eliminator
above the packed bed to remove entrained water droplets from the gas
before it leaves the tower.
11.4.2 TGCU Quench Column Packing, A2-DB1560

This bed of random packing provides good contact between hot process
gas entering below it and quench water fed above it inside the TGCU
Quench Column. The packing has a bed limiter above it and rests on a
bed support. The quench water is distributed over the packing by a
distributor tray. The packing is 304 S.S.; the other internals are 304 S.S.
support ring and clips inside the TGCU Quench Column to prevent direct
11.4.3 TGCU Contactor, A2-DA1561

The TGCU Contactor contains a single bed of random packing to provide
good contact between the process gas and the TGCU solvent to remove
H2S from the process gas. The tower has a 304 S.S. woven wire mist
eliminator above the top bed to remove entrained solvent droplets from
the gas before it leaves the tower.
11.4.4 TGCU Contactor Packing & Internals, A2-DB1561

This random packing bed provides good contact between process gas
entering below it and TGCU lean amine fed above it inside the TGCU
Contactor. The packing has a bed limiter above it and rests on a bed
support. The lean amine is distributed over the packing by a distributor
tray. The packing elements are 304 S.S.; the other internals are 304 S.S.
support ring and clips inside the TGCU Quench Column to prevent direct

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11.4.5 TGCU Stripper, A2-DA1562

The TGCU Stripper contains 28 valve trays to provide good contact
between the rich TGCU solvent and the reboiler vapors to strip H2S and
CO2 from the solvent. The rich amine enters on the fifth tray from the top;
the four trays above that are "water wash" trays that allow the reflux water
(entering on the top tray) to remove traces of MDEA from the overhead
vapor and minimize solvent losses.
column liquids to feed the TGCU Stripper Reboiler. The column section
located below this chimney tray serves to separate the outlet steam and
lean amine from the reboiler and to provide surge for the solvent
circulating system.
11.4.6 TGCU Stripper Trays, A2-DB1562

These 1-pass valve trays provide good contact between the rich TGCU
solvent fed above them and the reboiler vapors fed below them inside the
TGCU Stripper. The trays are designed per Shell's requirements. The
tray decks are 304 S.S., and the valves are fabricated from 304 S.S. to
resist corrosion and to prevent "sticking" to the tray decks. The chimney
tray deck is 304 S.S. The bottom valve tray has a seal pan for its
downcomer to maintain a liquid seal and prevent gas from blowing up the
downcomer.
The top four trays in the column are located above the rich amine feed
point and serve as water-wash trays to minimize the amount of amine
carried-over in the tower overhead. Since these trays have only the reflux
water flowing over them, the liquid rates for these trays are much lower
than for the trays lower in the column. For this reason, these four trays
are designed for minimum leakage (i.e., picket fence weirs, minimum
downcomer clearance, etc.).

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11.4.7 TGCU Reactor, A2-DC1560

The TGCU Reactor is of the down-flow type, with the feed gas entering
the top of the vessel and proceeding vertically downward through the
catalyst bed. A perforated baffle is installed below the inlet nozzle to
distribute the gas over the length of the vessel and prevent the inlet gas
stream from impinging directly on the catalyst bed.
A catalyst support grating is installed in the vessel to support the catalyst

bed in the center of the vessel. The support grating is covered with a
stainless steel screen to prevent the catalyst from sifting through the
grating. A small bead of castable refractory is used to seal the edges of
the support grating to prevent catalyst leaks between the grating and the
vessel shell.
11.4.8 TGCU Stripper Reflux Accumulator, A2-FA1560

This vertical pressure vessel removes condensed water from the stream
leaving the TGCU Stripper Reflux Condenser so that the water can be
used as reflux for the TGCU Stripper. The vessel has a 304 S.S. woven
wire mist eliminator in the top to remove entrained liquid droplets from the
gas before it leaves the vessel.
11.4.9 Catalyst for TGCU Reactor, A2-MC1560

Refer to the Basic Engineering Package for the type of catalyst used in
the TGCU Reactor.
11.4.10 TGCU Stripper Reboiler Condensate Pot, A2-FA1562

This vertical pressure vessel collects the condensate from the TGCU
Stripper Reboiler and returns it to the condensate system on level control.
This method of removing condensate from the exchanger provides much
smoother control of the heat input to the reboiler than a conventional
steam trap could.
As stated above, this vessel is simply a very good steam trap. During
normal operation, the steam pressure required to provide the necessary
reboil heat to the TGCU Stripper may be much less than the
3.5-4.2 kg/cm2(g) steam pressure available in the LP steam system. The
normal steam pressure in the shell of the reboiler may be such that the
water level in the condensate pot will rise upwards from the pot, perhaps
even within the shell of the reboiler. During these periods, the level valve
will remain fully open and the sight glass will indicate a full water level.

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This is a normal operating condition for this vessel. The vessel will usually
operate with a visible level only when the TGCU Stripper Reboiler is
operating near its maximum capacity with full steam pressure on the shell
of the exchanger. Under these conditions, the level control and level
valve will function normally and maintain a water level in the vessel.
11.4.11 TGCU Reactor Feed Heater, A2-EA1560

This shell and tube exchanger uses HP steam to heat the tailgas stream
from the fourth pass of the two Sulfur Condensers up to reaction initiation
temperature before it is mixed with hydrogen-rich reducing gas and flows
to the TGCU Reactor.
11.4.12 TGCU Waste Heat Reclaimer, A2-EA1561

The TGCU Waste Heat Reclaimer is a fixed tubesheet shell and tube heat
exchanger. The tubes are immersed in the water-filled section of the
shell, allowing the boiling water in the shell of the exchanger to cool the
hot gas leaving the TGCU Reactor catalyst bed by producing LP steam.
There is no pressure control on the shell side of the boiler; it simply
"floats" on the LP steam header pressure.
The boiler is equipped with level transmittersthat will shut down the TGCU
should the water level fall to within 75 mm of the top row of tubes.
Operation of the boiler without a sufficient water level could possibly
damage the tubes.
11.4.13 TGCU Quench Water Trim Cooler, A2-EA1562A/B

This shell and tube exchanger is used to provide the final cooling of the
quench water, with cooling water from the complex as the cooling
medium.
11.4.14 TGCU Lean/Rich Exchanger, A2-EA1564

This shell and tube exchanger conserves energy by providing heat
exchange between the rich amine and the lean amine, so that the hot lean
amine leaving the TGCU Stripper can preheat the rich amine before it
feeds the TGCU Stripper. This cross exchange saves reboiler duty by
preheating the rich amine, and reduces the load on the TGCU Lean amine
Cooler by partially cooling the hot lean amine.

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11.4.15 TGCU Stripper Reboiler, A2-EA1565

The TGCU Stripper Reboiler is a fixed tubesheet shell and tube heat
exchanger. The exchanger is arranged as a once-through vertical
thermosiphon reboiler, mounted on the side of the TGCU Stripper. The
static head of the solvent above the inlet nozzle on the lower channel
provides the driving force to circulate the solvent through the tubes.
LP steam on the shell of the exchanger heats the solvent inside the tubes,
partially vaporizing it to create stripping steam to remove the H2S and the
CO2 from the solvent flowing down the TGCU Stripper.
11.4.16 TGCU Lean Amine Trim Cooler, A2-EA1563

This shell and tube exchanger is used to provide the final cooling to the
TGCU solvent returning from the regeneration section of the process, with
cooling water from the complex as the cooling medium. Since the
selectivity of MDEA for absorbing H2S in the presence of CO2 is better at
lower temperatures, the use of cooling water is very beneficial to the
process and results in reducing the emission of SO2 from the TTO.
11.4.17 TGCU Quench Water Cooler, A2-EC1560

This forced-draft aerial exchanger is used to reject some of the heat from
cooling the process gas stream in the TGCU Quench Column by cooling
the circulating quench water stream. Fans are used to circulate air across
the finned tubes to remove heat from the quench water.
11.4.18 TGCU Stripper Reflux Condenser, A2-EC1562

This forced-draft aerial exchanger provides cooling to condense the
majority of the water from the acid gas stream leaving the overhead of the
TGCU Stripper. Fans are used to circulate air across the finned tubes to
remove heat from the overhead stream and condense the water to be
used as reflux for the tower.
11.4.19 TGCU Lean Amine Cooler, A2-EC1561

This forced-draft aerial exchanger provides some of the final cooling of the
lean amine stream returning from the regeneration section of the TGCU
process. Fans are used to circulate air across the finned tubes to remove
heat from the solvent.

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CAUTION
SINCE THE PUMPS DESCRIBED IN THE FOLLOWING SECTIONS ARE

CONSTRUCTED OF STAINLESS STEEL, DO NOT HYDROTEST THE
ASSOCIATED VESSELS OR PIPING WITH WATER CONTAINING HIGH
LEVELS OF CHLORIDES. AVOID ALLOWING WATER CONTAINING MORE
THAN 50 PPM CHLORIDES TO COME IN CONTACT WITH THESE PUMPS TO
PREVENT STRESS CORROSION CRACKING OF THE STAINLESS STEEL.
WARNING
THE LIQUID IN THESE PUMPS CONTAINS DISSOLVED H2S. THIS H2S CAN
BE RELEASED TO THE SURROUNDINGS WHEN LIQUID IS DRAINED FROM
THESE PUMPS OR FROM THE PIPING CONNECTED TO THE PUMPS.
ALWAYS OBSERVE PROPER PROCEDURES AND PRECAUTIONS WHEN
DRAINING LIQUID FROM THESE PUMPS OR PERFORMING MAINTENANCE
ON THEM. THE "GENERAL SAFETY" SECTION OF THESE GUIDELINES
SHOULD BE CONSULTED IF THERE IS ANY DOUBT ABOUT HOW TO WORK
SAFELY WHEN H2S MAY BE PRESENT.
11.4.20 TGCU Quench Water Pump, A2-GA1560A/B

These centrifugal pumps are used to circulate quench water to cool the
process gas in the TGCU Quench Column. Each pump is designed for
the total duty; the other pump is a 100% spare. These pumps are
equipped with tandem seals to reduce the likelihood of releasing H2S to
the surroundings.

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11.4.21 TGCU Rich Amine Pump, A2-GA1561A/B

These centrifugal pumps are used to send the rich amine from the TGCU
Contactor to the TGCU Stripper. Each pump is designed for the total
surroundings.
11.4.22 TGCU Stripper Reflux Pump, A2-GA1563A/B

These centrifugal pumps are used to send the reflux from the TGCU
Stripper Reflux Accumulator to the TGCU Stripper. Each pump is
designed for the total duty; the other pump is a 100% spare. These
11.4.23 TGCU Lean Amine Pump, A2-GA1562A/B

These centrifugal pumps are used to send the lean amine from the TGCU
Stripper to the TGCU Contactor. Each pump is designed for the total
surroundings.
11.4.24 TGCU Start-Up Blower, A2-GB1560

The TGCU Start-Up Blower is a single-stage fan, used to re-circulate
process gas within the TGCU Unit. Flexible connectors are used to isolate
the fan from the suction and discharge piping to allow the necessary
freedom for the expansion and movement that occurs during normal
operation.
The shaft seal is made gas-tight by using a gas-lubricated non-contacting

dual cartridge seal, so that process gas cannot escape to the
surroundings. The nitrogen seal purge should be kept in service at all
times, whether the blower is operating or not, to prevent leakage of
process gas.
The blower casing and impeller are constructed of carbon steel and
coated with "Heresite", a baked phenolic coating, for corrosion resistance.

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WARNING
THIS BLOWER HANDLES GASES CONTAINING H2S, SO2, AND

OTHER HARMFUL GASES. ALWAYS OBSERVE PROPER
MAINTENANCE ON THIS BLOWER. THE "GENERAL SAFETY"
H2S AND/OR SO2 MAY BE PRESENT.
CAUTION
WHEN THIS BLOWER IS NOT OPERATING, WATER CAN

CONDENSE FROM THE PROCESS GAS AND CAUSE CORROSION
DAMAGE TO THE BLOWER. TO PREVENT THIS, THE BLOWER IS
AUTOMATICALLY ISOLATED FROM THE PROCESS BY CLOSING
ITS SUCTION AND DISCHARGE BLOCK VALVES WHEN IT STOPS,
THEN PURGING THE BLOWER CASING WITH NITROGEN. THE
NITROGEN PURGE SHOULD BE CHECKED PERIODICALLY TO
CONFIRM THAT IT IS OPERATING PROPERLY.
11.4.25 Refractory for TGCU Reactor, A2-MR1560

A 50 mm bead of castable refractory is installed around the edges of the
catalyst bed support inside the TGCU Reactor. This seals the edges of
the bed support so that the small catalyst pellets cannot escape from the
bed.

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11.4.26 TGCU Reactor Feed Mixer, A2-ME1560

This static mixer is designed to thoroughly mix the tailgas leaving the
TGCU Reactor Feed Heater and the hydrogen-rich reducing gas before
the combined stream enters the TGCU Reactor.
11.4.27 TGCU Quench Water Filter, A2-FD1560A/B

a slipstream of the circulating quench water. If SO2 enters the TGCU
Quench Column and reacts with H2S to form small particles of colloidal
sulfur, the filter will also help remove them.
WARNING
A COMMON CONTAMINANT REMOVED BY THIS FILTER IS IRON

SULFIDE, WHICH IS PYROPHORIC AT AMBIENT TEMPERATURE.
IF THE FILTER ELEMENTS CONTAIN SUFFICIENT IRON SULFIDE,
THE ELEMENTS MAY SPONTANEOUSLY IGNITE ONCE THE
ELEMENTS DRY. ACCORDINGLY, EXERCISE PROPER CARE
WHEN HANDLING AND DISPOSING OF USED FILTER ELEMENTS.
11.4.28 TGCU Rich Amine Filter, A2-FD1562A/B

This full-flow filter is designed to remove solid particles 5 microns and
larger from the circulating rich TGCU solvent, which will help prevent
fouling of the downstream heat exchangers.
WARNING
THIS FILTER HANDLES LIQUID CONTAINING H2S AND OTHER

HARMFUL SUBSTANCES. ALWAYS OBSERVE PROPER
MAINTENANCE ON THIS FILTER. THE "GENERAL SAFETY"
H2S MAY BE PRESENT.

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11.4.29 TGCU Lean Amine Filter, A2-FD1563

a slipstream of the circulating lean TGCU solvent.
11.4.30 TGCU Amine Carbon Filter, A2-FD1564

This filter is designed to remove organic contaminants (trace
hydrocarbons, degradation products, etc.) from a slipstream of the
circulating lean TGCU solvent using a bed of activated carbon.
11.4.31 TGCU Amine After-Filter, A2-FD1565

This filter is designed to remove solid particles, particularly carbon fines,
5 microns and larger from the lean TGCU solvent leaving the TGCU
Amine Carbon Filter.
11.4.32 pH Meter Sample Filter, A2-FD1561A/B

These filters are designed to remove solid particles 5 microns and larger
from the small stream of quench water flowing to the pH analyzer probe.
There are two 100% filters so that one filter can remain in service while
the other filter is being cleaned.

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11.5.1 TGCU Reactor Feed Control Loops
The TGCU Reactor Feed Heater, A2-EA1560, and TGCU Reactor Feed
Mixer, A2-ME1560, condition the combined tailgas from the SRUs before
it enters the TGCU Reactor, A2-DC1560, by heating the tailgas and
mixing it with reducing gas (hydrogen). Saturated HP steam produced in
the SRUs is used to heat the tailgas to the desired reaction temperature
(~240°C [~464°F]). External reducing gas is then mixed with the tailgas to
supply some of the hydrogen needed to convert all of the sulfur
compounds to H2S in the reactor.
Thus, here are two important control parameters: the reactor feed
temperature and the hydrogen concentration in the reactor feed. The loop
diagram on page 11-22 illustrates the components of these control loops
when implemented in a distributed control system (DCS).
There are also controls for handling specific requirements during startup
and shutdown of the front-end of the TGCU. These control loops are
shown on the loop diagram as well. All of the control loops are discussed
in the sections that follow.
11.5.1.1 Reactor Feed Temperature Control

The feed to the TGCU Reactor is the gas leaving the TGCU Reactor
Feed Mixer. The temperature of this stream depends on the amount
of heating that takes places as the combined tailgas stream flows
through the TGCU Reactor Feed Heater. A2-TIC15820 on the mixer
outlet raises or lowers the setpoint of the steam pressure controller,
A2-PIC15820, to control this temperature by adjusting the steam
pressure inside the shell of the exchanger.
To raise the reactor feed temperature, A2-TIC15820 increases the

steam pressure by increasing the setpoint of A2-PIC15820. This will
cause A2-PIC15820 to open steam control valve A2-PV15820 more,
which results in two effects. First, as the valve opens more, the
pressure drop is reduced across the valve, increasing the steam
pressure inside the shell of the exchanger. This in turn increases the
saturation temperature of the steam inside the shell, increasing the
temperature driving force and thus raising the heat input to the
process gas in the tubes. Second, as the valve opens more, the
steam flow rate increases, supplying more heat to the exchanger to

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match the increase in the heat input. The net result is to increase the
heat transfer, raising the feed temperature accordingly.
Conversely, A2-TIC15820 lowers the reactor feed temperature by

reducing the setpoint of A2-PIC15820 so that it closes A2-PV15820
more. This drops the steam pressure inside the shell to reduce the
heat input, and reduces the steam flow to match. This reduces the
heat transfer, thus lowering the feed temperature.
11.5.1.2 Hydrogen Concentration Control

To ensure complete conversion of the sulfur compounds in the
TGCU Reactor, it is necessary to maintain an excess of hydrogen in
the gas leaving the reactor. The hydrogen concentration is
measured by the hydrogen analyzer, A2-AE15858, and supplied to
A2-AIC15816 in the DCS. The output from A2-AIC15816 is limited
from high and low extremes by A2-AY15816 (to protect the process
from analyzer malfunctions), and adjusts the flow rate of external
reducing gas being supplied to the TGCU Reactor Feed Mixer via
adjustment of the remote setpoint on the reducing gas flow controller,
A2-FIC15816. A2-AY15816 restricts the remote setpoint supplied to
A2-FIC15816 between 10% and 100% of the maximum range of the
reducing gas flow meter, 51.3 Nm3/H and 513.0 Nm3/H, respectively.
The normal sample point for hydrogen analyzer A2-AE15858 is the

treated gas leaving the overhead of the TGCU Contactor,
A2-DA1561, because this stream is the "cleanest" due to the H2S
removal accomplished in the tower. During startup of the TGCU,
however, there is no process gas flowing through the TGCU
Contactor until after operation of the TGCU Reactor has been "lined
out" and the process gas flow is directed into the TGCU Quench
Column and the TGCU Contactor. Until then, there is no gas flowing
in the TGCU Contactor overhead line, so an alternate sample point is
provided on the outlet of the TGCU Waste Heat Reclaimer,
A2-EA1561, to allow the analyzer to sample the gas leaving the
TGCU Reactor.
The 4-way selector valve, A2-HV15858, provided with the analyzer

allows the operators to switch between the two sample points. LP
purge gas is also connected to this valve, so that when one sample
point is supplying process gas to the analyzer, the other sample point

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is being back-purged with inert gas. This minimizes the possibility of

having one of the sample points plug when it is not in use.
The process gas that is being sampled is saturated with water, so the
data sheet for the analyzer system specifies that the sample
conditioning system includes a dryer. For the sample point on the
outlet of the TGCU Waste Heat Reclaimer, there is also the
possibility of elemental sulfur vapor being present in the gas during
process upsets. To prevent sulfur from reaching the analyzer and
damaging it, a "sacrificial sample loop" consisting of a coil of bare
tubing is provided in this sample line. The tubing coils provide heat
transfer surface, so that if sulfur does find its way to this point in the
process, the gas will cool off enough for the sulfur to solidify,
plugging the sample loop and stopping the flow of process gas to the
analyzer before the sulfur can damage the analyzer. Should this
occur, only the coiled tubing will need to be replaced, rather than the
expensive analyzer. Note that the sample lines are to free-drain from
the analyzer back to the sample points, so the tubing coils should be
oriented in the horizontal so that the coils due not cause a "pocket" in
the sample line for this sample point.
11.5.1.3 Controls for Startup and Shutdown

The front-end of the TGCU is also equipped with three sets of
controls for use during startup and shutdown:
a. Prior to introducing SRU tailgas into the TGCU, the equipment

in the front-end of the unit must be brought up to operating
temperature. This is accomplished by using the TGCU Startup
Blower, A2-GB1560, to re-circulate gas from the outlet of the
TGCU Waste Heat Reclaimer to the inlet of the TGCU Reactor
Feed Heater (via the TGCU Warmup/Bypass Valve,
A2-NV15800). This allows using the TGCU Reactor Feed
Heater to heat the gas and thereby bring all the equipment up
to operating temperature.
Flow controller A2-FIC15808 is provided to allow filling the

front-end with nitrogen prior to establishing the re-circulation
flow during startup. This same control can also be used to add
nitrogen during shutdown of the unit for cool-down purposes.
b. Prior to the initial startup of the unit, the catalyst in the TGCU
Reactor must be pre-sulfided so that it retains its activity when it

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is exposed to hydrogen at elevated temperatures. The catalyst

will also have to be pre-sulfided when fresh catalyst is added to
the reactor following a catalyst change-out. A source of H2S is
needed for pre-sulfiding the catalyst, for which a slipstream of
amine acid gas from the ARU serves nicely. Flow controller
A2-FIC15824 is provided to allow adding a small amount of acid
gas to give an H2S concentration of 1-2% in the nitrogen
circulating through the front-end of the unit during catalyst
pre-sulfiding activities.
c. After the TGCU has been operating for a period of time, the
catalyst becomes pyrophoric due to the presence of iron sulfide,
FeS. Exposing catalyst containing pyrophoric FeS to air may
result in uncontrolled burning of the FeS to form H2S and/or
SO2, which obviously will prevent the entrance of personnel into
the vessel. When the TGCU is to be shut down to replace the
catalyst, or for other maintenance activities that will allow
oxygen to enter the reactor, it is necessary to perform a
controlled oxidation ("passivation") of the FeS in the catalyst by
operating at low temperature (~150°C [~300°F]) and controlling
a small concentration (1-2%) of oxygen in the circulating gas.
This converts the FeS into non-pyrophoric iron oxide, Fe2O3,
while leaving the catalyst in its sulfided state. Flow controller
A2-FIC15805 is provided to allow adding a small amount of
utility air to the nitrogen circulating through the front-end of the
unit to provide the oxygen for catalyst passivation.

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TGCU Reactor Feed Control Loops

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11.5.2 Hydrogen and Hydrogen Sulfide Analyzer,

A2-AE15858/A2-AE15859
Analyzer A2-AE15858/A2-AE15859 has two separate sensors, one for
measuring hydrogen concentration and one for measuring hydrogen
sulfide concentration. The H2S sensor is a photometric sensor that is very
similar to the one used in the SRU air demand analyzers. It uses the
absorption of a specific wavelength of UV light to determine the H2S
concentration in the process gas.
The H2 sensor in this analyzer is actually a thermal conductivity sensor.

Hydrogen has a much higher thermal conductivity than the other gases
found in the process stream, so the thermal conductivity of the process
gas is a good indication of the hydrogen concentration. To make the
sensor reading as accurate as possible, it is necessary to "zero" and
"span" the sensor with special calibration gas mixtures that have the same
"background" thermal conductivity as the expected process gas. Although
this technique works well, always remember that this sensor does not
measure hydrogen concentration directly, so its reading (particularly at low
hydrogen concentrations) may not always be accurate.
The H2/H2S analyzer can sample the process gas from two different
locations, depending on the position of the selector valve inside the
analyzer enclosure. The first sample connection is on the outlet of the
TGCU Waste Heat Reclaimer. It should be used only during startup,
pre-sulfiding, and other special operations when the process gas is
bypassing the quench and contacting sections. This connection has a
"sacrificial" sample line, which is essentially a disposable sample cooling
coil. It is intended to protect the analyzer by cooling, condensing, and
freezing any sulfur vapor that may be present in the sample due to
process upsets. If this occurs, the cooling coil will plug before the sulfur
can reach the analyzer, sacrificing the inexpensive tubing to protect the
expensive analyzer.
The second sample point is on the overhead line from the TGCU
Contactor, and is the normal sampling point. During startup of the TGCU,
the hydrogen analyzer should be switched to this sample point as soon as
the Quench Column hand control in the DCS is used to open the Quench
Column Inlet Valve and close Quench Column Bypass Valve to send gas
through the TGCU Quench Column and the TGCU Contactor. There is
much less chance of damaging the analyzer with contaminants when
sampling gas at this point, so it is the preferred sample connection.

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Liquid water will destroy the H2 sensing element in this analyzer.

Although the sample conditioning system includes a dryer to remove
water vapor from the sample gas, liquid water can get through the dryer
and damage the analyzer. Since water tends to condense from the
process gas and accumulate in stagnant areas, make sure there is no
liquid in the sample line before switching from one sample point to
another.

The TGCU Waste Heat Reclaimer has three independent level
transmitters connected to the PLC that activate the TGCU ESD system
before the water level can get low enough to cause tube damage. The
shutdown is activated when two out of three transmitters show a low-low
level. These transmitters should be tested periodically to determine that
they are functioning properly. Since 2oo3 voting is used for the low-low
level shutdowns in the TGCU ESD, the level transmitters can be tested
one at a time without having to bypass the ESD system.
Consider A2-LT15845A on the Waste Heat Reclaimer, for example. The

procedure for testing A2-LT15845B and A2-LT15845C will be similar. The
procedure for testing A2-LT15845A is as follows:
(1) The outside operator notifies the DCS operator that he is

preparing to test shutdown level transmitter "A" on the Waste
Heat Reclaimer.
(2) The DCS operator confirms that A2-LI15845B and

A2-LI15845C are both indicating adequate level in the boiler,
then notifies the outside operator to proceed.

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CAUTION

OTHERWISE THE LOW-LOW LEVEL SHUTDOWN IN THE TGCU
ESD WILL BE ACTIVATED AS SOON AS THE OUTSIDE
OPERATOR BEGINS DRAINING THE LEVEL TRANSMITTER IN
THE NEXT STEP.
operator blocks-in A2-LT15845A by closing its block valves,
then opens the drain valve on the bottom of the transmitter to
drain the water from the instrument.
(4) If the transmitter is operating properly, the DCS will alarm that
there is a low level in the Waste Heat Reclaimer on
A2-LI15845A. The DCS operator acknowledges the alarm on
the DCS and reports it to the outside operator.
(5) After being notified of the alarm, the outside operator closes the
drain valve on A2-LT15845A, slowly opens its bottom block
valve to allow the transmitter to fill with water then opens its top
block valve. This should clear the low level alarm on
A2-LI15845A in the DCS.
(6) After confirming that the low level alarm has cleared, the other
level transmitters can be tested in a similar fashion.
having a level transmitter malfunction that causes a TGCU ESD

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11.5.4 Tailgas Switching Valve Controls

The tailgas switching valves and their controls for the Train 1 and Train 2
SRUs are depicted on the P&ID, dwg. no. 507000-7100-34, while the logic
flowcharts, show the logic for these controls for the Train 1 SRU.
However, it may be helpful to explain why the controls are implemented in
this manner. The discussion that follows will describe how these controls
allow routing the Train 1 SRU and Train 2 SRU tailgas streams to the
Thermal Oxidizer and the TGCU under different operating scenarios, and
will explain how the controls depicted on the P&ID correspond to the
different sections of the logic diagrams.
11.5.4.1 Repositioning the Tailgas Valves Following a TGCU ESD

As shown on the P&ID, prior to restarting the TGCU following a
TGCU ESD, the SRU tailgas valves to the TGCU (A2-HV15462 and
A2-HV15662) must be closed to satisfy the permissives for the
TGCU ESD system reset. However, before these valves can be
closed, the tailgas valves to the TTO (A2-HV15457 and
A2-HV15657) must be opened first to avoid blocking the tailgas flow
and causing the SRUs to shut down on high-high pressure. If the
valves are not opened and closed in the proper order, the SRUs
could inadvertently be shut down while preparing to restart the
TGCU.
For this reason, the TGCU ESD is an input to the PLC interlock
blocks that manipulate the controllers (A2-HIC15457, A2-HIC15462,
A2-HIC15657, and A2-HIC15662) for these valves. The PLCs and
DCS automatically reposition the valves following a TGCU ESD to
divert the SRU tailgas to the TTO, meaning that the valves are
already positioned properly for the subsequent restart of the TGCU.
The logic that accomplishes this for the Train 1 SRU is depicted on
the logic flow diagram. When the TGCU ESD is activated, the
Train 1 SRU PLC directs the DCS to set the output from
A2-HIC15457 to 100% to open A2-HV15457, proves the valve open,
then directs the DCS to set the output from A2-HIC15462 to 0% to
close A2-HV15462 and proves the valve closed. This diverts the
Train 1 SRU tailgas directly to the TTO. (The PLC logic will not take
these actions if the Train 1 SRU has its startup/run selector switch,
A2-HS15314, set to "STARTUP", since both tailgas valves will already
be closed by the startup logic for the Train 1 SRU)

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Note that this same logic is also used to open the tailgas valve to the
TTO and close the tailgas valve to the TGCU if the TGCU startup/run
selector switch (A2-HS15830) is set to "STARTUP". This safeguard is
to prevent sending SRU tailgas into the TGCU before the TGCU
Reactor is ready, as this could cause a severe upset in the TGCU
Quench Column and/or TGCU Contactor (and possibly damage the
piping, equipment, quench water, and/or solvent).
11.5.4.2 Introducing SRU Tailgas into the TGCU — Scenario 1

The first scenario to consider for introducing tailgas into the TGCU is
a normal startup of the SRUs and the TGCU. Before being routed to
the TGCU, the tailgas from both SRUs is sent to the TTO via valves
A2-HV15457 and A2-HV15657, while the TGCU uses the TGCU
Startup Blower to re-circulate gas to the TGCU Reactor Feed Heater
via the TGCU warmup/bypass valve, A2-NV15800. Once the TGCU
is warmed up and ready to accept tailgas, the Train 1 and Train 2
SRUs can be routed to the TGCU as follows (using the Train 1 SRU
for this example).
1. The operator toggles the "fast" transfer switch, A2-HS15463 in

the DCS, to "TRANSFER TO TGCU".
2. The PLC directs the DCS to set the output from A2-HIC15462 to
100% to open the Tailgas Valve to the TGCU, A2-HV15462, then
proves that the valve is open.
3. Since the Tailgas Valve to the TTO, A2-HV15457, is still open,

the SRU tailgas will continue flowing to the TTO at this time (the
path of least resistance).
4. Once the limit switches prove A2-HV15462 is open, the PLC

directs the DCS to set the output from A2-HIC15457 to 0% to
close A2-HV15457, then proves that the valve is closed.
5. Since A2-NV15800 is open at this time, some of the SRU tailgas

may still flow through this valve directly to the TTO. The TGCU
Startup Blower will pull the rest of the tailgas into the TGCU
Reactor Feed Heater.
6. If the second SRU (Train 2 in this example) is also ready to send

its tailgas to the TGCU, the operator can also toggle its "fast"
transfer switch in the DCS (A2-HS15663) to repeat these actions
for the second SRU.

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7. Once one or both of the tailgas valves to the TGCU is open and
the corresponding tailgas valve(s) to the TTO are closed, the
operator can use A2-HIC15800 in the DCS to close
A2-NV15800.
8. This will force all of the SRU tailgas to flow to the TGCU Reactor
Feed Heater.
9. Once A2-NV15800 is fully closed, all of the SRU tailgas must

flow to the TGCU Reactor Feed Heater because there are no
longer any other open paths to the TTO. The TGCU Startup
Blower can now be shut down by toggling A2-HPB15855 in the
DCS to "STOP" to open the blower bypass valve, turn off the
blower, and close the blower suction and discharge valves.
10. All of the SRU tailgas will now be flowing through the TGCU
Reactor Feed Heater, TGCU Reactor Feed Mixer, TGCU
Reactor, and TGCU Waste Heat Reclaimer, then flowing to the
TTO via the TGCU Quench Column bypass valve, A2-HV15851,
at the TGCU Startup Blower. Once the plant stabilizes and there
is excess hydrogen in the reactor outlet, the TGCU Quench
Column inlet valve, A2-HV15850, can be opened and
A2-HV15851 closed using A2-HIC15850 in the DCS to send the
process gas into the TGCU Quench Column and TGCU
Contactor.
For this scenario, the opening and closing of A2-HV15462 and

A2-HV15457, respectively, (or A2-HV15662 and A2-HV15657 for
Train 2) in Steps 2 and 3 can occur rapidly with no impact on either
the SRU or the TGCU. This is because A2-NV15800 will still be
open at this time, so there will be very little differential pressure
across A2-HV15462 (A2-HV15662) and there will not be an abrupt
change in pressure when A2-HV15462 (A2-HV15662) is opened or
when A2-HV15457 (A2-HV15657) is closed.
Note that A2-HS15463 and A2-HS15663 can also be used to take

the Train 1 SRU and/or Train 2 SRU tailgas out of the TGCU. Every
other toggle of these selector switches will take the opposite action to
open the tailgas valve to the TTO and then close the tailgas valve to
the TGCU. For instance, if a problem develops while introducing the
tailgas into the TGCU, toggling A2-HS15463 and A2-HS15663 to
"TRANSFER TO TTO" will immediately divert the SRU tailgas to the TTO

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and block it from flowing into the TGCU. Once the problem has been
corrected, A2-HS15463 and A2-HS15663 can be toggled once again
to "TRANSFER TO TGCU" to send the SRU tailgas into the TGCU.

The second startup scenario to consider is when the TGCU is
already processing tailgas from one SRU, and the tailgas from the
second SRU needs to be introduced into the TGCU. Assume that
the Train 2 SRU is currently feeding the TGCU. Due to the
back-pressure from the TGCU, the pressure downstream of
A2-HV15462 will be about 0.07 kg/cm2(g), while the pressure
upstream of this valve will be close to 0 kg/cm2(g) (since
A2-HV15457 will be open to the TTO at this time). If the Train 1
tailgas was quickly switched into the TGCU in the same manner as
described above for the first scenario, a major upset would result in
both SRUs and in the TGCU:
(1) As soon as A2-HV15462 started to open, tailgas from the

Train 2 SRU would begin to back-flow through A2-HV15462
and flow to the TTO, since the pressure downstream of
A2-HV15462 at that moment would be higher than the pressure
upstream of A2-HV15462. Since A2-HV15462 is a more direct
path to the TTO for the tailgas from the Train 2 SRU, most of
the Train 2 tailgas would flow through A2-HV15462 as it opens
rather than flow through the TGCU.
The outlet temperature from the TGCU Reactor Feed Heater

would begin to rise (due to the drop in tailgas flow), causing the
controls to begin reducing the steam flow rate to the heater.
Once A2-HV15462 was fully open, all of the Train 1 tailgas and
most of the Train 2 tailgas would be flowing directly to the TTO
through A2-HV15457. The TGCU controls would continue
reducing the steam flow rate to the TGCU Reactor Feed Heater
to try to keep its outlet temperature under control.
(2) With A2-HV15462 fully open, A2-HV15457 would begin to

close. This would begin forcing all of the Train 1 tailgas and
Train 2 tailgas into the TGCU Reactor Feed Heater.
The outlet temperature from the TGCU Reactor Feed Heater

would begin to drop, causing the controls to begin increasing
the steam flow rate to the heater. Once A2-HV15457 was fully

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closed, all of the Train 1 and Train 2 tailgas would be flowing to

the TGCU Reactor Feed Heater, causing an abrupt increase in
its operating pressure from about 0.07 kg/cm2(g) to about
0.25 kg/cm2(g). This would cause the air and acid gas flow
rates to the SRUs to suddenly drop, possibly causing the SRUs
to flame-out. If so, the SRUs and the TGCU would shut down
and the operators would have to start over again.
(3) If the SRUs and TGCU did manage to stay on-line, the TGCU
Reactor Feed Heater would be supplying less than half as
much heating as needed until the controls recover and bring the
steam flow rate up to the new requirements.
Until then, the inlet temperature to the TGCU Reactor would be

low, possibly causing incomplete conversion of SO2 in the
reactor and allowing SO2 to reach the quench water and solvent
systems and foul them. The reducing gas flow rate might also
require time to adjust to the higher tailgas flow rate, further
compounding the problems with conversion in the reactor.
So, the best that could be expected if the second SRU is routed to
the TGCU in the same manner as under the first scenario is an upset
in both SRUs, the TGCU Reactor Feed Heater, the TGCU Reactor,
the quench water system, and the solvent system. Depending on
how quickly the SRUs respond to sudden changes in operating
pressure, the SRU burners might flame-out. In this worst case, a
complete restart of the SRUs and the TGCU would then be required.
Instead of introducing the tailgas from the second SRU into the
TGCU in an abrupt manner, what is needed is a slow, controlled
redirection of the tailgas from the TTO to the TGCU. This can be
accomplished by the DCS operator using A2-HIC15457 and
A2-HIC15462:
1. Under this scenario, the TGCU is already processing tailgas

from the Train 2 SRU. This means that the TGCU
warmup/bypass valve, A2-NV15800, is already closed. This
signals the PLC to disable the "fast" transfer switches in the
DCS, A2-HS15463 and A2-HS15663 so that the rapid switching
sequence (scenario 1) cannot be activated inadvertently.

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2. The DCS operator initiates the over-ride for the Train 1 tailgas
valves by toggling the "slow" transfer switch, A2-HS15464 in the
DCS, to "OVER-RIDE".
The PLC temporarily removes the limit switches on

A2-HV15457 and A2-HV15462 from the "complete flowpath
interlock" for the Train 1 SRU alarms and deactivates the "valve
malfunction" alarms on these two valves, then directs the DCS
to release control of A2-HIC15457 and A2-HIC15462 to the
operator.
3. The operator uses A2-HIC15457 to slowly begin throttling the

tailgas flow with A2-HV15457, so that the pressure at the
front-end of Train 1 is slightly higher than at the front-end of the
Train 2 SRU. The DCS operator can monitor the flows and
pressure in the Train 1 SRU and adjust A2-HIC15457
accordingly.
4. Once A2-HV15457 is throttling, the operator uses A2-HIC15462

to slowly open A2-HV15462. Some of the Train 1 tailgas may
begin to flow into the TGCU at this time, but most of it will still
flow through A2-HV15457 directly to the TTO. The DCS
operator can monitor the flows and pressures in the Train 1
SRU and the TGCU, and adjust the rate at which A2-HV15462
is opened accordingly.
5. Once A2-HV15462 is fully open, the operator uses

A2-HIC15457 to slowly close A2-HV15457 the rest of the way
and send all of the Train 1 tailgas to the TGCU. The DCS
operator can monitor the flow rates and temperatures in the
TGCU, and adjust the rate at which A2-HV15457 is closed as
needed to allow time for the controls in the TGCU to respond.
6. Once A2-HV15457 is fully closed, the Train 1 SRU is flowing to

the TGCU along with the Train 2 SRU, and the TGCU is fully
on-line.
When A2-HV15462 is fully open and A2-HV15457 is fully

closed, the PLC will automatically restore the limit switches on
A2-HV15457 and A2-HV15462 to the "complete flowpath
interlock" in the SRU alarms, restore the malfunction alarms for
these valves to their normal configurations, and reset the "slow"

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transfer switch, A2-HS15464 in the DCS, back to "NORMAL" to

remove the over-ride.
One further point to note is that the "slow" transfer over-ride

switches can also be used to "back" tailgas out of the TGCU. If
the operator wants to shut down the TGCU in a controlled
fashion, this can be accomplished by using the TGCU Startup
Blower to circulate gas through the TGCU Reactor Feed Heater
while slowly "backing" the SRU tailgas out of the TGCU. The
steps to perform this are essentially the same as those listed
above (but in reverse order).

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11.5.5 TGCU Shutdown System

The purpose of the Tailgas Cleanup Unit Emergency Shutdown system
(TGCU ESD) is to shut off the flow of tailgas, reducing gas, pre-sulfiding
gas, nitrogen, and passivation air to the TGCU when serious problems
occur. The Cause and Effect Diagram, contained in the Instrumentation
and Controls Diagrams section of the Basic Engineering Package,
describes the TGCU ESD system in block format. For reference, the
causes and effects of the ESD system shown on this diagram are
explained below.

11.5.5.1 Causes
Any one of the causes listed below will activate the TGCU ESD
system:
a. Manual Shutdown Switch, A2-HS15827
An operator can activate the TGCU ESD system using the

NORMAL / ESD selector switch in the DCS.
b. Both SRU ESD Systems
For normal modes of operation, the TGCU ESD system is

activated when both SRU ESD systems are activated. Without
any SRU tailgas flowing through the front-end of the TGCU,
there is nothing to process in the unit, so the TGCU is shut
down whenever both sulfur plants shut down. (Note, however,
that the TGCU ESD is not activated if one of the SRUs is still
on-line when the other SRU shuts down.)
However, if the TGCU is not yet fully processing tailgas from

either SRU, there is no reason to shut it down if no SRUs are
running. This simplifies startup of the TGCU by allowing its
ESD system to be independent of the SRU ESD systems until
tailgas is introduced into the TGCU. The example logic below
shows this concept:

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c. Complete Flowpath Interlock (see Logic Flow Diagrams for the

limit switch tag numbers)
In order for the TGCU to operate without over-pressuring itself

or the Sulfur Drain Seal Assemblies in the upstream SRUs,
there must be a complete flowpath for SRU tailgas through the
TGCU to the TTO. The ESD logic can determine whether such
a complete flowpath exists by examining the status of the limit
switches on the process gas valves. There are basically three
different paths that the SRU tailgas can take to reach the TTO:
(1) The TGCU Warmup/Bypass Valve, A2-NV15800, and the

TGCU Outlet Valve, A2-HV15801, are both fully open.
(2) The process gas is diverted to the TTO upstream of the

TGCU Quench Column:
(a) The TGCU Quench Column Bypass Valve,

A2-HV15851, is fully open;
(b) Either the TGCU Startup Blower Bypass Valve,

A2-HV15853, is fully open, or both the TGCU Startup
Blower Suction Valve, A2-HV15852, and the TGCU
Startup Blower Discharge Valve, A2-HV15854, are
fully open; and
(c) The TGCU Outlet Valve is fully open.
(3) The process gas is flowing through the TGCU Quench

Column and the TGCU Contactor to the TTO:
(a) The TGCU Quench Column Inlet Valve,

A2-HV15850, is fully open; and
(b) The TGCU Outlet Valve is fully open.

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If the "open" limit switches do not indicate that at least one of

these flowpaths is valid, the "complete flowpath interlock" is
tripped and the TGCU ESD system is activated. Note that the
TGCU Complete Flowpath Interlock signal to the Complete
Flowpath Interlock logic for the Train 1 SRU and the Train 2
SRU is over-ridden for 60 seconds when this occurs, allowing
time for the SRU tailgas valves to be repositioned (see
Section 11.5.4.1) and preventing nuisance alarms in the SRUs.
d. TGCU Reactor Outlet High-High Temperature,

A2-TT15842A/B/C
These devices shut down the TGCU if the reactor outlet

temperature reaches 400°C. The most common cause of high
reactor outlet temperature is large concentrations of SO2 in the
SRU tailgas streams due to poor sulfur plant performance,
leading to excessive heat of reaction in the catalyst bed. These
devices will prevent excessive temperatures in the reactor from
causing damage to the reactor vessel, its catalyst, or its catalyst
bed support. Note that there are three independent transmitters
and 2oo3 voting logic is used for the ESD (i.e., at least two
transmitters must show high-high temperature) to avoid
spurious "trips" due to the malfunction of a single transmitter.
e. TGCU Waste Heat Reclaimer Low-Low Water Level,

A2-LT15845A/B/C
These devices activate the TGCU ESD system to prevent

having the water level drop below the top of the tubes in this
boiler while hot gas is flowing through the tubes, thereby
averting high effluent temperatures and higher than normal tube
wall temperatures. High effluent temperatures could cause high
overhead temperature from the TGCU Quench Column and
result in poor H2S removal in the TGCU Contactor, and high
tube wall temperatures could possibly damage the tubes due to
differential expansion. These devices are set to actuate if the
level falls to within 75 mm of the top of the tubes. Note that

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11.5.5.2 Effects
A TGCU shutdown, activated either manually or automatically, has
the following effects on the TGCU:
a. Opens the Train 1 SRU Tailgas Valve to the TTO, A2-HV15457,

proves it open, then closes the Train 1 SRU Tailgas Valve to
the TGCU, A2-HV15462, and proves it closed.
b. Opens the Train 2 SRU Tailgas Valve to the TTO, A2-HV15657,

proves it open, then closes the Train 2 SRU Tailgas Valve to
the TGCU, A2-HV15662, and proves it closed.
c. Disables the "fast" and "slow" tailgas transfer switches for the
Train 1 SRU (A2-HS15463 and A2-HS15464, respectively) and
for the Train 2 SRU (A2-HS15663 and A2-HS15664,
respectively).
d. Shuts off and depressurizes the nitrogen and plant air supplies
by closing block valves A2-NV15809 and A2-NV15811 and
e. Shuts off and depressurizes the reducing gas supply by closing

block valves A2-NV15817 and A2-NV15819 and opening vent
valve A2-NV15818.
f. Closes the reducing gas flow control valve, A2-FV15816, by

placing A2-FIC15816 in "manual" and setting its output to 0%.
g. Shuts off the pre-sulfiding gas flow by closing block valve

A2-NV15825.
h. Closes the TGCU Quench Column Inlet Valve, A2-HV15850,

and the TGCU Quench Column Bypass Valve, A2-HV15851, to
stop the flow of SRU tailgas into the TGCU.
i. Forces the output of A2-HIC15850 in the DCS (which controls

the TGCU Quench Column inlet and bypass valves) to 0% in
preparation for the subsequent restart.
j. Shuts down the TGCU Startup Blower, A2-GB1560; closes its

suction valve (A2-HV15852), its discharge valve (A2-HV15854),
and the nitrogen purge valve for the blower seal (A2-HV15856);
and opens its bypass valve (A2-HV15853) and the nitrogen
purge valve for the blower casing, (A2-HV15857).

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k. Resets DCS toggle switches A2-HS15817, A2-HS15825, and

A2-HS15809 to "OFF" and A2-HPB15855 to "STOP".
11.5.5.3 Non-ESD Shutdowns

TGCU ESD system, there are several interlocks of significance that
in this section.
a. TGCU Quench Column Low-Low Level, A2-LT15867A/B/C
The TGCU Quench Water Pump (A2-GA1560A/B) could be

TGCU Quench Column drops too low. These devices will
protect the pump by stopping it before this can occur. The
shutdown setpoint is 450 mm above the bottom seam of the
column. Note that there are three independent transmitters and
2oo3 voting logic is used for the S/D (i.e., at least two
transmitters must show low-low level) to avoid spurious "trips"
b. TGCU Quench Water Cooler Fan High Vibration,

A2-WSH15879
Each fan on the TGCU Quench Water Cooler (A2-EC1560) is

stop the associated fan and activate an alarm in the DCS. The
fan will not restart until the vibration switch is reset by an
operator.
c. TGCU Contactor Low-Low Level, A2-LT15895A/B/C
The TGCU Rich Solvent Pump (A2-GA1561A/B) could be

TGCU Contactor drops too low. These devices will protect the
setpoint is 450 mm above the bottom seam of the column.
voting logic is used for the S/D.
d. TGCU Lean Solvent Cooler Fan High Vibration, A2-WSH15902

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Each fan on the TGCU Lean Solvent Cooler (A2-EC1561) is

operator.
e. TGCU Stripper Low-Low Level, A2-LT15932A/B/C
The TGCU Lean Solvent Pump (A2-GA1562A/B) could be

TGCU Stripper drops too low. These devices will protect the
setpoint is 450 mm above the bottom seam of the column.
voting logic is used for the S/D.
f. TGCU Stripper Reflux Condenser Fan High Vibration,

A2-WSH15942
Each fan on the TGCU Stripper Reflux Condenser (A2-EC1562)

is provided with its own vibration switch. If the vibration sensed
operator.

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maintenance, and emergency procedures for the TGCU are discussed in the
remaining sections of this portion of the operating guidelines. The operator
should also be thoroughly acquainted with the equipment and the "Process
Description" section in these guidelines 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 the "procedures" sections will be more easily understood. In
addition, the following general discussion of principles and techniques will
clarify the reasons for some of the procedures.

After the initial startup, the front-end of the TGCU may contain some
sulfur, including the catalyst bed in the TGCU Reactor. Sulfur fires will
ignite at temperatures as low as 150°C if sufficient oxygen is available. In
addition, TGCU catalyst is pyrophoric at ambient temperatures when in its
sulfided state (which is its normal operating condition). For these reasons,
it is very important to minimize the time periods when air (or other gases
containing oxygen) is routed through the catalyst bed. Localized high
temperatures can exist in the catalyst bed even though the temperatures
measured around the reactor are low. Because of this, sulfur and/or
catalyst ignition sometimes occurs in a catalyst bed when it is not
anticipated by temperatures that are readily available for observation.
Under ordinary circumstances, oxygen-bearing gases will only be flowing

through the reactor when passivating its catalyst. When passivating the
catalyst in the reactor, observe the reactor temperatures frequently. If the
temperatures begin to increase above 150°C, reduce the amount of air
entering the reactor to limit the passivation so that the reactor
temperatures remain below 150°C. This will prevent the catalyst from
reacting with oxygen so that pre-sulfiding is not required during the
subsequent startup.
Do not use water to quickly cool the TGCU Reactor after a fire. Not only
will this damage the catalyst, the rapid cooling may cause structural
damage to the TGCU Reactor. The acidic water that forms may cause
corrosion damage to the TGCU Reactor or other equipment. Nitrogen is
available to the TGCU for use in cooling a hot catalyst bed.

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CAUTION

SURFACES) IN THE TGCU 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 RAPIDLY CORRODE THE STEEL.

IF THE TGCU WASTE HEAT RECLAIMER TUBES HAVE BECOME

PLUGGED, THE BEST WAY TO CLEAR THE TUBES IS TO
MECHANICALLY "ROD" THEM. IF SULFUR OR SULFUR
COMPOUNDS HAVE PLUGGED THE TUBES, IT IS OFTEN
HELPFUL TO APPLY HEAT TO THE TUBES BEFORE "RODDING",
AS THIS WILL MELT ANY SULFUR THAT MAY BE PART OF WHAT
HAS PLUGGED THE TUBES. ONE WAY TO DO THIS IS TO DRAIN
THE WATER FROM THE BOILER AND PUT STEAM ON THE
SHELL. DRAIN THE CONDENSATE PERIODICALLY TO KEEP LIVE
STEAM ON THE TUBES.
11.6.2 Catalyst Fouling

The catalyst bed in the TGCU Reactor may be severely fouled by
carry-over of heavy hydrocarbon liquids or vapors. This will cause
permanent damage to the catalyst and is to be avoided if possible, even if
shutting down the TGCU for periods is required. The most common
source of heavy hydrocarbons in TGCUs is contaminants in the reducing
gas stream. The pressure drop across the TGCU Reactor should be
monitored regularly to help detect this problem before the pressure drop
becomes so high that a plant shutdown is required to remove the fouled
catalyst.

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11.6.3 TGCU Reactor Operation

The purpose of the TGCU Reactor is to convert all of the sulfur
compounds in the tailgas from both SRUs into hydrogen sulfide. This is
accomplished by catalytic hydrogenation of the sulfur dioxide and sulfur
vapor, and hydrolysis of the organic sulfur compounds:
(1) SO2 + 3 H2 H2S + 2 H2O
(2) S + H2 H2S
(3) COS + H2O H2S + CO2
(4) CS2 + 2 H2O 2 H2S + CO2
The catalyst also promotes the classic "water gas shift" reaction:
(5) CO + H2O H2 + CO2
This effectively converts carbon monoxide in the tailgas gas into hydrogen
for use in reactions (1) and (2) above. This is an equilibrium reaction, so it
is typical for a small amount of CO to leave a reactor, depending on the
amount of hydrogen and carbon dioxide in the reactor outlet. The CO
concentration in the reactor outlet is usually less than 100 PPM, but may
be higher if the CO2 content of the feed gas is high or if the catalyst has
lost activity.
NOTE: A small portion of the COS and CS2 may either not react at all,
or be reduced by the hydrogen to form methane and/or methyl
mercaptan:
(6) COS + 4 H2 CH4 + H2S + H2O
(7) CS2 + 4 H2 CH4 + 2 H2S
(8) COS + 3 H2 CH3SH + H2O
(9) CS2 + 3 H2 CH3SH + H2S
These reactions should produce only a few PPM of methane

and/or mercaptan unless there is a large amount of COS/CS2 in
the SRU tailgas, or the TGCU catalyst has lost activity. Since
the TGCU amine will not remove mercaptans from the gas, any
mercaptans formed will escape to the Thermal Oxidizer and
cause increased SO2 emissions. Methane in the reactor
effluent may result in increased CO emissions from the Thermal

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Oxidizer (due to partial oxidation), depending on the operating

conditions in the Thermal Oxidizer. To avoid these problems,
the amount of COS/CS2 entering the TGCU should be
maintained as low as possible by proper operation of the
upstream SRUs (and amine and sour water stripping units).
All of these reactions are exothermic, causing the temperature of the gas
to rise as it flows through the reactor. The hydrogenation of the SO2 into
H2S is the predominant factor in the temperature rise, so the temperature
rise across the TGCU Reactor is usually a direct indication of the amount
of SO2 entering the TGCU from the SRUs. If the temperature rise is
higher than normal (about 50-60°C at design conditions), this is usually a
sign that the upstream sulfur plant(s) is off-ratio. The resulting high outlet
temperature from the TGCU Reactor cannot be corrected in the TGCU.
Rather, the problem must be corrected in the SRUs, or the upstream units
feeding the SRUs.
Regardless of the amount of SO2, sulfur vapor, and organic sulfur entering
the TGCU Reactor, all of it must be converted to H2S for proper operation
of the downstream equipment. This can be achieved (assuming normal
catalyst activity) by maintaining an adequate excess of hydrogen in the
TGCU Reactor outlet, so that all of the reactions go to completion. The
hydrogen concentration is normally measured in the treated gas leaving
the TGCU Contactor. Although the design material balance calls for a
hydrogen concentration of about 3% at this point, a concentration in the
range of 1-2% is normally adequate. However, controlling the
concentration at 3% or higher allows a much larger margin for tolerating
upsets in the upstream SRUs, and is generally preferred.
Unlike other TGCUs which use in-line burners to generate reducing gas
(because external hydrogen is not available), this TGCU receives
reducing gas from a hydrogen purification unit. However, poor ratio control
in either SRU can still lead to an excessively high outlet temperature from
the TGCU Reactor. If, for instance, an SRU is operating with excess air,
the H2S:SO2 ratio will be low in the SRU tailgas (registered as high air
demand) and the SO2 concentration will be high in the TGCU Reactor
feed. This will cause a large temperature rise in the reactor. Left
unchecked, the temperatures in the TGCU Reactor could rise to the point
of damaging the catalyst, the catalyst bed support, and/or the reactor
vessel itself. The thermocouples in the catalyst bed and in the outlet line
have alarms to provide an early warning of this condition. If the

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temperature reaches 400°C in the outlet line, the TGCU ESD system will
be activated to shut down the TGCU and divert the SRU tailgas to the
Thermal Oxidizer, before damaging the TGCU Reactor or its catalyst.
Be aware, however, that the "thermal mass" of the TGCU Reactor and its
catalyst bed is quite large relative to the gas flowing through them, so
temperature changes occur very slowly (particularly at low flow rates). For
this reason, it is important to watch the temperature trends around the
reactor and be prepared to take corrective action early so that the
corrections have time to take effect before a high-high temperature
shutdown is activated. It is particularly important to watch these
temperatures closely during periods of startup, shutdown, or
process upsets when the TGCU Reactor inlet temperature,
composition, and/or flow rate are changing significantly.
11.6.4 TGCU Catalyst

The active components for the hydrogenation reactions are cobalt and
molybdenum sulfides in the cobalt/molybdenum catalyst. The catalyst is
normally supplied by the catalyst vendor in its oxidized state, although
some vendors can supply pre-sulfided catalyst. Contacting the catalyst
with hydrogen at temperatures exceeding 200°C prior to sulfiding should
be avoided to prevent impairing the catalyst activity, as hydrogen will
irreversibly sinter the metal oxides to form metal hydrides that do not
catalyze the TGCU reactions. Pre-sulfiding the catalyst before exposing it
to hydrogen at high temperature yields a catalyst with stable, high activity.
The catalyst is pre-sulfided by contacting it with an H2S-containing gas

(such as the inlet amine acid gas to the SRUs) in the presence of
hydrogen. During this operation, the following reactions occur:
(1) CoO + H2S CoS + H2O
(2) MoO3 + x H2S + (3-x) H2 1/n MonSn*x + 3 H2O
The molybdenum sulfide will probably be present in the form of Mo2S3,

MoS2, and MoS3. These reactions are exothermic (heat liberating), so it is
necessary to carefully control pre-sulfiding operations to prevent
overheating the catalyst and/or equipment. The TGCU Startup
Procedures Section of these guidelines contains a complete description of
the suggested pre-sulfiding procedure.

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The catalyst should be exposed to air only under controlled conditions

when it is in the reduced (sulfided) state as it is pyrophoric (capable of
spontaneous ignition) and rapid oxidation could occur, causing damage to
the catalyst, the TGCU Reactor, and/or the downstream equipment and
piping. The pyrophoric nature of the catalyst is caused by the presence of
iron sulfide (FeS), which gradually builds up in the catalyst due to
accumulation of corrosion products from upstream equipment and piping.
Controlled burn-off of the catalyst (passivation) to eliminate FeS can be
accomplished by low-temperature oxidation which destroys the FeS but
leaves the active Co/Mo sulfides intact. The TGCU Reactor can then be
opened for maintenance, etc. The procedure to accomplish this catalyst
"passivation" is fully described in TGCU Shutdown Procedures Section
these guidelines.
The catalyst activity should be monitored regularly so that there is

forewarning of catalyst deactivation. Shell Global Solutions recommends
using a gas chromatograph to analyze the gas downstream of the TGCU
Reactor (TGCU Contactor overhead gas, for instance) for CO, H2, and
COS. The CO/H2 ratio (PPM CO divided by vol % H2) and the COS PPM
can then be plotted versus time. When the CO/H2 ratio and/or the COS
PPM rise rapidly, preparations should be made to replace the TGCU
catalyst within a few months.
11.6.5 TGCU Start-Up Blower Operation

Prior to introducing SRU tailgas into the TGCU during startup, the
equipment in the front-end of the unit must be brought up to operating
temperature. This is accomplished by using the TGCU Start-Up Blower,
A2-GB1560, to re-circulate gas from the outlet of the TGCU Waste Heat
Reclaimer to the inlet of the TGCU Reactor Feed Heater (via the TGCU
Warmup/Bypass Valve). This allows using the TGCU Reactor Feed
Heater to heat the gas and thereby bring all the equipment up to operating
temperature. A flow controller is provided to allow filling the front-end
equipment and piping with nitrogen prior to establishing the re-circulation
flow during startup. Once the tailgas from the SRU(s) is brought into the
TGCU, the re-circulation from the TGCU Start-Up Blower is no longer
needed, so the blower can then be shut down.

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11.6.6 TGCU Quench Column Operation

The operating conditions shown on the Process Flow Diagram for this
system (in terms of circulation rate and water temperature) should
generally be maintained. Decreasing the water circulation rate will
increase the bottoms temperature (which increases the corrosion rate),
while increasing the circulation rate increases the load on the pump and
the coolers. The flow rate and temperatures shown are usually a good
compromise between minimizing corrosion and minimizing utility costs.
The quench water circulation rate is controlled by the quench water flow
controller in the DCS, while the temperature is controlled by a temperature
controller adjusting the speed of one of the fans on the TGCU Quench
Water Cooler, A2-EC1560. Although the design values will give adequate
operation, there are advantages in maintaining the quench water
temperature (which controls the overhead temperature) as low as
possible. These conditions will minimize the temperature and water
content of the overhead gas leaving the TGCU Quench Column and thus
minimize the load on the TGCU Contactor. The bottoms temperature of
the TGCU Quench Column is not critical except for controlling corrosion;
this temperature depends on the gas feed rate and the temperature and
flow rate of the circulating quench water. However, operating the quench
water at a lower or higher temperature than the TGCU lean amine can
cause the TGCU amine system to be out of water balance. Normally,
both the quench water and the TGCU amine should operate at roughly the
same temperature to minimize the impact on the amine system water
balance.
A portion of the quench water is sent to SWS Flash Drum on level control
to balance the water condensed from the process gas by the circulating
quench water and maintain the bottoms level in the TGCU Quench
Column. This "bleed" water rate depends on the amount of water in the
SRU tailgas, and the amount of water contained in the gas leaving the
column.
The TGCU Quench Water Filter removes sulfur and particulates from the
circulating quench water to maintain water clarity. The flow rate to the
filter should be maintained at its design value to provide maximum
filtration.
The appearance of the circulating quench water is a good indicator of

whether the TGCU Reactor is operating properly. A sight glass is

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provided to allow the operator to observe the condition of the water. If

SO2 should escape from the TGCU Reactor, it will react with the H2S
dissolved in the water to form sulfur:
(1) 2 H2S + SO2 3 S + 2 H2O
This sulfur will be produced as tiny particles of solid sulfur, forming a

colloidal suspension in the water and giving the water a milky appearance.
The SO2 may also remain dissolved in the water and form a weak solution
of sulfurous acid:
(2) H2O + SO2 H2SO3
If sufficient acid is formed to drop the pH of the quench water below 7, the
acid will often scour the iron sulfide film (which normally protects the steel
from corrosion) from the carbon steel equipment and piping. The iron
sulfide particles will turn the quench water black (or green). Either color
change (milky or black/green) is a symptom of SO2 "break-through" from
the TGCU Reactor, meaning that inadequate reducing gas is being
supplied to the reactor. An abnormal increase in the pressure drop across
the TGCU Quench Water Filter is also a good indication of SO2
break-through, as the sulfur and/or iron sulfide particles collect on the filter
elements.
Should any of these events occur, immediately observe the readings on

the air demand analyzers in the SRUs, the hydrogen analyzer in the
TGCU, and the quench water pH analyzer. Make appropriate corrections
to the air:acid gas ratio in the SRU(s), the hydrogen rate to the TGCU
Reactor Feed Mixer, or both to eliminate the SO2 breakthrough. Also,
begin (or increase) caustic injection into the quench water to raise the pH
and minimize the corrosion to the system. Failure to maintain the proper
pH (generally 8.0-9.5) will quickly damage the quench water equipment
and piping due to acid corrosion, and may allow SO2 to reach the TGCU
Contactor and form heat-stable salts with the amine. Heat-stable salts
can cause accelerated corrosion in the TGCU amine system.
If a large SO2 deviation occurs (very low pH, very dirty quench water,
rapid plugging of the TGCU Quench Water Filter, etc.), it may be desirable
to dilute the quench water with fresh condensate makeup. This
accomplishes two things to facilitate cleanup of the quench water system:
the fresh makeup will dilute the SO2 and help raise the pH, and the
makeup will raise the level in the TGCU Quench Column and cause the
quench water column level controller to increase the "bleed" rate of

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quench water to the Sour Water Stripping Unit. The rate at which
condensate is added to the system must be regulated to keep the
temperature to the circulating pump low enough that the pump does not
cavitate. Experience will show how quickly condensate can be added
without causing pumping problems.
In this fashion, the TGCU Quench Column serves as a good scrubber

preceding the TGCU Contactor to prevent minor upsets in the SRUs or
the TGCU Reactor from degrading the TGCU amine with SO2.
Nevertheless, the hydrogen and pH analyzers in the TGCU should be
carefully observed and properly maintained to minimize the number and
duration of pH excursions in the quench water system. This will maximize
the service life of the quench water system and minimize the degradation
of the amine.
In addition, consider diverting the process gas from the TGCU Reactor to
the Thermal Oxidizer before it enters the TGCU Quench Column during
periods of large upsets when SO2 may break through the reactor, before
SO2 gets into the quench water and causes problems. Taking this
preventative measure will cause higher SO2 emissions from the Thermal
Oxidizer and put it out of compliance, but it will allow the TGCU to be
brought back to normal operation much more quickly by avoiding a pH
excursion in the quench system and the water cleanup operation that
often results (i.e., numerous filter changes in the TGCU Quench Water
Filter).
When the TGCU is operating in "normal" mode, the TGCU Reactor

effluent can be diverted directly to the Thermal Oxidizer simply by
reducing the output on the Quench Column bypass hand controller in the
DCS to 0%. This will open the TGCU Quench Column bypass valve, and
close the TGCU Quench Column inlet valve. Since the TGCU Start-Up
Blower bypass valve is open when the blower is not operating, this gives
the process gas a path to flow to the Thermal Oxidizer.
The TGCU Reactor effluent will then be diverted to the Thermal Oxidizer
and cannot cause problems in the TGCU columns if SO2 escapes from
the reactor. Once the upset has been corrected and gas flow into the
columns can be re-initiated by increasing the output on the Quench
Column bypass hand controller in the DCS to 100% output to restore flow
to the columns. These changes should be performed slowly enough to
minimize the "bobbles" on the air:acid gas ratio control in the SRUs, as
the operating pressures in the units will change as the valves are

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repositioned. Operator judgment should be used to determine whether

the process upset or the diversion of the process gas will have the worse
impact on TGCU operation and the duration of non-compliance due to
SO2 emissions from the Thermal Oxidizer.
11.6.7 TGCU Contactor Operation

The main requirement for the TGCU Contactor is to consistently produce
a vent gas for incineration which contains a low level of residual H2S.
Secondarily, a good degree of CO2 "slip" (rejection) to the vent gas is
desirable to minimize CO2 buildup due to the recycle of acid gas to the
upstream Claus sulfur plant.
The important parameters for controlling the H2S content of the TGCU
Contactor vent gas, assuming the amine is adequately stripped, are amine
temperature, amine flow rate, and contact time. The design values for
amine temperature and flow rate shown on the Process Flow Diagram
should give satisfactory operation, but it is possible to adjust these values
either to maximize the capacity of the system to tolerate upsets, or to
optimize the "slipping" of CO2 to the vent gas. The following discussion
should be helpful if improving plant operations is desired.
The single most important factor determining the H2S-absorbing capacity

of the amine is its temperature. The lower the temperature of the amine,
the more favorable is its selectivity for absorbing H2S over CO2. In fact,
lowering the amine temperature has a two-fold effect on improving its
ability to absorb H2S. First, at lower temperature the partial pressure of
H2S in the amine is lower, allowing the amine to treat the gas to a lower
H2S content (since the vent gas approaches equilibrium with the amine in
the top of the TGCU Contactor). Second, the higher selectivity at the
lower temperature means the amine picks up less CO2, resulting in less
heat of reaction and less temperature rise in the column, increasing the
ability of the amine to pick up H2S. Thus, the best possible operation
results when both the gas and the amine fed to the TGCU Contactor are
as cool as possible. For this reason, many operators leave the quench
water and amine coolers at full capacity so that the coolers provide
maximum cooling year-round.
As would be expected, keeping the amine circulation rate at its maximum

value gives the amine system the highest capacity to handle H2S "peaks"
due to upsets in the upstream systems. It may not be immediately
apparent, however, that high circulation rates are detrimental to amine

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performance when plant throughput is lower. Circulating more amine than

necessary increases the amount of CO2 absorbed by the amine by
increasing the contact time in the TGCU Contactor. This increase in CO2
pickup reduces the ability of the amine to pick up H2S.
In general, most companies favor operating TGCU amine systems to

provide maximum ability to tolerate upsets without going out of
compliance. These companies adhere to the following guidelines:
(1) Circulate amine at maximum capacity.
(2) Cool the quench water and amine as much as possible.
The amine strength should be monitored and the amine content of the
circulating amine should be maintained close to the 45% (by weight)
design value. Should the amine concentration decrease (normally due to
blowdown and other amine losses), it will be necessary to add fresh amine
to compensate. Laboratory procedures for analyzing TGCU amine are
given in Section 11.10 of these guidelines.
The amine should also be checked periodically for heat-stable salt

content. Heat-stable salts form when the amine in the amine (a base)
reacts with strong acids to form salts that do not decompose at the normal
amine regeneration temperature. The most common heat-stable salts
encountered in TGCU amine systems are SO2 salts, although oxygen
contamination of the amine is another common culprit for heat-stable salts
in these systems. Heat-stable salts increase the corrosivity of the amine
(particularly at higher temperatures, like in the TGCU Stripper Reboiler)
and increase the foaming tendencies of the amine. (Interestingly,
heat-stable salts sometimes improve the H2S-removal capability of the
amine, but the higher corrosion rate caused by the salt far outweighs this
advantage.)
A heat-stable salt content of 2 wt % or lower is desirable. Salt contents in

the 5-20 wt % range can be corrosive and should be avoided if possible.
The only way to reduce the heat-stable salt content of the amine is by
dilution, blowing down some of the circulating amine and making up with
fresh amine. There is no means for regenerating heat-stable salt from the
amine while it is in the TGCU, as vacuum distillation is required. (In
recent years, however, several companies have successfully reclaimed
amine on-line using ion exchange on a slipstream of the amine.) There
are firms that specialize in reclaiming amine (usually off-site), and it may
be economical to use such a firm if a large amount of amine has been

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contaminated with heat-stable salts. The best practice, however, is to

avoid forming heat-stable salt in the first place by proper operation of the
SRU and TGCU to avoid SO2 breakthrough from the TGCU Reactor, and
gas-blanketing the fresh amine to avoid oxygen contamination.
The H2/H2S analyzer on the TGCU Contactor overhead, measures the

concentrations of both H2 and H2S in the vent gas leaving the TGCU
Contactor. As such, it is an extremely useful troubleshooting and
optimizing tool for the TGCU. This analyzer should be maintained and
calibrated at appropriate intervals so that it will be on-line and available to
the operators.
The H2S concentration is particularly useful when trying to pinpoint the

cause of high SO2 emissions from the Thermal Oxidizer, as the TGCU
Contactor is not the only possible source of high emissions. There are
several valves in the SRU and the TGCU that can allow process gases
with high sulfur content to reach the Thermal Oxidizer if the valves leak or
are not fully closed. If the SO2 emissions from the Thermal Oxidizer are
high but the analyzer shows low H2S content in the TGCU Contactor
overhead, then a leaking valve is the most likely source of the excessive
sulfur reaching the Thermal Oxidizer. In particular, the automated bypass
valves in the TGCU may open slightly if their positioners or actuators are
not properly adjusted, or if sudden changes in ambient conditions cause
the positioners to move the valves slightly. If this situation occurs, it is
suggested (as the first step in troubleshooting the problem) that the
following valves be "stroked" slightly (in the order given below) to be sure
that they are fully closed:
(1) A2-NV15800 The TGCU Warmup/Bypass Valve can leak

SRU tailgas directly to the Thermal Oxidizer.
(2) A2-HV15851 If the TGCU Start-Up Blower is not operating

and A2-HV15853 is open ("normal" mode
operation), the TGCU Quench Column Bypass
Valve can leak TGCU Reactor effluent directly
to the Thermal Oxidizer.
(3) A2-HV15457 The Tailgas Valve to the TTO can leak SRU
A2-HV15657 tailgas directly to the Thermal Oxidizer.

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(4) A2-HV15441/641 The SRU Warmup Bypass Valves to the TTO

A2-HV15454/654 can leak SRU process gas directly to the
Thermal Oxidizer if the nitrogen purge fails or is
inadequate.
Check the SO2 emissions after stroking each valve. If the emissions are
still high after checking all the valves, then verify that both the H2S
analyzer and the SO2 analyzer are calibrated properly. If these valves are
not leaking, there is usually no obvious reason why these two analyzers
should show a discrepancy in the sulfur content of the TGCU effluent.
In such cases, a systematic sampling program is usually required to

isolate the source of the sulfur entering the Thermal Oxidizer. This
sampling program need not be elaborate, as gas detector tubes for H2S
and SO2 (such as Dräger tubes) are often sufficient for this purpose. The
main point is to start at the TGCU Contactor overhead and work toward
the Thermal Oxidizer, taking gas samples at each spot where gas may
enter the line, in order to determine when the sulfur content goes up and
isolate the source of the sulfur. Some detective work may still be
necessary, however, as there may not be sample points available at every
location. If so, and if there are several episodes of high emissions
requiring this type of sampling, consideration should be given to installing
additional sample points during the next plant turnaround.

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11.6.8 TGCU Stripper Operation

The lean amine must remain comparatively free of H2S and CO2 to assure
attainment of the vent gas specification. These acid gases are removed
from the rich amine in the TGCU Stripper by stripping them out with
steam. The stripping steam supplies heat to reverse the acid-base
reaction between the H2S/CO2 and the amine, and also reduces the
H2S/CO2 partial pressure in the vapor phase inside the column to promote
mass transfer from the liquid.
The stripping steam is produced by vaporizing some of the water in the

amine in the TGCU Stripper Reboiler, using LP (3.5-4.2 kg/cm2(g)) steam
for the heat input. The steam rate to the reboiler (and, hence, the amine
stripping rate) is controlled by the steam flow controller. Adjust this steam
rate as needed to keep the H2S and CO2 loading in the lean amine low,
i.e., below about 0.005 mole/mole or lower. For a given column operating
pressure, the overhead temperature is a direct indication of the stripping
rate: the higher the temperature, the more stripping. Column bottoms
temperature should not be used as a guideline for degree of stripping, as
it is a function only of amine concentration and column pressure.

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CAUTION

WITHOUT GOING OUT OF COMPLIANCE (I.E., WITH LITTLE
CHANGE IN THE H2S LOADING OF THE LEAN AMINE), REDUCING
THE STRIPPING STEAM RATE SIGNIFICANTLY CAN CAUSE
ACCELERATED CORROSION DUE TO HIGH CO2 LOADINGS IN
THE LEAN AMINE. SEVERAL PLANTS HAVE REPORTED
UNEXPECTEDLY HIGH CORROSION RATES IN THE HOT, HIGH
VELOCITY AREAS OF THE LEAN AMINE SYSTEM, SUCH AS THE
OUTLET ENDS OF THE REBOILER TUBES AND THE LEAN AMINE
PUMPS, AFTER REDUCING THE REBOILER STEAM.
IF IT IS NECESSARY TO OPTIMIZE THE STEAM TO THE TGCU

STRIPPER REBOILER, REDUCE THE STEAM BY SMALL
INCREMENTS AND CHECK THE LEAN AMINE LOADINGS (BOTH
H2S AND CO2) AFTER EACH CHANGE. DO NOT REDUCE THE
STEAM FURTHER IF EITHER LOADING BEGINS TO RISE
SIGNIFICANTLY, AND BE PREPARED TO PERFORM MORE
EXTENSIVE CORROSION MONITORING WHEN OPERATING THE
TGCU STRIPPER IN THIS MANNER. REFER TO SECTION 11.10
OF THESE GUIDELINES FOR THE PROCEDURES TO BE USED
TO DETERMINE THE LEAN AMINE LOADINGS.
The withdrawal of lean amine from the bottom of the TGCU Stripper is on
flow control to the TGCU Contactor. As a result, the level in the bottom of
the TGCU Stripper, which serves as the "surge" for the system, will
usually indicate if adjustments of water makeup to the amine system (or
water "bleed" from the system) are required to maintain the proper water
balance. Even if water must be bled from the system by diverting some of
the column reflux to The SWS Flash Drum, the amine content of that
waste stream should be low and only infrequent makeup of fresh amine
should be required.
It may also be necessary to "purge" ammonia from the reflux water

periodically by routing some of the reflux water to the Sour Water Stripper.

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Although the two-zone Reactor Furnaces in the SRUs will normally

destroy almost all of the ammonia entering with the SWS gas, PPM levels
of ammonia will typically leave the furnace and enter the TGCU with the
sulfur plant tailgas. This ammonia is usually removed by the circulating
water in the TGCU Quench Column, where it has the beneficial effect of
helping maintain a high pH in the quench water. In fact, ammonia (rather
than caustic) is used for pH control in many TGCUs. Over a period of
time, however, some of the ammonia may carry over into the TGCU
Contactor and dissolve in the TGCU amine.
When this ammonia-containing amine reaches the TGCU Stripper, the

ammonia becomes "trapped" because it is too light (volatile) to leave in
the column bottoms and too heavy to leave in the overhead (the acid gas).
As a result, the ammonia will become concentrated in the reflux water, to
the point where it exceeds its solubility limits and begins to cause plugging
problems. If this problem is suspected, simply "bleed" a small amount of
the reflux water to the disposal header to purge the ammonia from the
system, while monitoring the reflux flow rate to ensure that adequate
reflux is maintained to the TGCU Stripper. Operating experience will
show how often (and how much) the reflux must be purged in this manner
to prevent excessive ammonia concentrations for a particular plant. Due
to the moderate temperatures and fluid velocities typical for this section of
the plant, wet H2S-NH3 corrosion is usually not a concern.
There is full-flow of rich amine through the TGCU Rich Amine Filter, and a
slipstream of lean amine flow through the TGCU Lean Amine Filter, the
TGCU Amine Carbon Filter, and the TGCU Amine After-Filter. These four
filters will remove solids and organic contaminants from the circulating
amine, such as degradation or corrosion products. The flow rate through
the lean amine filters should be maintained at the design value, and the
filter elements should be changed as soon as the "change" pressure drop
is reached, to remove as many solids from the amine as possible. Finely
divided solids can cause foaming and thereby limit column capacity.
While it is possible to reduce foaming to some extent with anti-foam
agents, the presence of such agents may also reduce H2S/CO2 selectivity
in the TGCU Contactor, so it is preferable that they not be used as an
alternative to regular conscientious filter maintenance

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11.6.9 TGCU Amine Water Balance

The water content of the circulating amine in a TGCU is determined by the
following factors:
A. The water content of the feed gas to the TGCU Contactor (the
overhead from the TGCU Quench Column).
B. The water content of the vent gas leaving the TGCU Contactor.
C. The water content of the TGCU recycle gas leaving the TGCU
Stripper Reflux Accumulator.
D. The amount of water makeup to (or water "bleed" from) the amine
system.
For given operating pressures, the water content of each gas stream will
be determined by the temperature at the top of the respective vessel
(TGCU Quench Column, TGCU Contactor, and TGCU Stripper Reflux
Accumulator, respectively), and will increase as the temperature
increases. Since the TGCU Contactor inlet gas is at a slightly higher
pressure than the outlet (vent) gas, the inlet gas will normally contain less
water than is contained in the outlet gas (if both gas streams are at the
same temperature), thus requiring water makeup to maintain the proper
water content of the amine. This situation will be reversed if the TGCU
Contactor overhead temperature is lower than the TGCU Quench Column
overhead temperature, requiring a "bleed" of water to maintain water
balance.
Since the lean amine to the TGCU Contactor is on flow control and
withdrawal of the rich amine from the bottom of the TGCU Contactor is on
level control, a net gain or loss in the amine water balance will be reflected
by an increase or decrease, respectively, of the liquid level in the bottom
of the TGCU Stripper. Observation of this liquid level can thus guide
adjustment of water makeup/bleed rate or operating conditions to maintain
the desired water concentration of the circulating amine. Since the degree
of H2S removal can depend on the amine concentration of the amine, the
concentration should be maintained close to the design value (45 wt %)
by appropriate maintenance of water concentration. It is usually possible
to control the water balance without adding fresh water or "bleeding" water
to the Sour Water Stripping Unit by adjusting the operating temperatures
in the unit, as discussed in the following paragraphs. Following the steps
outlined below will allow controlling the water balance with minimum

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usage of treated makeup water and minimum impact on the sour water
system.
A persistently increasing liquid level in the bottom of the TGCU Stripper at

constant flow rates and conditions for TGCU Contactor feed gas and
amine indicates a gain in the amine water content. To reduce the water
content of the amine, the preferred sequence of gradual adjustments is:
A. Reduce or terminate water makeup to the amine. Makeup water is

steam condensate, added at the TGCU Stripper Reflux Accumulator.
(1) Decrease the TGCU Contactor feed gas temperature by

lowering the quench water temperature on the quench water
temperature controller and/or increasing the quench water flow
rate on the quench water flow controller.
This will reduce the amount of water entering the TGCU

Contactor, but the magnitude of adjustment available from this
step will generally be limited by the capacity of the aerial and
trim water coolers.
(2) Begin "bleeding" water (or increase the "bleed" water rate) from
the amine system with the flow controller on the discharge line
of the TGCU Stripper Reflux Pump.
Be careful, however, not to starve the TGCU Stripper for reflux

by withdrawing too much water. Use the DCS flow indicator for
the reflux water to monitor the operation so that adequate reflux
is maintained to the TGCU Stripper when bleeding water from
the amine system.
CAUTION
UNDER NORMAL CONDITIONS, THE REFLUX WATER

CONTAINS LITTLE OR NO AMINE BECAUSE OF THE "WASH
WATER" TRAYS ABOVE THE SOLVENT FEED TRAY IN THE
TGCU STRIPPER. HOWEVER, IF THE TGCU STRIPPER IS
FLOODING OR FOAMING (AS INDICATED BY HIGH OR
ERRATIC COLUMN DIFFERENTIAL PRESSURE), THE
REFLUX CAN CONTAIN LARGE AMOUNTS OF AMINE.

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IF THE "BLEED" WATER LINE IS IN USE AT SUCH TIMES, A

SIGNIFICANT QUANTITY OF SOLVENT CAN BE LOST TO
THE SOUR WATER SYSTEM, AND WILL HAVE TO BE
REPLACED WITH FRESH AMINE FROM THE STORAGE
TANK. FOR THIS REASON, THE "BLEED" WATER SYSTEM
SHOULD BE BLOCKED-IN DURING UPSETS IN THE TGCU
STRIPPER.
(3) Increase the TGCU Contactor overhead temperature by raising

the setpoint of the lean solvent temperature controller to
increase the lean solvent temperature.
This will increase the amount of water leaving in the vent gas,
but it will also reduce the H2S-removal capability of the solvent.
An increase in solvent flow rate will probably be needed to
maintain the same H2S content in the vent gas, increasing the
load on the TGCU Stripper and the other process equipment
associated with the circulating solvent. Additionally, some
impairment of the CO2 "slip" by the solvent would be expected
as a result of both the higher contact temperatures in the TGCU
Contactor and the higher solvent circulation. This will increase
the CO2 recycled to the sulfur plants and increase the CO2
content of the tailgas to the TGCU, further hampering the
H2S-removal capability of the solvent.
(4) Increase the TGCU recycle gas temperature by increasing the

temperature setpoint of the reflux temperature controller to raise
the outlet temperature from the TGCU Stripper Reflux
Condenser.
Although this will increase the water content of this stream and
reduce the water in the solvent, the effect will be small because
the quantity of recycle gas is small relative to the vent gas, and
the pressure of the recycle gas is considerably higher. This
adjustment is the least effective and would not normally be
considered during routine operations.
(5) Should the solvent inventory be difficult to control due to

continuing problems with an excessive amount of water in the
solvent, the steam-heated TGCU Stripper Reboiler should be
checked for tube leaks.

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B. Conversely, a persistently decreasing liquid level in the bottom of the

TGCU Stripper indicates a loss in the solvent water content. To
increase the water content of the solvent, the preferred sequence of
gradual adjustments is:
1. Reduce or terminate the "bleed" water from the TGCU Stripper

Reflux Accumulator.
2. Decrease the TGCU Contactor overhead temperature by

lowering the lean solvent temperature with the lean solvent
temperature controller to reduce the amount of water leaving in
the vent gas.
3. Decrease the TGCU recycle gas temperature with the aerial

cooling from the TGCU Stripper Reflux Condenser to reduce
the water loss in the stream as much as possible.
4. Begin water makeup (or increase the makeup water rate) to the
solvent system using the make-up flow controller to add
condensate to the TGCU Stripper Reflux Accumulator. The
TGCU Stripper Reflux Pump will then send the makeup water to
the TGCU Stripper, increasing the water content of the TGCU
solvent.
Be careful, however, to regulate the makeup rate so that the

temperature to the pump does not become hot enough to cause
cavitation. Also, make sure that the makeup water rate is not
so high that the pump cannot keep up, which would cause high
level in the TGCU Stripper Reflux Accumulator. Experience will
show how quickly condensate can be added without causing
pumping or level problems.
5. Increase the TGCU Contactor feed temperature by increasing

the temperature of the quench water feeding the TGCU Quench
Column by raising the setpoint of the quench water temperature
controller.
This will increase the water content of the gas entering the
TGCU Contactor, but it also increases the vapor load and
hampers H2S removal, so this step should not be taken to
extremes.

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11.6.10 TGCU Amine Loss

At the low process temperatures and low amine loadings normally
prevailing in the TGCU process, the loss of MDEA by chemical
degradation is expected to be negligible. Amine degradation can occur,
however, under abnormal operating conditions.
Amine degradation can occur via reaction with SO2, which can enter the
TGCU Contactor during periods when insufficient reducing gas is fed to
the TGCU Reactor. During such periods, most of the SO2 "breaking
through" the TGCU Reactor should be scrubbed out in the TGCU Quench
Column. However, any traces of SO2 entering the TGCU Contactor will
react with the MDEA to form a thermally non-regenerable complex (i.e.,
heat-stable salt). If present in sufficient quantity, this salt can alter the
H2S-amine equilibrium and prevent removal of H2S to the desired level in
the TGCU Contactor overhead. Heat-stable salts also increase the
corrosivity of the TGCU amine. Amine quality can be restored by
treatment with an amount of caustic equivalent to the non-regenerable salt
present but, if repeated caustic treatments are necessary due to repeated
mal-operation, the potential for salt deposition in the system may rise.
The equipment in the TGCU, including the seals of pumps and blowers,
should be operated at positive pressure to minimize the potential for
oxygen (air) ingress into the amine. Oxygen will react with the amine to
produce carboxylic acids that cause the solution to be corrosive. For this
same reason, it is important to maintain an inert gas "blanket" on the
MDEA storage tank to prevent oxygen contamination of the fresh amine.
Amine losses due to entrainment in the vent gas or the recycle gas can be
minimized by proper process operation (avoidance of column overloading,
foaming, etc.) and routine inspection of the vessel internals. Amine losses
in the water "bleed" from the TGCU Stripper reflux should be negligible if
the rectifying trays (the "wash water" trays above the amine feed point) in
the TGCU Stripper are operating properly (no flooding or foaming, no
mechanical damage).
The primary source of amine loss will likely be the mechanical losses from
pump drips, cleaning of filters, etc. Good housekeeping practices,
including prompt replacement or repair of leaking pumps, together with
proper collection of amine drips for reuse will minimize the mechanical
loss of amine.

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As discussed in the Sulfur Recovery Unit section of these guidelines,
operating the SRUs at low flow rates (below about 20-25% of design load)
can lead to several operating problems in the sulfur plant. It can also
cause poor column performance in the TGCU.
The TGCU contains three columns: the TGCU Quench Column and the
TGCU Contactor, which contain structured packing; and the TGCU
Stripper, which contains valve trays. In general, the liquid feed rate to
packed towers can decrease in proportion with the gas flow rate down to
about 50% of design gas flow rate. Below this point, the liquid rate cannot
be allowed to drop any further without risking poor column performance
due to uneven liquid distribution and wetting of the packing. Trayed
towers typically offer somewhat better turndown, allowing the liquid rate to
drop to 30-40% of design before "weeping" of the trays begins to
significantly affect performance.
At a total acid gas feed rate of 14 MT/D (of contained sulfur) to the SRUs,
the gas flow rates to the TGCU Quench Column and the TGCU Contactor
will be about 40% of design. In the case of the TGCU Quench Column,
simply setting the quench water flow rate to the column at about 50% of
design should maintain adequate performance. (It should be noted,
however, that there is really no detrimental effect if the quench water
circulation is simply left at the design value at all times. The only
drawback is slightly higher power consumption by the pump and aerial
cooler.)
In the packed TGCU Contactor, circulating more amine relative to the gas
flow rate should maintain performance. The liquid flow rate should be
maintained at a minimum of about 50%.
This higher amine circulation also has the advantage of absorbing more
CO2 from the TGCU Contactor feed, which is subsequently stripped from
the amine and recycled back to the SRUs. While TGCUs are normally
operated to minimize CO2 pickup, increasing the CO2 pickup in this
situation is advantageous. It raises the mass flow rate in the SRUs and
the TGCU, minimizing the operating problems throughout the SRU/TGCU
systems by preventing sulfur fog formation in the Sulfur Condensers. A
higher circulation rate also means the TGCU has more capacity to remove
H2S from the amine, making it less likely that SRU upsets will cause SO2

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emissions to exceed permit limits. It will also keep the TGCU Stripper
trays well above their minimum operating rate.
11.6.12 Pressure Drop Surveys

A commonly encountered problem in TGCUs (and sulfur plants and
Thermal Oxidizers) is a flow restriction due to high pressure drop. High
pressure drop is typically caused by a restriction at one point in the
equipment or piping, due to:
1. Accumulation of liquid (sulfur, etc.) in equipment or piping

2. Partial plugging of a catalyst bed (soot, carbon, polymers, etc.)
3. Partial plugging of a mist eliminator (sulfur, soot, catalyst, etc.)
4. Partial plugging of the packing and/or trays in a column
5. Flooding or foaming in a column
The first step in identifying the cause of the high pressure drop is to
determine which equipment pass or section of piping contains the
restriction. (It is unusual to have more than one area of high pressure
drop.) This is best accomplished by making a pressure survey of the
process side of the TGCU (and the SRUs and Thermal Oxidizer, if
necessary).
Due to the low operating pressure in the TGCU (generally 0.3 kg/cm2(g) or
less) and the low pressure drop in each equipment pass (generally
0.00-0.04 kg/cm2 per pass), a single pressure gauge must be used to
make the pressure survey in order to get meaningful results. The gauge
should be a low pressure gauge for best results (a -1 - 0 - +1.5 kg/cm2
gauge is recommended).
Beginning at the front end of the TGCU, use the pressure tap valves on
the inlet and outlet lines from each equipment pass to measure the
pressure at each point in the process. Proceed toward the back end of
the process until the pass with the high pressure drop is found. Note that
some of the pressure tap valves may be plugged with solid sulfur.
Rod-out the sample valves as necessary to obtain an accurate pressure
reading.

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WARNING

WHEN USING THE PRESSURE TAP VALVES, PARTICULARLY IF
THE VALVES ARE PLUGGED AND MUST BE CLEARED.
ALTHOUGH THE VALVES ARE ORIENTED TO MINIMIZE THE
POSSIBILITY OF FILLING WITH MOLTEN SULFUR, HOT SULFUR
MAY SUDDENLY BE EXPELLED FROM A VALVE WHEN THE PLUG
IS CLEARED. RELEASE OF TOXIC GASES (H2S AND SO2, IN
PARTICULAR) IS ALSO A POSSIBILITY. THE "GENERAL SAFETY"
H2S, SO2, OR MOLTEN SULFUR MAY BE PRESENT.
When troubleshooting problems of this nature, it is very helpful to have

pressure survey information taken previously when the unit was operating
properly. It is recommended that one or more pressure surveys be
performed early in the operating life of the plant, for comparison purposes
later if problems are encountered. Since the pressure drop of the TGCU
is a function of plant throughput (pressure drop is roughly proportional to
flow rate squared), it is even more helpful for troubleshooting purposes if
the early pressure surveys are performed at different plant throughput
rates. It is also important to record the gas flow rates to the SRUs (amine
acid gas, SWS gas, process air) and the TGCU (reducing gas) during the
pressure survey, since pressure drop depends so strongly on plant
throughput.

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service life for the TGCU Waste Heat Reclaimer. Without good
day-to-day control of the water quality, solids buildup, corrosion, and
Total Petrochemicals Co., Ltd.'s responsibility to see that a proper
is recommend that only those companies that have local technicians with
extensive experience specifically in boiler water treatment be selected to
assist with Samsung Total Petrochemicals Co., Ltd.'s program.
The design details incorporated in the TGCU Waste Heat Reclaimer have
proven to be very reliable when combined with good operator practice
regarding water treatment. However, even properly designed equipment
can be severely damaged during a short period of operation if the water
treatment program is inadequate or improper.
The TGCU Waste Heat Reclaimer is equipped with a continuous

blowdown valve to remove suspended and dissolved solids from the water
inside the boiler. In addition, this boiler is equipped with an intermittent
blowdown valve. The intermittent blowdown valve should be used on a
regular basis to give the boiler a good "blow" to prevent sludge from
accumulating in the bottom of its shell.
Prior to using the intermittent blowdown valve, use the level controller in
the DCS to raise the water level in the boiler up to the high level alarm
point. Then open the intermittent blowdown valve until the level drops
back to the normal liquid level. Watch the boiler level in the sight glass
activate the TGCU ESD and shut the TGCU down). Remember to reset
the level controller at the conclusion of this procedure.

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B. Check the rotation of the TGCU Start-Up Blower by operating it for a

short period (20 seconds or less) with its suction and discharge
valves closed:
C. Check the rotation of the following pumps by "bumping" them:
(1) TGCU Quench Water Pump.
(2) TGCU Rich Amine Pump.
(3) TGCU Stripper Reflux Pump.
(4) TGCU Lean Amine Pump.
D. Check the rotation of the fans on the TGCU Quench Water Cooler,
the TGCU Lean Amine Cooler, and the TGCU Stripper Reflux
Condenser, by operating each fan for a short period.
E. Check all piping and equipment to be sure that all blinds have been
F. Place the Instrument Air System in service to all instruments and

G. Turn on the steam supplies to all of the steam-jacketed sulfur vapor

from the jackets. Manually "stroke" each valve and check to be sure
each move freely.

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A. Fill the TGCU Waste Heat Reclaimer with treated boiler feed water
up to the high level alarm point. As the level rises, check the level
transmitters and the high level alarms for proper operation.
B. Use the quick-opening blowdown valve to lower the water level in the
boiler and check for proper operation of the level transmitters, the
low level alarms, and the low-low level shutdowns.
C. Fill the boiler with treated boiler feed water back up to the normal
liquid level.
D. Physically check all shutdown activating devices to ensure that they

activate the TGCU ESD system.
E. Physically check all devices activated by the TGCU ESD system to

G. The low-low level shutdowns for the pumps in the quench water and
amine systems will be tested while washing these systems as
described in the following sections.

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11.7.3 Commissioning Nitrogen and Utility Air to the Process

The nitrogen and utility air supplies to the process side of the TGCU must
be made ready for use prior to starting up the TGCU using the procedures
in Section 11.8 of these guidelines. This requires blowing down each
section of piping to ensure that there are no liquids and/or construction
debris in the headers and supply lines. The procedure below can be used
to make sure that these gas utility systems are ready for service.
A. Place the utility air controller in the DCS in "manual" and set its
output to 0%.
B. Place the nitrogen controller in the DCS in "manual" and set its
output to 0%.
C. Confirm that the following nitrogen and utility air valves are closed:
(1) The upstream block valve, flow control valve, and the
downstream block valve in the nitrogen supply line.
(2) The upstream block valve, flow control valve, and the
downstream block valve in the utility air supply line.
(3) The automated block valves, and the steam-jacketed block

valve in the common nitrogen / air line.
(4) The block valve in the HP nitrogen supply line located near the
TGCU Reactor.
(5) The gate valves upstream and the ball valves downstream of
the flow indicators in the purges to the sensing lines for the
TGCU Reactor d/P transmitter.
(6) The ball valves in the sensing lines for the TGCU Reactor d/P
transmitter.
(7) The gate and ball valves in the purge line to the shaft seal on
the TGCU Start-Up Blower.
(8) The gate valve in the LP nitrogen supply line, and the ball valve
downstream of the flow indicator in the purge line to the TGCU
Start-Up Blower discharge line.
(9) The gate valve upstream of the flow indicator in the supply line
to the sample switching valve for the H2/H2S analyzer.

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(10) The block valves in the nitrogen supply line to the TGCU
Stripper Reflux Accumulator.
D. Confirm that all of the manual vent/drain valves in the nitrogen and
utility air piping are closed.
E. If the orifice plate has already been installed in the utility air flow
meter, remove it for now
F. If the orifice plate has already been installed in the nitrogen flow
meter, remove it for now
G. Disconnect the nitrogen and utility air from the tailgas line by
performing the following steps:
(1) Unbolt the flanged connections at the steam jacketed block

valve and "drop out" this valve.
(2) Isolate and, if necessary, disconnect the steam supply and

condensate return connections for this valve.
(3) Cover the open end of the piping to prevent debris from
entering when the upstream piping is blown down.
H. Confirm that the H.P. nitrogen, L.P. nitrogen, and Utility Air supply
headers have been placed in service, with the pressure regulators
set properly and the safety relief valves in service, and with the main
supply header piping blown down and drained.
I. Rotate the spectacle blind in the utility air line to the "open" position.
J. Remove the following pressure regulators, then cover the

(1) The utility air supply regulator.
(2) The nitrogen supply regulator.
K. "Force" the PLC to open the two nitrogen blocks, and close the
nitrogen vent valve.
L. Confirm that these automated valves have moved to the proper

positions.
M. "Crack" the upstream block valve in the main utility air supply line
and allow air to blow through the piping until it is clear. Then close

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the block valve, reinstall the utility air supply pressure regulator, and
N. Using the utility air supply pressure regulator and the vent valve
downstream of the pressure control valve, adjust the utility air
regulator to the setpoint specified on the P&IDs.
O. "Crack" the block valve in the main nitrogen supply line and allow
nitrogen to blow through the piping until it is clear. Then close the
gate valve, reinstall the nitrogen supply pressure regulator, and
reopen the gate valve.
P. Using the pressure gauge and the vent valve downstream of the
nitrogen supply pressure regulator, adjust the nitrogen regulator to its
specified setpoint.
Q. Open the flow valve in the utility air line by setting the output of the
flow controller to 100% in the DCS, then use the downstream drain
valve to blow out this section of piping. Close the drain valve when
the piping is clear.
R. Open the flow valve in the nitrogen line by setting the output of the
flow controller to 100% in the DCS, then use the downstream drain
valve to blow out this section of piping. Close the drain valve when
the piping is clear.
S. "Crack" the block valve downstream of the flow valve and allow air to
blow through the piping until it is clear. Then close the bock valve.
T. Close the flow valve in the utility air line by setting the output of the
flow controller to 0% in the DCS
U. "Crack" the block valve downstream of nitrogen control valve and

allow nitrogen to blow through the piping until it is clear. Then close
the block valve.
V. Close the control valve in the nitrogen line by setting the output of the
flow controller to 0% in the DCS
W. Remove the "forces" from the PLC and confirm that both of the
automated block valves close and the automated vent valve opens.
X. Close the upstream block valve in the utility air supply line.

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Y. Rotate the spectacle blind in the utility air line to the "closed"
position.
Z. Close the upstream block valve in the nitrogen supply line until the
TGCU unit is ready for startup.
AA. Reconnect the nitrogen / air piping by performing the following steps:
(1) Reinstall the steam jacketed block valve and bolt the flanged
connections back together.
(2) Reinstate the steam supply and condensate return piping.
(3) If the steam system is already in service, establish steam flow

into the jacket by opening the steam supply valve. Open the
vent valve on the steam jacket long enough to vent the air from
the jacket.
(4) Reinstall the orifice plate in the utility air flow meter.
(5) Reinstall the orifice plate in the nitrogen flow meter.
BB. Open the block valve in the utility nitrogen supply line located near
the TGCU Reactor until the line is clear.
CC. The TGCU Reactor d/P transmitter has low pressure purges for both
of its sensing lines, each with a rotameter near where it connects to
the sensing line. Disconnect the upstream fitting at each rotameter
and briefly open its upstream gate valve to blow any liquids or debris
from its purge line. Reconnect each rotameter, disconnect the fitting
where each purge connects to the sensing line, open the upstream
gate valve, and open the ball valve downstream of each rotameter
briefly to blow any liquids or debris from the purge lines. Then
reconnect each purge to the sensing line and open its valve to place
it in service.
DD. Disconnect the fitting where each sensing line connects to its
process line, and open the ball valve in each sensing line briefly to
blow any liquids or debris from the lines. Then reconnect each
sensing line to its process line and open its ball valve to place it in
service.
NOTE: The two rotameters must be adjusted to the same flow rate
so that the pressure drop of the purge gas in the sensing
lines does not affect the reading of the d/P transmitter. One

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way to do this is to confirm that the equalizing valve on the

d/P transmitter manifold is closed, set the rotameter on the
upstream sensing line to a small flow rate (~0.8-1.6 Nm3/H),
and then adjust the flow rate of the other rotameter until the
meter reads zero d/P.
EE. Disconnect the upstream fitting (in the purge line to the shaft seal on
the TGCU Start-Up Blower) and open the upstream gate and ball
valves briefly to blow any liquids or debris from the purge line.
Reconnect the rotameter and disconnect the fitting where the purge
connects to the shaft seal. Open the upstream gate valve, open the
ball valve briefly to blow any liquids or debris from the purge line,
then reconnect the purge to the shaft seal and open the ball valve to
place it in service.
FF. The nitrogen purge valve for the blower casing should already be
open. Disconnect the upstream fitting (in the purge line to the TGCU
Start-Up Blower discharge line) and open the upstream gate valve
briefly to blow any liquids or debris from the purge line. Reconnect
the rotameter and disconnect the fitting where the purge connects to
the discharge line on the TGCU Start-Up Blower. Open the
upstream gate valve, open the downstream ball valve briefly to blow
any liquids or debris from the purge line, then reconnect the purge to
the discharge line.
GG. Re-open the ball valve downstream of the nitrogen purge valve and
allow the nitrogen to pressurize the TGCU Start-Up Blower and the
piping inside the suction and discharge block valves. Check all of
the blower and piping connections for visible or audible signs of
leakage (by applying masking tape or "Snoop" to the flanges,
listening for other leaks, etc.). When done, leave the ball valve open
so that the purge is in service.
HH. Disconnect the upstream fitting (in the nitrogen supply line to the
sample switching valves) and open the upstream gate valve briefly to
blow any liquids or debris from the purge line. Reconnect the
rotameter and disconnect the fitting where the purge connects to the
sample selector valve on the H2/H2S analyzer. "Crack" the gate
valve to blow nitrogen through the piping until it is clear. Then close
the gate valve, reconnect the piping, and reopen the gate valve.
II. Remove the nitrogen supply regulator to the Reflux Accumulator.

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JJ. "Crack" the upstream block valve in the nitrogen supply line and
allow nitrogen to blow through the piping until it is clear. Then close
the block valve, reinstall the nitrogen supply pressure regulator, and
KK. Using the nitrogen supply pressure regulator and the vent valve
downstream of the regulator, adjust the nitrogen regulator to the
setpoint specified on the P&IDs

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11.7.4 Commissioning Hydrogen to the Process

The external hydrogen supply must be made ready for use prior to starting
up the TGCU using the procedures in Section 11.8 of these guidelines.
This requires blowing down each section of piping to ensure that there are
no liquids and/or construction debris in the headers and supply lines.
Because of the fire hazard associated with venting high-purity hydrogen,

nitrogen should be used for the initial flushing of the hydrogen piping and
for setting the pressure regulator. Once this is completed, hydrogen can
then be used to check the setting of the pressure regulator by venting the
hydrogen to a safe location using the bypass valve.
A. Place the hydrogen controller in the DCS in "manual" and set its
output to 0%.
B. Confirm that the following valves are closed:
(1) The two block valves upstream of the pressure regulator.
(2) The reducing gas supply line automated block valves, the flow
control valve, the isolation valve downstream of the control
valve and the bypass valve around the control valve.
C. Confirm that all of the manual vent/drain valves in the hydrogen

piping are closed.
D. If the orifice plate has already been installed in the hydrogen flow
meter, remove it for now.
E. Rotate the spectacle blind in the hydrogen supply line to the "closed"
position.
F. Disconnect the hydrogen piping from the line going to the TGCU
Reactor Feed Mixer by performing the following steps:
(1) Unbolt the flanged connections at the steam jacketed block

valve and "drop out" this valve.
(2) Isolate and, if necessary, disconnect the steam supply and

condensate return connections for this valve.
(3) Cover the open end of the piping to prevent debris from
entering when the upstream piping is blown down.

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G. Remove the pressure regulator, then cover the downstream piping to

prevent debris from entering when the upstream piping is blown
down.
H. "Force" the PLC to open the block valves in the hydrogen supply line,
and close the vent valve.
I. Confirm that these automated valves have moved to the proper

positions.
J. Use a temporary "jumper" to connect a nitrogen supply to the drain

valve upstream of the pressure regulator.
K. "Crack" the gate valve upstream of the pressure regulator and allow
nitrogen to blow through the piping until it is clear. Then close the
gate valve, reinstall the pressure regulator and reopen the gate
valve.
L. Using the pressure gauge and the vent valve downstream of the
pressure regulator, adjust the hydrogen regulator to the setpoint
specified on the P&IDs.
M. Open the reducing gas supply line control valve by setting the output
of the hydrogen controller to 100% in the DCS, then use the
downstream drain valve to blow out this section of piping. Close the
drain valve when the piping is clear.
N. "Crack" the gate valve downstream of the reducing gas supply line
control valve and allow nitrogen to blow through the piping until it is
clear. Then close the gate valve.
O. Close the reducing gas supply line control valve by setting the output
of the hydrogen controller to 0% in the DCS.
P. Briefly open the bypass valve around the control valve and allow
nitrogen to blow through the piping until it is clean. Then close the
bypass valve.
Q. Remove the "forces" from the PLC and confirm that both of the
automated block valves close and the automated vent valve opens.
R. Close the gate valve where the nitrogen "jumper" is connected to

stop the flow of nitrogen, and disconnect the nitrogen jumper.
S. Reconnect the hydrogen piping by performing the following steps:

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(1) Reinstall the steam jacketed block valve and bolt the flanged
connections back together.
(2) Reinstate the steam supply and condensate return piping.
(3) If the steam system is already in service, establish steam flow

into the jacket by opening the steam supply valve. Open the
vent valve on the steam jacket long enough to vent the air from
the jacket.
(4) Reinstall the orifice plate in the hydrogen flow meter.
(5) Rotate the spectacle blind in the hydrogen supply line to the
"open" position.
T. Confirm that the hydrogen pressure regulator is properly adjusted:
(1) Open the two gate valves upstream of the pressure regulator.
(2) "Crack" the bypass valve to vent hydrogen to the flare. Adjust
the pressure regulator if necessary to maintain its setpoint,
observing the pressure on the pressure gauge.
(3) Close the bypass valve, and the gate valve immediately
upstream of the pressure regulator.

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CAUTION
THE LOW PRESSURE PROCESS PIPING (PROCESS GAS AND

SULFUR VAPOR) AND LOW PRESSURE PROCESS EQUIPMENT
IN THE TGCU ARE NOT DESIGNED TO BE HYDROSTATICALLY
TESTED. ONLY THE PIPING AND EQUIPMENT DOWNSTREAM
OF THE TGCU CONTACTOR (THE SOLVENT AND STRIPPER
SYSTEMS) ARE DESIGNED TO BE HYDROTESTED. USE THE
FOLLOWING PROCEDURE TO LEAK-TEST THE REST OF THE
TGCU.
The process piping and equipment in the TGCU can be checked for leaks
by using nitrogen to pressurize the process side of the equipment and
piping to about 0.6-0.7 kg/cm2(g), then checking flanges, etc. for leaks
(usually by applying masking tape or "Snoop" to the flanges, and by
listening for other leaks). In order to pressurize the TGCU with nitrogen, it
is necessary to block-in the unit by closing the outlet valve. This
procedure requires some special preparations to operate in this manner,
as detailed below.
The Complete Flowpath Interlock (see Section 11.5.5.1 of these

guidelines) must be temporarily disabled in order to operate the TGCU in
this manner. The Leak Test toggle switch in the DCS is used to direct the
PLC to bypass most of the unit shutdowns and to enable the on/off
selector switch for the nitrogen. This means that "jumpers" on the limits
switches or "forces" in the PLC are not necessary to perform this test. It
also means that it is not necessary to have water in the TGCU Waste
Heat Reclaimer during the test since the low-low water level S/D is also
bypassed.
This same procedure can be used to leak test the TGCU following
maintenance, before restarting the unit. Whenever plant maintenance
requires opening one or more of the flanged connections in the TGCU, it
is good practice to leak test the unit before returning it to service. This
allows detecting any leaking connections that may have resulted from the
maintenance operations before tailgas is reintroduced into the unit.

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To perform leak testing in a TGCU, proceed as follows:
A. Confirm that the nitrogen flow controller in the DCS is set to 0%

output and that the control valve in the nitrogen supply line is closed.
B. Confirm that the Quench Column inlet hand control in the DCS is set
to 0% output so that the TGCU Quench Column Bypass Valve will
open later in Step F when the Startup/Run selector switch is
switched to "STARTUP".
C. Confirm that the TGCU Quench Column is isolated from the quench
water circulation loop by confirming that the following valves are all
closed:
(1) The bypass valve and downstream block valve at the quench
(2) The block valve downstream of the pH analyzer.
(3) The suction valves at the TGCU Quench Water Pumps.
(5) The block valve in the caustic supply line at the tie-in to the
suction line.
(6) The block valve in the condensate fill line at the tie-in to the
suction line.
(7) The bypass valve and downstream block valve at the filtered
quench water flow control valve.
D. Confirm that the TGCU Contactor is isolated from the solvent

(2) The suction valves at the TGCU Rich Amine Pumps.
(3) The drain valve on the suction line to pumps.
(4) The block valves in the solvent makeup line at the tie-in to the
suction line.
(5) The block valve and globe valve in the condensate makeup line
at the tie-in to the suction line.

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E. Confirm that the spectacle blind in the utility air supply line is in the
"closed" position.
F. Switch the Startup/Run selector switch, the Startup/Run selector

switch, in the DCS to "STARTUP".
(1) Bypasses the SRU ESD inputs to the TGCU ESD.
(2) Disables the Tailgas Valves transfer switches.
(3) Opens the TGCU Quench Column Bypass Valve.
(4) Enables the Leak Test Switch.
G. Confirm that the SRU Tailgas Valves to the TGCU are closed.
H. Confirm that the TGCU Start-Up Blower Bypass Valve is fully open.
I. Confirm that the block valve(s), and the steam-jacketed block valve
in the nitrogen supply line are open.
J. Toggle the Leak Test Switch in the DCS to "ON".
(1) Bypasses the TGCU ESD to allow opening the nitrogen supply
valves via the nitrogen on/off push-button.
(2) Opens TGCU Warmup/Bypass Valve.
K. Close the TGCU Outlet Valve.
L. Toggle the Nitrogen On/Off switch, the nitrogen on/off push-button, in

the DCS to "ON".
(1) Opens the nitrogen block valves.
(2) Closes the nitrogen vent valve.
M. Use the nitrogen flow controller in the DCS to open the nitrogen flow
control valve and send nitrogen to the TGCU to begin pressurizing it.
N. Slowly increase the output from the nitrogen flow controller until the
pressure reaches 0.6-0.7 kg/cm2(g) as measured by the pressure
indicator in the DCS.

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Due to the volume inside the TGCU, it will take several minutes for
the pressure to build up in the unit.
O. Once the desired pressure has been achieved, set the output from
the nitrogen flow controller to 0% to close the nitrogen flow control
valve. Check all of the equipment and piping connections for visible
or audible signs of leakage.
P. Toggle the Nitrogen On/Off switch in the DCS to "OFF".
(1) Closes the nitrogen block valves.
(2) Opens the nitrogen vent valve.
Q. Toggle the Leak Test Switch in the DCS to "OFF".
The PLC will enable all of the ESDs for the TGCU again.
R. Open the TGCU Outlet Valve.
S. Re-open valves as necessary to restore the quench water and

solvent circulation loops that were isolated from the columns in
Steps C and D earlier.

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11.7.6 Washing the Quench Water System

and trash from the equipment and piping in the quench water system
before it is placed in operation. Washing of the system consists of three
steps: an initial water flush to remove dirt and trash from the system; an
acid wash to remove grease, rust, and scale; and a caustic wash to
acclimate the equipment and piping to alkaline pH.
WARNING

11.7.6.1 Water Flush

A. Place the quench water flow controller in the DCS in "manual"
and set its output to 100% to fully open the quench water flow
control valve.
B. Place the TGCU Quench Column level controller in the DCS in

"manual" and set its output to 0% to fully close the level control
valve.
C. Confirm that the Quench Column inlet hand control in the DCS
is set to 0% output so that the TGCU Quench Column inlet
valve is fully closed.
D. Place the filtered quench water flow controller in the DCS in

"manual" and set its output to 100% to fully open the filtered
E. Verify that the quench water flow control valve is fully open.
Open both of its isolation block valves and its bypass valve.

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F. Verify that the TGCU Quench Column level control valve is fully
closed. Close both of its isolation block valves and its bypass
valve.
G. Verify that the TGCU Quench Column inlet valve is fully closed.
(This will prevent water from entering the TGCU Reactor if the
TGCU Quench Column is accidentally over-filled.)
H. Verify that the filtered quench water flow control valve is fully
open. Open both of its isolation block valves and its bypass
valve.
I. The TGCU Quench Water Filter will not be used to filter solids
during this time, but the filter vessel and its piping are to be
flushed and cleaned. Remove the filter elements, then bolt-up
the filter. Open the inlet and outlet block valves on the filter,
and open the bypass valve around the filter.
J. Similarly, remove the elements from both pH Meter Sample

Filters and reinstall the filter housings. Open the inlet and outlet
block valves to the sample loop for the pH analyzer, and open
the inlet and outlet block valves for both pH Meter Sample
Filters.
K. The probe on the pH analyzer, the pH analyzer, should not be

installed until the quench water system has been cleaned and
refilled, ready for service. Verify that a temporary plug has
been screwed into the probe housing installed in the sample
piping.
L. Verify that the block valve in the caustic line is closed.
M. Add water (steam condensate) to the bottom of the TGCU

Quench Column through the condensate line.
N. Once there is an adequate level in the column, all the way to

the top of its level gauge open the suction valve on a TGCU
Quench Water Pump and use its drain valve to be sure the
discharge valve.
O. Watch the level in the TGCU Quench Column while placing the
pump in service to be sure the pump does not lose suction
while filling the downstream piping and equipment. If the level

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disappears in the column, shut the pump down until enough

condensate is added to reestablish the level, then restart the
pump.
P. Once circulation is achieved and the level in the TGCU Quench

Column is adequate (about halfway up in the level gauge),
discontinue the addition of condensate.
Q. Use the low point drain valves to flush out each section of the
R. Briefly open the bypass valve on the TGCU Quench Column

level control valve to flush this section of piping to The Sour
Water Stripping Unit. Open the upstream block valve, open the
TGCU Quench Column level control valve with the level
controller in the DCS, and use the downstream drain valve to
flush the control station. Once the flush water clears up, close
the TGCU Quench Column level control valve and the upstream
block valve.
S. Circulate the water and blow down the low point drains until all
to maintain the level in the TGCU Quench Column.
At some point during the washing procedure, the standby pump

should be placed in service while the other pump is shut down.
This will ensure cleaning out both pumps and their associated
piping.
T. Once the drain water is clear, completely drain the system.

Drain the system as quickly as possible, so that the water
velocity helps to flush the solids from all parts of the system.
U. Allow the pump to continue running while the system drains, but
watch the pump closely to verify that the low-low level shutdown
shuts the pump down below the shutdown setpoint. If the level
drops completely out of the gauge glass before the pump shuts
down, stop the pump manually and correct the problem with the
low-low level shutdown before proceeding further.
V. Verify that the caustic supply line has been flushed and is ready
for service.

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11.7.6.2 Acid Wash

solution.
A. Use the condensate makeup line to reestablish a level in the

TGCU Quench Column.
B. Once a level is established, start a TGCU Quench Water Pump

to begin circulating the water.
C. Add concentrated citric acid to the circulating water to make a

D. After circulating for about 3 hours, start the other TGCU

Quench Water Pump and shut down the first one.
E. Circulate the solution for a total of about 6 hours, blowing down

the low point drains occasionally. Add more condensate if
necessary to maintain the level in the TGCU Quench Column.
F. Briefly open the bypass valve on the TGCU Quench Column

level control valve to flush this section of piping to The Sour
Water Stripping Unit. Then open both block valves and use the
level controller in the DCS to open the TGCU Quench Column
level control valve briefly and flush the control station. Close
the TGCU Quench Column level control valve and the block
valves.
G. After 6 hours, shut down the pump and completely drain the
system.
11.7.6.3 Alkaline Wash

The washing operation is completed by circulating a weak alkaline
the system, and acclimate the system to high pH operation so that no
further scale is removed from the equipment and piping when the
normal quench water (8.0-9.5 pH) is circulated.

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A. Use the condensate makeup line to reestablish a level in the

TGCU Quench Column.
B. Once a level is established, start a TGCU Quench Water Pump

C. Adjust a TGCU Caustic Injection Pump to full stroke. Open the

block valve at the tank, the suction block valve, and the
discharge block valve on the pump. Start the pump, then open
the block valve in the caustic line where it enters the suction
line to the TGCU Quench Water Pump.
D. Allow the pump to run for long enough to displace the water in
the caustic supply piping (left from the earlier water flush
procedure). Add caustic to the circulating water to make a
0.02 wt% solution. This should give a pH in the range of 11-22.
E. Shut off the TGCU Caustic Injection Pump, and close the block
valve in the caustic supply at the injection point in the quench
water piping.
F. Check the pH of the circulating water. If the pH is less than 11,

add more caustic from the caustic makeup line until the pH is
11 or higher.
G. After circulating for about 1 hour, start the other TGCU Quench
Water Pump and shut down the first one.
H. Circulate the solution for a total of about 2 hours, blowing down

the low point drains occasionally. Add more condensate if
necessary to maintain the level in the TGCU Quench Column.
I. Briefly open the bypass valve on the TGCU Quench Column

level control valve to flush this section of piping to the sour
water header. Then open both block valves and use the level
controller in the DCS to open the TGCU Quench Column level
TGCU Quench Column level control valve and the block valves.
J. After 2 hours, shut down the pump and completely drain the
system.

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The quench water system should now be clean and ready to place in
service. All that remains is to refill the system with water and
establish the proper operating conditions. This includes
"pre-charging" the system with caustic to serve as a "buffer" so that
the system pH does not drop suddenly when process gas is first
introduced into the TGCU Quench Column and H2S from the gas
dissolves in the water.
A. Close the inlet and outlet block valves on the TGCU Quench
Water Filter, then install the proper element(s) in the filter.
Leave the block valves closed for now.
B. Close the inlet and outlet block valves on the pH analyzer

sample loop, then install the proper elements in both pH Meter
Sample Filters. Leave the block valves closed for now.
C. Use the condensate makeup line to reestablish a level in the

TGCU Quench Column.
D. Once a level is established, start a TGCU Quench Water Pump

E. Place the Quench Water flow controller in the DCS in service

and set its setpoint to its normal value. Close the bypass valve
on the quench water flow control valve.
F. Confirm that the TGCU Quench Column level control valve is

closed, then open both of its block valves. Place the level
controller in the DCS in service and set its setpoint to its normal
value.
G. Place the TGCU Quench Water Filter in service as follows:
the filter to fill with water. When the filter is full, close the
vent valve.
(3) Open the filter inlet block valve fully and open the outlet
block valve, then close the filter bypass valve.
(4) Place the filtered quench water flow controller in the DCS
in service and set its setpoint to its normal value. Close

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the bypass valve on the filtered quench water flow control

valve.
H. Adjust a TGCU Caustic Injection Pump to full stroke. Start the

pump, then open the block valve in the caustic line where it
enters the quench water piping.
I. Allow the pump to run for a few minutes until the pH of the
solution is in the range of 12-13.
J. Shut off the TGCU Caustic Injection Pump and close its suction
valve. Leave the block valve at the injection point in the quench
water piping open.
K. Install the pH analyzer probe in its housing in the sample loop,

following the manufacturer's instructions. Place the analyzer in
service by opening the block valves on one of the pH Meter
Sample Filters (the block valves should be closed on the other
filter) and opening the inlet and outlet valves on the sample
loop. Observe the flow indicator to verify flow through the
sample loop. Analyze a sample of the quench water to confirm
that the pH analyzer is measuring the correct pH.
L. Add additional caustic if necessary to adjust the pH to 11-13.
M. Commence cooling water flow to the TGCU Quench Water Trim

Cooler if it has not already been placed in service.
The quench water system is now ready for service. It can remain in
this operating mode indefinitely while the rest of the TGCU is
prepared for startup. Check the system periodically for indications of
plugging, etc. (low flow, erratic pump discharge pressure, high filter
pressure drop), as solid materials may accumulate at various points
11.7.7 Washing the Amine System

and trash from the equipment and piping in the solvent system before it is
placed in operation. Washing of the system consists of three steps: an
initial water flush to remove dirt and trash from the system; an acid wash
and rinse to remove grease, rust, and scale; and a weak amine wash and
rinse to acclimate the equipment and piping to alkaline pH.

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problems (column foaming, poor treating, heat exchanger fouling, rapid
filter plugging, etc.).
WARNING

11.7.7.1 Water Flush

(a) Set the output from the lean solvent flow controller to 100% to
fully open the lean solvent flow control valve.
(b) Open the manual block valve upstream of the lean solvent
filters.
(c) Set the output from the TGCU Contactor level controller to
100% to fully open the TGCU Contactor level control valve.
(d) Set the output from the TGCU Stripper Reboiler steam
flow controller to 0% to fully close the steam flow control valve.
(e) Set the output from the TGCU Stripper Reflux

Accumulator level controller to 0% to fully close the TGCU
Stripper Reflux Accumulator level control valve.
(f) Set the output from the bleed water flow controller to 0%
to fully close the bleed water flow control valve.
(g) Set the output from the makeup water flow controller to
0% to fully close the makeup water flow control valve.
(h) Set the output from the TGCU Stripper pressure

controller, to 0% to fully close the pressure control valve.

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B. Place the other TGCU Stripper pressure controller in

"automatic" with a setpoint of 0.85 kg/cm2(g). This will open the
pressure control valve to the flare if pressure builds in the
TGCU Stripper during this procedure.
C. Verify that the following control valves are fully open.

Open both of the isolation block valves and the bypass valve
(where applicable) at each control station.
(1) The lean solvent flow control.
(2) The lean solvent from the lean solvent filters.
(3) The TGCU Contactor level control, (the rich solvent from
the TGCU Contactor).
D. Verify that the following control valves are fully closed. Close
both of the isolation block valves and the bypass valve at each
control station.
(1) The steam flow control valve to the TGCU Stripper

Reboiler.
(2) The TGCU Stripper Reflux Accumulator level control

valve.
(3) The bleed water flow control valve from the TGCU Stripper
reflux.
(4) The makeup water flow control valve to the TGCU Stripper
Reflux Accumulator.
(5) The acid gas pressure control to the SRU.
E. Verify that the bypass valve on the pressure control valve to the
flare is closed. Open both of the isolation block valves at this
control station.
F. The TGCU solvent filters will not be used to filter solids during
this time, but the filter vessels and their piping are to be flushed
and cleaned. Remove the filter elements, then bolt-up the
individual filters. Open the inlet and outlet block valves on each
filter, and open the bypass valves for the filters.
G. Verify that the valves in the solvent makeup line are closed.

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H. Add water (steam condensate) to the bottom of the TGCU

Contactor through the condensate makeup line.
I. Once there is an adequate level in the TGCU Contactor, all the

way to the top of its level gauge open the suction valve on a
TGCU Rich Amine Pump and use its drain valve to be sure the
discharge valve.
Watch the level in the TGCU Contactor as the pump fills the
downstream piping and begins to fill the TGCU Stripper. When
the level drops to the low-low level shutdown should shut down
the pump. If it does not, stop the pump manually before it loses
suction and correct the problem with the low level shutdown
before proceeding.
J. Continue filling the TGCU Contactor with condensate and

pumping the water to the TGCU Stripper periodically, until the
level in the TGCU Stripper is all the way to the top of its level
gauge.
K. Once there is an adequate level in the TGCU Stripper, open the

suction valve on a TGCU Lean Amine Pump and use its drain
valve to be sure the pump is flooded with water. Start the
pump, then open its discharge valve.
As the pump fills the downstream piping and begins to return

water to the TGCU Contactor, watch the level in the TGCU
Stripper to be sure the pump does not lose suction. If the level
disappears in the column, shut the pump down, add more
condensate to the TGCU Contactor and pump it to the TGCU
Stripper to reestablish the level, then restart the TGCU Lean
Amine Pump.
L. As the level begins to rise in the TGCU Contactor, restart the

TGCU Rich Amine Pump. Watch the levels in both columns,
and shut a pump down if necessary to keep from emptying
either column.
M. Once the levels in both columns are adequate, discontinue the


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N. At this point, neither the flow into or the level of the TGCU
Contactor is being controlled. Both control stations are in
"manual" with the valves fully open to flush the piping as much
as possible. Depending on the hydraulics of the system, it may
be necessary to place either or both of these controls in
"automatic" to prevent losing the level in one of the columns. If
so, leave the bypass valve on the control station "cracked" so
that the bypass piping gets flushed.
O. Use the low point drain valves to flush out each section of the
P. Circulate the water and blow down the low point drains until all
to maintain the levels in the columns.
At some point during the washing procedure, the standby

TGCU Rich Amine Pump and standby TGCU Lean Amine
Pump should be placed in service while the other pumps are
shut down. This will ensure cleaning out both pumps and their
associated piping in each service.
Q. Once the drain water is clear, shut down the TGCU Rich Amine
Pump and completely drain the system. Drain the system as
quickly as possible, so that the water velocity will help flush the
solids from all parts of the system.
R. Allow the TGCU Lean Amine Pump to continue running while

the system drains, but watch the pump closely to verify that the
low-low level shutdown shuts the pump down when the level
falls to the shutdown setpoint. If the level drops completely out
of the gauge glass before the pump shuts down, stop the pump
manually and correct the problem with the low level shutdown
before proceeding further.
S. Confirm that the solvent transfer line (for MDEA makeup) has
been flushed and is ready for service.
11.7.7.2 Acid Wash

solution.

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A. Use the condensate makeup line to re-establish the levels in

the TGCU Contactor and the TGCU Stripper as before, and
B. Add concentrated citric acid to the circulating water to make a

C. Begin steam flow to the TGCU Stripper Reboiler and gradually

raise the temperature of the circulating solution. For maximum
effectiveness, the solution should be 65-95°C throughout the
system, so adjust the steam flow accordingly. The fans on the
TGCU Lean Amine Cooler should not be operating at this time,
and cooling water should not be flowing to the TGCU Lean
Amine Trim Cooler.
D. It is unlikely that any steam will leave the top of the TGCU
Stripper during this operation, so the TGCU Stripper Reflux
Accumulator should remain dry. If a level should develop in this
vessel, drain the water from the vessel using a drain valve on
one of the TGCU Stripper Reflux Pumps.
E. After circulating for about 3 hours, start the other TGCU Rich
Amine Pump and shut down the first one. Do the same with the
TGCU Lean Amine Pumps.
F. Circulate the hot solution for a total of about 6 hours, blowing

down the low point drains occasionally. Add more condensate
if necessary to maintain the levels in the columns.
G. After 6 hours, shut off the steam to the TGCU Stripper Reboiler,
shut down the pumps, and completely drain the system. Drain
the system as quickly as possible, so that the liquid velocity will
H. Use the condensate makeup line to reestablish the levels in the

TGCU Contactor and the TGCU Stripper as before, and
establish circulation of water to flush the system.
I. Switch to the other pumps for a few minutes, then shut down
J. Once again, use the condensate makeup line to reestablish the

levels in the TGCU Contactor and the TGCU Stripper as before,
and establish circulation of water in the system.

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K. Reestablish steam flow to the TGCU Stripper Reboiler and

gradually raise the temperature in the column.
L. When the temperature begins to rise in the TGCU Stripper

overhead line, start a fan on the TGCU Stripper Reflux
Condenser and place the reflux temperature controller in
service with a setpoint of 54°C.
M. When a level builds in the TGCU Stripper Reflux Accumulator,

drain it to the closed drain from the drain on one of the pump
cases.
N. Open the downstream block valve at the TGCU Stripper Reflux

Accumulator level control valve, then use the drain valve to
blow steam from the column backwards down the reflux line to
remove any debris. Continue until the steam blows clear, then
close the drain valve and the block valve.
O. Continue to circulate water and apply heat in the TGCU Stripper

Reboiler, until the water drained from the TGCU Stripper Reflux
Accumulator is clear. During this time, blow down the low point
drains occasionally and add more condensate if necessary to
maintain the levels in the columns, and switch to the other
TGCU Rich Amine Pump and TGCU Lean Amine Pump.
P. Once the reflux loop has cleared up (the drain water is clear),
shut off the steam to the TGCU Stripper Reboiler, shut down
the pumps, and completely drain the system. Drain the system
as quickly as possible, so that the liquid velocity will help flush
any remaining solids from the system.
Q. Check the pH of the water draining from the system. If

necessary, repeat Steps J through P until the pH of the drain
water is about the same as the pH of the condensate makeup.
11.7.7.3 Weak Amine Wash

The washing operation is completed by circulating a weak amine
the system, and acclimate the system to alkaline pH operation so
that no further scale is removed from the equipment and piping when
the normal solvent is circulated.

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A. Use the condensate makeup line to reestablish the levels in the

B. Add enough MDEA to the circulating water to reach a

C. Begin steam flow to the TGCU Stripper Reboiler and gradually

raise the temperature in the column.
D. When the temperature begins to rise in the TGCU Stripper

overhead line, check that at least one of the fans is running on
the TGCU Stripper Reflux Condenser.
E. When a level builds in the TGCU Stripper Reflux Accumulator,

open the suction valve on one of the TGCU Stripper Reflux
Pumps and use its drain valve to be sure the pump is flooded
with water. Start the pump, open its discharge valve, then open
the bypass valve on the TGCU Stripper Reflux Accumulator
level control valve to pump the water back into the TGCU
Stripper.
Watch the level in the TGCU Stripper Reflux Accumulator while

pumping it out. Shut the pump down when the vessel is empty,
then close the suction and discharge valves on the pump and
close the bypass valve on the TGCU Stripper Reflux
Accumulator level control valve.
F. Continue to circulate the solution and apply heat to the TGCU

Stripper Reboiler, pumping out the TGCU Stripper Reflux
Accumulator as required by alternating which pump is used.
During this time, blow down the low point drains occasionally
and add more condensate if necessary to maintain the levels in
the columns, and switch to the other TGCU Rich Amine Pump
and TGCU Lean Amine Pump.
G. During one of the pumping cycles for the TGCU Stripper Reflux
Accumulator, flush out the minimum flow spill-back line by
opening the manual block valve to allow circulation through this
line. Then close the manual block valve.
H. During another pumping cycle, flush out the bleed water piping
by setting the output of the bleed water flow controller to 100%

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to fully open the bleed water flow control valve, opening its
upstream and downstream block valves, and opening its
bypass valve. Then close the valves and set the output of the
bleed water flow control valve back to 0%.
I. Take a sample of the circulating solution and run a foam test on

it using the procedure in Section 11.10.
J. Once the solution drained from all the low point drain valves is
clear, shut off the steam to the TGCU Stripper Reboiler, shut
down the pumps, and completely drain the system. Drain the
system as quickly as possible, so that the liquid velocity will
K. Use the condensate makeup line to reestablish the levels in the

establish circulation of water to flush the system.
L. Switch to the other pumps for a few minutes, then shut down
M. If the solvent sample taken in Step I was foamy, repeat Steps A

through L until the solvent is not foamy.
11.7.7.4 Initial Solvent Fill

The solvent system should now be clean, ready to place in service.
All that remains is to fill the system with the proper solvent charge
and establish the proper operating conditions.
NOTE: This procedure prepares the TGCU solvent system for

operation in the shortest possible time. However, it does
allow the MDEA to come in contact with oxygen that is in
the TGCU Contactor. If a slightly longer TGCU startup
schedule can be tolerated, this deficiency can be
minimized or eliminated by deferring the procedure in this
section until nitrogen has been used to purge the TGCU
Quench Column and TGCU Contactor as described in the
following section.
A. Close the inlet and outlet block valves on the four TGCU
solvent filters, then install the proper elements and/or carbon in
the filters. Leave the block valves closed on each filter for now.

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B. Use the condensate makeup line to reestablish the levels in the

C. Add enough MDEA to the circulating water to reach a

D. Place in service and adjust the level controller on the TGCU

Contactor to maintain its normal setpoint. Stop the condensate
and/or amine makeup when the TGCU Stripper level is about
50-60%.
E. Begin steam flow to the TGCU Stripper Reboiler and gradually

raise the temperature in the column. Place the steam flow
controller in the DCS on "automatic" with its setpoint set to its
normal value.
F. Open the high point vent valve on the TGCU Stripper overhead
line and allow the steam to purge any air from the vessel. As
the pressure builds, the vent valve can be closed.
G. Monitor the stripper pressure, and adjust the overhead pressure

temperatures.
H. Ensure that the fans are running on the TGCU Lean Amine
Cooler and the TGCU Stripper Condenser. Commence cooling
water flow to the TGCU Lean Amine Trim Cooler.
I. Place the lean solvent temperature controller in "automatic" and

set its setpoint to its normal value.
J. When a level builds in the TGCU Stripper Reflux Accumulator,

open the suction valve on one of the TGCU Stripper Reflux
Pumps and use its drain valve to be sure the pump is flooded
with water. Open the block valves upstream and downstream
of the reflux flow control valve, place the reflux flow controller in
"automatic" with its setpoint set to its normal value, then start
the pump and open its discharge valve.
K. Open the block valves on the TGCU Stripper Reflux

Accumulator level control valve and place the level controller in
the DCS in "automatic" with its setpoint set to its normal value.

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The TGCU Stripper Reflux Accumulator level control valve will

now open as needed to pump water back into the TGCU
Stripper and maintain the desired level in the TGCU Stripper
Reflux Accumulator.
L. If the control loops on the TGCU solvent have not already been
placed in service, do so at this time. Switch the TGCU
contactor level controller and the lean solvent flow controller in
the DCS to "automatic" with their setpoints set to their normal
values.
M. Place each of the four TGCU solvent filters in service as

follows:
the filter to fill with solvent. When the filter is full, close its
vent valve.
N. Analyze a sample of the circulating solvent using the procedure

in these guidelines to determine the amine concentration. Add
more fresh MDEA using the solvent transfer line if needed to
bring the concentration up to the design value, 45 wt %.
O. Flush the makeup water line by setting the output from the
makeup water flow controller to 100% to fully open the makeup
water flow control valve, opening its upstream block valve, then
opening the downstream drain valve until the water runs clear.
Then set the output of the flow controller to 0% to close the
makeup water flow control valve, and open the downstream
block valve.
P. Confirm that the bleed water flow controller is in "manual' with

its output set at 0% and that the bleed water flow control valve
is closed, then open its upstream and downstream block valves.

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The solvent system is now ready for service. It can remain in this
operating mode indefinitely while the rest of the TGCU is prepared
for startup. Check the system periodically for indications of plugging,
etc. (low flow, erratic pump discharge pressure, high filter pressure
drop), as solid materials may accumulate at various points in the
system over time.

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11.7.8 Purging the Low Pressure TGCU Columns

Prior to starting up the TGCU using the procedures in Section 11.8 of
these guidelines, nitrogen should be used to purge the TGCU Quench
Column and the TGCU Contactor. This will displace the air introduced
into the columns while washing and filling them earlier.
At this point, the following conditions should exist in the TGCU:
1. The TGCU Start-Up Blower is not in service and is bypassed.
2. The quench water system and perhaps the amine system have
been cleaned and loaded with their respective initial fills of water
and amine. (The amine system may be waiting on purging of the
TGCU Contactor before the system is loaded with amine.)
11.7.8.1 Establishing Nitrogen Flow

To establish nitrogen flow into the TGCU, proceed as follows:
A. Confirm that the nitrogen flow controller in the DCS is set to 0%

output and that the control valve in the nitrogen supply line is
closed.
B. Confirm that the Quench Column inlet hand control in the DCS
is set to 0% output so that the TGCU Quench Column Bypass
Valve will open later in Step F when the Startup/Run selector
switch is switched to "STARTUP".
C. Confirm that the TGCU Quench Column is isolated from the

quench water circulation loop by confirming that the following
valves are all closed:

(2) The block valve downstream of the pH analyzer.
(3) The suction valves at the TGCU Quench Water Pumps.
(5) The block valve in the caustic supply line at the tie-in to
the suction line.
(6) The block valve in the condensate fill line at the tie-in to
the suction line.

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filtered quench water flow control valve.
D. Confirm that the TGCU Contactor is isolated from the solvent

circulation loop by confirming that the following valves are all
closed:
(2) The suction valves at the TGCU Rich Amine Pumps.
(3) The drain valve on the suction line to pumps.
(4) The block valves in the solvent makeup line at the tie-in to
the suction line.
(5) The block valve and globe valve in the condensate

makeup line at the tie-in to the suction line.
E. Confirm that the spectacle blind in the utility air supply line is in
the "closed" position.
F. Toggle the Startup/Run selector switch, the Startup/Run

selector switch, in the DCS to "STARTUP".
(2) Disables the Tailgas Valves transfer switches.
(4) Enables the Leak Test Switch.
G. Confirm that the SRU Tailgas Valves to the TGCU are closed.
H. Confirm that the TGCU Start-Up Blower Bypass Valve is fully

open.
I. Confirm that the block valve(s), and the steam-jacketed block

valve in the nitrogen supply line are open.
J. Confirm that the TGCU Outlet Valve is open.
K. Reset the TGCU ESD by toggling the push-button in the DCS to

"RESET".

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L. Set the output of the hand control in the DCS to 0% to close the
TGCU Warmup/Bypass Valve.
M. Toggle the Nitrogen On/Off switch in the DCS to "ON".
N. Use the nitrogen flow controller in the DCS to open the nitrogen
flow control valve and send nitrogen to the front end of the
TGCU.
O. Allow the nitrogen to continue flowing long enough to reduce

the oxygen concentration in the equipment and piping to less
than 1%. Use a portable oxygen analyzer to determine the
oxygen concentration.
11.7.8.2 Purging the TGCU Start-Up Blower

A. Visually confirm that the TGCU Start-Up Blower suction block
valve and the discharge block valve are closed, the bypass
valve is open, the nitrogen purge to the blower seal is in
service, and the local "stop" control at the bloweris set to the
"RUN" position.
B. Start the TGCU Start-Up Blower using the start/stop toggle

switch in the DCS.
(1) The nitrogen purge valveis closed.
(2) The TGCU Start-Up Blower Suction Valve is opened.
(3) The TGCU Start-Up Blower Discharge Valve is opened.
(4) After the limit switches prove these valves open, the
TGCU Start-Up Blower is started.
(5) Once the Startup Blower is started, the TGCU Start-Up

Blower Bypass Valve is closed.
C. As this valve is closed, the blower will start to load. As it does

so, the blower will begin to "pull" nitrogen through the TGCU

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Reactor Feed Heater and TGCU Reactor Feed Mixer and all of
the associated piping.
D. Allow the blower to continue running long enough to reduce the

oxygen concentration in the piping to less than 1%. Use a
portable oxygen analyzer to determine the oxygen
concentration.
E. When the oxygen concentration is below 1%, shut down the

TGCU Start-Up Blower using the start/stop toggle switch in the
DCS.
(1) Open the TGCU Start-Up Blower Bypass Valve.
(2) Prove the bypass valve open using the limit switches.
(3) Stop the TGCU Start-Up Blower
(4) Once the blower is stopped, the nitrogen purge valve is

opened, and the suction and discharge valves are closed.
11.7.8.3 Purging the Columns

All that remains is to open the vent valves on the low pressure
columns and allow the inert gas to displace the air in the columns.
A. Open all of the vent valves on the PI and PDT taps on the
TGCU Quench Column and the TGCU Contactor, and the vent
valves at the tops of the columns.
B. Increase the output from the Quench Column inlet hand control
in the DCS to 100% to open the TGCU Quench Column Inlet
Valve and close the TGCU Quench Column Bypass Valve.
C. Continue to vent inert gas until no measurable oxygen escapes

from the vents, then close all of the vent valves.
D. Decrease the output from the Quench Column inlet hand

control in the DCS to 0% to open the TGCU Quench Column
Bypass Valve and close the TGCU Quench Column Inlet Valve.
E. Set the output from the nitrogen flow controller to 0% to close

the nitrogen flow control valve.
F. Toggle the Nitrogen On/Off switch in the DCS to "OFF".

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(1) Closes the nitrogen block valves.
(2) Opens the nitrogen vent valve.
NOTE: If the initial solvent fill was not loaded into the solvent
system earlier to avoid exposing the MDEA to oxygen, this
can be accomplished now. Follow the procedure given in
the previous section to fill the solvent system with its initial
solvent charge.

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The procedure used to start up the TGCU depends on whether the catalyst in
the TGCU Reactor has been pre-sulfided. This first section describes the
procedure for the initial startup of the plant with a fresh catalyst charge (oxidized
state), or for startups after the catalyst charge has been replaced. Subsequent
startups will require a different procedure and are discussed later (Section
11.8.6 of these guidelines).
11.8.1 Initial Startup of the TGCU

During the initial startup, the catalyst in the TGCU Reactor is pre-sulfided
by contacting it with H2S in the presence of hydrogen. Subsequent
startups will probably not require this step. Once this has been
accomplished, the system can be placed into operation.

A. Confirm that the steam pressure controller in the DCS is in
"manual" with its output set to 0%, and that control valve in the
HP Steam supply line to the TGCU Reactor Feed Heater is
closed.
B. Place the reactor feed temperature controller in "automatic".
C. Confirm that reducing gas flow controller in the DCS is in

"manual" with its output set to 0%, and that the control valve in
the reducing gas supply line to the TGCU Reactor Feed Mixer
is closed.
D. Place the hydrogen controller in "automatic".
E. Verify that the automated shutdown valves, the upstream block

valves, and the downstream steam-jacketed block valve in the
reducing gas line to the TGCU Reactor Feed Mixer are all
closed.
F. Confirm that the pre-sulfiding gas flow controller in the DCS is

in "manual" with its output set to 0%, and that the control valve
in the pre-sulfiding gas line to the TGCU Reactor Feed Mixer is
closed.
G. Verify that the automated shutdown valve and the upstream

block valve in the pre-sulfiding gas line to the TGCU Reactor
Feed Mixer are both closed.

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H. Confirm that the nitrogen flow controller in the DCS is in

"manual" with its output set to 0% output, and that the control
valve in the nitrogen supply line is closed.
I. Verify that the automated shutdown valves in the nitrogen

supply line are both closed, then open the upstream block
valves and the downstream steam-jacketed block valve.
J. Confirm that the Quench Column hand control in the DCS is set
to 0% output, so that the TGCU Quench Column inlet valve will
remain fully closed and the TGCU Quench Column bypass
valve will open later when the TGCU startup/run selector switch
is switched to "STARTUP".
K. Confirm that the TGCU Waste Heat Reclaimer is filled with

water up to its normal liquid level.
L. Visually confirm that the SRU 1 Tailgas Valve to the TGCU is

closed.
M. Visually confirm that the SRU 2 Tailgas Valve to the TGCU is

closed.
N. Visually confirm that the manual TGCU Outlet Valve is fully

open.
O. Confirm that the Leak Test switch in the DCS is toggled to

"OFF".
P. Confirm that the TGCU Start-Up Blower Bypass Valve is fully

open.
Q. Verify that the local stop control for the TGCU Start-Up Blower
is set to the run position.

A. Toggle the Startup/Run selector switch in the DCS to

"STARTUP".
(2) Disables the Tailgas Valve transfer switchs.

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B. Reset the TGCU ESD by toggling the switch in the DCS to

"RESET".
C. Set the output of the TGCU Warmup/Bypass Valve hand control

in the DCS to 0% to close the TGCU Warmup/Bypass Valve
and visually confirm that the valve is closed.
D. Toggle the Nitrogen On/Off switch in the DCS to "ON".
E. Increase the output of the flow controller to 100% in the DCS to

open the control valve and send nitrogen to the front-end of the
TGCU.
F. Allow the nitrogen to purge the front-end of the TGCU for 15

minutes before proceeding to the next step.
11.8.1.3 Establishing Re-circulation Flow

Prior to pre-sulfiding the catalyst in the TGCU Reactor, it is
necessary to heat the reactor and catalyst up to 150-175°C. To do
this, nitrogen is re-circulated through the TGCU Reactor Feed Heater
with the TGCU Start-Up Blower. This re-circulating gas is heated
using HP steam in the TGCU Reactor Feed Heater, then flows
through the TGCU Reactor Feed Mixer, the TGCU Reactor, and the
TGCU Waste Heat Reclaimer bringing the reactor, catalyst, and
process heat exchange surfaces up to operating temperature.
A. Visually confirm that the TGCU Start-Up Blower suction block

valve and the discharge block valve are closed, the bypass
valve is open, the nitrogen purge to the blower seal is in
service, and the local "stop" control at the blower is set to the
run position.
B. Start the TGCU Start-Up Blower using the start/stop toggle

switch in the DCS.

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As this valve is closed, the blower will start to load. As it does

so, the blower will begin to "pull" nitrogen through the front-end
TGCU equipment and all of the associated piping.
C. Once the blower is running, open the TGCU Warmup/Bypass

Valve by increasing the output from the hand control to 100%.
As the TGCU Warmup/Bypass Valve opens, the TGCU

Start-Up Blower will begin re-circulating gas from the outlet of
the TGCU Waste Heat Reclaimer back to the TGCU Reactor
Feed Heater (via the TGCU Contactor overhead line).
D. Once re-circulation has been established, place the nitrogen

flow controller in "automatic" and reduce its setpoint to about
5-10% of maximum flow.
E. Slowly begin to increase the setpoint of the steam pressure

controller in the DCS to establish steam flow to the TGCU
Reactor Feed Heater and increase the temperature of the
re-circulating gas stream to 150-175°C.
F. Open the vent valve on the TGCU Waste Heat Reclaimer to

vent air from the steam section.
G. Confirm that the BFW level controller and control valve to the
TGCU Waste Heat Reclaimer are in service and functioning
properly.
H. Place the reactor feed temperature cascade control in service

as follows:
(1) Confirm that the remote setpoint that the reactor feed
temperature controller is supplying to the pressure
controller matches the current setting on the pressure
controller.

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(2) Confirm that the reactor feed temperature controller is in

(3) Switch the steam pressure controller to "cascade" so that

the temperature controller can now adjust the setpoint on
the pressure controller.
(4) If necessary, slowly adjust the setpoint of the reactor feed

temperature controller to 175°C.
(5) Verify that the steam pressure controller is adjusting the

HP steam pressure as needed to control the desired
temperature setting on the reactor feed temperature
controller.
I. As the equipment and piping heat up, inspect all of the

J. As the steam pressure builds in the TGCU Waste Heat

Reclaimer, close the vent valve on the steam space. The steam
pressure inside the boiler will now be "floating" on the LP steam
header.

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11.8.2 Pre-Sulfiding the TGCU Catalyst

Before introducing sulfur plant tailgas into the TGCU, the catalyst in the
TGCU Reactor must be "pre-sulfided" to convert the metals (cobalt and
molybdenum) from their inactive oxide state to their active sulfide state.
Once the catalyst has been pre-sulfided, it will remain in its active state
and will not require pre-sulfiding on subsequent startups. Only when the
catalyst is replaced will this pre-sulfiding procedure have to be repeated.
The catalyst is pre-sulfided by contacting it with H2S in the presence of

hydrogen. The amount of H2S must be controlled at a low concentration
to limit the temperature rise as the catalyst reacts with the sulfur, so that
excessively high temperatures are not created that could damage the
catalyst or the equipment. The catalyst will end up containing about
6 wt % sulfur at the conclusion of this procedure.
Before beginning, the following conditions should exist in the TGCU:
1. The outlet temperature from the TGCU Reactor Feed Heater is

on automatic control, maintaining about 175°C.
2. The nitrogen flow controller is in "automatic" with its set point set
at 5-10% of maximum flow to add a small amount of fresh
nitrogen to the system.
3. The TGCU Start-Up Blower is in service, re-circulating nitrogen
to the TGCU Reactor Feed Heater.
4. The Amine Regeneration Unit is operating and producing acid
gas. The H2S in this acid gas will be used to pre-sulfide the
TGCU catalyst.
Also, ensure that there is an adequate supply on hand (one or two boxes)
of gas detector tubes for measuring the H2S concentration into and out of
the TGCU Reactor. Sections 9.10.8 and 11.10.7 of these guidelines
describe how Dräger tubes can be used to measure the H2S
concentration of a gas stream. The H2S concentration will probably be in
the range of 1-2%, so Dräger Catalog No. CH 281 01 gas detector tubes
are appropriate.

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11.8.2.1 Establishing Reducing Gas Flow

Before introducing H2S into the TGCU Reactor, reducing gas must
be added to the re-circulating gas stream.
A. Confirm that the reducing gas controller in the DCS is set to 0%

output and that the control valve in the reducing gas supply line
is closed.
B. Prior to placing the H2/H2S analyzer in service, be sure that its

sample line does not contain any water, etc.:
(1) Close the sample valve on the TGCU Waste Heat

Reclaimer outlet channel.
(2) Disconnect the sample line from the sample valve and
from the 2-way analyzer sample switching valve. Drain any
water from the line and check that it is not plugged, then
reinstall the sample line.
(3) Repeat Step (2) for the other sample line (connected to
the sample valve on the TGCU Contactor overhead line).
(4) Switch the sample selector valve in the analyzer enclosure

so that the H2/H2S analyzer takes its sample from the
TGCU Contactor overhead line, and use the zero and
span gas to confirm the calibration of the analyzer. Make
any necessary adjustments to the analyzer per the
manufacturer's instructions.
(5) Switch the sample selector valve in the analyzer enclosure

so that the H2/H2S analyzer takes its sample from the
outlet of the TGCU Waste Heat Reclaimer, then open the
sample valve. The hydrogen analyzer will now be
sampling the process gas, as indicated by the reading on
the hydrogen controller in the DCS, while the other sample
line on the TGCU Contactor overhead line is now being
back-purged with nitrogen.
C. Open the upstream manual block valves and the

steam-jacketed block valve in the reducing gas supply line to
the TGCU Reactor Feed Mixer.

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D. To begin introducing reducing gas into the circulating gas

stream, toggle the Reducing Gas On/Off switch in the DCS to
"ON".
(1) Opens the reducing gas block valves.
(2) Closes the reducing gas vent valve.
E. Switch the reducing gas controller to "automatic" and slowly

begin to increase its setpoint to open the control valve and
begin introducing reducing gas into the re-circulating stream.
As the reducing gas flow rate increases, the hydrogen

concentration displayed on the hydrogen controller will
increase.
F. The reducing gas concentration should be 0.5-5% while

pre-sulfiding. If necessary, adjust the setpoint on the reducing
gas controller to control the reading in this range.
NOTE: It is important to control the hydrogen concentration

within this range while pre-sulfiding the catalyst. A
hydrogen reading lower than this could mean that a
reducing atmosphere is not being maintained inside
the TGCU Reactor to insure that the H2S properly
sulfides the catalyst. Conversely, too much hydrogen
can damage the catalyst by reacting with the cobalt
and molybdenum to form inactive metal hydrides.

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CAUTION
DO NOT ALLOW HYDROGEN TO CONTACT THE TGCU

CATALYST AT TEMPERATURES ABOVE 200°C IN THE
ABSENCE OF H2S. IF THERE IS NO H2S PRESENT, THE
HYDROGEN WILL REACT IRREVERSIBLY WITH THE
CATALYST TO FORM INACTIVE METAL HYDRIDES. IF ANY
DELAYS ARE ENCOUNTERED IN INTRODUCING H2S, STOP
THE FLOW OF REDUCING GAS UNTIL READY TO RESUME.
G. As described in previous sections of these guidelines, the

hydrogen controller can adjust the flow of hydrogen to the
TGCU Reactor Feed Mixer to control the hydrogen
concentration, via the limit relay. Place the hydrogen
concentration cascade control in service as follows:
(1) Confirm that the remote setpoint that the hydrogen

controller is supplying to the reducing gas flow controller in
the DCS matches the current setting on the flow controller.
(2) Confirm that the hydrogen controller is in "automatic" and

its setpoint is tracking its current reading.
(3) Switch the reducing gas controller to "cascade" so that the

concentration controller can now adjust the setpoint of the
flow controller.
(4) If necessary, slowly adjust the setpoint of the hydrogen

controller to 2%.
H. Periodically check that the hydrogen controller and the reducing

gas controller maintain the hydrogen concentration in the
proper range (0.5-5%) throughout the pre-sulfiding operation.

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11.8.2.2 Pre-Sulfiding the Catalyst

The sulfur for pre-sulfiding the TGCU catalyst comes from H2S in the
amine acid gas produced by the Amine Regeneration Unit. The
amount of acid gas entering the TGCU Reactor Feed Mixer is to be
adjusted to give an H2S concentration of about 1-2% going into the
TGCU Reactor. Gas detector tubes can be used to measure the H2S
concentration in the inlet and outlet from the TGCU Reactor. When
the outlet H2S concentration is essentially the same as the inlet
concentration, then the catalyst has absorbed all the sulfur that it can
and pre-sulfiding is complete at that temperature level.
A. Confirm that the pre-sulfiding gas flow controller in the DCS is

set to 0% output, and that the control valve in the pre-sulfiding
gas supply line is closed.
B. Verify that the automated shutdown valve, and the manual

block valves in the pre-sulfiding gas supply line are closed.
Rotate the spectacle blind to the open position, then briefly
open the drain valve to verify that there are no liquids in the line
between the control valve and the shutdown valve.
C. Open the manual block valves in the pre-sulfiding gas line.
D. Toggle the Pre-sulfiding Gas On/Off switch in the DCS to "ON".
The PLC should open the automated pre-sulfiding gas block

valve.
E. Place the pre-sulfiding gas flow controller in "automatic" and

increase its setpoint to slowly open the control valve and allow
a small flow of acid gas into the TGCU Reactor Feed Mixer.
Adjust the setpoint as necessary to give an H2S concentration
of 1-2% (measured with the gas detector tubes) in the inlet to
the TGCU Reactor.
F. Using the reactor feed temperature controller in the DCS, slowly

raise the TGCU Reactor inlet temperature stepwise to 200°C
while maintaining the H2S concentration in the inlet at 1-2% and
the hydrogen concentration indicated on the hydrogen controller
at 0.5-5%.
Look for signs that the H2S has begun to react with the catalyst
(i.e. the temperatures in the reactor begin to rise). If no

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temperature rise is seen in the TGCU Reactor, proceed to

Step I.
CAUTION
IF EXCESSIVE CATALYST BED TEMPERATURES OCCUR AT

ANY TIME ON THE REACTOR BED TEMPERATURE
INDICATORS IN THE DCS, REDUCE THE AMOUNT OF H2S IN
THE REACTOR INLET. THE TEMPERATURE RISE IN THE
REACTOR IS DUE TO THE HEAT OF REACTION FROM H2S
REACTING WITH THE CATALYST. REDUCING THE H2S
CONCENTRATION WILL REDUCE THE REACTION RATE AND
REDUCE THE TEMPERATURE RISE ACCORDINGLY.
DO NOT REDUCE THE H2S CONCENTRATION TO ZERO,

HOWEVER. THIS WOULD ALLOW HYDROGEN TO REACT
WITH THE CATALYST AND DAMAGE IT AS DISCUSSED
PREVIOUSLY.
G. Once the TGCU Reactor inlet temperature reaches 200°C,

maintain this temperature while sampling the H2S concentration
in the inlet and outlet of the reactor.
H. When the outlet H2S concentration is approximately equal to the

inlet concentration, pre-sulfiding is complete at this temperature
level.
I. Increase the inlet temperature stepwise to 230°C with the

reactor feed temperature controller.
J. Once the TGCU Reactor inlet temperature reaches 230°C,

maintain this temperature while sampling the H2S concentration
in the inlet and outlet of the reactor. When the outlet H2S
concentration is approximately equal to the inlet concentration,
pre-sulfiding is complete at this temperature level.
K. Increase the inlet temperature stepwise to 260°C with the

reactor feed temperature controller.

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After the entire bed reaches 260°C, hold it at this temperature

for 4 hours. Monitor the catalyst bed temperatures and the
TGCU Reactor outlet temperature through the temperature
indicators in the DCS carefully as the reaction front moves
through the bed. Do not allow any of these temperatures to
exceed 340°C, by reducing the inlet temperature and/or the
inlet H2S concentration as necessary.
L. At the conclusion of the 4 hour heat soak at 260°C, the H2S

concentration should be the same in the outlet gas as it is in the
inlet gas. If not, continue to hold the inlet at 260°C until the
concentrations are equal.
M. The catalyst is now in its active state. Discontinue the flow of

pre-sulfiding gas by reducing the setpoint of the pre-sulfiding
gas flow controller to 0%. Toggle the Pre-sulfiding Gas On/Off
switch in the DCS to "OFF" to close the block valve and visually
confirm that the valve is closed.
N. Close the manual block valves in the pre-sulfiding gas supply

line.
THE PRE-SULFIDING LINE WILL NOT BE USED AGAIN

UNTIL THE CATALYST IN THE TGCU REACTOR IS
REPLACED AND A FRESH CHARGE CATALYST MUST
BE PRE-SULFIDED. TO MINIMIZE THE CHANCE OF
INADVERTENTLY SENDING AMINE ACID GAS TO THE
TGCU REACTOR FEED HEATER, IT IS RECOMMENDED
THAT THE SPECTACLE BLIND BE ROTATED BACK TO
THE CLOSED POSITION AT THIS TIME.
O. Slowly lower the TGCU Reactor inlet temperature to its normal

value by adjusting the setpoint of the reactor feed temperature
controller.
P. Slowly adjust the setpoint of the hydrogen controller to its

normal values (3%). Verify that the reducing gas flow controller
is adjusting the rate accordingly.
The TGCU can continue operating in this manner indefinitely

until ready to bring SRU tailgas into the unit. During this time,
observe the temperatures in the TGCU Reactor and the

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hydrogen concentration on the hydrogen controller to be sure

that these control loops are operating properly. Also, continue
to observe the operation of the TGCU Waste Heat Reclaimer to
ensure that no problems develop in this boiler, and monitor the
operation of the TGCU Start-Up Blower.

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11.8.3 Routing SRU Tailgas to the TGCU

The TGCU is now ready to accept tailgas from the SRUs. At first, the
tailgas will be routed through just the front-end of the TGCU (TGCU
Reactor Feed Heater, TGCU Reactor Feed Mixer, TGCU Reactor, and
TGCU Waste Heat Reclaimer). Then, once this part of the process has
“lined out”, the process gas will be switched into the TGCU Quench
Column and the TGCU Contactor.
1. The Reactor Feed Heater is operating smoothly and the inlet

temperature to the TGCU Reactor is being controlled at
230-240°C.
2. The TGCU Reactor is up to normal operating temperature and its

catalyst has been pre-sulfided.

4. The H2/H2S analyzer has been calibrated and is sampling the

process gas leaving the TGCU Waste Heat Reclaimer.
5. The hydrogen controller is controlling the hydrogen at or above

the normal setpoint
6. One or both SRUs are operating smoothly on amine acid gas, or

amine acid gas and SWS gas, and the air demand indicated on
the air control is +2.0% or lower. (If the air demand is higher
than this, the tailgas from the SRU contains excessive amounts
of SO2 and could cause overheating of the TGCU Reactor.)
If any of these conditions are not true, do not attempt to bring SRU tailgas
into the TGCU. In particular, do not attempt switching tailgas into the
TGCU when the SRU(s) is(are) experiencing an upset. The result will
be multiple upset units to deal with. Instead, focus your attention on
stabilizing the operation of the SRU(s) first (usually by correcting a
problem in the upstream Amine Regeneration and/or Sour Water Stripper
units), and then use the procedure that follows to establish tailgas flow
into the TGCU.

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the TGCU, the tailgas from both SRUs is sent to the TTO while the
TGCU uses the TGCU Startup Blower to re-circulate gas to the
TGCU Reactor Feed Heater via the TGCU Warmup/Bypass Valve.
Once the TGCU is warmed up and ready to accept tailgas, the
Train 1 and Train 2 SRUs can be routed to the TGCU as follows
(using the Train 1 SRU for this procedure).
A. Confirm that the hydrogen controller is in "automatic" and controlling

the hydrogen concentration at or above its normal setpoint, (3%).
B. Toggle the SRU 1 "fast" transfer switch in the DCS, to "TRANSFER TO

TGCU".
(1) The SRU 1 Tailgas Valve to the TGCU is opened.
(2) After the limit switches prove this valve open, the SRU 1
Tailgas Valve to the TTO is closed.
Visually confirm that these valves have moved to the proper

positions.
At this point, the tailgas from SRU 1 can flow to the TTO via either of
two routes:
(1) Through the SRU 1 Tailgas Valve to the TGCU and then
through the TGCU Warmup/Bypass Valve.
(2) Through the SRU 1 Tailgas Valve to the TGCU and then
through the TGCU Reactor Feed Heater, the TGCU Reactor,
the TGCU Waste Heat Reclaimer, and the TGCU Start-Up
Blower.
C. If the second SRU (Train 2) is also ready to send its tailgas to the
TGCU, toggle the SRU 2 "fast" transfer switch in the DCS to repeat
these actions for the other SRU.
For this scenario, the opening and closing of Tailgas Valves to the
TGCU and the Tailgas Valves to the TTO in Steps B and C can
occur rapidly with no impact on either the SRU or the TGCU. This is
because the TGCU Warmup/Bypass Valve will still be open at this

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time, so there will be very little differential pressure across the

Tailgas Valves to the TGCU and there will not be an abrupt change
in pressure when the Tailgas Valves to the TGCU are opened or
when the Tailgas Valves to the TTO are closed.
Note: The “fast” transfer switches can also be used to take the
Train 1 SRU and/or Train 2 SRU tailgas out of the TGCU.
Every other toggle of these selector switches will take the
opposite action to open the tailgas valve to the TTO and
then close the tailgas valve to the TGCU.
In the next step, the TGCU Warmup/Bypass Valve is closed to force

the process gas to take the second path, so that the TGCU Start-Up
Blower can be shut down.
D. Slowly reduce the output from the hand control to 0% to close the
Now all of the SRU tailgas must flow through the TGCU Reactor
Feed Heater, etc. as this is the only open flowpath to the TTO.
E. With the SRU tailgas flowing through the TGCU Reactor Feed
Heater, the re-circulation from the TGCU Start-Up Blower is no
longer needed.
Shut down the TGCU Start-Up Blower using the start/stop selector
switch in the DCS.
(1) The TGCU Start-Up Blower bypass valve is opened and proved
open.
(2) The TGCU Start-Up Blower is stopped.
(4) The TGCU Start-Up Blower Suction Valve and the TGCU
Start-Up Blower Discharge Valve are closed.
Confirm that these valves have moved to the proper positions and
that the blower has stopped.
F. Place the nitrogen flow controller in "manual" and set its output to 0%
to close the control valve and stop the flow of nitrogen into the
TGCU.

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G. Toggle the Nitrogen On/Off switch in the DCS to "OFF".
(1) Closes nitrogen blocks.
(2) Opens nitrogen vent valve.
H. Close the downstream steam-jacketed block valve in the nitrogen

supply line where it joins the tailgas line to the TGCU Reactor Feed
Mixer.
I. Allow the TGCU to operate in this fashion until all operating

conditions are stable. In particular, observe the operation of the
reactor feed temperature controller and the hydrogen controller to
ensure that the TGCU Reactor inlet temperature remains under
control and there is adequate hydrogen (2% or higher) in the TGCU
Reactor outlet.
At this point, all of the tailgas from both SRUs is flowing into the
TGCU Reactor Feed Heater, mixing with the external reducing gas in
the TGCU Reactor Feed Mixer, entering the TGCU Reactor to
convert all of the sulfur compounds to H2S, being cooled in the
TGCU Waste Heat Reclaimer, and flowing through the TGCU
Quench Column Bypass Valve and the TGCU Start-Up Blower
Bypass Valve to the Thermal Oxidizer via the TGCU Contactor
overhead line and the TGCU Outlet Valve.
Once the operation of the TGCU front-end has stabilized, the

process gas can be introduced into the TGCU columns as described
in Section 11.8.5 of these guidelines. If the columns are not ready
the front-end of the TGCU can operate indefinitely in this manner
until ready to switch the process gas to the columns.

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second SRU needs to be introduced into the TGCU. Assume that
the Train 2 SRU is currently feeding the TGCU. Due to the
back-pressure from the TGCU, the pressure downstream of SRU 1
Tailgas Valve to the TGCU will be about 0.07 kg/cm2(g), while the
pressure upstream of this valve will be close to kg/cm2(g) (since the
SRU 1 Tailgas Valve to the TTO will be open to the TTO at this time).
If the Train 1 tailgas was quickly switched into the TGCU in the same
manner as described above for the first scenario, a major upset
would result in both SRUs and in the TGCU:
As soon as the SRU 1 Tailgas Valve to the TGCU started to open,

tailgas from the Train 2 SRU would begin to back-flow through the
SRU 1 Tailgas Valve to the TGCU and flow to the TTO, since the
pressure downstream of the SRU 1 Tailgas Valve to the TGCU at
that moment would be higher than the pressure upstream of the SRU
1 Tailgas Valve to the TGCU. Since the SRU 1 Tailgas Valve to the
TGCU is a more direct path to the TTO for the tailgas from the
Train 2 SRU, most of the Train 2 tailgas would flow through the SRU
1 Tailgas Valve to the TGCU as it opens rather than flow through the
TGCU. The outlet temperature from the TGCU Reactor Feed Heater
in the TGCU would begin to rise (due to the drop in tailgas flow)
while the controls began reducing the steam flow rate to the heater.
Once the SRU 1 Tailgas Valve to the TGCU was fully open, all of the
Train 1 tailgas and most of the Train 2 tailgas would be flowing
directly to the TTO. The TGCU controls would continue reducing the
steam flow rate to the TGCU Reactor Feed Heater to try to keep its
outlet temperature under control.
Then, once the SRU 1 Tailgas Valve to the TGCU was fully open, the
SRU 1 Tailgas Valve to the TTO would begin to close. This would
begin forcing all of the Train 1 tailgas and Train 2 tailgas into the
TGCU Reactor Feed Heater. The outlet temperature from it would
begin to drop while the controls began increasing the steam flow rate
to the heater. Once the SRU 1 Tailgas Valve to the TTO was fully
closed, all of the Train 1 and Train 2 tailgas would be flowing to the
TGCU Reactor Feed Heater, causing an abrupt increase in its
operating pressure from about 0.07 kg/cm2(g) to about 0.3 kg/cm2(g).

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This would cause the air and acid gas flow rates to the SRUs to
suddenly drop, possibly causing the SRUs to flame-out. If so, the
SRUs and the TGCU would shut down and the operators would have
to start over again.
If the SRUs and TGCU did manage to stay on-line, the TGCU
Reactor Feed Heater would only be supplying about half as much
heating as needed until the controls recover and bring the steam flow
rate up to the new requirements. Until the controls recover, the inlet
temperature to the TGCU Reactor would be low, possibly causing
incomplete conversion of SO2 in the reactor and allowing SO2 to
reach the quench water system and foul it. The reducing gas flow
rate might also require time to adjust to the higher tailgas flow rate,
further compounding the problems with conversion in the reactor.
So, the best that could be expected if the second SRU is routed to
the TGCU in the same manner as under the first scenario is an upset
in both SRUs, the TGCU Reactor Feed Heater, the TGCU Reactor,
and the quench water system. Depending on how quickly the SRUs
respond to sudden changes in operating pressure, the SRU burners
might flame-out. In this worst case, a complete restart of the SRUs
and the TGCU would then be required.
Instead of introducing the tailgas from the second SRU into the
TGCU in an abrupt manner, what is needed is a slow, controlled
redirection of the tailgas from the TTO to the TGCU. This can be
accomplished by the DCS operator using the hand controls for the
SRU 1 Tailgas Valve to the TTO and the SRU 1 Tailgas Valve to the
TGCU.
Under this scenario, the TGCU is already processing tailgas from the
Train 2 SRU. This means that the TGCU warmup/bypass valve is
already closed. This signals the PLC to disable the "fast" transfer
switches in the DCS, so that the rapid switching sequence
(scenario 1) cannot be activated inadvertently.
A. Initiate the over-ride for the Train 1 tailgas valves by toggling the
Train 1 "slow" transfer switch in the DCS, to "OVER-RIDE". The PLC
temporarily removes the limit switches on the SRU 1 Tailgas Valve to
the TTO and the SRU 1 Tailgas Valve to the TGCU from the
"complete flowpath interlock" for the Train 1 SRU alarms and
deactivates the "valve malfunction" alarms on these two valves, then

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directs the DCS to release control of the hand controls for these
valves to the operator.
B. Use the hand control to slowly begin throttling the tailgas flow with
the SRU 1 Tailgas Valve to the TTO, so that the pressure at the
Train 2 SRU. Monitor the flows and pressure in the Train 1 SRU and
adjust the hand control accordingly.
C. Once the SRU 1 Tailgas Valve to the TTO is throttling, use the other
hand control to slowly open the SRU 1 Tailgas Valve to the TGCU.
Some of the Train 1 tailgas may begin to flow into the TGCU at this
time, but most of it will still flow through the SRU 1 Tailgas Valve
directly to the TTO. Monitor the flows and pressures in the Train 1
SRU and the TGCU, and adjust the rate at which he opens the SRU
1 Tailgas Valve to the TGCU accordingly.
D. Once the SRU 1 Tailgas Valve to the TGCU is fully open, use the
hand control to slowly close the SRU 1 Tailgas Valve to the TTO the
rest of the way and send all of the Train 1 tailgas to the TGCU.
Monitor the flow rates and temperatures in the TGCU, and adjust the
rate at which he closes the SRU 1 Tailgas Valve to the TTO as
needed to allow time for the controls in the TGCU to respond.
E. Once the SRU 1 Tailgas Valve to the TTO is fully closed, the Train 1
SRU is flowing to the TGCU along with the Train 2 SRU, and the
TGCU is fully on-line.
Once both valves have moved into position, the PLC will
automatically restore the limit switches on the SRU 1 Tailgas Valve
to the TTO and the SRU 1 Tailgas Valve to the TGCU to the
"complete flowpath interlock" in the SRU alarms, restore the
malfunction alarms for these valves to their normal configurations,
and reset the "slow" transfer switch in the DCS, back to "NORMAL"
and remove the over-ride.
One further point to note is that the "slow" transfer over-ride switches
can also be used to "back" tailgas out of the TGCU. If the operator
wants to shut down the TGCU in a controlled fashion, this can be
accomplished by using the TGCU Startup Blower to circulate gas
through the TGCU Reactor Feed Heater while slowly "backing" the
SRU tailgas out of the TGCU. The steps to perform this are
essentially the same as those listed above (but in reverse order).

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11.8.4 Quench Water and Amine Systems

Before switching process gas into the TGCU Quench Column and the
TGCU Contactor, the quench water and amine systems should be
operating and ready to accept gas. The operating conditions described
below should have been established previously at the conclusion of the
washing operations, but are repeated below to serve as a "checklist"
before introducing process gas to the columns as described in
Section 11.8.5 that follows.
A. The quench water system should be charged with its initial fill of
water, so that the level in the TGCU Quench Column is at the normal
setpoint for the Quench Column level controller.
B. Quench water should be circulating to the TGCU Quench Column at

the normal setpoint for the quench water flow controller.
C. Cooling water should be flowing to the TGCU Quench Water Trim

Cooler and the TGCU Lean Amine Trim Cooler.
D. The fans should be operating on the TGCU Quench Water Cooler,

with the temperature controller on the quench water controlling at its
normal setpoint or lower.
E. The TGCU Quench Water Filter should be in service with the filtered
quench water flow controller controlling at its normal setpoint.
F. The quench water pH analyzer should be in service (with one pH

Meter Sample Filter in service, and the other blocked-in for use as a
spare) with the quench water pH analyzer in the DCS showing a pH
of 11 or higher. Add caustic to the quench water if necessary to
raise the pH to this level.
G. The amine system should be charged with its initial fill of amine, with
the level control in the DCS controlling the level in the TGCU
Contactor at its normal setpoint.
H. The MDEA concentration in the amine should be close to its design

value (45 wt %). Add more fresh MDEA if necessary to bring the
amine to this strength.
I. Amine should be circulating through the TGCU Stripper, the TGCU

Lean/Rich Exchanger, the TGCU Lean Amine Cooler, and the TGCU
Lean Amine Trim Cooler to the distributor tray at the top of the TGCU
Contactor at the normal setpoint for the flow controller.

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J. The fans should be operating on the TGCU Lean Amine Cooler, with
the temperature controller on the lean amine controlling at its normal
setpoint or lower.
K. The TGCU Rich Amine Filter should be in service.
L. The TGCU lean amine filters should be in service.
M. Steam should be flowing to the TGCU Stripper Reboiler at the

normal setpoint for the flow control.
N. The overhead temperature from the TGCU Stripper should be above

the low temperature alarm point for the temperature indicator.
O. The fans should be operating on the TGCU Stripper Reflux

Condenser with the temperature controller on the outlet from the
TGCU Stripper Reflux Condenser controlling at its normal setpoint or
lower.
P. The TGCU Stripper pressure controller to the SRU, should be in

"manual" with its output set to 0% so that the pressure control valve
is fully closed.
Q. The TGCU Stripper pressure controller to the flare should be in

"automatic" with its setpoint set at its normal value.
R. The level in the TGCU Stripper Reflux Accumulator should be at the

normal setpoint for the level control.
S. A TGCU Stripper Reflux Pump should be operating with the

minimum flow lined up to allow reflux to spill back into the TGCU
Stripper Reflux Accumulator whenever the level valve back to the
TGCU Stripper is closed.
With these operating conditions established, the back-end of the TGCU is

ready to accept the process gas from the front-end of the unit and begin
treating it.

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11.8.5 Process Gas Flow to the TGCU Columns

The last step in the startup of the TGCU is to bring the process gas from
the front-end of the TGCU into the TGCU Quench Column and the TGCU
Contactor. The TGCU will then remove the H2S from the gas before
sending it to the TTO. The H2S removed will be stripped from the amine
and sent to the flare initially. Once operation of the amine system
stabilizes, this acid gas will be recycled back to the SRUs.
Before introducing process gas into the TGCU columns, confirm that the
following conditions are all true:
1. The front-end of the TGCU is processing SRU tailgas and is

operating smoothly on automatic control.
2. The hydrogen controller is controlling the hydrogen concentration

in the outlet of the TGCU Reactor at or above its setpoint.
3. The proper operating conditions have been established for the

quench water and amine systems (see Section 11.8.4).
If any of these conditions are not true, do not proceed until correcting the
problem(s). Once all of these conditions are satisfied, complete the
startup of the TGCU as follows:
A. Confirm that the Quench Column hand control in the DCS is set to
0% output with the TGCU Quench Column Inlet Valve closed and the
TGCU Quench Column Bypass Valve open.
B. Use the drain valve downstream of the TGCU Waste Heat Reclaimer
to drain any liquids that may have accumulated in the TGCU Quench
Column inlet line.
C. Slowly increase the output from the Quench Column hand control to
100%, which will open the Quench Column inlet valve and admit
process gas to the TGCU Quench Column, then close the TGCU
Quench Column Bypass Valve to prevent gas from bypassing to the
Thermal Oxidizer.
Note that the pressure drop through the TGCU Quench Column and
the TGCU Contactor will raise the operating pressures of the SRU
and the TGCU and can affect the process gas flow rates, so allow
time for the flow and flow-ratio control loops to respond.

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D. When the output of the Quench Column hand control reaches 100%,
the Quench Column inlet valve should be fully open and the TGCU
Quench Column Bypass Valve fully closed to send all of the process
gas into the TGCU Quench Column. Visually confirm that these
valves are properly positioned.
E. As process gas flows into the columns, watch the operation of the
quench water system carefully. It is typical to see a slow decrease in
the quench water pH as H2S in the process gas dissolves into the
water, but a rapid decline in pH could indicate SO2 in the process
gas from incomplete reaction in the TGCU Reactor. Be ready to add
caustic if needed to keep the pH above 7.
NOTE: The quench water will probably turn black or green on this
first introduction of H2S into the system (due to small
particles of iron sulfide in the water). The TGCU Quench
Water Filter should clear up the water in a few hours.
F. If the quench water pH drops drastically or there is a sudden drop in

the hydrogen concentration on the hydrogen controller, the process
gas can be "backed" out of the columns by reducing the output of the
Quench Column hand control back to 0%. This will open the TGCU
Quench Column Bypass Valve to divert the gas to the TTO and close
the Quench Column inlet valve to stop gas from flowing into the
TGCU Quench Column. Once the operating problem is corrected
and the hydrogen controller is once again showing adequate
hydrogen, use the Quench Column hand control to re-initiate gas
flow to the columns.
G. Once the columns are operating stably, switch the H2/H2S analyzer
to take its sample from the TGCU Contactor overhead line by
checking that the sample line is clear of liquid, confirming that the
sample valve on the overhead line is open, and switching the sample
selector valve in the analyzer enclosure to sample from the TGCU
Contactor overhead line. (Note that the sample line on the outlet
from the TGCU Waste Heat Reclaimer is now being back-purged
with nitrogen.)
The gas stream from the TGCU Contactor is "cleaner" than the one
leaving the TGCU Waste Heat Reclaimer and is less likely to cause
problems in the hydrogen analyzer. However, if the Quench Column
hand control is used to divert gas to the TTO during an upset as

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described in the previous step, the analyzer must be switched back

to the outlet of the TGCU Waste Heat Reclaimer to get a good
reading, as gas will no longer be flowing in the TGCU Contactor
overhead line.
H. Once the operation of the TGCU Stripper has stabilized, route its
acid gas, which is presently going to the flare through a pressure
valve, back to the SRUs as follows:
(1) Confirm that the TGCU Stripper pressure controller to the SRUs
in the DCS is in "manual" with its output set to 0%.
(2) Confirm that the setpoint of the TGCU Stripper pressure

controller to the SRUs is tracking its current reading, then place
it in "automatic".
(3) Slowly raise the setpoint of the TGCU Stripper pressure

controller to the flare to 1.0 kg/cm2(g).
(4) If, necessary, adjust the setpoint of the TGCU Stripper pressure
controller to the SRU to its normal setpoint.
The TGCU Stripper pressure controller will now take over control of
the TGCU Stripper pressure by opening the pressure valve to send
the acid gas to the Acid Gas Knock-Out Drums in the SRUs. The
TGCU Stripper pressure controller to the flare will close the acid gas
pressure valve and stop the flow of acid gas to the flare. If the SRUs
shut down (or some other upset causes the TGCU Stripper pressure
to rise), the TGCU Stripper pressure controller to the flare will act as
an over-ride and divert the acid gas to the flare.
I. If desired, the quench water and amine systems can be optimized at

this time for more efficient operation, or for more capacity to handle
upsets. Section 11.6 offers suggestions and guidelines for these
systems. If maximizing the capacity to handle process upsets
without going out of compliance is desired, consider the following
suggestions:
(1) Lower the setpoint of the temperature controller on the quench

water to maximize the aerial cooling. This will cool the feed gas
to the TGCU Contactor as much as possible to minimize the
load on the column and improve amine selectivity and treating
ability.

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(2) Lower the setpoint of the temperature control on the lean amine
to maximize the aerial cooling. This will cool the amine to the
TGCU Contactor as much as possible to maximize the amine
selectivity and treating ability.
(3) Lower the setpoint of the temperature controller on the outlet

from the TGCU Stripper Reflux Condenser as much as
possible. This will minimize the water content of the TGCU acid
gas returning to the sulfur plant and improve the recovery there.
The aerial coolers and trim coolers will not be able to maintain these
temperatures when the ambient conditions are very warm, of course.
However, setting the controllers this way will keep the fan speed high
to maximize cooling at all times.
J. The TGCU is now fully on-stream. Before directing your attention

away from the TGCU, be sure that:
(1) Both SRU Tailgas Valves to the TTO and the TGCU
Warmup/Bypass Valve are fully closed (to prevent leakage of
SRU tailgas to the Thermal Oxidizer that would cause high SO2
emissions and the resulting permit violation).
(2) The TGCU Quench Column Bypass Valve is fully closed (to
prevent leakage of TGCU Reactor effluent to the Thermal
Oxidizer that would cause high SO2 emissions and the resulting
permit violation).
(4) The steam heating systems are in service on the jacketed sulfur
vapor valves and the steam traps are functioning properly.

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11.8.6 Normal Startup of the TGCU

The procedure for startup of the TGCU after it has been shut down will be
very similar to the procedure for the initial startup, Sections 11.8.1 through
11.8.5 of these guidelines, except that the catalyst will not require
pre-sulfiding. For ease of reference, the steps to be performed are written
in this Section to serve as a "check list" that can be easily followed on
subsequent startups. Refer to the previous Sections for the reasons and
details pertaining to the different steps performed.
Prior to commencing TGCU startup:
(1) Check for the completion of all maintenance work (connecting

lines, removing blinds, etc.) if such work was performed.
(2) If any of the flanged connections in the TGCU were opened for
maintenance or other purposes while the TGCU was off-line, it
is good practice to leak test the TGCU before returning it to
service. Refer to Section 11.7.5 of these guidelines for a
suggested procedure to accomplish this.
(3) Place all the steam heating systems on the sulfur vapor valve
jackets in service. Check all steam traps for proper operation,
and use the vent valves to sweep non-condensibles out of the
steam spaces.
(4) Physically check all shutdown activating devices to ensure that

they activate the TGCU ESD system.
(5) Physically check all devices activated by the TGCU ESD

system to ensure that they operate properly.

A. Confirm that steam pressure controller in the DCS is in
"manual" with its output set to 0%, and that control valve in the
HP Steam supply line to the TGCU Reactor Feed Heater is
closed.
B. Place the reactor feed temperature controller in "automatic".
C. Confirm that reducing gas flow controller in the DCS is in

the reducing gas supply line to the TGCU Reactor Feed Mixer
is closed.

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D. Place the hydrogen controller in "automatic".
E. Verify that the automated shutdown valves, the block valves, and
the downstream steam-jacketed block valve in the reducing gas
line to the TGCU Reactor Feed Mixer are all closed.
F. Confirm that pre-sulfiding gas flow controller in the DCS is in

the pre-sulfiding gas line to the TGCU Reactor Feed Mixer is
closed.
G. Verify that the automated shutdown valve and the upstream

block valves in the pre-sulfiding gas line to the TGCU Reactor
Feed Mixer are both closed.
H. Confirm that the nitrogen flow controller in the DCS is in

"manual" with its output set to 0% output, and that the control
valve in the nitrogen supply line is closed.
I. Verify that the shutdown valves are closed in the nitrogen

supply line, and the upstream block valves are open. Open the
downstream steam-jacketed block valve.
J. Confirm that the Quench Column hand control in the DCS is set
to 0% output, so that the TGCU Quench Column inlet valve will
remain fully closed and the TGCU Quench Column bypass
valve will open later in when the TGCU startup/run selector
switch is switched to "STARTUP".
K. Confirm that the TGCU Waste Heat Reclaimer is filled with

L. Visually confirm that both SRU Tailgas Valves to the TGCU are
closed.
M. Visually confirm that the manual TGCU Outlet Valve is fully

open.
N. Confirm that the Leak Test switch in the DCS is toggled to

"OFF".
O. Confirm that the TGCU Start-Up Blower Bypass Valve is fully

open.

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P. Verify that the local stop control for the TGCU Start-Up Blower
is set to the "RUN" position.
Q. Check that the sample line from the outlet of the TGCU Waste
Heat Reclaimer to the hydrogen analyzer is clear of liquids.
Confirm that sample valve on the outlet channel of the boiler is
open, then switch the sample selector valve in the analyzer
enclosure to sample from the outlet of the TGCU Waste Heat
Reclaimer.
Note that the other sample line on the TGCU Contactor

overhead line is now being back-purged with nitrogen.
11.8.6.2 Purging the Low Pressure TGCU Columns

Unless the water or the amine was drained from the low pressure
TGCU columns (the TGCU Quench Column and the TGCU
Contactor, respectively), or either column was opened for
maintenance during the prior shutdown, the columns will not contain
air and so will not require purging before proceeding with startup.
However, if the activities prior to this startup did allow air to enter
either or both columns, this air should be purged from the system
before proceeding so that a combustible mixture cannot form in the
columns as process gas is introduced.
If purging of the columns is required, nitrogen can be introduced

using the nitrogen flow controller to purge the air from the columns.
This procedure is given in Section 11.7.8 of these guidelines. Refer
to and follow this procedure to purge the columns before continuing
with Section 11.8.6.3 that follows.

A. Toggle the Startup/Run selector switch in the DCS to

"STARTUP".
(a) Bypasses both SRU ESD inputs to the TGCU ESD.
(b) Disables the Tailgas Valve toggle switches.
(c) Opens the TGCU Quench Column Bypass Valve.

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B. Reset the TGCU ESD by toggling the switch in the DCS to

"RESET".
C. Set the output of the hand control in the DCS to 0% to close the
TGCU Warmup/Bypass Valve and visually confirm that the
valve is closed.
D. Toggle the Nitrogen On/Off switch in the DCS to "ON".
E. Increase the output of the nitrogen flow controller to 100% in

the DCS to open the control valve and send nitrogen to the
front-end of the TGCU.
F. Allow the nitrogen to purge that front-end of the TGCU for 15

minutes before proceeding to the next step.
11.8.6.4 Establishing Re-circulation Flow

A. Start the TGCU Start-Up Blower using the start/stop toggle
switch in the DCS.

As this valve is closed, the blower will start to load. As it does

so, the blower will begin to "pull" nitrogen through the front-end
TGCU equipment and all of the associated piping.
B. Once the blower is running, open the TGCU Warmup/Bypass

Valve by increasing the output from the hand control to 100%.

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As the TGCU Warmup/Bypass Valve opens, the TGCU

Start-Up Blower will begin re-circulating gas from the outlet of
the TGCU Waste Heat Reclaimer back to the TGCU Reactor
Feed Heater (via the TGCU Contactor overhead line).
C. Once re-circulation has been established, place the nitrogen

flow controller in "automatic" and reduce its setpoint to about
5-10% of maximum flow.
D. Slowly begin to increase the setpoint of the steam pressure

controller in the DCS to establish steam flow to the TGCU
Reactor Feed Heater and increase the temperature of the
re-circulating gas stream to 150-175°C.
E. Open the vent valve on the TGCU Waste Heat Reclaimer to

vent air from the steam section.
F. Confirm that the BFW level controller and control valve to the
TGCU Waste Heat Reclaimer are in service and functioning
properly.
G. Place the reactor feed temperature cascade control in service

as follows:
(1) Confirm that the remote setpoint that the reactor feed
temperature controller is supplying to the pressure
controller matches the current setting on the pressure
controller.
(2) Confirm that the reactor feed temperature controller is in

(3) Switch the steam pressure controller to "cascade" so that

the temperature controller can now adjust the setpoint on
the pressure controller.
(4) If necessary, slowly adjust the setpoint of the reactor feed

temperature controller to 175°C.
(5) Verify that the steam pressure controller is adjusting the

HP steam pressure as needed to control the desired
temperature setting on the reactor feed temperature
controller.

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11.8.6.5 Establishing Reducing Gas Flow

Before introducing SRU Tailgas into the TGCU Reactor, reducing
gas must be added to the re-circulating gas stream.
A. Open the upstream manual block valves and the

steam-jacketed block valve in the reducing gas supply line to
the TGCU Reactor Feed Mixer.
B. Toggle the Reducing Gas On/Off switch in the DCS to "ON".
(1) Opens reducing gas block valves.
(2) Closes reducing gas vent valve.
C. Place the reducing gas controller in "automatic" and slowly

begin to increase its setpoint to open the control valve and
begin introducing reducing gas into the re-circulating stream.
As the reducing gas flow rate increases, the hydrogen

concentration displayed on the hydrogen controller will
increase.
D. Place the hydrogen concentration cascade control in service as

follows:
(1) Confirm that the remote setpoint that the hydrogen

controller is supplying to the reducing gas flow controller
matches the current setting on the flow controller.
(2) Confirm that the hydrogen controller is in "automatic" and

its setpoint is tracking its current reading.
(3) Switch the reducing gas controller to "cascade" so that the

concentration controller can now adjust the setpoint of the
flow controller.
(4) If necessary, slowly adjust the setpoint of the hydrogen

controller to its normal value.

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The TGCU is now ready to accept tailgas from the SRUs.
1. The Reactor Feed Heater is operating smoothly and the inlet

temperature to the TGCU Reactor is being controlled at
230-240°C.
2. The TGCU Reactor is up to normal operating temperature and its

catalyst has been pre-sulfided.

4. The H2/H2S analyzer has been calibrated and is sampling the

process gas leaving the TGCU Waste Heat Reclaimer.
5. The hydrogen controller is controlling the hydrogen at or above

the normal setpoint
6. One or both SRUs are operating smoothly on amine acid gas, or

amine acid gas and SWS gas, and the air demand indicated on
the air control is +2.0% or lower. (If the air demand is higher
than this, the tailgas from the SRU contains excessive amounts
of SO2 and could cause overheating of the TGCU Reactor.)
tailgas into the TGCU. In particular, do not attempt switching
tailgas into the TGCU when the SRU(s) is(are) experiencing an
upset. The result will be multiple upset units to deal with. Instead,
focus your attention on stabilizing the operation of the SRU(s) first
Regeneration and/or Sour Water Stripper units), and then use the
procedure that follows to establish tailgas flow into the TGCU.

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Introducing SRU Tailgas into the TGCU — Scenario 1
the TGCU, the tailgas from both SRUs is sent to the TTO while the
TGCU uses the TGCU Startup Blower to re-circulate gas to the
TGCU Reactor Feed Heater via the TGCU Warmup/Bypass Valve.
Once the TGCU is warmed up and ready to accept tailgas, the
Train 1 and Train 2 SRUs can be routed to the TGCU as follows
(using the Train 1 SRU for this procedure).
A. Confirm that the hydrogen controller is in "automatic" and controlling

the hydrogen concentration at or above its normal setpoint, (3%).
B. Toggle the SRU 1 "fast" transfer switch in the DCS, to "TRANSFER TO

TGCU".
(1) The SRU 1 Tailgas Valve to the TGCU is opened.
(2) After the limit switches prove this valve open, the SRU 1
Tailgas Valve to the TTO is closed.

positions.
C. If the second SRU (Train 2) is also ready to send its tailgas to the
TGCU, toggle the SRU 2 "fast" transfer switch in the DCS to repeat
these actions for the other SRU.
For this scenario, the opening and closing of Tailgas Valves to the
TGCU and the Tailgas Valves to the TTO in Steps B and C can
occur rapidly with no impact on either the SRU or the TGCU. This is
because the TGCU Warmup/Bypass Valve will still be open at this
time, so there will be very little differential pressure across the
Tailgas Valves to the TGCU and there will not be an abrupt change
in pressure when the Tailgas Valves to the TGCU are opened or
when the Tailgas Valves to the TTO are closed.
Note: The “fast” transfer switches can also be used to take the
Train 1 SRU and/or Train 2 SRU tailgas out of the TGCU.
Every other toggle of these selector switches will take the

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opposite action to open the tailgas valve to the TTO and

then close the tailgas valve to the TGCU.
D. Slowly reduce the output from the hand control to 0% to close the
Now all of the SRU tailgas must flow through the TGCU Reactor
Feed Heater, etc. as this is the only open flowpath to the TTO.
E. Shut down the TGCU Start-Up Blower using the start/stop selector
switch in the DCS.
(1) The TGCU Start-Up Blower bypass valve is opened and proved
open.
(2) The TGCU Start-Up Blower is stopped.
(4) The TGCU Start-Up Blower Suction Valve and the TGCU
Start-Up Blower Discharge Valve are closed.
Confirm that these valves have moved to the proper positions and
that the blower has stopped.
F. Place the nitrogen flow controller in "manual" and set its output to 0%
to close the control valve and stop the flow of nitrogen into the
TGCU.
G. Toggle the Nitrogen On/Off switch in the DCS to "OFF".
(1) Closes nitrogen blocks.
(2) Opens nitrogen vent valve.
H. Close the downstream steam-jacketed block valve in the nitrogen

Mixer.
I. Allow the TGCU to operate in this fashion until all operating

conditions are stable. In particular, observe the operation of the
reactor feed temperature controller and the hydrogen controller to
ensure that the TGCU Reactor inlet temperature remains under

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control and there is adequate hydrogen (2% or higher) in the TGCU

Reactor outlet.
At this point, all of the tailgas from both SRUs is flowing into the
TGCU Reactor Feed Heater, mixing with the external reducing gas in
the TGCU Reactor Feed Mixer, entering the TGCU Reactor to
convert all of the sulfur compounds to H2S, being cooled in the
TGCU Waste Heat Reclaimer, and flowing through the TGCU
Quench Column Bypass Valve and the TGCU Start-Up Blower
Bypass Valve to the Thermal Oxidizer via the TGCU Contactor
overhead line and the TGCU Outlet Valve.
Once the operation of the TGCU front-end has stabilized, the

process gas can be introduced into the TGCU columns.
Introducing SRU Tailgas into the TGCU — Scenario 2

second SRU needs to be introduced into the TGCU. Under this
scenario, the TGCU is already processing tailgas from the Train 2
SRU. This means that the TGCU warmup/bypass valve is already
closed. This signals the PLC to disable the "fast" transfer switches in
the DCS, so that the rapid switching sequence (scenario 1) cannot
be activated inadvertently.
A. Initiate the over-ride for the Train 1 tailgas valves by toggling the
Train 1 "slow" transfer switch in the DCS, to "OVER-RIDE". The PLC
temporarily removes the limit switches on the SRU 1 Tailgas Valve to
the TTO and the SRU 1 Tailgas Valve to the TGCU from the
"complete flowpath interlock" for the Train 1 SRU alarms and
deactivates the "valve malfunction" alarms on these two valves, then
directs the DCS to release control of the hand controls for these
valves to the operator.
B. Use the hand control to slowly begin throttling the tailgas flow with
the SRU 1 Tailgas Valve to the TTO, so that the pressure at the
Train 2 SRU. Monitor the flows and pressure in the Train 1 SRU and
adjust the hand control accordingly.

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C. Once the SRU 1 Tailgas Valve to the TTO is throttling, use the other
hand control to slowly open the SRU 1 Tailgas Valve to the TGCU.
Some of the Train 1 tailgas may begin to flow into the TGCU at this
time, but most of it will still flow through the SRU 1 Tailgas Valve
directly to the TTO. Monitor the flows and pressures in the Train 1
SRU and the TGCU, and adjust the rate at which he opens the SRU
1 Tailgas Valve to the TGCU accordingly.
D. Once the SRU 1 Tailgas Valve to the TGCU is fully open, use the
hand control to slowly close the SRU 1 Tailgas Valve to the TTO the
rest of the way and send all of the Train 1 tailgas to the TGCU.
Monitor the flow rates and temperatures in the TGCU, and adjust the
rate at which the SRU 1 Tailgas Valve to the TTO is closed to allow
time for the controls in the TGCU to respond.
E. Once the SRU 1 Tailgas Valve to the TTO is fully closed, the Train 1
SRU is flowing to the TGCU along with the Train 2 SRU, and the
TGCU is fully on-line.
Once both valve have moved into position, the PLC will automatically
restore the limit switches on the SRU 1 Tailgas Valve to the TTO and
the SRU 1 Tailgas Valve to the TGCU to the "complete flowpath
interlock" in the SRU alarms, restore the malfunction alarms for
these valves to their normal configurations, and reset the "slow"
transfer switch in the DCS, back to "NORMAL" and remove the
over-ride.
11.8.6.7 Quench Water and Amine Systems

Before switching process gas into the TGCU Quench Column and
the TGCU Contactor, the quench water and amine systems should
be operating and ready to accept the process gas.
A. The quench water system should be filled with water, so that

the level in the TGCU Quench Column is at the normal setpoint
for the Quench Column level controller.
B. Quench water should be circulating to the TGCU Quench

Column at the normal setpoint for the quench water flow
controller.
C. Cooling water should be flowing to the TGCU Quench Water

Trim Cooler and the TGCU Lean Amine Trim Cooler.

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D. The fans should be operating on the TGCU Quench Water

Cooler, with the temperature controller on the quench water
controlling at its normal setpoint or lower.
E. The TGCU Quench Water Filter should be in service with the

filtered quench water flow controller controlling at its normal
setpoint.
F. The quench water pH analyzer should be in service (with one

pH Meter Sample Filter in service, and the other blocked-in for
use as a spare) with the quench water pH analyzer in the DCS
showing a pH of 11 or higher. Add caustic to the quench water
if necessary to raise the pH to this level.
G. The amine system should be filled with amine, with the level
control in the DCS controlling the level in the TGCU Contactor
at its normal setpoint.
H. The MDEA concentration in the amine should be close to its

design value (45 wt %). Add more fresh MDEA if necessary to
bring the amine to this strength.
I. Amine should be circulating through the TGCU Stripper, the

TGCU Lean/Rich Exchanger, the TGCU Lean Amine Cooler,
and the TGCU Lean Amine Trim Cooler to the distributor tray at
the top of the TGCU Contactor at the normal setpoint for the
flow controller.
J. The fans should be operating on the TGCU Lean Amine Cooler,

with the temperature controller on the lean amine controlling at
its normal setpoint or lower.
K. The TGCU Rich Amine Filter should be in service.
L. The TGCU lean amine filters should be in service, with the flow
controller controlling at its normal setpoint.
M. Steam should be flowing to the TGCU Stripper Reboiler at the

normal setpoint for the flow controller.
N. The overhead temperature from the TGCU Stripper should be

above the low temperature alarm point for the temperature
indicator.

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O. The fans should be operating on the TGCU Stripper Reflux

Condenser with the temperature controller on the outlet from
the TGCU Stripper Reflux Condenser controlling at its normal
setpoint or lower.
P. The TGCU Stripper pressure controller to the SRU should be in

"manual" with its output set to 0% so that the pressure valve is
fully closed.
Q. The TGCU Stripper pressure controller to the flare should be in

"automatic" with its setpoint set to its normal value.
R. The level in the TGCU Stripper Reflux Accumulator should be

at the normal setpoint for the level control.
S. A TGCU Stripper Reflux Pump should be operating with the

minimum flow lined up to allow reflux to spill back into the
TGCU Stripper Reflux Accumulator whenever the level valve
back to the TGCU Stripper is closed.
With these operating conditions established, the back-end of the

TGCU is ready to accept the process gas from the front-end of the
unit and begin treating it.
11.8.6.8 Process Gas Flow to the TGCU Columns

The startup of the TGCU can now be completed by switching the
process gas to flow into the columns. Before introducing process
gas into the TGCU columns, confirm that the following conditions are
all true:
1. The front-end of the TGCU is processing SRU tailgas and is

operating smoothly on automatic control.
2. The hydrogen controller is controlling the hydrogen

concentration in the outlet of the TGCU Reactor at or above its
setpoint.
3. The proper operating conditions have been established for the

quench water and amine systems.
If any of these conditions are not true, do not proceed until correcting
the problem(s). Once all of these conditions are satisfied, complete
the startup of the TGCU as follows:

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A. Confirm that the Quench Column hand control in the DCS is set
to 0% output with the TGCU Quench Column Inlet Valve closed
and the TGCU Quench Column Bypass Valve open.
B. Use the drain valve downstream of the TGCU Waste Heat

Reclaimer to drain any liquids that may have accumulated in
the TGCU Quench Column inlet line.
C. Slowly increase the output from the Quench Column hand

control to 100%, which will open the Quench Column inlet valve
and admit process gas to the TGCU Quench Column, then
close the TGCU Quench Column Bypass Valve to prevent gas
from bypassing to the Thermal Oxidizer.
Note that the pressure drop through the TGCU Quench Column
and the TGCU Contactor will raise the operating pressures of
the SRU and the TGCU and can affect the process gas flow
rates, so allow time for the flow and flow-ratio control loops to
respond.
D. When the output of the Quench Column hand control reaches

100%, the Quench Column inlet valve should be fully open and
the TGCU Quench Column Bypass Valve fully closed to send
all of the process gas into the TGCU Quench Column. Visually
confirm that these valves are properly positioned.
E. As process gas flows into the columns, watch the operation of

the quench water system carefully. A sudden drop in pH
usually indicates SO2 in the process gas from incomplete
reaction in the TGCU Reactor. Be ready to add caustic if
needed to keep the pH above 7.
F. If the quench water pH drops drastically or there is a sudden

drop in the hydrogen concentration on the hydrogen controller,
the process gas can be "backed" out of the columns by
reducing the output of the Quench Column hand control back to
0%. This will open the TGCU Quench Column Bypass Valve to
divert the gas to the TTO and close the Quench Column inlet
valve to stop gas from flowing into the TGCU Quench Column.
Once the operating problem is corrected and the hydrogen
controller is once again showing adequate hydrogen, use the
Quench Column hand control to re-initiate gas flow to the
columns.

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G. Once the columns are operating stably, switch the H2/H2S

analyzer to take its sample from the TGCU Contactor overhead
line by checking that the sample line is clear of liquid,
confirming that the sample valve on the overhead line is open,
and switching the sample selector valve in the analyzer
enclosure to sample from the TGCU Contactor overhead line.
(Note that the sample line on the outlet from the TGCU Waste
Heat Reclaimer is now being back-purged with nitrogen.)
H. Once the operation of the TGCU Stripper has stabilized, route

its acid gas, which is presently going to the flare through the
pressure valve, back to the SRU as follows:
(1) Confirm that the TGCU Stripper pressure controller to the

SRU in the DCS is in "manual" with its output set to 0%.
(2) Confirm that the setpoint of the TGCU Stripper pressure

controller is tracking its current reading, then place it in
"automatic".
(3) Slowly raise the setpoint of the TGCU Stripper pressure

controller to the flare to 1.0 kg/cm2(g).
(4) If necessary, adjust the setpoint of the TGCU Stripper

pressure controller to its normal setpoint.
The TGCU Stripper pressure controller will now take over

control of the TGCU Stripper pressure by opening the pressure
valve to send the acid gas to the Acid Gas Knock-Out Drum in
the SRU. The TGCU Stripper pressure controller to the flare
will close the next pressure valve and stop the flow of acid gas
to the flare. If the SRU shuts down (or some other upset
causes the TGCU Stripper pressure to rise), the TGCU Stripper
pressure controller to the flare will act as an over-ride and divert
the acid gas to the flare.
I. If desired, the quench water and amine systems can be

optimized at this time for more efficient operation, or for more
capacity to handle upsets.
J. The TGCU is now fully on-stream. Before directing your

attention away from the TGCU, be sure that:

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(1) The SRU Tailgas Valve to the TTO and the TGCU
Warmup/Bypass Valve are fully closed (to prevent leakage of
SRU tailgas to the Thermal Oxidizer that would cause high SO2
emissions and the resulting permit violation).
(2) The TGCU Quench Column Bypass Valve is fully closed (to
prevent leakage of TGCU Reactor effluent to the Thermal
Oxidizer that would cause high SO2 emissions and the resulting
permit violation).
(4) The steam heating systems are in service on the jacketed sulfur
vapor valves and the steam traps are functioning properly.

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The procedures to be used in performing a planned shutdown of the TGCU will
vary depending on the extent and type of work to be performed in and around
the unit during the downtime period. If there are no plans for opening the TGCU
such that air would be allowed entry to the catalyst bed in the TGCU Reactor,
few special procedures are required in performing the shutdown. In general,
unless there is a suspected problem in the TGCU Reactor or the catalyst is to
be replaced, there is no benefit to be gained from opening up the TGCU
Reactor. If the TGCU Reactor does not need to be opened (or exposed to
significant air entry during some other maintenance procedure), there is no need
to passivate the TGCU Reactor catalyst. This greatly simplifies and shortens
the shutdown procedure. Section 11.9.1 that follows is an example of such a
procedure.
If the catalyst is to be replaced, if the TGCU Reactor must be entered, or if

maintenance on some other portion of the plant will allow a significant amount of
air to enter the TGCU Reactor, then more extensive and lengthy procedures
must be followed to accomplish a satisfactory shutdown and minimize the time
required for performance of the desired maintenance work. Section 11.9.2 that
follows is an example of a procedure for this circumstance.
There are a couple of special circumstances related to shutdown procedures

that are also discussed. Section 11.9.3 discusses considerations for the
shutdown procedure when the tubes in the TGCU Waste Heat Reclaimer are
leaking. Special precautions to observe while the TGCU is shut down are
discussed in Section 11.9.4.

quickly identifying and correcting the problem so the TGCU can be put back
on-line in a minimum amount of time.
The TGCU is affected directly and indirectly by shutdowns and outages that
occur in other systems within the Sulfur Block. The more important aspects of
the effects these other systems can have on the TGCU are discussed in
Section 11.9.6.

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situation.

When there are no plans to open up the TGCU Reactor, there is no need
to passivate the catalyst during the shutdown procedure. Even when
entry to other parts of the TGCU is planned, this can normally be
accomplished without exposing the catalyst bed to significant amounts of
air by using slip-blinds to isolate the TGCU Reactor prior to purging, etc.
Under these circumstances, the shutdown procedure given in this section
may be used as a guide.

gases or the formation of flammable vapor mixtures. It is particularly
important to isolate the TGCU from the reducing gas and pre-sulfiding gas
supply lines. Any equipment containing amine solution that is to be
opened or entered should be drained completely, then flushed with
condensate or steamed out to avoid the possibility of skin or eye irritation.
It is always best, but not absolutely necessary, to purge the sulfur-bearing

gases from as much of the TGCU as possible prior to shutting the TGCU
down. This minimizes the chance of sulfur plugging in the piping or
equipment during the subsequent restart, and minimizes the purging and
cleaning required prior to vessel entry. This is accomplished by diverting
the SRU tailgas to the Thermal Oxidizer, then using nitrogen to purge the
front-end of the TGCU to the Thermal Oxidizer.
It is generally preferable to shut down the TGCU in a controlled fashion,

particularly if the SRUs are to remain on-line, to minimize the impact on
the other process units. If time does not allow performing a controlled
shutdown, however, the unit can be shut down by simply activating the
TGCU ESD system (using the manual shutdown switch). This will
automatically block the feeds into the TGCU (SRU tailgas, reducing gas,
pre-sulfiding gas, and nitrogen/utility air) and divert the SRU tailgas to the
Thermal Oxidizer, although it results in a much bigger "bobble" to the
SRUs.

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To shut the TGCU down in a controlled fashion and purge the

sulfur-bearing gases from the front-end of the unit, proceed as follows:
A. Check that the sample line from the outlet of the TGCU Waste Heat
Reclaimer to the H2/H2S analyzer is clear of liquids. Confirm that
sample valve on the outlet channel of the boiler is open, then switch
the sample selector valve in the analyzer enclosure to the "START-UP"
position (taking sample from the outlet of the TGCU Waste Heat
Reclaimer).
B. Visually confirm that the TGCU Start-Up Blower Bypass Valve is fully
open and that the DCS indicates that the valve is open.
C. Slowly reduce the output from the Quench Column hand control in
the DCS to divert the process gas from the TGCU columns and send
it to the Thermal Oxidizer. The Quench Column hand control will
open the TGCU Quench Column Bypass Valve, then close the
TGCU Quench Column Inlet Valve.
D. When the output of the Quench Column hand control reaches 0%,
the TGCU Quench Column Bypass Valve should be fully open and
the Quench Column inlet valve fully closed to send all of the process
gas to the Thermal Oxidizer via the TGCU Start-Up Blower Bypass
Valve.

that the DCS indicates that the TGCU Quench Column Bypass Valve
is open, and that the TGCU Quench Column Inlet Valve is closed.
E. Toggle the Nitrogen On/Off switch in the DCS to "ON".
(1) Opens nitrogen block.
(2) Closes nitrogen vent valve.
F. Open the downstream steam-jacketed block valve in the nitrogen

Mixer.
G. Increase the output of the nitrogen flow controller to 100% in the

DCS to fully open the control valve and send nitrogen to the
front-end of the TGCU.

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H. Slowly increase the output from the TGCU Warmup/Bypass Valve

hand control in the DCS to 100% to fully open the TGCU
Warmup/Bypass Valve.
Some of the SRU tailgas will continue to flow through the TGCU
Reactor Feed Heater, etc. to the TTO through the TGCU Start-Up
Blower Bypass Valve, but most of the tailgas will flow instead through
the TGCU Warmup/Bypass Valve to the TTO.
I. Toggle the fast transfer switch for SRU 1 in the DCS to "CLOSE".
The PLC will open the SRU 1 Tailgas Valve to the TTO then close
the SRU 1 Tailgas Valve to the TGCU. All of the SRU 1 tailgas is
now flowing directly to the TTO via the SRU 1 Tailgas Valve, and
none of the tailgas is entering the TGCU.

positions. Verify that the DCS indicates that the SRU 1 Tailgas
Valve to the TTO is open and that the SRU 1 Tailgas Valve to the
TGCU is closed.
J. Toggle the fast transfer switch for SRU 2 in the DCS to "CLOSE".
The PLC will open the SRU 2 Tailgas Valve to the TTO then close
the SRU 2 Tailgas Valve to the TGCU. All of the SRU 2 tailgas is
now flowing directly to the TTO via the SRU 2 Tailgas Valve, and
none of the tailgas is entering the TGCU.

positions. Verify that the DCS indicates that the SRU 2 Tailgas
Valve to the TTO is open and that the SRU 2 Tailgas Valve to the
TGCU is closed.
NOTE: If a status does not change, or if a valve

malfunction alarm is activated, it means that the limit
switches on the associated valve never confirmed that the
valve moved to the proper position. If this problem cannot
be corrected, it will not be possible to continue with this
procedure to shut down the TGCU in a controlled fashion.
Instead, use the S/D button to activated the TGCU ESD
system and shut down the TGCU immediately.
K. Toggle the Reducing Gas On/Off switch in the DCS to "OFF".

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The PLC will close the reducing gas block valves, open the vent
valve, and force the control valve to "manual" and 0% output.
Confirm that the DCS indicates that these valves have moved to the
proper position.
L. Close the steam-jacketed block valve in the reducing gas supply line.
M. Reduce the output from the hand control in the DCS to 0% to close
the TGCU Warmup/Bypass Valve. Visually confirm that the valve is
closed.
N. Now that the reducing gas has been isolated and the tailgas from the
SRU has been switched to the Thermal Oxidizer, allow the front-end
of the TGCU to operate in this fashion for about 15 minutes to purge
the process gas out to the Thermal Oxidizer.
O. Place the HP steam pressure controller for the TGCU Reactor Feed
Heater in "manual" and set its output to 0% to close control valve.
P. Activate the TGCU ESD system using the S/D button.
Q. Close the steam-jacketed valve in the nitrogen supply line where it

joins the tailgas line to the TGCU Reactor Feed Mixer.
R. Close the manual TGCU Outlet Valve.
WARNING
THE OVER-PRESSURE PROTECTION FOR THE TGCU IS

THROUGH THE THERMAL OXIDIZER VENT STACK. HOWEVER,
IF THE TGCU OUTLET VALVE IS CLOSED WHILE THE TGCU IS
SHUT DOWN, STEPS MUST BE TAKEN TO ENSURE THAT THE
TGCU IS NOT COMPLETELY BLOCKED-IN BY CREATING
ANOTHER OPENING FROM THE TGCU TO THE ATMOSPHERE
SO THAT THE TGCU CANNOT BE OVER-PRESSURED.
S. Visually confirm that:
(1) The SRU 1 Tailgas Valve to the TGCU is closed.

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(3) The TGCU Outlet Valve is closed.
(4) The nitrogen/utility air to the TGCU Reactor Feed Heater is

blocked-in and bled.
(5) The reducing gas to the TGCU Reactor Feed Mixer is blocked-in
and bled.
(6) The pre-sulfiding gas shutdown valve is closed.
(7) The suction and discharge valves for the TGCU Startup Blower
are closed and the nitrogen purge is in service.
(8) The TGCU Quench Column inlet valve and the TGCU Quench
Column Bypass valve are closed.
(9) All steam heating services on the sulfur vapor valve jackets are
still functioning and the steam traps are operating properly.
T. All temperatures in the front-end of the TGCU should be monitored to

confirm that no air leaks into the system (due to "drafting" from the
Thermal Oxidizer, for instance) and causes a fire in the catalyst bed.
If desired, a small flow of nitrogen can be introduced into the

front-end of the TGCU by using the Leak Test switch in the DCS to
allow opening the block valves on the nitrogen supply line, then
opening the control valve to establish a small flow of nitrogen.
"Crack" the TGCU Outlet Valve to allow the nitrogen to escape to the
Thermal Oxidizer and prevent over-pressuring the TGCU.
U. Allow the TGCU amine to continue to circulate with steam flowing to

the TGCU Stripper Reboiler, until the all of the H2S and CO2 have
been stripped from the amine. Once the H2S/CO2 content of the
"rich" amine is essentially the same as the "lean" amine, the steam
can be shut off to the TGCU Stripper Reboiler.
V. Continue to circulate the TGCU amine and operate the TGCU Lean
Amine Cooler, the TGCU Lean Amine Trim Cooler, and the TGCU
Stripper Reflux Condenser until the amine is cool.
W. Once the amine is cool (60°C or less throughout the system), shut
down the equipment in the following order:
(1) The TGCU Quench Water Pump.
(2) The TGCU Rich Amine Pump.

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(3) The TGCU Lean Amine Pump.
(4) The TGCU Stripper Reflux Pump.
(5) The fans on the TGCU Quench Water Cooler, TGCU Lean
Amine Cooler, and TGCU Stripper Reflux Condenser.
X. If the TGCU will be down for an extended period, special precautions

should be taken to prevent the TGCU Waste Heat Reclaimer tubes
from cooling to the point where water can condense inside them.
Most of the corrosion that occurs in TGCUs is due to the acidic water
Close the steam outlet valve on the boiler and open the vent valves
on the boiler to de-pressure it. Make sure that the boiler level control
continues to operate properly so that the water level does not drop
below the tubes until they have cooled and the boiler is fully
de-pressured. Once the boiler is de-pressured, block-in its BFW
supply and drain the water from it. Then use a temporary "jumper" to
supply LP steam to the boiler shell. Drain the condensate from the
boiler occasionally to keep the tubes safely above the water
condensation temperature (100-110°C).

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When the TGCU Reactor must be opened for maintenance or to replace
the catalyst, it is normally necessary to passivate the catalyst as a part of
the shutdown procedure. After the TGCU has been operating for a period
of time, the catalyst becomes pyrophoric due to the presence of iron
sulfide, FeS. Exposing catalyst containing pyrophoric FeS to air may
result in uncontrolled burning of the FeS to form H2S and/or SO2, which
obviously will prevent the entrance of personnel into the vessel.
For this reason, controlled oxidation ("passivation") of the FeS in the

catalyst is carried out at low temperature (~150°C) by admitting a small air
flow into the circulating gas. This converts the FeS into non-pyrophoric
iron oxide, Fe2O3, while leaving the catalyst in its sulfided state. The only
SO2 produced during passivation should come from the FeS present.
Pre-sulfiding of the catalyst will not be required during the next startup
(assuming the catalyst is not replaced).
This procedure requires an ample supply of a suitable inert gas (nitrogen,

etc.) to circulate through the TGCU Reactor and cool it. Make sure a
supply of inert gas is available and ready to use before beginning this
procedure. Utility air is used for passivating the catalyst.
In an emergency, or if the catalyst is to be replaced, it can be handled in a

pyrophoric state if it is kept under water or nitrogen. Soaking the catalyst
in water will, however, weaken the catalyst substrate and make the
catalyst more susceptible to crumbling and attrition. For this reason, and
due to the corrosive nature of liquid water on the TGCU Reactor vessel
and piping, this practice is not recommended.
There are service companies, however, that can unload the TGCU
catalyst bed after it has been cooled to near ambient temperature using
nitrogen. The service company then performs all necessary work relating
to removing and replacing the catalyst under a nitrogen "blanket". This
eliminates the need to passivate the catalyst, reducing the time required to
replace the TGCU catalyst. Some refineries and gas plants also purchase
pre-sulfided replacement catalyst, resulting in less time for the subsequent
startup.
The procedure in this section is used to make the TGCU catalyst safe for
atmospheric air replacement.

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A. Follow the procedure given previously in Section 11.9.1 to purge the

front-end of the TGCU, to shut down the quench water system, and
to strip, cool, and shut down the amine system, but do not Activate
the TGCU ESD system using the S/D button, or isolate the nitrogen
supply, or close the TGCU outlet Valve (Steps P-R) in
Section 11.9.1).
NOTE: Do not drain the water from the TGCU Waste Heat
Reclaimer (Step X in Section 11.9.1). The boiler and its
BFW controls must remain in service until the completion
of the catalyst passivation procedure.
B. Confirm that the TGCU Outlet Valve is open and start a small
nitrogen purge into the bottom of the TGCU Quench Column. (This is
typically done by hooking up a temporary jumper to a connection on
one of the level bridles.)
This will purge through both the TGCU Quench Column and the
TGCU Contactor and ensure that the SO2 formed during passivation
does not contaminate the quench water or the amine.
C. If the H2/H2S analyzer is not already switched to sample from the

outlet of the TGCU Waste Heat Reclaimer, check that the sample
line from the outlet of the TGCU Waste Heat Reclaimer to the
analyzer is clear of liquids, confirm that the sample valve on the
outlet channel of the boiler is open, then switch the sample selector
valve in the analyzer enclosure to the "STARTUP" position.
D. Visually confirm that the TGCU Start-Up Blower suction block valve
and discharge block valve are closed, the bypass valve is open, the
nitrogen purge to the blower seal is in service, and the local "stop"
control at the blower is set to the run position.
E. Start the TGCU Start-Up Blower using the start/stop toggle switch in
the DCS.

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(4) After the limit switches prove these valves open, the TGCU
Start-Up Blower is started.
(5) Once the Startup Blower is started, the TGCU Start-Up Blower
Bypass Valve is closed.
As this valve is closed, the blower will start to load. As it does so, the
blower will begin to "pull" nitrogen through the TGCU Reactor Feed
Heater and TGCU Reactor Feed Mixer and all of the associated
piping.
F. Once the blower operation has stabilized, open the TGCU

Warmup/Bypass Valve by increasing the output from its hand control
to 100%.
As the TGCU Warmup/Bypass Valve opens, the TGCU Start-Up

Blower will begin re-circulating gas from the outlet of the TGCU
Waste Heat Reclaimer back to the TGCU Reactor Feed Heater (via
the TGCU Contactor overhead line).
G. Once re-circulation has been established, place nitrogen flow

controller in "automatic" and adjust its setpoint to 5-10% of maximum
flow.
H. Allow the front-end of the TGCU to operate in this manner until the
following conditions are both satisfied:
(1) The hydrogen controller shows 0.5% or less hydrogen

concentration in the circulating gas.
(2) The catalyst bed in the TGCU Reactor has been cooled below
150°C per the temperatures indicated in the DCS for the
catalyst bed and for the reactor outlet.
I. Verify that the utility air flow controller is in "manual" and set to 0%
output.
J. Verify that flow control valve, the upstream block valve, and the
downstream block valve are all closed in the utility air supply line.
K. Rotate the spectacle blind in the utility air line to the "open" position,
then open the upstream block valve and the downstream block valve.
L. Slowly increase the output from the flow controller to open the flow
valve and admit a small amount of utility air into the circulating gas
and begin passivating the catalyst. A maximum oxygen

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concentration in the range of 0.5-1.0% will probably be required

during the initial stages of passivation.
CAUTION
THE AMOUNT OF AIR ADDED MUST BE LIMITED INITIALLY

TO AVOID EXCESSIVE TEMPERATURE RISE ACROSS THE
TGCU REACTOR AS THE FeS IN THE CATALYST IS
OXIDIZED. TEMPERATURES IN EXCESS OF 175°C MAY
CAUSE THE SULFIDED CATALYST TO REACT WITH THE
OXYGEN. IF THIS OCCURS, THE CATALYST WILL HAVE TO
BE PRE-SULFIDED DURING THE NEXT STARTUP. ALSO,
CATALYST DAMAGE MAY OCCUR IF LOCAL CATALYST
TEMPERATURES BECOME EXCESSIVE.
DO NOT ALLOW THE CATALYST BED TEMPERATURES TO

EXCEED 150°C. REDUCE THE UTILITY AIR FLOW AS
NECESSARY TO KEEP THE REACTOR BED
TEMPERATURES AND THE OUTLET TEMPERATURE AT
150°C OR BELOW.
M. As the temperature rise across the reactor starts to decrease, the

oxygen concentration in the circulating gas may be increased by
using the flow controller to open the flow valve further and increase
the air flow into the circulating stream.
N. When there is no longer any temperature rise across the reactor, the
passivation of the catalyst is complete. Discontinue the flow of
nitrogen to the front-end of the TGCU by placing the nitrogen flow
controller in "manual" and setting its output to 0% to close the control
valve. Observe the TGCU Reactor temperatures to ensure that no
further reaction occurs (leave the nitrogen flowing to the TGCU
Quench Column).
If the catalyst bed temperatures start to rise when the nitrogen flow is
discontinued, re-establish nitrogen flow until the bed cools again,
then stop the nitrogen flow. Repeat this step as necessary until there
is no temperature rise in the reactor with the nitrogen flow shut off.

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O. Once the nitrogen flow has been discontinued, the TGCU Start-Up
Blower is no longer needed for re-circulation. Shut down the blower
as follows:
(1) Reduce the output from the hand control to 0% to close the
TGCU Warmup/Bypass Valve and stop the recycle flow to the
TGCU Reactor Feed Heater.
Verify that the valve has closed, and that the DCS indicates that
this valve has closed.
(2) Shut down the blower using the start/stop selector switch in the
DCS.
The PLC will open the TGCU Blower Bypass Valve, stop the
blower, turn on the nitrogen purge, and close its suction and
discharge valves. Verify that the DCS indicates each valve has
moved to the proper position.
P. Use the flow controller to raise the utility air flow to 80% or more and
allow air to cool the TGCU Reactor.
Continue the air flow until the temperature leaving the TGCU Reactor
is about the same temperature as the air entering the TGCU
Reactor.
Q. At the completion of the cooling operation, activate the TGCU ESD

using the S/D button to shut down and isolate the utility air.
R. Close the upstream block valve and the downstream block valve in
the utility air supply line, then rotate the spectacle blind to the
"closed" position. Close the steam-jacketed block valve at the
junction with the tailgas line to the TGCU Reactor Feed Heater.
S. Discontinue the flow of nitrogen to the TGCU Quench Column, then

close the TGCU Outlet Valve.

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WARNING
THE OVER-PRESSURE PROTECTION FOR THE TGCU IS

THROUGH THE THERMAL OXIDIZER VENT STACK. HOWEVER,
IF THE TGCU OUTLET VALVE IS CLOSED WHILE THE TGCU IS
SHUT DOWN, STEPS MUST BE TAKEN TO ENSURE THAT THE
TGCU IS NOT COMPLETELY BLOCKED-IN BY CREATING
ANOTHER OPENING FROM THE TGCU TO THE ATMOSPHERE
SO THAT THE TGCU CANNOT BE OVER-PRESSURED.
T. Visually confirm that:
(3) The TGCU Outlet Valve is closed.
(4) The nitrogen to the TGCU Reactor and the TGCU Quench
Column is positively isolated from the TGCU.
(5) The pre-sulfiding gas shutdown valve is closed.
(6) The TGCU Start-Up Blower is shut down, with its suction and
discharge valves closed and the nitrogen purge in service.
(7) The TGCU Quench Column inlet valve and the TGCU Quench
Column bypass valve are closed.
(8) All steam heating services on the sulfur vapor valve jackets are
still functioning and the steam traps are operating properly.
U. The TGCU catalyst is now passivated and cooled, and can be safely
handled. The TGCU is now ready to be isolated and made safe for
entry.
V. If the TGCU will be down for an extended period, special precautions

should be taken to prevent the TGCU Waste Heat Reclaimer tubes
from cooling to the point where water can condense inside them.
Most of the corrosion that occurs in TGCUs is due to the acidic water

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Close the steam outlet valve on the boiler and open the vent valves
on the boiler to de-pressure it. Make sure that the boiler level control
continues to operate properly so that the water level does not drop
below the tubes until they have cooled and the boiler is fully
de-pressured. Once the boiler is de-pressured, block-in its BFW
supply and drain the water from it. Then use a temporary "jumper" to
supply LP steam to the boiler shell. Drain the condensate from the
boiler occasionally to keep the tubes safely above the water
condensation temperature (100-110°C).

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One special circumstance that merits discussion is shutting down the
TGCU when there are tube leaks in the TGCU Waste Heat Reclaimer.
a chance to form acid and cause rapid corrosion. When the TGCU is shut
down, however, several problems can develop:
1. Liquid water may accumulate in the equipment or piping and

form a variety of acids (sulfurous, polythionic, etc.) that will
rapidly corrode the steel.
2. Water and/or steam may reach the TGCU Reactor catalyst and
weaken or damage it.
A. Switch the SRU tailgas from the TGCU to the Thermal Oxidizer.
B. Activate the TGCU ESD system using the S/D button.
C. Close the TGCU Outlet Valve.
D. De-pressure the TGCU Waste Heat Reclaimer, taking care to reduce

the pressure slowly enough to avoid over-stressing the boiler.
E. Maintain a visible water level in the boiler. Water must remain in the
boiler until it is de-pressured to prevent overheating damage to the
tubes.
F. Once the boiler is fully de-pressured, drain the water from the boiler
to prevent any further leakage into the process side of the
equipment.
G. The TGCU is now ready to be isolated and made safe for entry.

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11.9.4 Special Precaution During Shutdowns
CAUTION
THE FOLLOWING PROCEDURE IS VERY IMPORTANT TO

PROTECT THE TGCU DURING SHUTDOWNS. FAILURE TO
OBSERVE THESE PRECAUTIONS CAN LEAD TO "STUCK"
VALVES IN THE PROCESS GAS LINES, RESULTING IN AN
EXTENSIVE (AND EXPENSIVE) SHUTDOWN TO REPAIR THE
VALVE(S).
When a TGCU is shut down for any appreciable length of time, water
vapor in the process gas can condense and accumulate in the low spots.
Since the process gas contains CO2, H2S, SO2, and other compounds, the
condensed water can be quite acidic. As this acid water trickles over the
piping, it corrodes the metal. If this water then reaches a steam-jacketed
valve or pipe, the water will boil away and deposit the corrosion products
on the heated surface. This occurrence can quickly cause a
steam-jacketed valve to become "stuck", which usually results in an
extended shutdown to repair the valve before that TGCU can be restarted.
This problem can be prevented, by keeping water from accumulating near

these valves during shutdowns. The valves to be protected are:
TGCU Warmup/Bypass Valve

TGCU Outlet Valve
The most positive means for preventing condensation of water in the unit
is to purge it with inert gas (nitrogen, etc.). One way to accomplish this is
as follows:
A. Confirm that the Quench Column hand control in the DCS is set to
0% output.
B. Confirm that the SRU Tailgas Valve to the TGCU is closed.
C. Confirm that the Leak Test switch in the DCS is toggled to "OFF".
D. Switch the Startup/Run selector switch in the DCS to "STARTUP".

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The PLC will open the TGCU Quench Column Bypass Valve. Verify
that the DCS indicates that the Quench Column Bypass Valve is
open.
E. Toggle the Leak Test switch to "ON".
F. Close the TGCU Warmup/Bypass Valve by reducing the output of

the hand control to 0%. Verify that the DCS indicates that the valve
has closed.
G. Verify that the TGCU Start-Up Blower Bypass Valve is open and that
the DCS indicates that the valve is fully open.
H. Open the steam-jacketed block valve in the nitrogen supply line.
I. Toggle the Nitrogen On/Off switch in the DCS to "ON".
J. Place the nitrogen flow controller in "manual" and adjust its output to
open the control valve slightly and establish a small flow of nitrogen
into the front-end of the TGCU.
K. "Crack" the TGCU Outlet Valve open slightly to allow the nitrogen to
flow to the Thermal Oxidizer. Adjust the TGCU Outlet Valve to
"pinch" so that the pressure in the TGCU is slightly positive (about
0.07-0.15 kg/cm2(g)) on the pressure indicator in the DCS.
L. With the valves arranged in this manner, the purge gas will proceed
as follows:
(1) Through the TGCU Rector Feed Heater, TGCU Reactor Feed
Mixer, TGCU Reactor, and TGCU Waste Heat Reclaimer.
(2) Through the TGCU Quench Column Bypass Valve.
(3) Through the TGCU Start-Up Blower Bypass Valve.
(4) Through the TGCU Contactor overhead line, flowing past the
(5) Through the TGCU Outlet Valve and out to the Thermal
Oxidizer.
This will keep purge gas sweeping through or past all of the
steam-jacketed process gas valves so that condensed water will not
accumulate and cause problems.

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If it is not possible to purge the TGCU with inert gas while it is shut
down, it is possible to protect these valves by using drain valves to
prevent the accumulation of water near the steam-jacketed valves.
In order to accomplish this, drain valves in the following locations are
used:
(1) In the bottom of the TGCU Contactor overhead line, between

the TGCU Warmup/Bypass Valve and the TGCU
Warmup/Bypass Valve.
(2) In the bottom of the outlet line from the TGCU Waste Heat
Reclaimer.
With these drain valves open, there should not be significant

accumulation of condensed water near any of the steam-jacketed
process gas block valves.
WARNING
BE CERTAIN THAT THE SRU TAILGAS VALVES TO THE

TGCU, AND THE TGCU OUTLET VALVE ARE CLOSED IF THE
SRU IS OPERATING WHEN THE TGCU IS SHUT DOWN.
LEAVING EITHER OF THESE VALVES OPEN WHILE THE SRU
IS OPERATING WILL ALLOW SRU TAILGAS TO ENTER THE
TGCU, RESULTING IN SOLVENT CONTAMINATION,
CORROSION DAMAGE, AND POSSIBLE PERSONNEL
EXPOSURE TO H2S AND SO2.
MAKE CERTAIN ALL THESE DRAIN VALVES ARE CLOSED

BEFORE ATTEMPTING TO RESTART THE TGCU.
To use these drain valves, proceed as follows:
A. Confirm that the SRU Tailgas Valves to the TGCU are closed.
B. Close the TGCU Outlet Valve. Make sure that this valve is
closed tightly.
C. Open the two special drain valves. Observe appropriate

precautions to prevent personnel exposure to H2S and/or SO2
that may still be contained in the unit, or that may leak into the

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unit later. It is recommended that warning signs be posted to

identify the hazard that exists near these drain valves.
D. Check the drain valves periodically to be sure that process gas

is not escaping to the surroundings.
E. Close the drain valves before attempting to restart the

TGCU.

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The TGCU ESD system can be initiated by any of the actuating devices
outlined in Section 11.5 of these guidelines. The operator must determine
and correct the condition causing the shutdown before the TGCU can be
restarted. The problems outlined below should be investigated first by the
operator in his troubleshooting procedure.

TGCU Reactor 1. The sulfur plant(s) is(are) off-ratio
High-High Outlet Temperature causing the SRU tailgas stream to
contain large amounts of SO2,
resulting in excessive heat release
in the catalyst bed.
2. Malfunction of the reactor feed
heater temperature control system
or control valve.
3. The utility air normally used during
shutdown operations to passivate
the catalyst has been left open.
TGCU Waste Heat Reclaimer 1. Loss of make-up water supply

Low-Low Level pressure.
2. Make-up water line plugged, or
manual block valve closed or
pinched.
3. Malfunction of the level control
system.
Complete Flowpath Interlock 1. The TGCU outlet block valve is not

fully open.
2. An automated process gas valve in
the TGCU has failed to open fully
as directed by the PLC.
3. Malfunction of the limit switch is
causing a false indication that the
valve is not open.

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The Tailgas Cleanup system is directly or indirectly affected by shutdowns
and/or outages in five other systems in the complex. These effects are
described below.
11.9.6.1 Amine Regeneration Unit Outages

Amine acid gas flow from the Amine Regeneration Unit(s) can be
interrupted for a variety of reasons. For instance, the gas flow to the
absorber in the complex can be blocked manually or automatically,
the amine flow from the flash tank to the stripper can be interrupted,
etc. When these events occur, the acid gas flow will not cease
immediately due to the residence time in the amine distribution
piping, the flash tank, and the stripper. If processing in the affected
Amine Regeneration Unit is restarted within the time frame of this
system residence time, the amine acid gas flow to the SRUs
upstream of the TGCU will probably dip, but should not stop
completely.
If the interruption in the Amine Regeneration Unit is long enough,

though, the amine acid gas flow can fall far enough to cause the acid
gas flame(s) in the SRU(s) to become unstable, at which point the
SRU ESD system will be activated by "flame failure".
Section 11.9.6.3 below describes the effect of this on the TGCU.

the SRUs generally has minimal impact, outages in this system are
usually of little consequence to the SRUs or the TGCU.
11.9.6.3 Sulfur Recovery Unit ESD System

The SRU ESD systems stop the flow of acid gas to the affected
SRU. As a result, the tailgas flow from that SRU ceases almost
immediately. If only a single SRU shuts down, the TGCU will stay
online processing SRU tailgas from the remaining SRU. However, if
both SRUs shutdown, then there would be no SRU tailgas flowing
through the front-end of the TGCU, and consequently nothing to
process. So, the TGCU is shut down whenever the both of the sulfur
plants shut down.

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However, if the TGCU is not yet processing tailgas from either SRU,
there is no reason to shut it down if the SRUs are not running. This
simplifies startup of the TGCU by allowing its ESD system to be
independent of the SRU ESD systems until tailgas is introduced into
the TGCU.
11.9.6.4 Thermal Oxidizer ESD System

A TTO ESD has no direct effect on the TGCU, as the flow of TGCU
effluent to the Thermal Oxidizer will not be interrupted. However,
when the TTO ESD shuts down the Thermal Oxidizer Burner, the
sulfur compounds in the Thermal Oxidizer feed gas will no longer be
oxidized to sulfur dioxide. This means that hydrogen sulfide will be
vented to the atmosphere from the top of the Thermal Oxidizer Vent
Stack. Under normal circumstances, this is not a cause for concern
because the TGCU is processing the SRU tailgas. Since the H2S
content of the TGCU effluent should be low and the stack is tall,
dangerous ground level concentrations of H2S should not develop.
However, note the warning that appears in Section 12.6.2 of these

guidelines regarding high temperature in the Thermal Oxidizer if the
SRU tailgas and/or TGCU effluent gas contains excessive amounts
of H2S. Also, note that the operating permit for this plant may not
allow venting un-incinerated gases for extended periods. Review the
permit before operating in this mode for a lengthy period.
If the H2S concentration in the TTO feed gas is high (above 3.0%),
do not attempt to restart the Thermal Oxidizer. Instead, direct your
attention to the amine or SWS unit upstream of the SRUs that is
probably causing the problem and bring the SRUs back on-ratio.
This will allow the TGCU to reduce the H2S concentration in the
Thermal Oxidizer feed gas to an acceptable level, so that restart of
the Thermal Oxidizer can proceed smoothly.
Failure to correct the upstream problem(s) first will likely lead to

the TTO shutting down again on high-high temperature,
requiring another restart of the TTO.

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There are three impacts on the TGCU if the complex steam system
is shut down. One of these will only create problems if the steam
supply to the TGCU is unavailable for a long period of time - the
heating for the steam-jacketed process gas valves will be lost,
possibly leading to solid sulfur freezing in these valves.
The most immediate impact on the TGCU will be the loss of

LP steam to the TGCU Stripper Reboiler if the steam outage lasts
long enough. As the heat input to the reboiler declines, stripping of
the acid gas from the amine will decline and the H2S in the TGCU
effluent gas leaving the TGCU Contactor will begin to increase. This
will quickly lead to high SO2 emissions from the Thermal Oxidizer
Vent Stacks as indicated in the DCS.
A third impact on the TGCU will be the loss of LP steam to the

stripper reboilers in the Amine Regeneration Unit if the steam outage
lasts long enough. As the heat input to the reboilers declines,
stripping of the acid gas from the amine will decline and the amine
acid gas flow rate to the SRUs will gradually diminish. If the amine
acid gas flow falls far enough to cause an acid gas flame to become
unstable, the SRU ESD system will be activated by "flame failure" as
described previously in the discussion about the Amine Regeneration
Unit outages, with the resulting impact on the TGCU as previously
described in Section 11.9.6.3.

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This Section contains analytical procedures for determining:
1. The concentrations of total amine in the TGCU solvent (Section 11.10.2).
2. The concentrations of H2S and CO2 in the TGCU solvent (Sections

11.10.3 and 11.10.4).
3. The foaming tendency of TGCU solvent (Section 11.10.5).
4. The H2S content of the TGCU Contactor overhead gas (Sections 11.10.6
and 11.10.7).
5. The performance level of the TGCU Reactor catalyst (Section 11.10.8).
11.10.1 General Procedures for Analyzing TGCU Solvent1,2

An amine solution which is to be analyzed should first be inspected
visually. If conducted by an experienced person, such an inspection will
often yield important clues to the identity of a number of contaminants.
For example, a green color in an amine solution usually indicates finely
divided iron sulfide in sub-colloidal particle size (<1 micron), whereas a
finely divided black suspension indicates the presence of larger
(>3 micron) iron sulfide particles. A green or blue solution can indicate the
possibility of either copper or nickel, while an amber colored solution may
contain suspended or dissolved iron oxide. Iron may complex with the
amine an give the solution an amber or dark red color. Thermal
degradation of the amine may give the solution a dark red to brown color.
Amines sometimes display a red or dark brown color resulting from
oxidation, particularly when combined with thermal degradation. An oil
slick on the solution or an oil-like odor is indicative of hydrocarbon
contamination. The presence of these contaminants, however, must be
proven by analysis.
The next step in analyzing an amine solution is the determination of the

percent amine and the acid gas content (H2S and CO2). Both rich and
lean solutions may be analyzed for these constituents, and from the
analyses the extent of acid gas loading and efficiency of stripping can be
ascertained. Procedures for these analyses are given in Sections 11.10.2
through 11.10.4 that follow.
1
The Dow Chemical Company, Gas Conditioning Fact Book, 1962, pp. 310-311.
2
Dow Chemical U.S.A., Gas Treating from Dow, 1987, pp. 8-1-1 – 8-1-2.

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In addition to the procedure in Section 11.10.2, the amine concentration of

the solvent can be determined by performing Kjeldahl and Van Slyke
nitrogen analyses. The Kjeldahl determination indicates the total nitrogen
content of the solution, including nitrogen from the amine and from amine
degradation products. The Van Slyke method, on the other hand, shows
amine content, but does not reveal the extent to which the original amine
has been degraded or tied up as heat stable salts. The difference
between the results obtained through Kjeldahl and Van Slyke analyses
usually indicates the degree of amine degradation. As would be
expected, little difference is obtained with initial or unused solution. These
analyses are not commonly performed in plant laboratories, but are
generally left to the chemical solvent supplier.
Heat stable salts can also be determined by a total anion assay. The
amine solution is passed through an ion exchange column containing ion
exchange resin in the hydrogen form. Acid salts are thus broken down
and the acids recovered in the column effluent, while the amine is
absorbed in the column. The acid in the effluent is determined by
potentiometric titration, and from these results plus the original amine
concentration the amount of amine in the form of heat stable salts is
calculated. Again, this type of analysis is commonly left for the chemical
solvent supplier to perform.
The foaming characteristics of an amine solution are determined

empirically in a simple apparatus consisting of an air (or gas) supply,
pressure regulator or gas manometer, graduated glass cylinder, and a gas
dispersion tube. The amine solution is poured into the graduated cylinder
and air passed through at a constant rate. After five minutes, the height of
the foam is recorded, the air flow is interrupted, and the time for the foam
to break is determined. The results thus obtained will indicate whether or
not evaluation of anti-foam agents is desirable. Section 11.10.5 describes
this procedure more completely.
A water analysis can be conducted on the amine solution to obtain a

material balance and serve as an approximate check on the amine
concentration. This is typically determined using the Karl Fischer method
of analysis, but most plant laboratories leave this procedure to the
chemical solvent supplier.
Ordinarily, the above analyses will provide an accurate picture of the

condition of the amine plant solution. At times, however, unusual
operational difficulties may be encountered in amine sweetening units

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because of contaminants which are not revealed by the usual analytical

methods. When this occurs, infrared spectroscopic analysis may often be
utilized to good advantage.
Infrared spectroscopy is based on the principle that each molecule or

functional group exhibits its own particular absorption characteristics when
exposed to infrared light of a definite wavelength. A wide variety of
functional groups can be readily detected and identified by infrared
techniques. For example, it has been found that degraded or oxidized
amine solutions may contain ammonia, formic acid, a di-functional acid, a
carbonyl compound yielding a glyoxal dinitrophenylhydrazone derivative,
and a high molecular weight material that exhibits the characteristics of a
Jones polymer. Also, both mono- and di-substituted amines have been
identified. Each component exhibits its own particular effects on
corrosion, foaming, and acid gas absorption, effects which can be
determined only by the separate evaluation of each contaminant. Once
these effects are determined, a knowledge of functional groups present
and their relative concentration makes it possible to anticipate which types
of contaminants may be causing difficulties. The chemical solvent
supplier can usually perform this type of analysis more easily than the
plant laboratory.
Steps should be taken to ensure that the amine solution samples taken
are representative of the circulating solvent. Samples should be taken in
glass or plastic containers. Metal containers will cause low results for H2S
because sulfides will react with the metal walls of the container. Do not
use copper tubing to withdraw the samples; the copper will contaminate
the amine solution, and H2S will react with the copper and give low
results.
Special care should be exercised when taking samples of the rich amine
solution to avoid personnel exposure to H2S. Hot, fully loaded amine
solution can flash acid gas when released to atmospheric pressure,
causing low acid gas loading results in addition to the dispersion of H2S to
the surroundings. Take samples of the rich solution from the coolest point
in the process (the TGCU Contactor outlet, usually), and cool the samples
in a stainless steel coil immersed in an ice bath or cold water to prevent
flashing. The solution should be allowed to flow to a drain in this fashion
for several minutes before taking the sample to be sure that circulating
amine is being taken.

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In the laboratory procedures that follow, several different reagents are

used that can be harmful if proper care is not exercised. Acids, bases,
and flammable substances are utilized in these procedures, so adherence
to proper laboratory safety practices is necessary to ensure the safety of
all personnel.

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11.10.2 Determination of Amine Concentration in TGCU Solvent

The amine concentration in the TGCU solvent can be determined by acid
titration of the lean solution. This technique is not specific for free amine,
however, as amine present in the solution as an amine-acid salt will also
react during the titration. This technique will also give erroneous results if
there are other basic materials in the solution, such as caustic or soda ash
(sometimes used to "neutralize" heat stable salts).

0.5 N Hydrochloric Acid (HCl)
Bromophenol Blue Indicator
(3',3'',5',5''-tetrabromophenolsulfonephthalein)
2. Procedure:
a. Place about 95 ml of distilled or deionized water in a 250 ml

beaker or Erlenmeyer flask.
b. Add about 5 ml of lean amine solution to the water in the beaker

via pipette, recording the actual quantity.
c. Add 5 drops of Bromophenol Blue indicator to the solution in the

beaker and stir well.
d. Titrate the solution in the beaker with 0.5 N HCl to a faint yellow
color. Alternatively, if a pH meter is available, titrate to a pH of
4.5. Record the amount of HCl used in the titration.

+ –
R2HN + HCl R2HNH + Cl
where R2HN = CH3-N-(CH2-CH2-OH)2 = MDEA

(methyldiethanolamine)
As the hydrochloric acid is added to the solution, it reacts with the

amine to form a chloride salt. Once all the amine has reacted, the
continued addition of acid causes the pH of the solution to drop, until
the Bromophenol Blue indicator changes from blue to yellow. Note
that HCl reacts with the amine on a 1:1 molar basis.

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4. Calculation of Weight Percent Amine:
ml HCl  Normality of 

 Amine   100%   Used  HCl Solution
Weight %
  Mole     
Amine  Weight  1000 ml / l   ml of    Sp. Gravity of 
  Sample  Amine Sample 

simplified to:
ml HCl Normality of 

 Used   HCl Solution 
Weight % Amine  11.253     
 ml of 
Sample 
 

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11.10.3 Determination of Total Acid Gas Loading in TGCU Solvent

The total acid gas (H2S + CO2) loading, relative to the amine
concentration, in either the lean or rich TGCU solvent can be determined
by base titration of the solution. This procedure does not distinguish
between H2S and CO2. However, together with the procedure in
Section 11.10.4, the individual concentrations of H2S and CO2 can be
determined.
1. Reagents: Methanol (CH3OH), Anhydrous

0.5 N Potassium Hydroxide (KOH) Solution in Methanol
Thymolphthalein Indicator in Methanol
2. Procedure:
a. Place about 125 ml of methanol in a 250 ml beaker or

Erlenmeyer flask.
b. If a pH meter is available, insert the pH meter probe into the

methanol in the beaker and adjust the pH of the methanol to
11.2 by titrating the methanol in the beaker with the 0.5 N KOH.
c. If a pH meter is not available, add 5 drops of Thymolphthalein

indicator to the methanol in the beaker. Titrate the solution in
the beaker with 0.5 N KOH until the solution turns a faint blue
color, indicating a pH of 11.2. The change to faint blue will be
sudden, so add the KOH slowly (one drop at a time).
d. Add about 20 ml of lean amine solution to the methanol in the

solution is being tested, use about 10 ml of solution instead.
e. Titrate the solution in the beaker with 0.5 N KOH back to a pH

of 11.2 (or until the solution again turns a faint blue color when
using Thymolphthalein indicator). Record the amount of KOH
used in this titration.

+ –
H2S + KOH K + HS + H2O
+ –
CO2 + KOH K + HCO3
As the potassium hydroxide is added to the solution, it reacts with the

H2S and CO2 to form potassium hydrosulfide and potassium

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hydrogen carbonate salts. Once all of the acid gas has reacted, the
continued addition of base causes the pH of the solution to rise, until
the Thymolphthalein indicator changes from colorless to blue. Note
that KOH reacts with H2S and CO2 on a 1:1 molar basis.
4. Calculation of Acid Gas Loading (molar basis):
ml KOH   Normality of 

Moles Acid Gas  Amine   100%   Used  KOH Solution
  Mole    
Mole Amine  Weight  1000 ml / l   ml of    S.G. of    Wt % Amine
 
Sample Sample  in Solvent 
Note that "ml KOH used" refers to the amount used in the second
titration, step 2.e. The "wt % amine in solvent" can be determined
using the procedure in Section 11.10.2.

simplified to:
ml KOH  Normality of 

 Used   KOH Solution 
 11.253     
Moles Acid Gas
Mole Amine  ml of   Wt % Amine 
Sample    in Solvent 
   
5. Special Considerations:
a. Excess moisture in the equipment will give false readings.

Water may be used to clean the equipment if the equipment is
thoroughly dried prior to use with the anhydrous methanol.
b. The faint blue titration endpoint using Thymolphthalein indicator

is not definite. It may best be determined by comparing the
color of the solution against a reference prepared by titrating a
second sample of methanol-Thymolphthalein to the same color.
c. The KOH solution and Thymolphthalein indicator solution

should be kept tightly closed to prevent loss of methanol by
vaporization. Any vaporization of methanol from the KOH
solution will change the normality of the solution.
d. The Thymolphthalein indicator solution can be prepared by

dissolving 5 grams of thymolphthalein in 100 ml of anhydrous
methanol.

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11.10.4 Determination of H2S and CO2 Loading in TGCU Solvent

The H2S loading, relative to the amine concentration, in either the lean or
rich TGCU solvent can be determined by titration of the solution with
iodine. Since CO2 does not react with iodine, this procedure is specific for
H2S. Together with the total acid gas loading determined using the
procedure in Section 11.10.3, the individual concentrations of H2S and
CO2 can be determined.

Concentrated Hydrochloric Acid (HCl) or Sulfuric Acid
(H2SO4)
Standard Starch Solution - 1%
0.1 N Iodine Solution (I2)
0.1 N Sodium Thiosulfate Solution (Na2S2O3)
2. Procedure:
a. Measure about 25 ml of chilled iodine solution and place it in a

250 ml beaker or Erlenmeyer flask. Record the amount of
iodine solution used.
b. Carefully add about 25 ml of concentrated acid to the beaker.
c. Add about 5 ml of standard starch solution to the beaker, then

re-chill the beaker in an ice batch for 2-3 minutes.
d. Slowly add 10-20 ml of lean amine solution to the solution in the

solution is being tested, use 1-2 ml of solution instead.
e. Use about 25 ml of distilled or deionized water to rinse the

inside of the beaker, then swirl the contents gently to mix the
solution without splashing it.
f. Titrate the excess iodine in the sample with the sodium

thiosulfate solution until the blue color disappears. The end
point is a pale yellow or clear color. The approach of the
endpoint is usually indicated by a milky brown tint at the top of
the liquid surface. As the endpoint nears, slow the rate of
titration and use a small amount of distilled or deionized water
to wash the flask. Record the amount of sodium thiosulfate
solution used in this titration.

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g. Check the pH of the titrated solution with pH paper to be sure

the solution is acidic. If the solution is not acidic, repeat the
procedure but use more acid in step 2.b.
H2S + I2 S + 2 HI
I2 + Na2S2O3 2 S + NaI + NaIO3
When the solvent is added to the iodine solution, the H2S in the
solvent reacts with the iodine to form hydrogen iodide and elemental
sulfur. The solution contains an excess of iodine to ensure that all of
the H2S reacts. The iodine solution is chilled prior to adding the
solvent to eliminate or minimize the evolution of H2S gas. Note that
H2S reacts with iodine on a 1:1 molar basis.
When the sodium thiosulfate solution is added to the solution, it

reacts with the remaining iodine to form sodium iodide and sodium
iodate, along with more elemental sulfur. (It is this elemental sulfur
that may cause the titrated solution to appear pale yellow.) Once the
last bit of iodine is consumed, the starch solution loses its
characteristic blue color. The amount of H2S in the solvent sample is
then calculated from the difference between the total iodine and the
iodine that reacts with the sodium thiosulfate. Note that sodium
thiosulfate reacts with iodine on a 1:1 molar basis.
The purpose of the concentrated acid is to neutralize the amine so

that it will release the H2S (a weaker acid) so it can react with the
iodine. If the titrated solution is not acidic in step 2.g, then the amine
was not fully neutralized and the H2S determination will not be
correct.
4. Calculation of H2S Loading (Molar Basis):
ml I2 Normality of   1 liter   1 g - mole 

 
g - moles
   
I2 Used  used   I2 Solution  1000 ml   2 g - equivalent 
g - moles  ml  Normality of   1 liter   1 g - mole 

Na2S2O3  Na2S2O3    Na2S2O3     
Used  used   Solution  1000 ml   2 g - equivalent 
   

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g - moles   g - moles 
 Amine   I2 Used   Na2S2O3 Used
  Mole   100 % 
Moles H2S
Mole Amine  Weight   ml of    S.G. of    Wt % Amine 
  Sample  Sample   in Solvent 
The "wt % amine in solvent" can be determined using the procedure

in Section 11.10.2.

the solution is about 45 wt% MDEA. Using these values and
substituting the first and second equations into the third, these
equations can be simplified to:
Normality  Normality of 
ml I2   of I   ml Na2S2O3   Na S O 
Used  2  Used   2 2 3
Moles H2S  Solution   Solution 
 5.626 
Mole Amine  ml of    Wt % Amine
Sample  in Solvent 
5. Calculation of CO2 Loading (Molar Basis):
Using the total acid gas loading determined with the procedure in
Section 11.10.3, the CO2 loading of the solvent is determined by
difference:
Moles CO2  Moles Acid Gas   Moles H2S 

     
Mole Amine  Mole Amine   Mole Amine 
6. Other Common Units:
The loadings calculated above can be easily converted to other units

commonly used within the industry:
Grains H2S  Moles H2S   Wt % Amine   S.G. of 

 166.7    
 Moles H2S 
 
Wt % Amine 
Wt % H2S  0.2858   

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SCF CO2  Moles CO2   Wt % Amine   S.G. of 

 0.2653    
 Moles CO2 
 
Wt % Amine 
Wt % CO2  0.3693   
Note that these conversions are specifically for MDEA. Other

amines require different conversion factors.

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11.10.5 Determination of Foaming Tendency of TGCU Solvent

The procedure described in this section is an empirical method for
measuring the foaming tendency of aqueous amine solvents, universally
accepted within the industry.
1. Principle:
Air is bubbled through a solvent sample at a fixed rate for five

minutes, at which time the foam height is measured. The air flow is
stopped and the time for the foam to disappear is measured. The
foam height and "break" time are indicative of how high the foaming
tendency of the solvent is.
2. Equipment: 1000 ml Graduated Cylinder

Aquarium Air Pump (or laboratory air supply) with
Bubble Stone
Stop Watch (or regular watch with a second hand)
3. Procedure:
a. Pour about 200 ml of the sample solution into the graduated

cylinder and insert the bubble stone into the bottom of the
cylinder.
b. Record the level of sample in the cylinder (in ml).
c. Start the air pump or air supply to agitate the sample with
oil-free air at 4 liters per minute (0.2 Nm3/H).
d. After five minutes, record the height of the foam in the cylinder
(in ml). Then turn off the air supply and measure the time in
seconds for the foam to "break". For consistency, foam "break"
is defined as the first clear "fish eye" in the surface of the liquid
in the cylinder.
4. Calculation:
Foam Height = Height of Foam - Initial Height of Sample (in ml)
5. Interpretation:
Considerable experience with this test has shown that if the foam
height exceeds 200 ml or the "break" time exceeds 5 seconds, the
plant may be experiencing a foaming problem. The higher the foam

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height and/or the longer it takes to "break", the more severe the
problem.
6. Other Considerations:
a. A nitrogen cylinder with the pressure regulated to about

0.35 kg/cm2(g), equipped with a flow rotameter, may be used
instead of air. Be sure to keep the tubing and fittings oil-free.
b. This procedure can be used to evaluate the effects of anti-foam

agents on the solvent. However, care must be exercised in
cleaning the equipment between tests since a very small
quantity of residual anti-foam agent will affect the test.
c. Foaming is sometimes caused by contaminants in the solvent

that can be removed by activated carbon treatment. The effect
of activated carbon filtration can be evaluated by running foam
tests on treated and untreated samples. The sample is treated
by mixing it with a quantity of carbon (12-20 mesh) to remove
the contaminant, then filtering the mixture through Whatman
No. 41 filter paper.

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11.10.6 H2S Conc. in TGCU Contactor Ovhd by the Tutweiler Method

The overhead gas from the TGCU Contactor can be sampled from the
sample connection near the sample line for the H2/H2S analyzer.
1. Using a 500 ml Tutweiler apparatus, sample and titrate the treated

gas leaving the TGCU Contactor as outlined in Section 7.10.1 of
these guidelines.
H2S + I2 2 HI + S

for example.)

Mole % H2S     Iodine Solution   (11.85)    
Solution Used     289   P - V.P. 
three factors (which correct the actual H2S content to compensate for
expansion due to temperature, pressure, and water content) can be
combined and calculated as a function of temperature only. This has
been done for the 500-ml gas sample and is included as the
Tutweiler Factor Chart in Section 9.10 of these guidelines (Chart 2).
Therefore, the equation above can be simplified to:
ml Iodine  Normality   Factor from 

PPM H2S  10,000   Solution    of Iodine    Tutweiler 
 Used   Solution  Factor Chart 
     

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11.10.7 H2S Conc. in TGCU Contactor Ovhd Using Gas Detector Tubes
As an alternative to the traditional wet-chemistry method described in the
preceding Section 11.10.6 for determining the concentration of H2S in the
TGCU Contactor overhead gas, gas detector tubes can be used to quickly
and easily make this determination. Although the discussion that follows
The following Dräger tubes can be used with this procedure:
H2S 5/b Dräger Cat. No. CH 298 01
H2S 100/a Dräger Cat. No. CH 291 01


a. Dräger Cat. No. CH 298 01, H2S 5/b

50 PPM to 600 PPM when one sample stroke is used. If
desired, the range can be reduced to 5 PPM to 60 PPM by
using 10 sample strokes. Each tube contains a substrate of a
white lead compound. When exposed to H2S, the lead

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compound is converted to brown lead sulfide. The H2S

concentration in PPM can be read directly from the marks on
the tube according to the length of the brown stain when using
10 sample strokes. If only one sample stroke is used, the tube
reading is multiplied by 10 to give the PPM of H2S. This lead
sulfide reaction is not affected by any of the other compounds
normally found in the overhead gas from the TGCU Contactor.
b. Dräger Cat. No. CH 291 01, H2S 100/a

100 PPM to 2,000 PPM when one sample stroke is used. Each
tube contains a substrate of a white lead compound. When
exposed to H2S, the lead compound is converted to brown lead
sulfide. The H2S concentration in PPM can be read directly
from the marks on the tube according to the length of the brown
stain. This lead sulfide reaction is not affected by any of the
other compounds normally found in the overhead gas from the
TGCU Contactor.
11.10.7.2 Sampling the TGCU Contactor Overhead Gas

The overhead gas from the TGCU Contactor can be sampled from
the sample connection near the sample line for the H2/H2S analyzer.
1. Before beginning, check the Dräger pump for leaks by inserting

2. Attach a short piece of rubber tubing to the process sample

valve.
3. Break off the tips at each end of a Dräger tube and insert it into
the sample pump (with the arrow on the side of the tube pointing
toward the pump).
4. Purge the rubber tubing by venting gas to the atmosphere for a

few seconds. Pinch the rubber tubing closed at the end, close
the gas sample valve, slip the end of the rubber tubing onto the
end of the Dräger tube, and reopen the sample valve.

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5. Stroke the sample pump one time (be sure to compress the
bellows until reaching the stops) and allow the pump to draw the
gas sample into the detector tube. The sample stroke is
6. Close the sample valve and remove the rubber tubing from the
end of the Dräger tube and from the sample valve.
7. Read the length of the brown stain using the marks on the tube
and record the reading.
Mole (or Volume) PPM H2S (wet basis):
 
PPM H2S  
Stain 
 
Tube  1013
    
Length  Factor   Baro. Pres., mbar 
The last factor corrects the measurement for pressure effects when
samples are taken at elevations above sea level. Note that the
average barometric pressure at the complex is
14.7 PSIA = 1013 mbar.
The "Tube Factor" depends on the type of Dräger tube used and the
number of sample strokes:
Dräger Tube Catalog No. Sample Strokes Tube Factor
H2S 5/b CH 298 01 1 10

H2S 5/b CH 298 01 10 1
H2S 100/a CH 291 01 1 1

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11.10.8 Monitoring the Performance Level of TGCU Catalyst

The activity of the cobalt-molybdenum catalyst in the TGCU Reactor
should remain adequate for years. For trouble-shooting purposes,
however, its activity should be monitored at regular intervals, beginning at
the initial startup, to establish its baseline performance.
Two of the reactions that occur in the TGCU Reactor (refer to

Section 11.6.3 of these guidelines for a complete discussion) are:
CO + H2O H2 + CO2
COS + H2O H2S + CO2
The first reaction is the classic "water gas shift" reaction. Since this is an
equilibrium reaction, an equilibrium constant for the reaction can be
expressed in terms of the reactant and product concentrations:
Keq 
H2CO2
COH2O
This equilibrium constant is mainly a function of temperature. Since the
TGCU Reactor outlet temperature for a given plant is fairly constant, as
are the concentrations of CO2 and H2O in the process gas, then the ratio
of CO to H2 in the TGCU Reactor effluent should remain fairly constant as
long as the catalyst activity does not change.
Similarly, the hydrolysis of COS to convert it to H2S is an equilibrium

reaction. Its equilibrium constant can be expressed as:
Keq 
H2SCO2
COSH2O
Since the temperature, H2S concentration, H2O concentration, and CO2
concentration of the TGCU Reactor outlet should all be fairly constant,
then the COS concentration of the gas leaving the TGCU Reactor should
be fairly constant.
It is for these reasons that Shell recommends using a gas chromatograph

to analyze the TGCU Reactor effluent gas for H2, CO, and COS on a
regular basis (once per month, for instance). Using the results of the
chromatograph analyses, the CO/H2 ratio and the COS concentration can
be plotted over time and allow trends to be detected in the catalyst
activity.

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The CO/H2 ratio is usually plotted as PPM CO divided by % H2, and the
COS is usually plotted as PPM. From the discussions above, it is clear
that a trend upward in either value, CO/H2 ratio or COS concentration,
indicates lower catalyst activity. Shell suggests planning to replace the
catalyst within a few months once either value begins to rise rapidly. Note
that the sample for the chromatograph can be taken from the gas leaving
the TGCU Quench Column, since the H2, CO, and COS concentrations
(on a dry basis) will be the same there as those leaving the TGCU
Reactor. Because this gas stream is cooler and contains less water, it is
often easier to sample and analyze than the TGCU Reactor effluent.
As discussed in Section 11.6.3, it is also typical to find methane and/or

methyl mercaptan in the TGCU Reactor effluent gas resulting from side
reactions between hydrogen and the COS and CS2 produced in the
Reactor Furnace in the sulfur plant. It can be informative to record the
concentrations of CH4 and/or CH3SH from the chromatographic analyses
as well. An increase in either component may indicate a loss in TGCU
catalyst activity. However, higher CH4 and/or CH3SH concentrations
leaving the TGCU Reactor may also be due to higher COS/CS2
concentrations entering the TGCU Unit due to lower catalyst activity in the
sulfur plant. In order to allow determining whether such an increase is
due to loss of activity in the sulfur plant or the TGCU Unit, it is helpful to
analyze the TGCU Reactor inlet gas periodically with the gas
chromatograph and record the amount of COS, CS2, and CO in the TGCU
Reactor feed. Collecting samples of this gas is somewhat more difficult
because the gas contains sulfur vapor, but the additional information
provided by analyzing this stream can be extremely helpful for monitoring
plant operations.

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Table of Contents
12. TAILGAS THERMAL OXIDIZER ............................................................................ 12-2
12.2 SAFETY ............................................................................................................... 12-2
12.4.1 Thermal Oxidizer, A2-BA1570 ...................................................................... 12-4
12.4.2 Thermal Oxidizer Burner, A2-BA1571 .......................................................... 12-4
12.4.3 Steam Knock-out Drum, A2-FA1570 ............................................................ 12-4
12.4.4 Thermal Oxidizer Air Blower, A2-GB1570A/B .............................................. 12-4
12.4.5 Thermal Oxidizer Vent Stack, A2-ME1570 ................................................... 12-5
12.4.6 Refractory for Thermal Oxidizer, A2-MR1570 .............................................. 12-5
12.4.7 Thermal Oxidizer Waste Heat Boiler, A2-BF1570 ........................................ 12-5
12.5.1 Thermal Oxidizer Burner Management System ........................................... 12-7
12.5.2 Thermal Oxidizer Temperature Control ...................................................... 12-10
12.5.3 Thermal Oxidizer Excess Oxygen Control.................................................. 12-10
12.5.5 Thermal Oxidizer Shutdown System .......................................................... 12-13
12.6.2 Effect of Upstream Operations on the Thermal Oxidizer ............................ 12-21
12.6.3 "Swapping" Air Blowers During Operation .................................................. 12-23
12.6.4 Boiler Water Treatment .............................................................................. 12-24
12.7.3 Commissioning Fuel Gas, Pilot Gas, and I/A to the Process ..................... 12-28
12.8.2 Normal Startup ........................................................................................... 12-48
12.9.1 Planned Shutdown - No Entry .................................................................... 12-59
12.9.2 Planned Shutdown for Entry ....................................................................... 12-61
Issued 30 August 2011 Tailgas Thermal Oxidation Page 12-1

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12. TAILGAS THERMAL OXIDIZER

The purpose of the Tailgas Thermal Oxidation (TTO) system is to receive the
tailgas from Sulfur Recovery Units (SRUs) or the Tailgas Cleanup Unit (TGCU),
the vapors from the Sulfur Surge Tanks, and the spent degassing air from the
Sulfur Degassing Unit (SDU), thermally incinerate all the sulfur compounds to
sulfur dioxide (SO2), and disperse the effluent safely to the atmosphere. The
effluent will normally contain less than 200 PPMV of SO2 on a dry, 0% oxygen
basis. High-pressure superheated steam is produced by waste heat recovery
from the thermal oxidation process.
12.2 Safety
WARNING

HYDROGEN SULFIDE AND SULFUR DIOXIDE. CLOSE ATTENTION

THIS PLANT.

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The Systems Diagram, Material Balance and Process Flow Diagram, Dwg. Nos.
507000-7000-01, and 507000-7000-10 through -11, are contained in the
"Process Flow Diagrams" Section of the Basic Engineering Package. Please
refer to these drawings to follow this description of the process.
When the TGCU is operating, the TGCU effluent containing H2S and COS flows
to the Thermal Oxidizer, A2-BA1570, at about 39°C [102°F]. When the TGCU
Unit is not in service, tailgas from each SRU containing H2S, SO2, COS, CS2,
and elemental sulfur flows directly to the Thermal Oxidizer at about 156°C
[313°F]. The spent degassing air from the Sulfur Degassing Unit and the sweep
air streams from each Sulfur Surge Tank (both containing traces of H2S and
sulfur vapor) are also routed to the Thermal Oxidizer. In the Thermal Oxidizer,
essentially all of the sulfur compounds are incinerated to SO2 by the
high-temperature oxidizing atmosphere created inside the Thermal Oxidizer. In
addition, most of the carbon monoxide (CO) in the feed stream is oxidized to
carbon dioxide, resulting in very low CO emissions from the Tailgas Thermal
Oxidation system.
Heat is provided to the Thermal Oxidizer by combustion of fuel gas in the

Thermal Oxidizer Burner, A2-BA1571. Combustion air for the burner is supplied
by the Thermal Oxidizer Air Blower, A2-GB1570A/B. The fuel gas flow rate is
adjusted to maintain the furnace temperature at 816°C [1500°F] to ensure
complete incineration of the sulfur compounds and carbon monoxide in the feed
to the Thermal Oxidizer.
The effluent from the Thermal Oxidizer flows to the Thermal Oxidizer Waste
Heat Boiler, A2-BF1570. The gas is cooled to about 288°C [550°F] as it
generates and superheats steam at 45.0 kg/cm2(g) [640 PSIG], which is
exported to the HP steam header at about 400°C [752°F] for use as motive
steam to the Sulfur Pit Ejector and for use elsewhere in the refinery. (Note that
the HP steam produced in each SRU is also superheated in this boiler by
combining it with the steam this boiler generates.) The cooled effluent is then
dispersed to the atmosphere from the top of the Thermal Oxidizer Vent Stack,
A2-ME1570.

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12.4.1 Thermal Oxidizer, A2-BA1570

The Thermal Oxidizer is a non-catalytic thermal incineration chamber.
The furnace shell is internally lined with refractory insulation to protect it
against the extreme process temperatures inside. The maximum
operating temperature is about 1000°C. Although the furnace can
withstand short excursions above this temperature, prolonged operation
above this temperature can damage the refractory or the downstream
boiler.
12.4.2 Thermal Oxidizer Burner, A2-BA1571

This burner is specifically designed to burn fuel gas to provide the heat
input for the Thermal Oxidizer. The burner assembly consists of the main
fuel gas burner tip, a pilot, two flame scanners, two viewports, and
specially designed air distribution baffles to effect proper combustion.
This complete unit is installed in the front of the Thermal Oxidizer.
The StackMatch® ignitor/pilot assembly is designed to be retracted or

extracted after the main burner has been lit. If it is extracted, the block
valve can be closed to isolate it from the furnace atmosphere. The
assembly includes filters for the incoming fuel gas and air, which should
be checked (and cleaned, if necessary) after each use so that there is no
chance of a plugged filter causing delays during the next startup.
12.4.3 Steam Knock-out Drum, A2-FA1570

This vertical vessel is installed in the common HP steam line from the
Waste Heat Boilers in the SRUs and the steam drum on the Thermal
Oxidizer Waste Heat Boiler. Its purpose is to remove any water droplets
(condensed or entrained) from the steam before it is routed to the
superheater pass in the Thermal Oxidizer Waste Heat Boiler, so that the
superheated steam exported to the refinery does not contain excessive
amounts of solids. The water collected in this vessel is routed to the high
pressure condensate header via a steam trap.
12.4.4 Thermal Oxidizer Air Blower, A2-GB1570A/B

These single-stage centrifugal fans provide the combustion air required to
burn fuel gas in the Thermal Oxidizer Burner. The air flow rate is
controlled by throttling a valve in the common blower discharge line. The

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fans 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 inlet filter and
silencer.
12.4.5 Thermal Oxidizer Vent Stack, A2-ME1570

The Thermal Oxidizer Vent Stack disperses the effluent from the Thermal
Oxidizer Waste Heat Boiler safely to the atmosphere. It is a free-standing
stack typically constructed of carbon steel and externally insulated to keep
its metal shell safely above the acid dewpoint of the process gas flowing
inside the stack.
12.4.6 Refractory for Thermal Oxidizer, A2-MR1570

The refractory lining in the firing chamber of the Thermal Oxidizer consists
of a layer of fireclay firebrick, installed with high temperature air-setting
mortar. The inlet plenum of the Thermal Oxidizer, exposed to the high
temperatures produced by the Thermal Oxidizer Burner, is covered with a
layer of castable refractory.
The refractory lining inside the furnace includes a "choke ring" located
about two-thirds of the way down the length of the furnace. The purpose
of the choke ring is to promote mixing between the TGCU effluent gas (or
SRU tailgas) and the hot combustion products from the Thermal Oxidizer
Burner, ensuring efficient oxidation of the sulfur compounds and carbon
monoxide that are present in the tailgas.
12.4.7 Thermal Oxidizer Waste Heat Boiler, A2-BF1570

The Thermal Oxidizer Waste Heat Boiler is a water-tube style boiler. It
includes a superheater pass for the steam produced in this boiler, plus
steam produced in the SRUs. The superheater consists of two sections
with a desuperheater between the two sections and a desuperheater on
the steam outlet. There are also two sections of boiler tubes, the screen
section and the main section. Hot gas entering the boiler flows first across
the screen section tubes, then across the two superheater sections, then
lastly across the main section of boiler tubes.
The main boiler tube section contains tubes connecting the steam drum
on top of the boiler to the mud drum on the bottom of the boiler, as well as
side wall tubes. The screen section contains rows of tubes also
connected to the mud and steam drums. The hot gas entering the boiler

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casing boils water as it circulates in the screen and main boiler tubes,
generating 48.5 kg/cm2(g) saturated steam.
The saturated steam generated in the boiler tubes exits the steam drum at
and is combined with saturated HP steam generated by the Waste Heat
Boilers in the SRUs. The combined steam is routed to the first
superheater section, then to the first desuperheater, and then to the
second superheater section. The resulting superheated steam is routed to
the second desuperheater and then to the HP steam header at about 45
kg/cm2(g) and 400°C.

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12.5.1 Thermal Oxidizer Burner Management System

The Thermal Oxidizer Burner Management System (BMS), controlled by a
programmable logic controller (PLC), has been designed to ensure a safe
firing order. It requires a certain sequence of steps before permitting
ignition. The function of the various system components is described
below.
12.5.1.1 Startup/Run Interlocks

The "startup" and "run" interlock logic is shown on the Logic Flow
Diagrams contained in the Instrumentation and Controls Diagrams
section of the Basic Engineering Package. The purpose of this logic
is to simplify lighting the Thermal Oxidizer Burner by automatically
positioning the process gas switching valves in the proper sequence
for safe operation:
(1) Before attempting ignition of the burner, any process gas from
the SRUs and/or TGCU Unit should be blocked from flowing
into the Thermal Oxidizer in case the process gas is
combustible. Setting selector switch A2-HS15785 on the local
TTO control panel to "STARTUP" will open the bypass valve,
A2-HV15741, prove the valve open, then close the inlet valve,
A2-HV15740, so that the process gas is diverted directly to the
Thermal Oxidizer Vent Stack.
(2) Once the pilot burner in the Thermal Oxidizer Burner has been
lit, process gas can then be directed into the Thermal Oxidizer.
Setting selector switch A2-HS15785 to "RUN" will automatically
open the inlet valve, prove the valve open, then close the
bypass valve.
These two process gas valves constitute the Complete Flowpath

Interlock for the TTO. Although this interlock is not part of the
TTO ESD system (since the TTO always has a direct path to its vent
stack), it is a part of the Complete Flowpath Interlocks that are
included in the SRU Complete Flowpath alarms and TGCU ESD
system. By automating the valve switching steps and including
checks of the limit switches in the logic, the chance of accidentally
causing an SRU or a TGCU shutdown due to an incomplete flowpath

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(or over-pressure resulting from an incomplete flowpath) while

starting up the Thermal Oxidizer is greatly reduced.
If either of the switching valves does not move to the proper position,
the corresponding status light on the local TTO control panel should
continue to blink. This will alert the operators to investigate the
problem and take any required corrective action so that the BMS
allows proceeding.
12.5.1.2 Flame Scanners

The flame scanners, A2-BE15763A and A2-BE15763B, monitor the
pilot and main fuel gas burners. If a scanner detects a flame, the
associated flame proven signal will indicate. If neither scanner
detects a flame, the TTO ESD system is activated. Since a "flame
proven" signal from either scanner satisfies the system, maintenance
may be performed on one flame scanner while the other remains in
service. Note that a third flame scanner, A2-BE15758, is furnished
with the pilot to detect its flame, but it is used only to activate its
status light (A2-GL15758) on the local TTO control panel and a
status indicator (A2-BL15758) in the DCS.
12.5.1.3 Purge Cycle

To ensure the unit is safe for firing, a purge cycle must be completed
before the pilot can be ignited. To purge the Thermal Oxidizer, a
Thermal Oxidizer Air Blower is used to send a high rate of air through
the Thermal Oxidizer for 45 seconds. The air flow must then be
reduced to a low rate to allow ignition of the pilot.
12.5.1.4 Ignition Cycle

After the purge cycle is complete, pressing the "IGNITION"
push-button (A2-HPB15765) causes the BMS to initiate an attempt to
ignite the pilot. The BMS closes the pilot burner purge air valve
(A2-HV15782), opens the pilot air block valve (A2-NV15753), closes
the vent valve in the fuel gas to the pilot (A2-NV15756), opens the
pilot fuel gas block valves (A2-NV15755 and A2-NV15757), and
energizes the ignition system (A2-BX15758).
After a 15 second ignition trial, the ignition system is de-energized. If

a pilot flame is established, one or both flame scanners will indicate
"flame proven" and the block valves in the air and fuel gas supplies

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to the pilot will remain open. Otherwise, the air and fuel gas supplies
to the pilot are blocked-in and the purge cycle must be repeated.
12.5.1.5 Main Fuel Gas Firing

After the pilot burner is lit, the main fuel gas supply is enabled.
Pressing the "MAIN FUEL ON" push-button (A2-HPB15767) on the
local TTO control panel will close the vent valve in the fuel gas to the
main burner (A2-NV15747) and open the main fuel gas block valves
(A2-NV15746 and A2-NV15748). The main fuel gas control valve
(A2-TV15749) can then be adjusted using either A2-HIC15745 on
the local TTO control panel or A2-TIC15749 in the DCS to control the
firing rate of the main burner. DCS control of the firing rate of the
Thermal Oxidizer is accomplished by switching A2-HS15749 from
"local" to "remote" so that A2-TIC15749 in the DCS can then control
the temperature in the Thermal Oxidizer. The fuel gas flow rate can
be increased as necessary to heat the refractory in the Thermal
Oxidizer according to the refractory warmup schedule, and to heat
the water in the Thermal Oxidizer Waste Heat Boiler.
Note that the main fuel gas control valve has a minimum firing rate,
as set by the "minimum fire" relay in the DCS, A2-TY15749. The
proper setting for A2-TY15749 will be determined during startup by
finding the minimum firing rate to maintain a stable flame on the main
fuel gas burner.
12.5.1.6 Pilot On/Off Switch

Push-button A2-HPB15774 on the local TTO control panel is used to
turn the pilot burner on and off. If the pilot burner is "on", pressing
this push-button will extinguish the burner by closing the two block
valves and opening the vent valve in its fuel gas supply, closing the
block valve in its air supply, de-energizing its ignition system, and
opening the valve to begin purging the burner with air.
If the burner is "off " (and the "flame proven" is already satisfied by
the main burner tip), pressing this push-button will ignite the burner
by closing the valve to cease purging the burner with air, closing the
vent valve and opening the two block valves in its fuel gas supply,
opening the block valve in its air supply, and energizing A2-BX15758
for 15 seconds.

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12.5.2 Thermal Oxidizer Temperature Control

The Thermal Oxidizer is designed to cause thermal incineration of all the
sulfur compounds that enter with the sulfur plant tailgas stream,
converting them into sulfur dioxide, SO2. This is accomplished by
providing a high-temperature oxidizing atmosphere inside the Thermal
Oxidizer, so that free oxygen can react with the sulfur compounds to form
SO2. The Thermal Oxidizer has also been designed to provide near
complete oxidation of the carbon monoxide (CO) normally found in TGCU
effluent gas and sulfur plant tailgas, converting the carbon monoxide into
carbon dioxide, CO2.
Although a temperature of 550°C is usually adequate to ensure complete

oxidation of the sulfur compounds, a temperature in excess of 760°C is
normally required to achieve significant oxidation of CO. This temperature
is achieved in the Thermal Oxidizer by combusting fuel gas in the Thermal
Oxidizer Burner. The amount of fuel gas fed to the burner is controlled by
A2-TIC15749 in the DCS, which senses the Thermal Oxidizer outlet
temperature and adjusts the fuel gas flow accordingly. Since the TGCU
effluent gas and/or the SRU tailgas streams contains variable amounts of
combustible gases (H2S, H2, CO, etc.), the controller must respond quickly
to accommodate fluctuations caused by SRU and/or TGCU operations.
The design setpoint for this controller is 816°C. Actual operations may
determine that a lower temperature gives satisfactory CO destruction,
which would reduce the amount of fuel gas consumed by the Thermal
Oxidizer Burner (but would also reduce the steam production from the
Thermal Oxidizer Waste Heat Boiler).
12.5.3 Thermal Oxidizer Excess Oxygen Control

As discussed earlier, the Thermal Oxidizer must maintain an oxidizing
atmosphere so that there is free oxygen in the furnace to react with the
sulfur compounds and the carbon monoxide. Operating the Thermal
Oxidizer Burner with excess air provides this free oxygen, so that after
combusting the fuel gas supplied to the burner sufficient oxygen remains
to oxidize the sulfur compounds entering the Thermal Oxidizer. Sulfur
plant Thermal Oxidizers are normally designed to supply at least 25%
more air than stoichiometric requirements to ensure complete conversion
of the sulfur compounds.
There are no provisions in this plant at present for automatically

controlling the amount of excess air in the Thermal Oxidizer. If optimum

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operation is desired, the oxygen analyzer that is part of the CEMS,

A2-AE15153, on the Thermal Oxidizer Vent Stack can be used to
measure the amount of oxygen in the stack gas, and the setpoint of the air
flow controller, A2-FIC15760, can be adjusted as necessary to give the
desired oxygen concentration in the Thermal Oxidizer effluent.

The Thermal Oxidizer Waste Heat Boiler has independent level
transmitters, A2-LT15150A/B/C, connected to the PLC that activate the
TTO ESD system before the water level can get low enough to cause
boiler damage. The shutdown is activated when two out of three
transmitters show a low-low level. These transmitters should be tested
periodically to determine that they are functioning properly.
Consider A2-LT15150A on the Thermal Oxidizer Waste Heat Boiler, for

example. The procedure for testing A2-LT15150B and A2-LT15150C will
be similar. The procedure for testing A2-LT15150A is as follows:
(1) The outside operator notifies the DCS operator that he is preparing
to test shutdown level transmitter A2-LT15150A on the Thermal
(2) The DCS operator confirms that A2-LI15150B and A2-LI15150C are
both indicating adequate level in the boiler, then notifies the outside
operator to proceed.
CAUTION

OTHERWISE THE LOW-LOW LEVEL SHUTDOWN IN THE TTO ESD
WILL BE ACTIVATED AS SOON AS THE OUTSIDE OPERATOR
BEGINS DRAINING THE LEVEL TRANSMITTER IN THE NEXT
STEP.
operator blocks-in A2-LT15150A by closing its block valves, then

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opens the drain valve on the bottom of the transmitter to drain the
water from the instrument.
(4) If the transmitter is operating properly, the DCS will alarm that there
is a low level in the Thermal Oxidizer Waste Heat Boiler on
A2-LI15150A. The DCS operator acknowledges the alarm on the
DCS and reports it to the outside operator.
(5) After being notified of the alarm, the outside operator closes the drain
valve on A2-LT15150A, slowly opens its bottom block valve to allow
the transmitter to fill with water then opens its top block valve. This
should clear the low level alarm on A2-LI15150A in the DCS.
(6) After confirming that the low level alarm has cleared, the other level
transmitters can be tested in a similar fashion.
having a level transmitter malfunction that causes a TTO ESD

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12.5.5 Thermal Oxidizer Shutdown System

The purpose of the Tailgas Thermal Oxidation Emergency Shutdown
system (TTO ESD) is to shut off the flow of fuel gas, fuel gas, and
combustion air to the Thermal Oxidizer when serious problems occur.
The Cause and Effect Diagram, contained in the Instrumentation and
Controls Diagrams section of the Basic Engineering Package, describes
the TTO ESD system in block format. For reference, the causes and
effects of the ESD system shown on this diagram are explained below.

12.5.5.1 Causes
Any one of the causes listed below will activate the TTO ESD
system:
a. Manual Shutdown Switches, A2-HS15783 and A2-HS15784
An operator can activate the TTO ESD system using either of

two manual shutdown switches:
(1) A2-HS15783 is a NORMAL / ESD selector switch in the

DCS.

on the local TTO control panel.
b. No Thermal Oxidizer Air Blower Running, A2-GB1570A/B

starter contacts
If neither Thermal Oxidizer Air Blower is running, TGCU effluent

and/or SRU tailgas could flow backwards down the combustion
air line and escape from the blowers. The motor starter
contacts are used to determine whether a blower is running,
and will activate the TTO ESD system if neither is running.
c. Thermal Oxidizer Combustion Air Low-Low Flow,

A2-FT15760A/B/C

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Loss of air flow from the Thermal Oxidizer Air Blower could
cause the Thermal Oxidizer Burner flame to become unstable,
or allow TGCU effluent and/or SRU tailgas to flow backwards
down the combustion air line and escape from the blowers.
These devices will activate the TTO ESD to block the air line
before this can occur. The shutdown setpoint is 20% of normal
flow. Note that there are three independent transmitters and
2oo3 voting logic is used for the ESD (i.e., at least two
transmitters must show low-low flow) to avoid spurious "trips"
d. Burner Fuel Gas Supply Low-Low Pressure, A2-PT15744A/B/C
Loss of the fuel gas supply would cause the fuel gas pressure
to drop at the burner. This device will shut down the TTO
before flame instability creates the potential for an explosion.
The setpoint for these transmitters is 0.35 kg/cm2(g). Note that
e. Burner Fuel Gas High-High Burner Pressure,

A2-PT15751A/B/C
A malfunction of the fuel gas pressure control could cause

excessive firing of the main burner in the Thermal Oxidizer
Burner. These devices will prevent this unsafe condition by
shutting down the Thermal Oxidizer. The setpoint for the
transmitters is 3.5 kg/cm2(g). Note that there are three
ESD.
f. Thermal Oxidizer Burner Flame Failure, A2-BY15763A and

A2-BY15763B
Dual flame scanners are aimed to observe the flames from both
the pilot burner and the main gas burner. If the neither scanner
detects a flame (2oo2), a "flame failure" occurs and activates
the TTO ESD system. If only one scanner detects a flame
(1oo2), a malfunction alarm is activated in the DCS, but the
TTO ESD system is not activated. A third flame scanner,
A2-BY15758, is furnished with the pilot to detect its flame, but it
is used only to activate its status light (A2-GL15758) on the

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local control panel and a status indicator (A2-BL15758) in the

DCS.
g. Thermal Oxidizer High-High Temperature, A2-TT15749A/B/C
These devices activate the TTO ESD system and shut down
the Thermal Oxidizer Burner if a temperature of 1000°C or
higher is measured in the Thermal Oxidizer. Temperatures
higher than this can overheat the refractory inside the Thermal
Oxidizer to the point that it weakens and fails, causing heat
damage to the Thermal Oxidizer shell. Excessive temperatures
in this furnace can also lead to damage of the tubes or casing
of the Thermal Oxidizer Waste Heat Boiler installed
downstream. Note that there are three independent
transmitters and 2oo3 voting logic is used for the ESD.
h. Superheated Steam High-High Temperature, A2-TT15142AB/C
These devices activate the TTO ESD system and shut down
the Thermal Oxidizer Burner if the temperature of the
superheated steam leaving the second superheater pass of the
Thermal Oxidizer Waste Heat Boiler reaches 420°C. Steam
temperatures higher than this can lead to damage of the
superheater tubes, or damage the piping and equipment
downstream in the steam header and its users.
i. Steam Separator High-High Liquid Level, A2-LT15148A/B/C
If the steam trap that drains the Steam Scrubber, A2-FA1570,

should fail, a level of condensate could begin to build inside the
vessel. These devices activate the TTO ESD system to shut
down the Thermal Oxidizer Burner before this condensate can
carry-over into the hot tubes in the superheater passes of the
Thermal Oxidizer Waste Heat Boiler and cause damage to the
tubes. They are set to actuate if the liquid level reaches
1280 mm above the bottom seam of the vessel. Note that there
used for the ESD.
j. Thermal Oxidizer Waste Heat Boiler Low-Low Water Level,

A2-LT15150A/B/C

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These devices prevent the water level from dropping too low in
the steam drum of the boiler. Hot combustion gas flows outside
the boiler tubes and will destroy these tubes if they are not
cooled by water boiling inside the tubes. The setpoint for these
devices will be specified by the boiler vendor. Note that there
used for the ESD.
k. Thermal Oxidizer Vent Stack High-High Temperature,

A2-TT15155A/B/C
During periods when the Thermal Oxidizer is shut down, if the

sulfur plants continue to run but the TGCU is not on-line,
elemental sulfur in the SRU tailgas may condense inside the
Thermal Oxidizer, the Thermal Oxidizer Waste Heat Boiler,
and/or the Thermal Oxidizer Vent Stack. If the plant is operated
in this manner for extended periods, a considerable amount of
liquid sulfur may accumulate. This liquid sulfur may ignite once
the Thermal Oxidizer is restarted and air is flowing through the
system. The heat from the sulfur fire could damage the
non-refractory lined surfaces of the boiler casing and stack if
allowed to continue burning. These devices detect the high
temperature from the fire and shut the Thermal Oxidizer back
down before equipment damage occurs. The setpoint for the
transmitters is 400°C. Note that there are three independent
transmitters and 2oo3 voting logic is used for the ESD.
l. Pilot Ignition Safety Interlock Timer Expired, BMS logic
Once the pre-ignition steps have been completed and the BMS
gives a "PERMIT TO IGNITE" for the pilot burner in the Thermal
Oxidizer Burner (signaled by illuminating status indicator light
A2-AL15773 on the local TTO control panel), an ignition safety
interlock timer is started in the BMS. If an ignition attempt is not
made within 5 minutes, the TTO ESD system will be activated
to shut down the Thermal Oxidizer. This prevents a potentially
unsafe condition from persisting, where a leaking fuel gas valve
could cause an explosive mixture to form in the Thermal
Oxidizer, since the air flow is low at this point in the startup
procedure.

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12.5.5.2 Effects
A Thermal Oxidizer shutdown, activated either manually or
automatically, has the following effects on the Tailgas Thermal
Oxidation system:
a. Shuts down the Thermal Oxidizer Air Blower, A2-GB1570A/B.
b. Closes the air flow control valve, A2-FV15760, to prevent

back-flow and venting of any hazardous gases to the
atmosphere.
c. Initiates the Thermal Oxidizer Burner Shutdown system, which

(1) Shuts off and depressurizes the main fuel gas supply by
(2) Shuts off the pilot air supply by closing block valve
A2-NV15753.
(3) Shuts off and depressurizes the pilot gas supply by closing
block valves A2-NV15755 and A2-NV15757 and opening
vent valve A2-NV15756.
(4) De-energizes the ignition system, A2-BX15758.
(5) Begins purging the pilot burner with air by opening block
valve A2-HV15782.
d. Initiates back-purging of the stack gas analyzer, A2-AE15152,

to prevent any un-oxidized sulfur leaving the TTO from fouling
the analyzer.

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maintenance, and emergency procedures of the Tailgas Thermal Oxidation
system are discussed in the remaining sections of this portion of the operating
guidelines. The operator should also be thoroughly acquainted with the
equipment and the "Process Description" section in these guidelines 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 the "procedures" sections will be more easily
understood. In addition, the following general discussion of principles and
techniques will clarify the reasons for some of the procedures.

During periods when the TTO is shut down, if either SRU continues to run
and the TGCU Unit is not on-line, elemental sulfur in the SRU tailgas may
condense inside the Thermal Oxidizer, the Thermal Oxidizer Waste Heat
Boiler, and/or the Thermal Oxidizer Vent Stack. If the plant is operated in
this manner for extended periods, a considerable amount of liquid sulfur
may accumulate. This liquid sulfur will ignite once the TTO is restarted
and air is flowing through the system. The heat from the sulfur fire will
damage the tubes in the boiler and/or the non-refractory lined surfaces of
the boiler, outlet line, and stack if allowed to continue burning.
If this situation develops, connect a steam trap to the bottom connection

on the steam-jacketed nozzle in the bottom of the Thermal Oxidizer Waste
Heat Boiler casing and supply LP steam to the top connection. Then
remove the blind flange from the nozzle and allow the liquid sulfur to drain
from the casing. Once the sulfur has been removed, a safe restart of the
TTO should then be possible.

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WARNING
IF EITHER SRU IS ON-LINE WHILE DRAINING SULFUR FROM THE
BOILER CASING, TGCU EFFLUENT OR SRU TAILGAS MAY BE
RELEASED TO THE SURROUNDINGS FROM THE DRAIN NOZZLE.
THIS PROCESS GAS CONTAINS TOXIC GASES (H2S AND
PERHAPS SO2). ALWAYS OBSERVE PROPER PROCEDURES
AND PRECAUTIONS WHEN USING THIS DRAIN CONNECTION.
THE "GENERAL SAFETY" SECTION OF THESE GUIDELINES
SHOULD BE CONSULTED IF THERE IS ANY DOUBT ABOUT HOW
TO WORK SAFELY WHEN H2S OR SO2 MAY BE PRESENT.
Too rapid heating or cooling can damage the refractory installed in the
Thermal Oxidizer. The Initial Cure and Normal Warmup schedules for the
refractory are provided by the refractory vendor. These schedules should
be adhered to quite closely.
Explosive mixtures of air and gases in the equipment are a potential

danger. During an automatic shutdown, all air, pilot gas, and fuel gas
flows are shut off simultaneously. Any malfunction of these devices could
leak an explosive mixture into the unit. For this reason, the PLC requires
purging of the Thermal Oxidizer before attempting pilot ignition, and
requires re-purging the furnace if the burner does not light but fuel gas
was admitted.

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CAUTION

SURFACES) IN TTO 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 RAPIDLY CORRODE THE STEEL.

IF THE FINNED BOILER TUBES HAVE BECOME FOULED, THE

BEST WAY TO CLEAN THE TUBES IS TO BLAST THEM WITH
COMPRESSED AIR. IF SULFUR OR SULFUR COMPOUNDS HAVE
FOULED THE TUBES, IT MAY BE HELPFUL TO APPLY HEAT TO
THE TUBES, AS THIS WILL MELT ANY SULFUR THAT MAY BE
PART OF WHAT HAS FOULED THE TUBES. ONE WAY TO DO
THIS IS TO DRAIN THE WATER FROM THE BOILER AND PUT
STEAM IN THE STEAM DRUM. DRAIN THE CONDENSATE
PERIODICALLY FROM THE MUD DRUM TO KEEP LIVE STEAM ON
THE TUBES.

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12.6.2 Effect of Upstream Operations on the Thermal Oxidizer

The process gases to be incinerated in the Thermal Oxidizer can have a
widely varying content of combustible gases, such as hydrogen, carbon
monoxide, hydrogen sulfide, and even hydrocarbons on occasion. As a
result, the temperature control system for the Thermal Oxidizer can be
subjected to sudden swings in fuel gas demand, leading to temperature
excursions if the changes occur more rapidly than the control system can
accommodate.
Sudden drops in combustible content are most often caused by low H2S in
the TTO feed gas. This will usually only occur when SRU tailgas is being
routed directly to the TTO because the TGCU Unit is not in service.
Under these circumstances, if too much process air is fed to either SRU,
nearly all of the H2S will be consumed in the sulfur plant and the tailgas
from that SRU will contain only SO2. This will be indicated by high air
demand on the air demand controller in the SRU in question. However,
the sudden drop in the Thermal Oxidizer temperature is usually of no
consequence since the TTO feed contains very little H2S under these
circumstances, meaning that the potential loss of H2S oxidation efficiency
in the Thermal Oxidizer is not really of concern. The low furnace
temperature alarms in the DCS will alert the operator when this condition
occurs, as will the high air demand alarm on the air demand controller in
the DCS.
The more serious problem is when the combustible content of the TTO
feed gas suddenly increases and causes high temperature in the furnace.
The most common cause of this is high hydrocarbon content in the sulfur
plant feed stream(s). Hydrocarbons require 3-15 times more combustion
air per mole than H2S does. A sudden increase in the hydrocarbon
concentration of the acid gas (due to upsets in the upstream units) will
"starve" the sulfur plant(s) for air because the air demand controller(s)
cannot adjust the air:acid gas ratio enough to keep the SRU(s) on-ratio.
The available oxygen will burn the hydrocarbons preferentially over H2S,
with the result that insufficient H2S is reacted to form SO2. The SO2 that
does form will be completely consumed by the Claus reaction in the
furnace(s) and the catalyst beds, allowing large quantities of unreacted
H2S to leave the sulfur plant(s).
Even if the TGCU is in service at the time, H2S in these quantities will
overwhelm the capability of the TGCU solvent to absorb H2S. Thus,

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regardless of whether the TGCU is in service or not, these large quantities

of H2S will reach the Thermal Oxidizer and cause high furnace
temperature there. Even though the TTO temperature control system will
begin to cut back the fuel gas to the Thermal Oxidizer Burner, it is
possible that the TTO feed gas will contain so much H2S that the
temperature can be excessive even with the fuel gas valve at its
"minimum fire" position.
If the H2S concentration is high enough, or the change is sudden enough,

the high-high furnace temperature shutdownwill be tripped and the
TTO ESD system will be activated to shut down the Thermal Oxidizer.
However, the high-H2S gas will still be flowing into the Thermal Oxidizer,
since the TTO feed gas is not interrupted by a TTO ESD. This means that
large amounts of H2S may be vented un-incinerated from the Thermal
Oxidizer Vent Stack.
WARNING
IF THIS SITUATION OCCURS, DIRECT YOUR ATTENTION

IMMEDIATELY TO CORRECTING THE UPSET IN THE UPSTREAM
UNIT THAT IS CAUSING THE PROBLEM IN THE SULFUR
PLANT(S). IN EXTREME CASES, IT MAY BE NECESSARY TO
SHUT DOWN THE SRUS AND THE TGCU UNIT UNTIL THE
UPSTREAM PROBLEMS HAVE BEEN CORRECTED, SO THAT
EXCESSIVE AMOUNTS OF H2S DO NOT CONTINUE TO BE
VENTED FROM THE THERMAL OXIDIZER VENT STACK.
DO NOT ATTEMPT TO RESTART THE THERMAL OXIDIZER UNTIL

THE PROBLEM HAS BEEN CORRECTED AND THE H2S CONTENT
OF THE TTO FEED GAS IS BACK TO ACCEPTABLE LEVELS.
ATTEMPTING TO RESTART THE THERMAL OXIDIZER WHEN ITS

FEED GAS CONTAINS EXCESSIVE H2S WILL SIMPLY LEAD TO
THE THERMAL OXIDIZER GOING DOWN AGAIN ON HIGH-HIGH
TEMPERATURE.

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12.6.3 "Swapping" Air Blowers During Operation

While the TTO is running, it is often 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 minimal impact on the process by
starting and stopping the blowers in the proper sequence. The procedure
given below is one technique for swapping blowers.
One of the complicated aspects associated with swapping blowers is the

impact that bringing the off-line blower on-line can have on the air flow.
When the second blower is brought on-line, there is a potential to
suddenly double the air flow to the TTO. This would not only disturb the
process, it could possibly blow out the flame in the burner. For this
reason, the switch from one blower to the other must be made in a
controlled fashion.
The procedure below describes how to switch from the "A" blower to the
"B" blower, for example. That is, the "A" blower is running to the TTO and
the "B" blower is not currently running. The procedure to switch from the
"B" blower to the "A" blower in the TTO is similar.
Make sure the SRUs, TGCU, and TTO are operating stably before
proceeding.
A. Confirm that the manual discharge valve on the off-line blower, the
"B" blower, is closed.
B. Start the "B" blower using its local start/stop control station.
C. Once the blower starts, slowly open its discharge valve, allowing time
for the air flow controller to adjust the air flow control valve to keep
the combustion air flow rate at the proper value.
D. Once the discharge valve on the "B" blower is fully open, slowly
close the discharge valve on the "A" blower, again allowing time for
air flow controller to adjust the air flow control valve.
E. Once the discharge valve on the "A" blower is fully closed, shut down
the "A" blower using its local start/stop control station.
F. The blower swap is now complete. Before leaving the area, visually
confirm that:
(2) The discharge valve on the off-line blower is closed.

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(4) The process has returned to steady operation.


service life for the Thermal Oxidizer Waste Heat Boiler. Without good
day-to-day control of the water quality, solids buildup, corrosion, and
Total Petrochemicals Co., Ltd.'s responsibility to see that a proper
is recommended that only those companies that have local technicians
with extensive experience specifically in boiler water treatment be
selected to assist with Samsung Total Petrochemicals Co., Ltd.’s program.
The design details incorporated in the Thermal Oxidizer Waste Heat Boiler
have proven to be very reliable when combined with good operator
practice regarding water treatment. However, even properly designed
equipment can be severely damaged during a short period of operation if
the water treatment program is inadequate or improper.
The Thermal Oxidizer Waste Heat Boiler is equipped with a continuous

blowdown on the steam drum to remove suspended and dissolved solids
from the water inside the boiler. In addition, the boiler is equipped with an
intermittent blowdown connection on the bottom of its mud drum. This
intermittent blowdown valve should be used on a regular basis to give the
boiler a good "blow" to prevent sludge from accumulating in the bottom of
the drum. Sludge must not be allowed to coat the boiler tubes. The
consequence of fouling the inside of the boiler tubes is tube failure from
overheating, as the fouling will impair the heat transfer and allow the hot
combustion gases to destroy the tubes.

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Prior to using the intermittent blowdown valve, use the level controller in
the DCS to raise the water level in the boiler up to the high level alarm
point. Then open the intermittent blowdown valve until the level drops
back to the normal liquid level. Watch the boiler level in the sight glasses
activate the TTO ESD and shut the Thermal Oxidizer down). Remember
to reset the level controller at the conclusion of this procedure.

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B. Check and lubricate all equipment, in accordance with the

C. Check the rotation of the Thermal Oxidizer Air Blowers by operating

each blower for a short period with its discharge valve closed.

F. Place all of the instrument air purges in service.
G. Turn on the steam supplies to all of the steam-jacketed sulfur vapor

from the jackets. Manually "stroke" each valve and check to be sure
it moves freely.

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A. Fill the Thermal Oxidizer Waste Heat Boiler with treated boiler feed
water up to the high level alarm point. As the level is rising, check
the level transmitters and the high level alarms for proper operation.
B. Use the quick-opening blowdown valve to lower the water level in the
boiler and check for proper operation of the level transmitters, the
low level alarms, and the low-low level shutdowns.
C. Fill the boiler with treated boiler feed water back up to the normal
liquid level.
NOTE: The Thermal Oxidizer Waste Heat Boiler vendor

recommends performing a "boil-out" with an aqueous
alkaline solution during the initial startup to remove oil,
grease, dirt, and biological material from the boiler drums
and tubes. For this "boil-out" during the initial startup, the
recommended chemical solution can be added to the
boiler drum at this time as boiler feed water is added to
bring the level back to the normal level points. Refer to the
vendor's literature for the chemicals to be used. The
"boil-out" can be performed during the refractory cure-out.
D. Physically check all shutdown activating devices to ensure that they

activate the TTO ESD system.
E. Check all devices activated by the TTO ESD system to ensure that
they operate properly.

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12.7.3 Commissioning Fuel Gas, Pilot Gas, and I/A to the Process
The fuel gas, pilot gas (vaporized C4 LPG), and instrument air supplies to
the process side of the Thermal Oxidizer must be made ready for use
prior to starting up the Thermal Oxidizer using the procedures in these
guidelines. This requires blowing down each section of piping to ensure
that there are no liquids and/or construction debris in the headers and
supply lines. The procedure below can be used to make sure that these
gas utility systems are ready for service.
A. Select local manual control for the main fuel gas control valve by
switching the hand switch in the DCS to "local".
B. Set the manual fuel gas control on the local TTO control panel to 0%
output.
C. Confirm that the following fuel gas, pilot gas, and instrument air
valves are closed:
(2) The manual block valve(s) in the main pilot gas supply line.
(3) The main fuel gas automated block valves, the fuel gas control
valve, and the block valve at the burner in the main fuel gas line
to the Thermal Oxidizer Burner.
(4) The manual block valve(s), and the two automated block valves
in the pilot gas supply line to the pilot.
(5) The block valve(s) in the main instrument air supply line.
(6) The manual block valves and the automated block valve in the
air supply line to the pilot.
(7) The manual block valve in the air supply line to the purges for
the burner instruments.
(8) The block valves in the purge lines to the burner instruments.
D. Confirm that all of the manual vent/drain valves in the main fuel gas,
pilot gas, pilot air, and purge air piping are closed.
E. If the orifice plate has already been installed in the fuel gas flow
meter, remove it for now.

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F. Disconnect the fuel gas, pilot gas, and instrument air from the burner
system by performing the following steps:
(1) Unbolt the flanged connection at the burner in the main fuel gas
supply line.
(2) Disconnect the pilot gas supply tubing where it connects to the
pilot.
(3) Disconnect the instrument air supply tubing where it connects to

the pilot.
(4) Cover the open ends of these connections on the burner to

prevent debris from entering when the upstream piping is blown
down.
G. Remove the following pressure regulators, then cover the

(1) The main fuel gas supply regulator.
(2) The pilot instrument air supply regulator.
(3) The pilot gas supply regulator.
(4) The purge instrument air supply regulator.
H. "Force" the PLC to open the following valves, then confirm they are
open:
(1) The automated block valves in the main fuel gas supply line to
the burner.
(2) The automated block valves in the pilot gas supply line to the
pilot.
(3) The automated block valve in the instrument air supply line to
the pilot.
I. "Force" the PLC to close the following valves, then confirm they are
closed:
(1) The automated vent valve on the main fuel gas supply line to
the burner.

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(2) The automated vent valve on the pilot gas supply line to the
pilot.
J. "Crack" the manual block valve in the main fuel gas supply line
(upstream of the pressure regulator) and allow fuel gas to blow
through the piping until it is clear. Then close the block valve,
reinstall the main fuel gas supply pressure regulator, and reopen the
gate valve.
K. Using the pressure gauge and the vent valve downstream of the
main fuel gas supply regulator, adjust the main fuel gas regulator to
its specified setpoint.
L. Use the manual fuel gas controller on the local control panel to fully
open the control valve in the main fuel gas line, then use the
downstream drain valve to blow out this section of piping. Close the
drain valve when the piping is clear, then close the control valve.
M. Open the bypass valve around the main fuel gas control valve.
"Crack" the block valve at the burner and allow fuel gas to blow
through the piping until it is clear. Then close the block valve and
bypass valve.
N. "Crack" the block valve in the main pilot gas supply line to the pilot
(upstream of the pressure regulator) and allow pilot gas to blow
reinstall the pilot gas supply pressure regulator, and reopen the block
valve.
O. Using the pressure gauge and the vent valve downstream of the pilot
gas supply regulator, adjust the regulator to its specified setpoint.
P. "Crack" the block valve downstream of two automated block valves

and allow pilot gas to blow through the piping until it is clear. Then
close the block valve.
Q. "Crack" the block valve in the instrument air supply line to the pilot
and blow air through the piping until it is clear. Then close the block
valve, reinstall the pilot instrument air supply pressure regulator, and
R. Using the pressure gauge and the vent valve downstream of the pilot
instrument air supply regulator, adjust the regulator to its specified
setpoint.

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S. "Crack" the block valve downstream of the pilot air supply automated
block valve and allow instrument air to blow through the piping until it
is clear. Then close the block valve.
T. Remove the "forces" from the PLC and confirm that all of the
automated block valves close and all of the automated vent valves
open.
U. Close the block valve in the main fuel gas supply line (upstream of
the regulator), the block valve in the pilot gas supply to the pilot
(upstream of the regulator), and the block valve in the instrument air
supply to the pilot (upstream of the regulator) until the TTO is ready
for startup.
V. Reconnect the fuel gas, pilot gas, and instrument air to the burner
systems by performing the following steps:
(1) Bolt the flanged connection at the burner in the main fuel gas
supply line back together.
(2) Reinstall the pilot gas supply tubing where it connects to the
pilot.
(3) Reinstall the instrument air supply tubing where it connects to

the pilot.
(4) Reinstall the orifice plate in the fuel gas flow meter.
W. "Crack" the block valve in the instrument air supply line to the purge
rotameters (upstream of the purge pressure regulator) and blow air
reinstall the purge instrument air supply pressure regulator, and
X. Using the pressure gauge and the downstream drain valve, adjust
the purge instrument air regulator to its specified setpoint.
Y. Open the drain valve to blow out this section of piping until it is clear,
then close the drain valve.
Z. Each of the low pressure purges for the burner instruments has a
rotameter near where it connects to the process. Disconnect the
upstream fitting at each rotameter and open its upstream ball valve
briefly to blow any liquids or debris from the purge line. Reconnect
each rotameter, disconnect the fitting where each purge enters the

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process, open its upstream ball valve, and open its needle valve
briefly to blow any liquids or debris from the purge line. Then
reconnect each purge to the process and open its needle valve to
place it in service.

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The procedure used to start up the Thermal Oxidizer depends on whether the
refractory in the Thermal Oxidizer is up to operating temperature. This first
section describes the procedure for the initial startup of a new plant, and
subsequent startups when the refractory is cold (less than 500°C in the Thermal
Oxidizer). Subsequent startups with the refractory already up to operating
temperature can use a different procedure, discussed later in Section 12.8.2 of
these guidelines.
12.8.1 Initial Firing / Refractory Cure-out

During the initial startup, the Thermal Oxidizer and downstream
equipment will be warmed up to operating conditions following the initial
refractory cure-out schedule for the Thermal Oxidizer. This cure-out
schedule should be provided by the refractory vendor.
CAUTION
IT IS CRITICAL THAT THE WARMUP PROCEDURES BE

FOLLOWED VERY CLOSELY. THE REFRACTORY MATERIAL
MUST BE HEATED SLOWLY TO ALLOW THE CONTAINED WATER
TO VAPORIZE AND ESCAPE FROM THE REFRACTORY LINING,
WITHOUT EXERTING EXCESSIVE INTERNAL PRESSURE AND
CAUSING LINING DAMAGE.

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A. Check that all devices in the TTO ESD have been satisfied,
(1) Low-low air flow.
(3) Flame failure.
The PLC logic provides bypasses for these three conditions so

that the system can be started up.
B. Select local manual control for the air flow control valve by
C. Place the air flow controller in "automatic".
D. Select local manual control for the fuel gas control valve by
E. Place the Thermal Oxidizer temperature controller in

"automatic".
F. "Toggle" the superheated steam hand switch in the DCS to give

the blow-off pressure controller control of the superheater
pressure via the steam blow-off control valve.
G. Place the blow-off pressure controller in "manual" and set its

output to 100% to fully open the steam blow-off control valve.
H. Place the Thermal Oxidizer Waste Heat Boiler steam pressure

controller in "automatic" and adjust its setpoint to 0.7 kg/cm2(g)
(or whatever value the boiler manufacturer recommends) in
preparation for "boil-out".
I. Adjust the output from the temperature controller for the

interstage desuperheater, to 0%. Switch the controller to
"automatic" and adjust its setpoint to its normal value.
J. Adjust the output from the temperature controller for the

discharge desuperheater, to 0%. Switch the controller to
"automatic" and adjust its setpoint to its normal value.
K. Confirm that the Thermal Oxidizer Waste Heat Boiler is filled

with water up to its normal liquid level.

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L. Confirm that the superheated steam blow-off control valve is

fully open.
M. Confirm that the two desuperheater BFW supply control valves,

and their bypass valves are closed. Confirm that the upstream
and downstream block valves around the control valves are
open.
N. Open the vent valves on the boiler to vent air from the steam
section.
O. Set the manual fuel gas control on the local TTO control panel
to 0% output.
Visually confirm that the main fuel gas valve, its bypass valve,
and the two main fuel gas shutdown valves are closed.
P. Set the manual air control on the local TTO control panel to 0%
output.
Visually confirm that the air flow control valve is closed.

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A. Switch the Startup/Run selector switch on the local TTO control
panel to "STARTUP".
(1) The TTO bypass valve is opened.
The "BYPASS OPEN" status light on the local TTO control

panel will flash until the valve has moved to the proper
position, then remain steadily illuminated.
(2) The TTO inlet valve is closed.
The "INLET OPEN" status light will flash until the valve has

limit switches on the associated valve never
confirmed that the valve moved to the proper
and the valve moves to the proper position.
Note that the valve may have actually moved to the

proper position, but a faulty limit switch may not be
detecting that the valve is in the proper position.

Confirm that the "BYPASS OPEN" light on the panel is illuminated,
and that the "INLET OPEN" light on the panel is extinguished.
B. Verify that both of the local start/stop controls for the Thermal
Oxidizer Air Blower have their selector switches turned to the
"STOP" position.
C. Verify that the discharge valves are closed on both air blowers.
D. Start a Thermal Oxidizer Air Blower:
(1) Use the local start/stop control station to start the desired
blower.
(2) Once the blower comes up to speed, open its discharge

valve.

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E. Once an air blower is running, press the "ESD RESET"

push-button on the local TTO control panel to reset the
TTO ESD and extinguish the "RESET REQUIRED" light. This will

flashing) on the local TTO control panel.
NOTE: If the "LIMITS SATISFIED" light is flashing, this means that

a limit switch is not satisfied. The limit switches on the
main fuel gas valves and the TTO inlet valve must all
indicate that their valves are closed.
sequence to proceed until these valves are proven
closed. Once the problem with the valves or their limit
switches has been corrected, the "LIMITS SATISFIED"
light will stop flashing and glow steadily, and the
light-off sequence can proceed.
G. Adjust the output of the local manual air control to open the air
flow control valve and allow a large air flow, 80% or more on the
flow indicator, to purge the furnace and downstream equipment
for 5 minutes. The "PURGE REQUIRED" light will be extinguished
and the "PURGE COMPLETE" light will be illuminated after about
40 seconds, but continue to purge the system for a full
5 minutes prior to this first time ignition attempt.
H. Open the following manual block valves:
(1) The block valves in the pilot gas to the ignitor/pilot.
(2) The block valves in the air supply to the ignitor/pilot.
I. Adjust the output of the local manual air control to reduce the
air flow on the flow indicator to 10-20%. This will extinguish the
light, and the PLC will "enable" the ignition circuit.
NOTE: Once the "PERMIT TO IGNITE" light is illuminated, an

ignition safety interlock timer starts. If an ignition
attempt is not made within 5 minutes, the TTO ESD
system will be activated to shut down the Thermal
Oxidizer. This prevents a potentially unsafe condition

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from persisting, where a leaking fuel gas valve could

cause an explosive mixture to form in the Thermal
Oxidizer, since the air flow is low at this point in the
startup procedure.
If either scanner detects a flame before the "PILOT ON"

push-button is pressed, this will activate the TTO ESD
system and the "flame scanner malfunction" alarm in
the DCS. This will stop the air blower and extinguish
the flame (unless of course, a flame scanner is giving a
false indication). A flame prior to ignition usually
indicates a leaking fuel gas valve. If this occurs, check
these valves before proceeding with startup, as a
leaking valve can allow an explosive mixture to form in
the Thermal Oxidizer without warning.
J. Press the "PILOT ON" push-button to initiate an ignition attempt.

The PLC will do the following:
(1) The air purge valve for the pilot burner is closed.
(2) The ignitor/pilot air block valve is opened.
(3) The ignitor/pilot gas vent valve is closed and the block
valves are opened.
(4) The ignition system is energized to begin sparking the

ignitor inside the pilot in a series of pulses.
(5) The "PILOT ON" light is illuminated.
K. The air and pilot gas pressure regulators for the ignitor may
require some adjustment when first put in service before the
ignitor will light the pilot. However, once set properly, the ignitor
should ignite the pilot readily on subsequent startups. Refer to
the SRU Section of these guidelines for a suggested procedure
to adjust these regulators.
L. If neither flame scanner detects a flame after 15 seconds of

sparking the ignitor, the ignition try is aborted, the TTO Burner

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M. When either of the flame scanners detects a flame from the

pilot burner, the appropriate "FLAME PROVEN" light(s) are
illuminated. The pilot air and pilot gas valves will remain open
after the ignition trial, and the PLC will perform the following
activities:
(1) The "LIMITS SATISFIED" and "PERMIT TO IGNITE" lights are

extinguished.
(2) The "PILOT ON" light remains illuminated.
(3) The ignition system is de-energized.
(4) The startup bypass in the PLC for the "flame failure" S/D is
disabled.
(5) The "MAIN FUEL START" push-button on the local TTO

control panel is enabled.
(6) The "RUN" position on the Startup/Run selector switch on

the local TTO control panel is enabled.
N. After the pilot is lit, use the local manual air control to increase
the air flow rate to about 50%, or as high a rate as can be
maintained without blowing the pilot out. When curing
refractory, it is best to keep the air flow as high as possible to
help distribute the heat more evenly and to heat the
downstream equipment more quickly.
O. The heat input from the pilot should be sufficient to reach the
first "hold" point in the refractory warmup schedule, 100-150°C.
If the temperature is too high, increase the air flow rate. If the
temperature is too low, decrease the air flow rate.

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12.8.1.3 Thermal Oxidizer Waste Heat Boiler "Boil-Out"

The Thermal Oxidizer WHB vendor recommends performing a
"boil-out" with an aqueous alkaline solution during the initial startup
to remove oil, grease, dirt, and biological material from the boiler
drum and tubes. This boiler "boil-out" can be performed in
conjunction with the refractory cure-out of the Thermal Oxidizer.
Refer to the vendor's literature for the specific procedure to be used.
During "boil-out", the steam produced in the steam drum of the

Thermal Oxidizer Waste Heat Boiler will flow through the superheater
pass of the boiler and then be vented to atmosphere through the
steam blow-off valve. Note that if the SRU(s) is being warmed up at
the same time, any high pressure steam being produced by its
Waste Heat Boiler will also be flowing through the superheater pass
of the Thermal Oxidizer Waste Heat Boiler. Depending on the firing
rate in the SRU(s), the steam flow may become too high to maintain
the desired pressure in the Thermal Oxidizer Waste Heat Boiler
steam drum (usually 0.7-1.0 kg/cm2(g)) even with the blow-off valve
fully open. If this is the case, the firing rate will have to be reduced in
the SRU(s) to reduce the steam production until "boil-out" of the
Thermal Oxidizer Waste Heat Boiler is completed.
Once "boil-out" has been completed, the steam pressure in the

steam drum can be raised to its normal operating pressure. Confirm
that WHB steam pressure control is in "automatic", then adjust its
setpoint to its normal setting. Then place the steam pressure
controller in control by confirming that its setpoint is tracking the
current reading and switching the controller to "automatic". Slowly
adjust its setpoint to its normal setting.

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12.8.1.4 Igniting the Main Gas Burner, Refractory Cure-out and Warmup
temperature, the main gas burner can be placed in service. The
local manual control has control of the main fuel gas valve at this
time because the hand switch in the DCS is switched to "local". The
fuel gas flow rate can be monitored using the flow indicator on the
local TTO control panel and the flow indicator in the DCS.
A. Verify that the hand switch in the DCS is set to "local" to give
local manual control of the fuel gas control valve.
B. Confirm that the output from the manual fuel gas control on the
local TTO control panel is set to 0%, that the fuel gas control
valve and its bypass valve are closed, and that the two block
valves at the control station are both open.
C. Open the manual block valve in the main fuel gas line and the
manual block valve at the burner.
D. If the air flow rate is not at least 50%, use the local manual air
control to set the air flow at 50% as indicated by the flow
indicator.
E. Press the "MAIN FUEL START" push-button on the local TTO

control panel, to commission the main fuel gas. The PLC
(1) The main fuel gas vent valve is closed.
(2) The main fuel gas automated block valves are opened.
(3) The fuel gas control valve is released to operator control.
(4) The "MAIN FUEL ON" light on the local TTO control panel is
illuminated.
(5) A 2-minute low-low air flow S/D bypass timer is started.
NOTE: Be sure the air flow is above the low-low flow shutdown
point, about 20% on the flow indicator, or the TTO ESD
will be activated when the bypass timer expires and the
Thermal Oxidizer will shut down.
F. Use the manual fuel gas control on the local TTO control panel
to slowly open the fuel gas control valve until the burner lights

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and has a stable flame. The "minimum fire" setting required for
this particular burner at the normal air flow will be determined
later.
G. The manual fuel gas control may now be used to manually

control the furnace temperature. Make adjustments to the
output as needed to follow the appropriate refractory cure-out or
warmup schedule (from the refractory vendor), either the chart
for the initial cure-out or the chart for normal warmup.
The temperature of the Thermal Oxidizer is indicated on the

local panel by a temperature indicator. The temperature is also
indicated by the temperature control in the DCS, which can be
used to monitor or control the warmup of the Thermal Oxidizer
in the DCS. It is often helpful to maintain a log of air flow using
the flow indicator on the local panel or the air flow controller in
the DCS, fuel gas flow using the flow indicator on the local
panel or the flow indicator in the DCS, and furnace temperature
using a temperature indicator on the local panel or the
temperature control in the DCS during the cure-out for future
reference.
NOTE: During the early stages of warmup when the furnace

temperature is supposed to be low, the fuel gas flow
rate may be too high with the control valve at its
"minimum fire" position. If this is the case, use the
local manual air control to raise the air flow in order to
control the furnace temperature at the proper value.
H. As the firing rate increases, raise the air flow rate with the local
manual air control to 75%-80% as indicated by the flow
indicator.
I. Once the main fuel gas burner in the Thermal Oxidizer Burner
is operating smoothly, the pilot burner can be shut down and
retracted or extracted. For the initial startup of the Thermal
Oxidizer, this step should be performed after the "minimum fire"
setting for DCS the fuel gas control valve relay has been
determined.
Press the "PILOT STOP" push-button on the local TTO control

panel. The PLC performs the following actions to block the pilot
air and "double block and bleed" the pilot gas:

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(1) The automated block valve in the air supply to the

ignitor/pilot is closed.
(2) The ignitor/pilot pilot gas automated block valves are

closed.
(3) The pilot gas vent valve is opened.
(4) The air purge valve for the pilot burner is opened.
(5) The "PILOT ON" light is extinguished.
Verify that the air and pilot gas valves have moved to their
proper positions and that the pilot burner is being purged with
air as indicated by the rotameter.
J. Close the following manual block valves:
(1) The manual block valves in the pilot gas supply to the
ignitor/pilot.
(2) The manual block valves in the air supply to the

ignitor/pilot.
K. Loosen the packing gland on the pilot and retract or extract the
pilot assembly:
(c) Confirm that the pilot is still being purged with air as
indicated by the air flow rotameter.
(b) Close the block valve at the burner to isolate the pilot
from the furnace.
(c) Close the block valve in the purge air to the pilot
burner.

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VERY HOT. HANDLE IT

purged with air as indicated by the rotameter.
L. Frequently confirm that the proper water level is maintained in

the Thermal Oxidizer Waste Heat Boiler. Confirm that the level
control system is functioning properly.
M. As steam pressure starts to build in the Thermal Oxidizer Waste

Heat Boiler, confirm that the boiler pressure controller in the
DCS is in "automatic" and controlling the steam pressure at its
setpoint. Allow the vent valves to sweep non-condensibles out
of the steam spaces on the boiler.
N. Confirm that the superheater pass pressure controller in the

DCS is in "automatic" with the proper setpoint.
At this time, the steam pressure "toggle" switch in the DCS has
not yet been reset, so the steam leaving the superheater pass
is still being vented to atmosphere through the silencer.
O. Confirm that the interstage desuperheater temperature

controller and the discharge despuerheater temperature
controller in the DCS are in "automatic".
P. As the equipment and piping heat up, inspect all of the

Ensure that all slide plates, rollers, spring hangers, etc. are
functioning properly.
Q. As the steam pressure builds in the boiler, the vent valves on

the steam sections may be closed.
R. As the superheated steam temperature begins to increase,

confirm that the temperature controllers on the desuperheaters

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are adding BFW as needed to prevent excessive temperatures

around the superheat passes of the boiler.
S. Switch the combustion air flow control from the local TTO
control panel to the DCS as follows:
(1) Confirm that the air flow controller in the DCS is in

"automatic", its output is tracking the output from the
manual air control on the local TTO control panel as
indicated by the hand indicator in the DCS, and its setpoint
is tracking its current reading.
(2) Switch the air flow control hand switch from "local" to
"remote". The air flow controller now has control of the air
flow control valve, and will be controlling the air flow rate
with its last value as the setpoint.
(3) Slowly adjust the setpoint of the air flow controller to its
normal value.
T. Switch the temperature control of the Thermal Oxidizer from the

local TTO control panel to the DCS as follows:
(1) Confirm that the temperature control in the DCS is in

"automatic", its output is tracking the output of the manual
fuel gas control on the local TTO control panel as
indicated by the hand indicator in the DCS, and its setpoint
is tracking its current reading.
(2) Switch the temperature hand switch from "local" to

"remote". The temperature control now has control of the
fuel gas control valve, and will be controlling the
temperature with its last value as the setpoint.
U. Adjust the setpoint of the temperature controller as necessary

so that the Thermal Oxidizer continues to follow the appropriate
refractory cure-out or warmup schedule.
V. When the temperature of the superheated steam leaving the

superheater pass of the Thermal Oxidizer Waste Heat Boiler
reaches the proper value and is under control, the high
pressure steam can be directed to the export header. After
confirming that the steam header is ready to accept steam,
"toggle" the reset permit switch in the DCS.

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The relay in the DCS will begin ramping down the output to the
steam blow-off valve. As the valve closes, the pressure in the
steam header will begin to increase until it is high enough to
open the check valve and the steam begins flowing to the
export header. Confirm that the blow-off valve closes fully.
W. At the conclusion of the refractory cure-out during the initial

startup, the "minimum fire" setting for the burner needs to be
determined:
(1) Adjust the output of the manual fuel gas flow control on the
local TTO control panel so that the reading displayed on
the hand indicator in the DCS matches the current output
from the temperature control.
(2) Switch the hand switch in the DCS from "remote" to

"local".
(3) While observing the flame through one of the viewports on

the burner, slowly reduce the fuel gas flowrate by reducing
the output of the manual fuel gas control until the flame
starts to become unstable.
(4) Raise the fuel gas flowrate back up slightly using the
manual fuel gas control until the flame is stable again.
(5) This is the actual "minimum fire" setting required for this
particular burner. Record the fuel gas flowrate on the flow
indicator in the DCS and the output on the manual fuel gas
control on the local TTO control panel.
(6) Use the manual fuel gas control to raise the fuel gas
flowrate back up to the value before starting this step.
Confirm that the temperature control is still in "automatic"
and its output is tracking the manual fuel gas control, then
switch the hand switch back to "remote" and adjust the
setpoint of the temperature control to its normal setpoint.

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12.8.1.5 Routing SRU/TGCU Tailgas to the Thermal Oxidizer

A. When the Thermal Oxidizer temperature reaches 816°C, the
TTO is ready to be placed in service. Switch the Startup/Run
selector switch on the local TTO control panel to "RUN".
(1) The TTO inlet valve is opened.
(2) After the limit switches prove this valve open, the TTO
bypass valve is closed.

Confirm that the "INLET OPEN" light on the panel is illuminated,
and the "BYPASS OPEN" light on the panel is extinguished.
B. The Thermal Oxidizer is now on-stream, ready to incinerate

SRU tailgas or TGCU effluent. Before directing your attention
away from the Thermal Oxidizer, be sure that:
(1) The Thermal Oxidizer is operating smoothly, with both the

combustion air and fuel gas on automatic control.
(2) The Thermal Oxidizer Waste Heat Boiler level, pressure,
and steam temperature controls are functioning properly.
(3) The stack gas analyzers are performing satisfactorily.

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12.8.2 Normal Startup

The procedure for startup of the unit after it has been shut down for a
short period, not long enough to get cold (less than about 500°C in the
Thermal Oxidizer), will be very similar to the procedure for the initial
startup, Section 12.8.1 of these guidelines. However, the steps to be
performed are written in this Section to serve as a "check list" that can be
easily followed on subsequent startups. Refer to the previous Section for
the reasons and details pertaining to the different steps performed.
WARNING
THE THERMAL OXIDIZER MAY BE SAFELY RESTARTED WHILE

THE SRUS ARE RUNNING (WITH OR WITHOUT THE TGCU
ON-LINE) BECAUSE THE TTO FEED GAS IS BYPASSED AROUND
THE THERMAL OXIDIZER DURING STARTUP. HOWEVER, IF THE
FEED GAS TO THE TTO CONTAINS AN EXCESSIVE AMOUNT OF
COMBUSTIBLES, THE THERMAL OXIDIZER WILL SHUT DOWN ON
HIGH-HIGH FURNACE TEMPERATURE WHEN THE TTO INLET
VALVE IS OPENED.
THE MAJOR COMBUSTIBLE THAT MAY EXIST IN THE TTO FEED

GAS IS H2S, ESPECIALLY IF THE SULFUR PLANT IS UPSET AND
RUNNING WITH DEFICIENT AIR, OR THE TGCU IS UPSET AND
ALLOWING H2S TO "SLIP". THIS WOULD BE INDICATED BY LOW
AIR DEMAND ON THE AIR DEMAND CONTROLLER IN THE DCS,
AND/OR HIGH H2S ON THE TGCU H2S ANALYZER IF THE TGCU IS
OPERATING.
HOWEVER, IF EITHER ANALYZER IS OUT OF SERVICE OR IF

THERE IS ANY REASON TO SUSPECT HIGH H2S IN THE TTO
FEED GAS, THE FEED GAS SHOULD BE TESTED FOR H2S TO
DETERMINE WHETHER IT IS SAFE TO RESTART THE TTO. GAS
DETECTOR TUBES (DRÄGER TUBES, ETC.) MAY BE USED TO
SAMPLE THE TTO FEED GAS. REFER TO THE LABORATORY
PROCEDURES GIVEN IN THESE GUIDELINES.

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IF THE AIR DEMAND IN THE SRU(S) IS LOW (BELOW –3.0%) OR

THE H2S CONCENTRATION IN THE FEED GAS TO THE THERMAL
OXIDIZER IS HIGH (ABOVE 3%), DO NOT ATTEMPT TO RESTART
THE TTO. INSTEAD, DIRECT YOUR ATTENTION TO THE AMINE
OR SWS UNIT(S) UPSTREAM OF THE SRUS (WHICH ARE
PROBABLY CAUSING THE PROBLEM) AND BRING THE SRU(S)
BACK ON-RATIO, OR CORRECT THE OPERATING PROBLEM IN
THE TGCU. THIS WILL REDUCE THE CONCENTRATION OF H2S
IN THE TTO FEED GAS TO AN ACCEPTABLE LEVEL, SO THAT
RESTARTING THE THERMAL OXIDIZER PROCEEDS SMOOTHLY.
FAILURE TO CORRECT THE UPSTREAM PROBLEM(S) FIRST

WILL LIKELY LEAD TO THE THERMAL OXIDIZER SHUTTING
DOWN AGAIN, REQUIRING ANOTHER RESTART OF THE TTO.
Prior to commencing Thermal Oxidizer startup:
1. Check for the completion of all maintenance work (connecting lines,

removing blinds, etc.) if such work was performed.
2. Place all steam heating systems in service. Check all steam traps
for proper operation, and use the vent valves to sweep
3. Physically check all shutdown-activating devices to ensure that they

activate the TTO ESD system.
4. Physically check all devices activated by the TTO ESD system to

5. Confirm that the Thermal Oxidizer Waste Heat Boiler is filled with

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A. Check that all devices on the TTO ESD have been satisfied,
(1) Low-low air flow.
(3) Flame failure.
B. Select local manual control for the air flow control valve by
C. Place the air flow controller in "automatic".
D. Select local manual control for the fuel gas control valve by
E. Place the Thermal Oxidizer temperature controller in

"automatic".
F. Confirm that the following controllers are in "automatic" with

their setpoints:
(1) The Thermal Oxidizer Waste Heat Boiler steam pressure

controller.
(2) The Thermal Oxidizer Waste Heat Boiler superheater

pressure controller.
(3) The interstage desuperheater temperature controller.
(4) The export steam temperature controller.
G. Set the manual fuel gas control on the local TTO control panel
to 0% output.
Visually confirm that the main fuel gas valve and its bypass
valve are closed.
H. Set the manual air control on the local control panel to 0%

output.
Visually confirm that the air flow control valve is closed.
I. Prepare the pilot burner for service:
(1) If the pilot is in the retracted position:

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(a) Loosen the packing gland on the pilot.
(b) Slide the pilot forward until it reaches the limit of the
retraction bar.
(2) If the pilot was extracted earlier:
(a) Insert the pilot assembly into its packing gland and
open the block valve at the furnace.
(b) Slide the pilot assembly forward until it reaches the

limit of the retraction bar.
(c) Reconnect the retaining chain.
(d) Open the block valve in the purge air to the pilot and
confirm that the pilot is now being purged with air.
(3) Tighten the packing gland on the pilot.
purged with air.

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A. Switch the Startup/Run selector switch on the local TTO control
panel to "STARTUP".
The PLC will open the TTO bypass valve and close the TTO
inlet valve. Verify that the "BYPASS OPEN" light on the panel is
now illuminated and the "INLET OPEN" light on the panel is
extinguished.

limit switches on the associated valve never
confirmed that the valve moved to the proper
and the valve moves to the proper position.
B. Verify that the local start/stop controls for the blowers have their
selector switches turned to the "STOP" position.
C. Verify that the discharge valves are closed on both air blowers.
D. Start a Thermal Oxidizer Air Blower:
(1) Use the local start/stop control station to start the desired
blower.
(2) Once the blower comes up to speed, open its discharge

valve.
E. Once an air blower is running, press the "ESD RESET"

push-button on the local TTO control panel to reset the
TTO ESD and extinguish the "RESET REQUIRED" light. This will

flashing) on the local TTO control panel.

that a limit switch is not indicating that the fuel gas
valves and the TTO inlet valve are all closed.
sequence to proceed until these valves are proven
closed. Once the problem with the valves or their

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limit switches has been corrected, the "LIMITS

(1) The manual block valves in the pilot gas to the ignitor/pilot.
(2) The block valves in the air supply to the ignitor/pilot.
H. Adjust the output of the local manual air control to open the air
flow control valve and allow a large air flow, 80% or more on the
flow indicator, to purge the furnace for 40 seconds and
extinguish the "PURGE REQUIRED" light. The "PURGE COMPLETE"
light will then be illuminated.
I. Adjust the output of the local manual air control to reduce the
air flow on the flow indicator to 10-20%. This will extinguish the
light.
NOTE: Remember that the ignition safety timer will shut down
the Thermal Oxidizer if an ignition attempt is not made
J. Press the "PILOT ON" push-button to initiate an ignition attempt.

sparking the ignitor, the ignition try is aborted, the TTO Burner
sequence to return to Step H.
L. When either of the flame scanners detects a flame from the

pilot burner, the pilot air and natural gas valves will remain open
and the PLC will enable the "MAIN FUEL START" switch on the
local TTO control panel.
M. Adjust the output of the local manual air control to increase the
air flow on the flow indicator to at least 50%.

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12.8.2.3 Igniting the Main Gas Burner

A. Confirm that the output from the manual fuel gas control on the
local TTO control panel is set to 0%, that the fuel gas control
valve and its bypass valve are closed, that the block valves at
the control station are both open, and that the manual block
valves in the main fuel gas line and the block valve at the
burner are open.
B. If the air flow rate is not at least 50%, use the local manual air
control to set the air flow at 50% as indicated by the flow
indicator.
C. Press the "MAIN FUEL START" push-button on the local TTO

control panel to open the main fuel gas block valves.
NOTE: Be sure the air flow is above the low-low flow shutdown
point, about 20% on the flow indicator, or the TTO ESD
will be activated when the bypass timer expires and the
Thermal Oxidizer will shut down. (This timer begins
running when the "MAIN FUEL START" push-button is
pressed, and has a 2 minute duration.)
D. Use the manual fuel gas control to increase the firing rate and
bring the Thermal Oxidizer back to its normal operating
temperature.
E. As the firing rate increases, raise the air flow rate with the local
manual air control to 75%-80% as indicated by the flow
indicator.
F. Press the "PILOT STOP" push-button on the local TTO control

panel to block the pilot air and to "double block and bleed" the
pilot gas. Verify that the "PILOT ON" light is extinguished.
G. Close the following manual block valves:
(1) The manual block valves in the pilot gas to the pilot.
(2) The manual block valves in the air supply to the pilot.

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H. Loosen the packing gland on the pilot and retract or extract the
pilot assembly:
(c) Confirm that the pilot is still being purged with air.
(b) Close the block valve at the furnace to isolate the

pilot from the furnace.
(c) Close the block valve in the purge air to the pilot
burner.

VERY HOT. HANDLE IT

purged with air.
I. Confirm that the Thermal Oxidizer Waste Heat Boiler steam

pressure controller is in "automatic" and is controlling the steam
pressure properly.
J. Confirm that the superheated steam temperature controllers are

in "automatic" and are controlling the steam temperature
properly.
K. Switch the combustion air flow control from the local TTO
control panel to the DCS as follows:
(1) Confirm that the air flow controller in the DCS is in

"automatic", its output is tracking the output from the

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manual air control on the local TTO control panel, and its
setpoint is tracking its current value.
(2) Switch the air flow control hand switch from "local" to
"remote". The air flow controller now has control of the air
flow control valve, and will be controlling the air flow rate
with its last value as the setpoint.
(3) Slowly adjust the setpoint of the air flow controller to its
normal value.
L. Switch the temperature control of the Thermal Oxidizer from the

local TTO control panel to the DCS as follows:
(1) Confirm that the temperature control in the DCS is in

"automatic", its output is tracking the output of the manual
fuel gas control on the local TTO control panel, and its
setpoint is tracking its current value.
(2) Switch the hand switch from "local" to "remote". The

temperature control now has control of the fuel gas control
valve, and will be controlling the temperature with its last
value as the setpoint.
(3) Slowly adjust the setpoint of the temperature control to its

normal value.

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12.8.2.4 Routing SRU/TGCU Tailgas to the Thermal Oxidizer

A. When the Thermal Oxidizer temperature reaches 816°C, the
TTO is ready to be placed in service. Switch the Startup/Run
selector switch on the local TTO control panel to "RUN".
The PLC will open the TTO inlet valve, then close the TTO
bypass valve. The "INLET OPEN" light will be illuminated, then the
"BYPASS OPEN" light will be extinguished as the valves move to
their new positions.
B. If the temperature of the superheated steam leaving the

superheater pass of the Thermal Oxidizer Waste Heat Boiler fell
low enough to activate the low-low temperature interlock while
the Thermal Oxidizer was being restarted, the steam will be
venting to atmosphere at this time. After confirming that the
steam temperature is under control at the proper value and the
steam header is ready to accept steam, "toggle" the steam
reset permit switch in the DCS to slowly close the steam
blow-off valve and send the steam to the export header.
C. The Thermal Oxidizer is back on-stream, incinerating SRU

tailgas or TGCU effluent. Before directing your attention away
from the Thermal Oxidizer, be sure that:
(1) The Thermal Oxidizer is operating smoothly, with both the

combustion air and fuel gas on automatic control.
(2) The Thermal Oxidizer Waste Heat Boiler level, pressure,

and steam temperature controls are functioning properly.
(3) The stack gas analyzers are performing satisfactorily.

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The procedures to be used in performing a planned shutdown of the Thermal
Oxidizer will vary depending on the extent and type of work to be performed in
and around the TTO during the downtime period. If there are no plans for
entering the TTO equipment, no special procedures are required in performing
the shutdown. Section 12.9.1 that follows is an example of such a procedure.
However, if you plan to enter any vessels for inspection or maintenance, then
more extensive and lengthy procedures must be followed to accomplish a
satisfactory shutdown and minimize the time required for performance of the
desired maintenance work. Section 12.9.2 that follows is an example of a
procedure for this circumstance.
One special circumstance that may exist during a shutdown is to have tube
leaks in the Thermal Oxidizer Waste Heat Boiler. This special case is discussed
in Section 12.9.3.

quickly identifying and correcting the problem so the Thermal Oxidizer can be
put back on-line in a minimum amount of time.
The TTO is affected directly and indirectly by shutdowns and outages that occur
in other systems both within the Sulfur Block and outside the battery limits. The
more important aspects of the effects these other systems can have on the
Thermal Oxidizer are discussed in Section 0.
situation.

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12.9.1 Planned Shutdown - No Entry

When there are no plans to enter any of the equipment in the TTO
system, no special shutdown procedures are required. Under these
circumstances, the shutdown procedure given in this section may be used
as a guide.
It is generally preferable to shut down the Thermal Oxidizer in a controlled

fashion to minimize the impact on the other process units, particularly if
the SRUs and/or TGCU are to remain on-line. If time does not allow
performing a controlled shutdown, however, the Thermal Oxidizer can be
shut down by simply activating its TTO ESD system (using either the local
push-button or the DCS "toggle" switch). This will automatically block the
fuel gas, pilot gas, and combustion air feeding the Thermal Oxidizer.
A. If the SRUs and/or the TGCU are to be shut down also, shut down
the TGCU first using the appropriate procedures from Section 11.9
Then shutdown the SRUs using the appropriate procedures from
Section 9.9.
NOTE: If the SRUs are to remain in service while the TTO is shut
down, SRU tailgas or TGCU effluent (plus the Sulfur Surge
Tank sweep air and spent degassing air) will be flowing
through the Thermal Oxidizer. Since these gases contains
H2S (and possibly SO2), they should not be allowed to
escape to the surroundings except from the top of the
Thermal Oxidizer Vent Stack. The operating permit for
this plant may not allow venting un-oxidized process gases
for extended periods.
In addition to H2S and SO2, SRU tailgas, Sulfur Surge

Tank sweep air, and spent degassing air also contain
elemental sulfur. This sulfur may condense in the Thermal
Oxidizer system while it is shut down.
B. If the SRUs and the TGCU have been shut down, continue firing the
Thermal Oxidizer Burner with the main fuel gas burner for several
minutes to clear as much of the sulfur gases out of the system as
possible.
C. Use the "toggle" switch in the DCS or the push-button on the local
TTO control panel to activate the TTO ESD system.

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D. Switch the Startup/Run selector switch on the local TTO control

panel to "STARTUP".
This will open the Thermal Oxidizer Bypass valve and prove it open,
then close the Thermal Oxidizer Feed valve.
E. Close the manual block valves in the discharge lines of the Thermal
Oxidizer Air Blowers.
F. Visually confirm that:
(1) The main fuel gas shutdown valves are closed and the vent
valve is open.
(2) The block valves in the main fuel gas line and pilot gas supply
line are closed.
(3) The automated block valve in the air supply to the ignitor/pilot,
and the automated block valves in the pilot gas supply to the
ignitor/pilot, are closed and the pilot gas vent valve is open.
(4) The Thermal Oxidizer Air Blowers are shut down and their
discharge valves are closed.
(5) The air flow control valve is closed.
G. If the Thermal Oxidizer will be down for an extended period, special

precautions should be taken to prevent the boiler tubes from cooling
to the point where water can condense on them. Most of the
corrosion that occurs in TTOs is due to the acidic water that can form
if the plant is allowed to get cold.
Allow the Thermal Oxidizer Waste Heat Boiler to cool enough to

reduce the steam pressure to about 1.0 kg/cm2(g). Then
de-pressure the boiler and drain the water from it. Use a temporary
"jumper" to supply LP steam to the boiler, and drain the condensate
from it occasionally. This will keep the tubes safely above the water
condensation temperature (100-110°C) and above the temperature
at which sulfur freezes (119°C).

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12.9.2 Planned Shutdown for Entry

When vessel entry for maintenance, inspection, or other purposes is
required, the Thermal Oxidizer must be cooled down and isolated. The
procedure below may be used as a guide for performing this type of
shutdown.
A. Shut down the TGCU first with the appropriate procedures.
B. Shut down the SRU with the appropriate procedures.
C. Shut down the SDU with the appropriate procedures.
D. Shut down the Sulfur Surge Tank Vent Ejectors as follows:
(1) Close the gate valve and the globe valve in the motive steam
supply line.
(2) Close its manual discharge valve.
WARNING
NEVER BLOCK-IN THE EJECTORS COMPLETELY (CLOSING

BOTH THE SUCTION VALVE AND THE DISCHARGE VALVE
AT THE SAME TIME) WHILE THE HP MOTIVE STEAM
SUPPLY LINE IS CONNECTED TO THE EJECTOR. A LEAK IN
THE MOTIVE STEAM BLOCK VALVES COULD ALLOW THE
HP STEAM TO OVER-PRESSURE THE EJECTOR BODY.
E. Continue firing the Thermal Oxidizer Burner with the main fuel gas
burner for several minutes to clear as much of the sulfur gases out of
the system as possible.
F. Use the temperature controller to gradually reduce the temperature

in the Thermal Oxidizer. To prevent damage to the refractory lining
in the furnace, do not allow the temperature to drop more rapidly
than 100-150°C per hour.
NOTE: As the furnace temperature drops, the fuel gas flow rate
will become progressively lower. Once the fuel gas control
valve reaches its "minimum fire" position, it will not be
possible to drop the temperature any further.

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G. Once the furnace temperature reaches 100-150°C, the burner can

be extinguished and the air blower used to provide the rest of the
cooling:
(1) Shut down the Thermal Oxidizer by pressing the S/D

push-button on the local TTO control panel.
(2) Visually confirm that the main fuel gas shutdown valves are
closed and the vent valve is open.
(3) Visually confirm that the automated block valves in the pilot gas
supply to the ignitor/pilot are closed and the vent valve is open.
(4) Close the gate valve in the main fuel gas supply line and the
gate valve at the burner.
(5) Switch the Startup/Run selector switch on the local TTO control
panel to "STARTUP".
(6) Switch the air flow control hand switch in the DCS to "local" so
that the manual air control on the local TTO control panel has
control of the air flow control valve.
(7) Start a Thermal Oxidizer Air Blower and open its discharge
valve.
(8) Press the "ESD RESET" push-button on the local TTO control
panel.
(9) Adjust the manual air control to send a large flow, 80% or more
on the combustion air flow line alarms, to the Thermal Oxidizer.
H. Allow the large flow of air to continue until the Thermal Oxidizer
reaches ambient temperature.
I. Once the Thermal Oxidizer is cool, use the "toggle" switch in the
DCS, or the push-button on the local TTO control panel to activate
the TTO ESD system.
J. Close the manual block valves in the discharge lines of the Thermal
Oxidizer Air Blowers.
K. Visually confirm that:
(1) The main fuel gas shutdown valves are closed and the vent
valve is open.

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(2) The block valves in the main fuel gas line and the pilot gas
supply line are closed.
(3) The automated block valve in the air supply to the ignitor/pilot
and the automated block valves in the pilot gas supply to the
ignitor/pilot are closed and the pilot gas vent valve is open.
(4) The Thermal Oxidizer Air Blowers are shut down and their
discharge valves are closed.
(5) The air flow control valve is closed.
L. Isolate the Thermal Oxidizer from all potential contaminating gases

using slip blinds or by disconnecting the piping. In particular, isolate
the Thermal Oxidizer from the SRUs and the TGCU using slip-blinds,
etc.
WARNING
THE THERMAL OXIDIZER INLET LINE CONTAINS TOXIC

GASES (H2S AND SO2). THE "GENERAL SAFETY" SECTION
OF THIS MANUAL SHOULD BE CONSULTED IF THERE IS
ANY DOUBT ABOUT HOW TO WORK SAFELY WHEN THESE
GASES ARE PRESENT.
CAUTION
SINCE ISOLATION OF THE THERMAL OXIDIZER RESULTS IN

THE LOW PRESSURE PIPING AND EQUIPMENT IN THE
SRUS AND TGCU BEING COMPLETELY BLOCKED-IN, THE
ACID GAS TO THE SRUS, SWS GAS TO THE SRUS, FUEL
GAS TO THE SRUS, REDUCING GAS TO THE TGCU, AND
NITROGEN PURGES TO THE SRUS AND THE TGCU
SHOULD ALSO BE BLINDED OR DISCONNECTED. THIS
WILL ENSURE THAT A LEAKING VALVE, ESPECIALLY FUEL
GAS OR NITROGEN, WILL NOT BE ABLE TO
OVER-PRESSURE THE SRUS AND/OR THE TGCU.

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M. Once the Thermal Oxidizer is isolated, the TTO system 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.
N. If the Thermal Oxidizer will be down for an extended period, special

precautions should be taken to prevent the boiler tubes from cooling
to the point where water can condense on them. Most of the
corrosion that occurs in TTOs is due to the acidic water that can form
if the plant is allowed to get cold.
Allow the Thermal Oxidizer Waste Heat Boiler to cool enough to

reduce the steam pressure to about 1.0 kg/cm2(g). Then
de-pressure the boiler and drain the water from it. Use a temporary
"jumper" to supply LP steam to the boiler, and drain the condensate
from it occasionally. This will keep the tubes safely above the water
condensation temperature (100-110°C) and above the temperature
at which sulfur freezes (119°C).

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One special circumstance that merits discussion is shutting down the TTO
when there are tube leaks in the Thermal Oxidizer Waste Heat Boiler.
a chance to form acid and cause rapid corrosion. When a Thermal
Oxidizer is shut down, however, several problems can develop:
1. Liquid water may accumulate in the equipment or piping and

form a variety of acids (sulfurous, polythionic, etc.) that will
rapidly corrode the steel.
2. Liquid water may reach the refractory linings in the equipment

and damage the linings.
3. If there is a large tube leak in the boiler, water may back-flow into
the hot Thermal Oxidizer and rapidly vaporize, possibly violently
enough to damage its refractory lining or create high pressure in
the Thermal Oxidizer.

A. Shut down the TGCU, shut down the SDU and shut off the Sulfur
Surge Tank Vent Ejectors. Shut down the SRUs.
B. Begin cooling down the Thermal Oxidizer using the procedure in

Section 12.9.2. Do not activate the TTO ESD to shut down the air
blower (Step I in Section 12.9.2) until the Thermal Oxidizer Waste
Heat Boiler has been drained in Step E below.
C. De-pressure the Thermal Oxidizer Waste Heat Boiler, taking care to

reduce the pressure slowly enough to avoid over-stressing the boiler.
D. Maintain a visible water level in the boiler. Water must remain in the
boiler until it is de-pressured and the Thermal Oxidizer has been
cooled to prevent overheating damage to the tubes.
E. Once the Thermal Oxidizer is cool and the boiler is fully

de-pressured, drain the water from the boiler to prevent any further
leakage into the process side of the equipment.
F. The TTO is now ready to be isolated and made safe for entry.

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The TTO ESD system can be initiated by any of the actuating devices
outlined in Section 12.5.9.1 of this manual, or by a power failure. The
operator must determine and correct the condition causing the shutdown
before the TTO can be restarted. The problems outlined below should be
investigated first by the operator in his troubleshooting procedure.
If the malfunction causing the emergency shutdown can be determined

and corrected in a short period of time, the TTO can be put back on-line
using the normal restart procedure outlined in Section 12.8.2 of this
manual.

Thermal Oxidizer Burner 1. Malfunction of the flow control valve or flow
Low-Low Combustion control system.
Air Flow 2. Blower discharge block valve is closed or
pinched.
3. The discharge block valve on the spare
blower is open, allowing air to escape.
4. Blower shutdown due to mechanical
problems with the blower, the motor, or the
switchgear.
5. High pressure drop from plugging in the
waste heat boiler.
Thermal Oxidizer Air 1. Equipment damage has caused the blower

Blower to quit running.
Neither Blower Running 2. A failure in the starter contacts is causing a
false indication that the blower is not
running.
Thermal Oxidizer Burner 1. A manual block valve is closed or pinched.

Fuel Gas 2. Header pressure is low due to problems
Low-Low Pressure elsewhere.
3. Malfunction of the fuel gas pressure
regulator.
Thermal Oxidizer Burner 1. Malfunction of the fuel gas pressure

Fuel Gas regulator.
High-High Burner 2. Malfunction of the temperature control
Pressure system.
3. The burner has been damaged (tip plugged
or obstructed, etc.).

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Thermal Oxidizer Burner 1. Failure of a component in the flame sensor
Flame Failure circuit.
2. Condensation of sulfur or water vapor on
the lens of the flame scanners.
3. Low fuel gas flow due to:
a. Malfunction of the temperature control
valve or the temperature control
system.
b. Malfunction of the fuel gas pressure
regulator.
c. A manual valve is closed or pinched.
d. Fuel gas header pressure is low due to
problems elsewhere.
4. Low combustion air flow due to:
a. Malfunction of the flow control valve or
the flow control system.
b. Blower discharge block valve is closed
or pinched.
c. The discharge block valve on the spare
blower is open, allowing air to escape.
d. Blower shutdown due to mechanical
problems with the blower, the motor, or
the switchgear.
e. High pressure drop from plugging in the
waste heat boiler.
Thermal Oxidizer 1. A sulfur plant is off-ratio, causing the

High-High Temperature tailgas from that SRU to contain large
amounts of H2S (a combustible gas).
2. An upset in the TGCU is allowing large
amounts of H2S to enter the Thermal
Oxidizer.
3. Malfunction of the temperature control
system or control valve.
4. Sulfur fire from accumulation of liquid sulfur
in the bottom of the Thermal Oxidizer.

SULFUR BLOCK

Thermal Oxidizer Waste 1. Low steam flow through the superheater
Heat Boiler pass.
Superheated Steam 2. Malfunction of the interstage temperature
High-High Temperature control system or the desuperheating
system.
3. Malfunction of the discharge temperature
control system or the desuperheating
system.
Thermal Oxidizer Waste 1. Loss of make-up water supply pressure.

Heat Boiler 2. Make-up water line plugged, or manual
Low-Low Level block valve closed or pinched.
Thermal Oxidizer Vent 1. High temperature in the Thermal Oxidizer.

Stack 2. Sulfur fire from accumulation of liquid sulfur
High-High Temperature in the bottom of the stack or the Thermal
Oxidizer Waste Heat Boiler casing.
3. Loss of water level in the Thermal Oxidizer
Waste Heat Boiler which was not detected
by the low-low level S/D.
4. Fouling of the tubes in the Thermal

SULFUR BLOCK

The Tailgas Thermal Oxidation system is directly or indirectly affected by
shutdowns and/or outages in four other systems in the complex. These
effects are described below.
12.9.5.1 ATU / ARU Outages

Acid gas flow from the ARU can be interrupted for a variety of
reasons. When these events occur, the acid gas flow will not cease
immediately. If processing in the ARU is restarted within the time
frame of the system residence time, the ARU acid gas flow to the
SRUs will probably dip, but should not stop completely.
If the interruption in an ARU is long enough, though, the ARU acid

gas flow can fall far enough to cause the acid gas flame in the SRUs
to become unstable, at which point the SRU ESDs will be activated
by "flame failure". Section 12.9.5.3 below describes the effect of this
on the TTO.

the SRUs generally has minimal impact, outages in this system are
usually of little consequence to the SRUs or to the TTO.
12.9.5.3 SRU ESD System

The SRU ESD system stops the flow of acid gas to the SRU. As a
result, the tailgas flow from the SRU ceases almost immediately.
However, the Thermal Oxidizer will continue to operate, with the
temperature control on the Thermal Oxidizer cutting back the flow of
fuel gas to the Thermal Oxidizer Burner to the amount needed to
heat its combustion air (plus the sweep air from the Sulfur Surge
Tank and the spent degassing air) to the operating temperature of
the Thermal Oxidizer. The Thermal Oxidizer can run in this mode
indefinitely.
When acid gas flow resumes to the SRU(s), SRU tailgas and/or
TGCU effluent will begin to flow once again to the Thermal Oxidizer.
The temperature control will automatically increase the fuel gas flow

SULFUR BLOCK
as needed to increase the firing rate and continue oxidizing the gas
streams feeding the TTO.
12.9.5.4 TGCU ESD System

When the TGCU ESD system is activated, the warmup/bypass valve
in the TGCU opens immediately to divert the SRU tailgas streams to
the TTO. At the same time, the PLC opens the Tailgas Valve to the
TTO, proves the valve open, then closes the Tailgas Valve to the
TGCU. Once this switch is complete, the SRU tailgas streams are
blocked off from the TGCU and flow directly to the Thermal Oxidizer.
When the TGCU warmup/bypass valve first opens, the pressure drop
through the TGCU will no longer be imposing back-pressure on the
SRUs. Depending on the magnitude of this change in back-pressure
(which is mainly determined by the unit throughput), there may be a
temporary "bobble" in the feed and air flow rates to the SRUs.
Although this will probably cause brief deviations from the proper
air:acid gas ratio in the SRUs, the "bobble" should not be large
enough to cause a "flame failure" shutdown in the SRUs. If so, the
SRUs will remain on-line with their tailgas flowing to the TTO.

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SAMSUNG TOTAL PETROCHEMICALS CO., LTD.

NO. 2 AROMATICS COMPLEX

2. GENERAL SAFETY ..................................................................................................... 2-1

Issued 30Aug11 Table of Contents Page i

Issued 30Aug11 Table of Contents Page ii

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Issued 30Aug11 Table of Contents Page v

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Issued 30Aug11 Table of Contents Page vii

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Issued 30Aug11 Table of Contents Page x

Issued 30Aug11 Table of Contents Page xi

Issued 30Aug11 Table of Contents Page xii

Issued 30Aug11 Table of Contents Page xiii

THE INFORMATION IN THESE GUIDELINES IS CONFIDENTIAL. SOME OF

We have tried to present all of the information from an operations viewpoint by

4. Instrumentation and Control Systems

5. Operating Principles and Techniques

Issued 30 August 2011 Introduction Page 1-1

9. Setpoints (Controllers, Alarms, Shutdowns, PCVs, PSVs)

10. Analytical Procedures

Issued 30 August 2011 Introduction Page 1-2

Issued 30 August 2011 General Safety Page 2-i

2.4.1.4 Odor ...................................................................................................... 2-15

Issued 30 August 2011 General Safety Page 2-ii

2.7.1.2 Toxicity Information ............................................................................... 2-31

Issued 30 August 2011 General Safety Page 2-iii

2.14.3 Chemical Sorting and Identification .............................................................. 2-47

G. UOP/ESM S-2001 Sulfur Conversion Catalyst

H. Criterion 234 Tailgas Treating Catalyst

Issued 30 August 2011 General Safety Page 2-iv

An employee's knowledge of the hazardous chemicals and compounds with which he

2.1 Definition of Terms

The minimum temperature to which a substance (the substance may be

B. Flammability Limits (explosive limits)

When flammable vapors are mixed in air, there is a minimum

Flash point is the lowest temperature of a liquid at which sufficient vapors

Issued 30 August 2011 General Safety Page 2-1

D. Specific Gravity (solids and liquids)

E. Specific Gravity (gases)

Specific volume of a substance is the volume of a unit mass of the

Toxicity is the ability of a chemical or compound to produce injury once it

Issued 30 August 2011 General Safety Page 2-2

2.2 Hydrogen Sulfide (H2S)

2.2.1.2 Toxicity Information

LCLo: 800 PPM / 5 minutes (death of humans after

LCLo (Lethal Concentration Low) is the lowest concentration of a

2.2.1.3 Permissible Exposure Limits

TLV (Threshold Limit Value) is the highest level of exposure to a

2.2.1.5 Physical Data

Issued 30 August 2011 General Safety Page 2-3

2.2.1.6 Reactivity Data

Issued 30 August 2011 General Safety Page 2-4

2.2.1.7 Corrosivity Data

b. H2S can cause sulfide stress cracking (SSC) in a variety of

c. At elevated temperature (generally, above 650°F/343°C), H2S

d. H2S is considered to be non-corrosive to aluminum, glass, and

2.2.1.8 Water Solubility

2.2.1.9 Other Characteristics

Issued 30 August 2011 General Safety Page 2-5

2.2.1.10 Fire and Explosion Hazard