SULPHURIC ACID PLANT

Criteria of erection of Equipments to Built in Reliability

CORRECTNESS IN CIVIL CONSTRUCTION

Proper layout to be done with proper measurements. Excavation of the Ground for Equipment Foundations. Proper mixing of Concrete to be used Confirm the Concrete Temperature and its proper setting. Control of Measurements.

CORRECTNESS IN CIVIL CONSTRUCTION

Reference with other foundation or Measurements. Prepare template for foundation bolts to be kept in position and check with vessel to be installed. Concrete surface leveling to be controlled. Homogeneous Mixing to be done while concreting. Surface finish to be considered for long life. Proper leveling of Foundation to be taken care.

CORRECTNESS IN CIVIL FOUNDATIONS

Proper curing to be done. Honey combings should not be allowed. Torrsteel rods should not be projected from the surface of concrete. Proper care to be taken for Concrete Joints by providing Rubber or PP Joint seal or Proper sealant to be provided to avoid leakages. After removing of centering, plastering to be completed immediately. So that proper jointing to be possible to give extra strength.

IMPORTANCE OF GOOD LAYOUT

Consider that the pressure drop in the system should not be effected while running of the plant. Energy saving should be considered. Heat loss should be avoided from the system. Generation of Heat to be converted into the power generation. Laying of Pipe lines and Ducts should not be effected by layout. Pressure drop should not effected unless otherwise stated.

IMPORTANCE OF ERECTING VESSELS

Check the Measurements of Foundation. Check the elevation of Foundations. Check the Equipment Foundation Measurements, which is installing on Foundation. Check the foundation bolts location and its Measurements. Check the Foundation bolt holes on the Base plate of the Equipments.

IMPORTANCE OF ERECTING VESSELS

If any deviation, correct it before installation. Orientation of nozzles for Equipment is very important while erection of equipment. Consider the equipment erection should not give hindrance to another equipment at the time of erection. Care about the leveling of equipment and check with Master level. Care to be taken Foundation bolts should not be damaged while erection of equipment.

Welding
1. Welding is the major role in the projects. 2. Weld Type of Arc, Tig and Mig 3. Arc welding is considered for ducting, Unpressurised vessels, Structural, General etc. 4. Tig. welding is for Pressure vessels, Pipe lines of Low and High Lines. Ducting of Gas or Air flow. 5. Where the Expansion bellows are provided on Duct Lines, there is a chance of Leakage of gasses during sudden expansion. Tig welding is preferred. 6. Arc welding may not give that much chance for welding of ducts where the expansion joints are provided.

Welding
7. Testing of welding joints like, Penetrate test, Dip test, X-Ray Test, Magnetic Test, Ultrasonic Test etc. 8. Failure of Welding of joint will show by above tests. 9. For doing the welding joint, you have to take care about the edge preparation, Clearance between two faces. 10.For Tig welding, you have to care about the oxygen penetration while welding to avoid oxidation. There by failure of joint will take place.

Welding
11.Provide curtains to reduce the joint failure. 12.Better to provide closed area like Tig welding to be done with closed room. 13.Field joints are not possible to do like that, so you have to provide close atmosphere for doing the welding of joints of high or low pressure lines. 14.It is also important to take the welding joint into normality by doing the Annealing process. So that joint failure will reduce.

Plant Flooring, Position of Valves and Flat forms

1. Valves should be provided in such a location to avoid loss of heat or Loss of Pressure etc. 2. Valves should be positioned in such a way for free maintenance. 3. Flat forms should be provided for opening and closing of valves, maintenance of valves in that location. 4. Flat forms structural should not be effected for movement of the plant operating people, movement of equipments like trolleys, Fork lifts etc. 5. Flat forms should be inter-connected, if possible with other supports or flat forms.

Plant Flooring, Position of Valves and Flat Forms

5. Flat forms are to be covered with Grid plates to reduce corrosion and for maintenance. 6. Flat forms are to be provided proper security system by providing of Railings, Shoe toy boards etc. 7. Plant are is provided proper Drainage system separately for Rain water as well as Blow down water from various vessles. 8. Drainages are to be covered with proper grid plates, so that we can be able to see what is passing in that area.

Plant Flooring, Position of Valves and Flat Forms

9. Plant area to be covered with proper flooring to maintain neat and clean. 10.Plant area to be provided walk ways, so that visitors should follow the proper approach to the plant area. 11.Name Plates are to be provided to identify the equipment name, Location of the plant area etc. 12.While considering the flat forms you have to care about the safety to the work force to escape from the position, if any suddenly unsafe conditions are generated.

Plant Flooring, Position of Valves and Flat Forms

13. Considering of Gland leaks, which are common from Gas Duct valves due to high gas temperature at inside the ducts while running of the plant. 14. You have to design properly about the glands, which are to cooled with atmospheric air. 15. Gland cooling to be provided which is projected from the Insulation to reduce the damage (or burn) of Gland rope by high temperature.

Plant Flooring, Position of Valves and Gland Leaks

16. Proper gland ropes are to be used which are suitable to the particular atmosphere to avoid the gland leakages. 17. Plant area should be maintained neat and clean to avoid unwanted accidents. 18. Inside the plant, you have to earmark the locations to keep the maintenance equipments during the maintenance period.

Plate Heat Exchangers & Towers

1. While circulation of Sulphuric Acid in Towers, some of broken saddle pieces are flow along with acid in towers and collected in to the Acid Circulation tank. 2. These are extracted by pump which are floated in liquid while running due to agitation in acid pump tank by returning acid from tower with velocity. 3. These ceramic pieces are pass though pump and will jam at inlet of the plate heat exchangers or shell and tube heat exchanger on shell side. There by reduce the flow of Sulphuric acid to the towers.

Plate Heat Exchangers and Towers

5. If these are ceramic particles pass through Plate Heat Exchanger, will get jam at acid distribution Header there by pressure drop will increase across the Plate Heat Exchangers and Distribution Headers. To avoid, you have to provide mesh of lower the size of the Plate Heat Exchanger Openings and Lower size of the Acid Distribution holes. 6. Acid will flow across the openings and reduce the pressure drop in the circulation system. 7. Acid is highly corrosive at higher temperature, so that suitable material and proper shape to be required to use.

Sulphur Gun for Spraying

1. Sulphur gun spraying is basically based on Air flow as well as swirling motion of Sulphur flow. 2. Sulphur should not fall on furnace inside before spraying. To avoid that falling of Sulphur Nozzle should be Pressurized by flow and swirling motion to be provided. 3. Sulphur Furnace inlet air flow is also required to provide swirling flow along with Sulphur Gun nozzle. 4. Gun barrel pipe as well as supply jacketed pipe to be designed as required to provide sufficient flow to the Gun nozzle.

Instrument Erection and PLC Positioning

a. PLC Control panel to be installed in Plant operation control room. b. Cable racks and Cable identification should be properly earmarked by provided tags, like numbers or letters. c. Cable joints are not allowed for instrumentation system. d. Cable junction boxes are to be provided in such a location to avoid the damage of junction boxes by rain, sun rays etc.

Instrument Erection and PLC Positioning

e. Local Indicators are to be provided with proper cover. f. Control valves and Controllers are to be provided in proper direction to look locally by the operating peoples. g. Proper controlling system to be provided based on the operational condition of the plant. h. Plant tripping is to be provided in proper way, it should not deviate the system failure.

Instrument Erection and PLC Positioning

i. Plant tripping should help us the Process failure, System failure and to reduce the damage of the plants. j. Plant tripping will help us to control the Environmental pollution based on the settings of the plant with ventilations through chimneys.

CLOSEUP
a. Plants should run at clean atmosphere. b. Plants should operate with in controlled environmental conditions. c. Plants should operate with in the recommended operating condition. d. Plant should be the unit, the Operating people as well as Management should feel happy to run. e. Management should not feel burden to run the plants with in the controlled conditions.

POWER GENERATION
a. For Economical Operation of Sulphuric Acid Plant should be minimum 250 MT/Day. So, that Power Generation should be 2500 HP. b. Plant will consume 865 KW the balance 1000 KW will be exported to other plants. c. We can save lot of energy from the plant. This cost will be: 1865x24x5=2,23,800 Rs per day. It means Rs. 800.00 Lacks will be generated from the plant. d. By Comparison we have to invest 20% more that the actual cost of the project of Sulphuric Acid Plant.

PREPARED BY
YALAMATI SATYANARAYANA PROJECT MANAGER M/S. HARIKA INDUSTRIES HYDERABAD INDIA CELL: +919849963639 / +966590288534 YALAMATI.SATYANARAYA@GMAIL.COM