mechanical integrity best practice for sulfuric acid plants · •overpressure of equipment...
Transcript of mechanical integrity best practice for sulfuric acid plants · •overpressure of equipment...
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mechanical integrity best
practice
for sulfuric acid plants
Larry Moore, PE
AVP & Principal Engineer,
Mining and Metallurgy
FM Global Corporate Offices
Johnston RI USA
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objectives
• acid plant hazards and risks
• mechanical integrity factors
• conclusions
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Who is FM Global?
One of the world’s largest and oldest industrial
property insurance and risk management
organizations specializing in understanding
and engineering risk from fires, explosions,
mechanical and electrical breakdown, and
natural hazards
• mining
• mineral and coal processing
• metallurgical refining
• petrochemical, chemical and pharmaceutical
• power generation
• semiconductor
• pulp and paper
• warehousing
• general manufacturing
• telecommunications
• $US 6 Billion surplus
• 51 offices worldwide
• 4800 employees
• 1500 loss prevention engineers
• 80 specialized in mining and metallurgy
• industrial loss prevention
• standards
• technology
• research
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sulfur dioxide acid plant
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Sulfur Burning Acid Plantsulfur burning acid plant
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• corrosion to equipment
• corrosion to structures
• overpressure of equipment
• implosion of equipment
• heat of reaction
• environmental release
• fire
• explosion
• mechanical damage to rotating equipment
• refractory failure
• storage tank collapse
• catalyst poisoning
acid plant hazards
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reactions to produce acid appear simple but
control of hazards is far from simple:
• SO2 and sulfuric acid highly corrosive
• SO3 is highly reactive and unstable
• exothermic heat is generated by process
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history, being the most patient of teachers,
is always willing to repeat any lessons
forgotten - or ignored - by its students
some loss case studies to demonstrate this
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corrosion in an acid plant heat exchanger
Nickel
Refining Plant
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Plant produces:
• high purity nickel metal
• high purity cobalt metal
• by-product ammonium sulfate
• acid leaching in high pressure autoclave reactors
• solvent extraction
• hydrogen sulfide reactions
• hydrogen reduction reactions
• ammonia reactions
• hydrogen sintering
• briquetting
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There are no pyro-metallurgical processes (smelting or roasting)
nor SO2 waste emissions at this plant
Instead
acid for processes is produced by burning sulphur
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Steam Equipment & Heat
Recovery
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heat exchangers
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what happened
• acid plant designed for continuous operation with
typically 2 shutdowns maximum per year
• heat exchanger had 5 to 7 year life
• plant had significant commissioning problems
• acid plant cycled an estimated 100 times in two years
• chance for operational error multiplied
• chance for moisture entry multiplied
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what happened
• strong acid entered exchanger
• strong acid mostly due to carryover
• moisture then entered the circuit (steam leak or moisture due
to many start-up/shut downs)
• strong acid diluted below 93%
• tubes were cut as if by a “laser”
• significant corrosion and sulfate build-up to plant found as
well.
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results
• heat exchanger had to be replaced
• entire plant down due to lack of acid for
processes
• several month outage of entire plant
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wet electrostatic
precipitator
acid leak attacks
carbon steel tube
sheet
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electrostatic
precipitator
sparking burns hole
in adjacent tube
may cause fire
if plastic is present
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electrostatic
precipitator
broken discharge
electrode
may cause fire
if plastic is present
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corrosion on
SO2 blower
blades
excess carry
over of acid mist
from drying tower
can corrode
metal blades and
cause
catastrophic
failure
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pregnant
converter
bulging caused by
stress from
weight of converter
and internal
pressure
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converters
damaged refractory
caused by thermal
cycling - allowed heat to
damage steel shell
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• poorly designed candle filters allowed
significant acid carry-over resulting in
damage to heat exchanger from corrosion
and sulfate build-up
• stick tests & drain tests indicated that there
was significant acid mist carryover from the
absorption towers.
• when opened, candle filters were found to be
shrunken, sagging, and tearing away.
• approximately $3m in damage.
acid plant loss lesson - candle filter failure
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filter tearing sagging distorts brackets
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heat
exchangers
corrosion and
sulfate fouling
of tubes can
cause
overheating
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SO2 blower overspeed to
destruction =
entire plant shutdown
for 9 months
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zinc refinery
occupancy:
gas cleaning plant
downstream of zinc roaster
an explosion with an ensuing fire
occurred in the electrostatic
precipitator units that resulted in
physical damage to equipment and
temporarily interrupted production
operations for the Zinc and Sulfuric
Acid plant
The blast from the explosion physically
damaged 3 electrostatic precipitators
including sections of the ducting
system, frames, expansion joints, and
plastic valves
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plastic fire hazards
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Copper Smelter
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smelter
furnace
Damper
FRP
Cooler
Cooling Water
Water Spray
Thermocouple
SS Duct FRP Duct
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sequence of events:
• cooling water pumps for saturation
tower flood due to overflow from nearby tank
• cooling water supply fails
• hot gases at 2100o F enter plastic tower and
duct
• by-pass damper designed to send hot gases
to stack fails
• thermocouple designed to shutoff process
fails when wetted (and cooled) by poorly
located waterspray nozzle
• plastic vessels and ducts destroyed
copper smelter
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primary factors:
• lack of process safety management
program
• process hazard analysis not conducted
• management of change not done
• many changes and good intentions over
many years cause system to fail in
unexpected sequence
• lack of fixed fire protection
• smelter shut down 11 days
Copper Smelter
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Nickel Smelter
Air Cleaning Plant
Downstream of Nickel
Smelter
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ESP’s prior to loss
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Primary Factors:
• Plant undergoing planned shutdown
• Wire discharge electrodes inside ESP dropped
onto polypropylene diffuser mesh
• Short circuit tripped remote circuit breaker
• Breaker reportedly reset several times but kept
tripping
• Ignition of plastic internals
• No detection/waterspray out of service due to
shutdown sequence
• Fire noticed by black smoke
• Fire suppressed – exposures protected by hose
streams
• Fire Destroyed two (of eight) plastic precipitators
Nickel Smelter
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Damaged tower
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damaged tower
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sulfuric acid storage tank
acid tank failure with
environmental release
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mechanical integrity
best practice
factors
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harsh corrosive operating conditions of acid
plants require careful extra attention to
• reliability engineering
• material selection
• good operating principals
• superior maintenance procedures
because
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extensive downtimes are not an option
especially for waste emission (pollution control) acid
plants associated with metallurgical smelting
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FM Global experience shows that the mechanical
integrity of equipment can be reliably assessed using
seven key Best Practice factors:
• environment
• design and operating conditions
• age and history
• maintenance
• operators
• safety devices
• contingency planning
primarily impacts frequency of loss
primarily impacts severity of loss
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environment factors:
• there is no evidence of corrosion on the outside of equipment, under
insulation, or structural members or cladding.
• there is no imminent potential for structural collapse due to corrosion.
• there is no evidence of or potential for accelerated degradation of FRP
materials due to UV
• exposures to natural hazards (wind, freeze, flood, etc.) have been identified
and quantified.
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corrosion on
structural steel
can cause
structural failure
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corrosion under
insulation
can cause failure of
vessel and loss of
containment
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design and operating condition factors:
• corrosion has been documented, corrected and monitored.
• a corrosion detection and measurement system is in place and effective.
• plant design includes inherently safer water-acid interfaces
• plant design includes methods to detect and remove acid mist carry over
• metal materials of construction suitable to operating conditions have been
used. (hint: don’t skimp on cost in this factor)
• a program for managing physical metallurgy issues is in place
• the plant is operated in accordance with manufacturer’s recommendations.
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sulfuric acid corrosion rates* (mils per year)
ºF 99% 98% 97% 95% 90% 80%
200 <1 4 10 30 500 10,000
300 <1 5 20 60 6,000 90,000
400 <1 10 40 120 60,000 20,000
* 310 SS
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water
acid
cooling tower
heat exchanger
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P acid
acid
P water >
water
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acid
P waterP acid >
water
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design and operating condition factors:
•corrosion has been documented, corrected and monitored.
•a corrosion detection and measurement system is in place and effective.
•plant design includes inherently safer water-acid interfaces
• plant design includes methods to detect and remove acid mist carry over
•metal materials of construction suitable to operating conditions have been
used. (i.e., don’t skimp on cost in this factor)
•a program for managing physical metallurgy issues is in place
•the plant is operated in accordance with manufacturer’s recommendations.
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acid drain - cold pass gas heat exchanger
HX
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acid drain – SO2 blower
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age and history factors:
•the plant operates at or below original design capacity or has been subjected
to a formal de-bottlenecking procedure.
•There has been no history of abnormal process cycling
•refractory in heat exchangers is within its design life
•modifications have been properly managed using a MOC program
•the catalyst is still within its expected life
•the same catalyst has been used as per the initial design or an MOC
procedure was used to understand the process chemistry.
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maintenance factors:
• internal inspection program
•a corrosion measurement program is used and is effective
•there is a high quality water quality monitoring.
•a comprehensive maintenance program exists for all alarms, sensors, probes.
•there is a program for double blocking on all hazardous acid pipe work.
•there a program to ensure no short-bolting on acid tank man holes/access
ports.
•mist eliminator pads are carefully checked for proper condition
•regular inspections and checks (i.e., stick testing for water entry)
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stick tests
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operator factors:
• process safety management is culturally embedded
•operators and engineers understand the process chemistry, especially
potential upset conditions.
•there is a good overall understanding of the process and equipment
•safe start-up/shut-down procedures are provided and documented
•operators are knowledgeable about the importance of draining during shut
down.
•operators are knowledgeable about weak strength of atmospheric storage
tanks.
• communication with other plants on site
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safety devices:
•a means of detecting and alarming water entry into acid systems is provided
•all pressure vessel components have suitable pressure relieving devices.
•large rotating equipment SO2 blowers have fixed automatic vibration monitors
and shutdown interlocks
•suitable vacuum breakers are provided for acid tanks
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contingency planning factors:
•two smaller plants are better than one large plant
•agreements and service contracts regarding bottleneck equipment are in place
for vendors, suppliers and OEM technical advisors.
• a spare so2 blower and motor are available
•design drawings for long lead time components are current and available.
•a source of available spare parts has been documented if parts are not on site
and if the OEM is no longer in business, or the equipment is obsolete.
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conclusions
• acid plants have unique hazards and exposures many of a mechanical
integrity nature
• acid plants often do not fall under a PSM law and voluntary application of
PSM is not widespread nor culturally embedded in this industry
• most critical PSM elements are process hazard analysis, management of
change, and mechanical integrity
• key equipment factors can be used to help understand and control
mechanical integrity hazards
• encourage mechanical integrity “best practices” for this industry
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“It is unwise to pay too much. But it’s worse to pay too
little. When you pay too much, you lose a little money,
that is all. When you pay too little, you sometimes lose
everything, because the thing you bought was incapable
of doing the thing you bought it to do. The common law
of business balance prohibits paying a little and getting a
lot. It can’t be done. If you deal with the lowest bidder, it
is well to add something for the risk you run. And if you
do that, you will have enough to pay for something
better.”
John Ruskin (1819-1900), a prominent 19th century English critic who was an astute
observer of social and economic issues