Operating Guidelines
Transcript of Operating Guidelines
-
8/3/2019 Operating Guidelines
1/792
SAMSUNG TOTAL PETROCHEMICALS CO., LTD.
SULFUR BLOCK
NO. 2 AROMATICS COMPLEXDAESAN, KOREA
OPERATING GUIDELINES
Prepared byOrtloff Engineers, Ltd.Midland, Texas USA
Project 507000Fall 2011
-
8/3/2019 Operating Guidelines
2/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page i
1. INTRODUCTION .......................................................................................................... 1-12. GENERAL SAFETY ..................................................................................................... 2-1
2.1 DEFINITION OF TERMS ....................................................................................... 2-12.2 HYDROGEN SULFIDE (H2S) ................................................................................ 2-3
2.2.1 Description and Properties ............................................................................. 2-32.2.2 First Aid .......................................................................................................... 2-72.2.3 Precautions (remember these facts) .............................................................. 2-82.2.4 Good Work Practices ...................................................................................... 2-9
2.3 SULFUR DIOXIDE (SO2) ..................................................................................... 2-102.3.1 Description and Properties ........................................................................... 2-102.3.2 First Aid ........................................................................................................ 2-132.3.3 Precautions ................................................................................................... 2-14
2.4 SULFUR .............................................................................................................. 2-152.4.1 Description and Properties ........................................................................... 2-152.4.2 Precautions ................................................................................................... 2-202.4.3 Fire Fighting .................................................................................................. 2-21
2.5 AMMONIA (NH3) .................................................................................................. 2-222.5.1 Description and Properties ........................................................................... 2-222.5.2 First Aid ........................................................................................................ 2-262.5.3 Precautions ................................................................................................... 2-26
2.6 METHYLDIETHANOLAMINE (MDEA, CH3-N-(CH2-CH2-OH)2) ........................... 2-282.6.1 Description and Properties ........................................................................... 2-282.6.2 First Aid ........................................................................................................ 2-292.6.3 Precautions ................................................................................................... 2-30
2.7 SODIUM HYDROXIDE (CAUSTIC SODA, NAOH) ............................................. 2-312.7.1 Description and Properties ........................................................................... 2-312.7.2 First Aid ........................................................................................................ 2-352.7.3 Precautions ................................................................................................... 2-36
2.8 SULFUR PLANT SAFETY ................................................................................... 2-372.8.1 Hydrogen Sulfide .......................................................................................... 2-372.8.2 Sulfur Dioxide ............................................................................................... 2-372.8.3 Sulfur Storage Tank ...................................................................................... 2-38
2.9 HOT WORK ......................................................................................................... 2-392.10 VESSEL ENTRY.................................................................................................. 2-392.11 PIPES AND LINES .............................................................................................. 2-41
2.11.1 General ......................................................................................................... 2-412.11.2 Before Breaking Lines .................................................................................. 2-42
-
8/3/2019 Operating Guidelines
3/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page ii
2.11.3 When Breaking Lines ................................................................................... 2-422.12 ELECTRICAL EQUIPMENT ................................................................................ 2-42
2.12.1
Electrical Repairs .......................................................................................... 2-43
2.12.2 Grounding ..................................................................................................... 2-432.12.3 Conduit, Cables, and Wires .......................................................................... 2-432.12.4 Fuses ............................................................................................................ 2-432.12.5 Switching ...................................................................................................... 2-432.12.6 Hand Tools and Portable Equipment ............................................................ 2-442.12.7 Miscellaneous ............................................................................................... 2-44
2.13 BOILERS AND OTHER DIRECT-FIRED EQUIPMENT ...................................... 2-452.13.1 General ......................................................................................................... 2-452.13.2 Boilers ........................................................................................................... 2-452.13.3 Direct-Fired Equipment ................................................................................. 2-46
2.14 LABORATORY SAFETY ..................................................................................... 2-472.14.1 Good Housekeeping ..................................................................................... 2-472.14.2 Equipment .................................................................................................... 2-472.14.3 Chemical Sorting and Identification .............................................................. 2-472.14.4 Chemical Handling ....................................................................................... 2-48
2.15 MATERIAL SAFETY DATA SHEETS (MSDS) .................................................... 2-493. GENERAL .................................................................................................................... 3-1
3.1 ORGANIZATION ................................................................................................... 3-13.2 GENERAL PRECOMMISSIONING PROCEDURES ............................................. 3-2
3.2.1 Mechanical ..................................................................................................... 3-23.2.2 Electrical ......................................................................................................... 3-33.2.3 Instrumentation ............................................................................................... 3-5
3.3 DESIGN BASIS ..................................................................................................... 3-73.3.1 Plant Capacity ................................................................................................ 3-73.3.2 Sulfur Block Feed Streams ............................................................................. 3-73.3.3 Effluent Stream Conditions ........................................................................... 3-123.3.4 Other Design Requirements ......................................................................... 3-133.3.5 Utility Information .......................................................................................... 3-143.3.6 Plant Site Conditions .................................................................................... 3-16
4. POWER DISTRIBUTION .............................................................................................. 4-14.1 PURPOSE OF SYSTEM ....................................................................................... 4-14.2 SAFETY ................................................................................................................. 4-1
4.2.1 General ........................................................................................................... 4-14.2.2 Hazardous (Classified) Areas ......................................................................... 4-1
-
8/3/2019 Operating Guidelines
4/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page iii
4.3 EQUIPMENT DESCRIPTION ................................................................................ 4-24.3.1 Motors and Motor Controls ............................................................................. 4-2
5. PLANT CONTROL SYSTEMS ..................................................................................... 5-15.1 DISTRIBUTED CONTROL SYSTEM .................................................................... 5-15.2 PROGRAMMABLE LOGIC CONTROL SYSTEM ................................................. 5-25.3 EMERGENCY SHUTDOWN SYSTEMS ............................................................... 5-35.4 LOCAL CONTROL PANELS ................................................................................. 5-3
6. UTILITY SYSTEMS ...................................................................................................... 6-16.1 PURPOSE OF SYSTEM ....................................................................................... 6-16.2 SYSTEM DESCRIPTION ...................................................................................... 6-1
6.2.1 Nitrogen Supply .............................................................................................. 6-16.2.2 C4 LPG and Treated Fuel Gas Supply .......................................................... 6-26.2.3 Hydrogen Supply ............................................................................................ 6-26.2.4 Plant Air .......................................................................................................... 6-36.2.5 Instrument Air ................................................................................................. 6-36.2.6 Sour Water Disposal ....................................................................................... 6-36.2.7 Steam, Condensate, Boiler Feed Water, and Blowdown ............................... 6-4
6.3 PRECOMMISSIONING, STARTUP, AND SHUTDOWN PROCEDURES............. 6-87. AMINE TREATING & AMINE REGENERATION ......................................................... 7-1
7.1 PURPOSE OF SYSTEM ....................................................................................... 7-17.2
SAFETY ................................................................................................................. 7-1
7.3 PROCESS DESCRIPTION .................................................................................... 7-2
7.3.1 General ........................................................................................................... 7-27.3.2 Water Washing ............................................................................................... 7-27.3.3 Sour Gas Contacting ...................................................................................... 7-37.3.4 Solvent Regeneration ..................................................................................... 7-3
7.4 EQUIPMENT DESCRIPTION ................................................................................ 7-67.4.1 Wash Water Column, A2-DA1510 .................................................................. 7-67.4.2 Amine Absorber, A2-DA1511 ......................................................................... 7-67.4.3 Flash Gas Contactor, A2-DA1512 .................................................................. 7-67.4.4 Stripper, A2-DA1513 ...................................................................................... 7-67.4.5 Wash Water Column Packing, A2-DB1510 .................................................... 7-77.4.6 Amine Absorber Trays, A2-DB1511 ............................................................... 7-77.4.7 Stripper Trays, A2-DB1513 ............................................................................ 7-77.4.8 Amine Absorber Overhead Cooler, A2-EA1510 ............................................. 7-87.4.9 Lean/Rich Exchanger, A2-EA1511A/B ........................................................... 7-87.4.10 Stripper Reboiler, A2-EA1512A/B .................................................................. 7-8
-
8/3/2019 Operating Guidelines
5/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page iv
7.4.11 Stripper Reflux Condenser, A2-EC1511 ......................................................... 7-87.4.12 Lean Amine Cooler, A2-EC1510 .................................................................... 7-87.4.13
Wash Water Feed Knock-Out Drum, A2-FA1510 ........................................... 7-8
7.4.14 Amine Absorber Feed Knock-Out Drum, A2-FA1511 ..................................... 7-97.4.15 Amine Absorber Overhead Knock-Out Drum, A2-FA1512 ............................. 7-97.4.16 Rich Amine Flash Drum, A2-FA1513 ............................................................. 7-97.4.17 Stripper Reflux Accumulator, A2-FA1514 ..................................................... 7-107.4.18 Stripper Reboiler Condensate Pot, A2-FA1515A/B ...................................... 7-107.4.19 ATU Skim Oil Sump, A2-FA1516 ................................................................. 7-107.4.20 ATU Skim Oil Pump Sump, A2-FA1517A/B ................................................. 7-107.4.21 ATU Amine Drips Tank, A2-FA1580 ............................................................. 7-117.4.22 MDEA Storage Tank, A2-FB1580 ................................................................ 7-117.4.23 Wash Water Filter, A2-FD1510A/B ............................................................... 7-117.4.24 Rich Amine Filter, A2-FD1511A/B ................................................................ 7-117.4.25 Lean Amine Filter, A2-FD1512 ..................................................................... 7-117.4.26 Lean Amine Carbon Filter, A2-FD1513 ........................................................ 7-127.4.27 Lean Amine After-Filter, A2-FD1514 ............................................................ 7-127.4.28 ATU Amine Drips Filter, A2-FD1580 ............................................................ 7-127.4.29 Wash Water Pump, A2-GA1510A/B ............................................................. 7-137.4.30 Lean Amine Pump, A2-GA1511A/B ............................................................. 7-137.4.31 ATU Skim Oil Pump, A2-GA1512A/B ........................................................... 7-137.4.32 Rich Amine Pump, A2-GA1513A/B .............................................................. 7-137.4.33 Lean Amine Booster Pump, A2-GA1514A/B ................................................ 7-137.4.34 Stripper Reflux Pump, A2-GA1515A/B ......................................................... 7-137.4.35 MDEA Transfer Pump, A2-GA1580 .............................................................. 7-14
7.5 INSTRUMENTATION AND CONTROL SYSTEMS ............................................. 7-157.5.1 Treated Fuel Gas H2S Analyzer ................................................................... 7-157.5.2 ATU Emergency Shutdown Systems ........................................................... 7-15
7.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ............................. 7-197.6.1 Amine Absorber Operation ........................................................................... 7-197.6.2 Stripper Operation ........................................................................................ 7-227.6.3
Amine Water Balance ................................................................................... 7-24
7.6.4 Amine Loss ................................................................................................... 7-277.6.5 Operation at Low Flow Rates ....................................................................... 7-29
7.7 PRECOMMISSIONING PROCEDURES ............................................................. 7-307.7.1 Preliminary Check-out .................................................................................. 7-307.7.2 Shutdown System Check-out ....................................................................... 7-317.7.3 Leak Testing the Process Piping and Equipment ......................................... 7-31
-
8/3/2019 Operating Guidelines
6/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page v
7.7.4 Washing the Wash Water System ................................................................ 7-337.7.5 Washing the Amine System ......................................................................... 7-387.7.6
Purging the Low Pressure Columns ............................................................. 7-50
7.8 STARTUP PROCEDURES .................................................................................. 7-52
7.8.1 Wash Water and Amine Systems ................................................................. 7-527.8.2 Sour Fuel Gas Flow to the Columns ............................................................. 7-53
7.9 SHUTDOWN PROCEDURES ............................................................................. 7-567.9.1 Planned Shutdown - ATU ............................................................................ 7-577.9.2 Planned Shutdown - ATU and ARU ............................................................. 7-607.9.3 Emergency Shutdown .................................................................................. 7-627.9.4 Effects of Shutdowns and Outages in Other Systems .................................. 7-63
7.10 ANALYTICAL PROCEDURES ............................................................................ 7-647.10.1 General Procedures for Analyzing ATU/ARU Solvent, ................................. 7-647.10.2 Determination of Amine Concentration in ATU/ARU Solvent ....................... 7-687.10.3 Determination of Total Acid Gas Loading in ATU/ARU Solvent ................... 7-707.10.4 Determination of H2S and CO2 Loading in ATU/ARU Solvent ...................... 7-727.10.5 Determination of Foaming Tendency of ATU/ARU Solvent .......................... 7-767.10.6 H2S Conc. in Amine Absorber Ovhd by the Tutweiler Method ..................... 7-787.10.7 H2S Conc. in Amine Absorber Ovhd Using Gas Detector Tubes ................. 7-79
8. SOUR WATER STRIPPING ......................................................................................... 8-18.1 PURPOSE OF SYSTEM ....................................................................................... 8-18.2 SAFETY ................................................................................................................. 8-18.3 PROCESS DESCRIPTION .................................................................................... 8-2
8.3.1 General ........................................................................................................... 8-28.3.2 Sour Water Collection ..................................................................................... 8-28.3.3 Sour Water Stripping ...................................................................................... 8-3
8.4 EQUIPMENT DESCRIPTION ................................................................................ 8-58.4.1 Sour Water Stripper, A2-DA1520 ................................................................... 8-58.4.2 Sour Water Stripper Packing and Internals, A2-DB1520 ................................ 8-58.4.3 Stripper Trays, A2-DB1521 ............................................................................ 8-58.4.4 SWS Cross Exchanger, A2-EA1520 .............................................................. 8-58.4.5 Sour Water Stripper Reboiler, A2-EA1521 ..................................................... 8-68.4.6 SWS Quench Water Cooler, A2-EC1520 ....................................................... 8-68.4.7 SWS Bottoms Cooler, A2-EC1521 ................................................................. 8-68.4.8 Sour Water Flash Drum, A2-FA1520 .............................................................. 8-68.4.9 SWS Skim Oil Sump, A2-FA1522 .................................................................. 8-78.4.10 SWS Skim Oil Pump Sump, A2-FA1523A/B .................................................. 8-78.4.11 Sour Water Tank, A2-FB1520 ........................................................................ 8-7
-
8/3/2019 Operating Guidelines
7/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page vi
8.4.12 Sour Water Filter, A2-FD1520A/B .................................................................. 8-78.4.13 Sour Water Transfer Pump, A2-GA1520A/B .................................................. 8-78.4.14
SWS Feed Pump, A2-GA1521A/B ................................................................. 8-8
8.4.15 SWS Quench Water Pump, A2-GA1522A/B .................................................. 8-88.4.16 SWS Bottoms Pump, A2-GA1523A/B ............................................................ 8-88.4.17 SWS Skim Oil Pump, A2-GA1524A/B ............................................................ 8-8
8.5 INSTRUMENTATION AND CONTROL SYSTEMS ............................................... 8-98.5.1 SWS Shutdowns and Alarms ......................................................................... 8-9
8.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ............................. 8-118.6.1 SWS Stripper Operation ............................................................................... 8-118.6.2 Quench Water Circulation ............................................................................ 8-128.6.3 pH Control .................................................................................................... 8-13
8.7 PRECOMMISSIONING PROCEDURES ............................................................. 8-148.7.1 Preliminary Check-out .................................................................................. 8-148.7.2 Washing the Sour Water System ................................................................. 8-15
8.8 STARTUP PROCEDURES .................................................................................. 8-198.8.1 Initial Startup of the SWS ............................................................................. 8-198.8.2 Normal Startup of the SWS .......................................................................... 8-23
8.9 SHUTDOWN PROCEDURES ............................................................................. 8-298.9.1 Planned Shutdown ....................................................................................... 8-298.9.2 Effects of Shutdowns and Outages in Other Systems .................................. 8-31
9.
SULFUR RECOVERY .................................................................................................. 9-4
9.1 PURPOSE OF SYSTEM ....................................................................................... 9-49.2 SAFETY ................................................................................................................. 9-49.3 PROCESS DESCRIPTION .................................................................................... 9-5
9.3.1 Overview ......................................................................................................... 9-59.3.2 General ........................................................................................................... 9-69.3.3 Feed Gas Processing ..................................................................................... 9-69.3.4 Thermal Processing ........................................................................................ 9-79.3.5 Catalytic Processing ....................................................................................... 9-89.3.6 Air Control System .......................................................................................... 9-99.3.7 Molten Sulfur Handling ................................................................................. 9-109.3.8 Steam Production ......................................................................................... 9-10
9.4 EQUIPMENT DESCRIPTION .............................................................................. 9-119.4.1 Reactor Furnace, A2-BA1530 (A2-BA1540) ................................................. 9-119.4.2 Acid Gas Burner Assembly, A2-BA1531 (A2-BA1541) ................................ 9-129.4.3 Acid Gas Knock-Out Drum, A2-FA1530 (A2-FA1540) ................................. 9-129.4.4 SWS Gas Knock-Out Drum, A2-FA1531 (A2-FA1541) ................................ 9-12
-
8/3/2019 Operating Guidelines
8/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page vii
9.4.5 Reactor, A2-DC1530 (A2-DC1540) .............................................................. 9-139.4.6 Catalyst for Sulfur Plant Reactors, A2-MC1530 (A2-MC1540) ..................... 9-139.4.7
Acid Gas Preheater, A2-EA1530 (A2-EA1540) ............................................ 9-13
9.4.8 Sulfur Condenser, A2-EA1531 (A2-EA1541) ............................................... 9-139.4.9 Reactor No. 1 Feed Heater, A2-EA1532 (A2-EA1542) ................................ 9-149.4.10 Reactor No. 2 Feed Heater, A2-EA1533 (A2-EA1543) ................................ 9-149.4.11 Reactor No. 3 Feed Heater, A2-EA1534 (A2-EA1544) ................................ 9-159.4.12 Sulfur Surge Tank, A2-FB1530 (A2-FB1540) ............................................... 9-159.4.13 Acid Gas Knock-Out Drum Pump, A2-GA1530A/B (A2-GA1540A/B) .......... 9-169.4.14 SWS Gas Knock-Out Drum Pump, A2-GA1531A/B (A2-GA1541A/B) ......... 9-179.4.15 Sulfur Storage Tank Vent Ejector, A2-EE1530 (A2-EE1540) ....................... 9-179.4.16 Process Air Blower, A2-GB1530A/B (A2-GB1540A/B) ................................. 9-189.4.17 Air Blower Suction Screen/Silencer, A2-FD1530A/B (A2-FD1540A/B) ........ 9-199.4.18 Process Air Vent Silencer, A2-FG1530A/B (A2-FG1540A/B) ....................... 9-199.4.19 Sulfur Drain Seal Assembly, A2-ME1530A-D (A2-ME1540A-D) .................. 9-199.4.20 Refractory for Reactor Furnace and Waste Heat Boiler, A2-MR1530(A2-MR1540) .............................................................................................................. 9-209.4.21 Ceramic Ferrules for Waste Heat Boiler, A2-MR1532 (A2-MR1542) ........... 9-209.4.22 Refractory for Waste Heat Boiler, A2-MR1533 (A2-MR1543) ...................... 9-209.4.23 Refractory for Sulfur Condenser, A2-MR1534 (A2-MR1544) ....................... 9-209.4.24 Refractory for Reactor, A2-MR1535 (A2-MR1545) ...................................... 9-219.4.25 Rainshield for Reactor Furnace, A2-ME1531 (A2-ME1541) ........................ 9-219.4.26 Ceramic Ferrule for Reactor Furnace, A2-MR1531 (A2-MR1541) ............... 9-219.4.27 Waste Heat Boiler, A2-BF1530 (A2-BF1540) ............................................... 9-22
9.5 INSTRUMENTATION AND CONTROL SYSTEMS ............................................. 9-249.5.1 SRU Air:Acid Gas Ratio Control Loop .......................................................... 9-249.5.2 Acid Gas Burner Management System ........................................................ 9-309.5.3 Process Air Blower Controls ......................................................................... 9-349.5.4 Reactor Furnace Temperature Control ......................................................... 9-399.5.5 Knock-Out Drum Pump Control .................................................................... 9-419.5.6 "Ride-Through" System Considerations ....................................................... 9-419.5.7
Boiler Low-Low Level S/D Transmitter Testing ............................................ 9-44
9.5.8 SRU Emergency Shutdown Systems ........................................................... 9-46
9.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ............................. 9-569.6.1 Equipment Damage ...................................................................................... 9-569.6.2 Cold Catalyst Bed Startup ............................................................................ 9-589.6.3 Sulfur Solidification ....................................................................................... 9-609.6.4 Ammonia Salt Formation .............................................................................. 9-61
-
8/3/2019 Operating Guidelines
9/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page viii
9.6.5 Catalyst Fouling ............................................................................................ 9-629.6.6 Operation of SRUs in Parallel ....................................................................... 9-629.6.7
Process air Blower Operation ....................................................................... 9-65
9.6.8 Reactor Furnace Temperature ..................................................................... 9-709.6.9 Ammonia Destruction Considerations .......................................................... 9-739.6.10 Sulfur Recovery Efficiency ............................................................................ 9-769.6.11 Operation at Low Flow Rates ....................................................................... 9-789.6.12 Pressure Drop Surveys ................................................................................ 9-829.6.13 Boiler Water Treatment ................................................................................ 9-84
9.7 PRECOMMISSIONING PROCEDURES ............................................................. 9-869.7.1 Preliminary Check-out .................................................................................. 9-869.7.2 Shutdown System Check-out ....................................................................... 9-879.7.3 Leak Testing the Process Piping and Equipment ......................................... 9-889.7.4 Purging the Inlet Knock-Out Drums .............................................................. 9-939.7.5 Commissioning Fuel Gas and Instrument Air to the Process ....................... 9-959.7.6 Commissioning Nitrogen to the Process ...................................................... 9-999.7.7 Commissioning the Sulfur Surge Tank Heating and Ventilation ................. 9-1029.7.8 Pre-filling the Sulfur Drain Seal Assemblies ............................................... 9-104
9.8 STARTUP PROCEDURES ................................................................................ 9-1059.8.1 Initial Firing / Refractory Cure-out ............................................................... 9-1059.8.2 Amine Acid Gas Flow ................................................................................. 9-1179.8.3 SWS Gas Flow ........................................................................................... 9-1249.8.4 Routing SRU Tailgas to the TGCU ............................................................. 9-1279.8.5 Normal Startup - Cold System .................................................................... 9-1299.8.6 Normal Startup - Hot System ...................................................................... 9-1469.8.7 Firing Supplemental Fuel Gas .................................................................... 9-158
9.9 SHUTDOWN PROCEDURES ........................................................................... 9-1649.9.1 Planned Shutdown - No Reactor Entry ....................................................... 9-1659.9.2 Planned Shutdown for Reactor Entry ......................................................... 9-1709.9.3 Shutting Down When Boiler Tubes Are Leaking ........................................ 9-1809.9.4 Emergency Shutdown ................................................................................ 9-1819.9.5
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 ............. 9-1879.10.2 H2S Concentration in Acid Gas by the Tutweiler Method ........................... 9-1899.10.3 H2S and SO2 Concentration in Tailgas by the Tutweiler Method ................ 9-1929.10.4 Tailgas Analysis Table ................................................................................ 9-1969.10.5 Tailgas Analysis Operating Chart ............................................................... 9-197
-
8/3/2019 Operating Guidelines
10/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page ix
9.10.6 Essential Apparatus for Tutweiler Analysis ................................................ 9-1999.10.7 Materials for Tutweiler Analysis .................................................................. 9-2009.10.8
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 .................................................. 10-310.1 PURPOSE OF SYSTEM ..................................................................................... 10-310.2 SAFETY ............................................................................................................... 10-410.3 PROCESS DESCRIPTION .................................................................................. 10-510.4 EQUIPMENT DESCRIPTION .............................................................................. 10-7
10.4.1 Sulfur Degassing Reactor, A2-DC1550 ........................................................ 10-710.4.2 Sulfur Storage Tank, A2-FB1550 ................................................................. 10-710.4.3 Sulfur Feed Pump, A2-GA1532A/B (A2-GA1542A/B) .................................. 10-810.4.4 Sulfur Loading Pump, A2-GA1550A/B ......................................................... 10-810.4.5 Degassing Air Blower, A2-GB1550A/B ......................................................... 10-910.4.6 Bed Support and Limiter for Sulfur Degassing Reactor, A2-DC1551 ........... 10-910.4.7 Degassed Sulfur Drain Seal Assembly, A2-ME1550 .................................... 10-9
10.5 INSTRUMENTATION AND CONTROL SYSTEMS ........................................... 10-1110.5.1 Sulfur Feed Rate Control ............................................................................ 10-1110.5.2 Degassing Air Flow ..................................................................................... 10-1210.5.3 Sulfur Degassing Unit Startup Interlock ...................................................... 10-1310.5.4 Snuffing Steam ........................................................................................... 10-1310.5.5 Sulfur Loading ............................................................................................ 10-1410.5.6 Sulfur Loading Pump Local Stop Switches ................................................. 10-1710.5.7 Sulfur Degassing Shutdown System .......................................................... 10-1810.5.8 Sulfur Loading ESD System ....................................................................... 10-21
10.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ........................... 10-2310.6.1 Equipment Damage .................................................................................... 10-2310.6.2 Degassing Air Blower Operation ................................................................ 10-2610.6.3 Sulfur Solidification ..................................................................................... 10-2910.6.4 Sulfur Pumping ........................................................................................... 10-29
10.7 PRECOMMISSIONING PROCEDURES ........................................................... 10-3110.7.1 Preliminary Check-out ................................................................................ 10-3110.7.2 Commissioning the Heating and Ventilation Systems ................................ 10-3210.7.3 Purging the Sulfur Degassing Reactor ....................................................... 10-37
10.8 STARTUP PROCEDURES ................................................................................ 10-4010.8.1 Initial Startup of the Sulfur Degassing Unit ................................................. 10-4010.8.2 Normal Startup of the Sulfur Degassing System ........................................ 10-4610.8.3 Initial Sulfur Loading Operation .................................................................. 10-51
-
8/3/2019 Operating Guidelines
11/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page x
10.8.4 Normal Sulfur Loading Operation ............................................................... 10-5310.9 SHUTDOWN PROCEDURES ........................................................................... 10-54
10.9.1
Planned Shutdown - No Reactor Entry ....................................................... 10-54
10.9.2 Planned Shutdown for Reactor Entry ......................................................... 10-5510.9.3 Shutdown for Tank Entry ............................................................................ 10-57
11. TAILGAS CLEANUP .............................................................................................. 11-111.1 PURPOSE OF SYSTEM ..................................................................................... 11-111.2 SAFETY ............................................................................................................... 11-211.3 PROCESS DESCRIPTION .................................................................................. 11-3
11.3.1 General ......................................................................................................... 11-311.3.2 Tailgas Hydrogenation/Hydrolysis ................................................................ 11-311.3.3 Process Gas Cooling .................................................................................... 11-411.3.4 Gas Contacting ............................................................................................. 11-511.3.5 Solvent Regeneration Section ...................................................................... 11-611.3.6 Steam Production/Consumption ................................................................... 11-7
11.4 EQUIPMENT DESCRIPTION .............................................................................. 11-811.4.1 TGCU Quench Column, A2-DA1560 ............................................................ 11-811.4.2 TGCU Quench Column Packing, A2-DB1560 .............................................. 11-811.4.3 TGCU Contactor, A2-DA1561 ...................................................................... 11-811.4.4 TGCU Contactor Packing & Internals, A2-DB1561 ...................................... 11-811.4.5 TGCU Stripper, A2-DA1562 ......................................................................... 11-911.4.6 TGCU Stripper Trays, A2-DB1562 ............................................................... 11-911.4.7 TGCU Reactor, A2-DC1560 ....................................................................... 11-1011.4.8 TGCU Stripper Reflux Accumulator, A2-FA1560 ....................................... 11-1011.4.9 Catalyst for TGCU Reactor, A2-MC1560 ................................................... 11-1011.4.10 TGCU Stripper Reboiler Condensate Pot, A2-FA1562 ........................... 11-1011.4.11 TGCU Reactor Feed Heater, A2-EA1560 ............................................... 11-1111.4.12 TGCU Waste Heat Reclaimer, A2-EA1561 ............................................ 11-1111.4.13 TGCU Quench Water Trim Cooler, A2-EA1562A/B ................................ 11-1111.4.14 TGCU Lean/Rich Exchanger, A2-EA1564 .............................................. 11-1111.4.15 TGCU Stripper Reboiler, A2-EA1565 ..................................................... 11-1211.4.16 TGCU Lean Amine Trim Cooler, A2-EA1563 ......................................... 11-1211.4.17 TGCU Quench Water Cooler, A2-EC1560 ............................................. 11-1211.4.18 TGCU Stripper Reflux Condenser, A2-EC1562 ...................................... 11-1211.4.19 TGCU Lean Amine Cooler, A2-EC1561 ................................................. 11-1211.4.20 TGCU Quench Water Pump, A2-GA1560A/B ......................................... 11-1311.4.21 TGCU Rich Amine Pump, A2-GA1561A/B ............................................. 11-1411.4.22 TGCU Stripper Reflux Pump, A2-GA1563A/B ........................................ 11-14
-
8/3/2019 Operating Guidelines
12/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page xi
11.4.23 TGCU Lean Amine Pump, A2-GA1562A/B ............................................. 11-1411.4.24 TGCU Start-Up Blower, A2-GB1560 ....................................................... 11-1411.4.25
Refractory for TGCU Reactor, A2-MR1560 ............................................ 11-15
11.4.26 TGCU Reactor Feed Mixer, A2-ME1560 ................................................ 11-1611.4.27 TGCU Quench Water Filter, A2-FD1560A/B .......................................... 11-1611.4.28 TGCU Rich Amine Filter, A2-FD1562A/B ............................................... 11-1611.4.29 TGCU Lean Amine Filter, A2-FD1563 .................................................... 11-1711.4.30 TGCU Amine Carbon Filter, A2-FD1564 ................................................ 11-1711.4.31 TGCU Amine After-Filter, A2-FD1565 .................................................... 11-1711.4.32 pH Meter Sample Filter, A2-FD1561A/B ................................................. 11-17
11.5 INSTRUMENTATION AND CONTROL SYSTEMS ........................................... 11-1811.5.1 TGCU Reactor Feed Control Loops ........................................................... 11-1811.5.2 Hydrogen and Hydrogen Sulfide Analyzer, A2-AE15858/A2-AE15859 ...... 11-2311.5.3 Boiler Low-Low Level S/D Transmitter Testing .......................................... 11-2411.5.4 Tailgas Switching Valve Controls ............................................................... 11-2611.5.5 TGCU Shutdown System ........................................................................... 11-33
11.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ........................... 11-3911.6.1 Equipment Damage .................................................................................... 11-3911.6.2 Catalyst Fouling .......................................................................................... 11-4011.6.3 TGCU Reactor Operation ........................................................................... 11-4111.6.4 TGCU Catalyst ........................................................................................... 11-4311.6.5 TGCU Start-Up Blower Operation .............................................................. 11-4411.6.6 TGCU Quench Column Operation .............................................................. 11-4511.6.7 TGCU Contactor Operation ........................................................................ 11-4811.6.8 TGCU Stripper Operation ........................................................................... 11-5211.6.9 TGCU Amine Water Balance ...................................................................... 11-5511.6.10 TGCU Amine Loss .................................................................................. 11-5911.6.11 Operation at Low Flow Rates .................................................................. 11-6011.6.12 Pressure Drop Surveys ........................................................................... 11-6111.6.13 Boiler Water Treatment ........................................................................... 11-63
11.7 PRECOMMISSIONING PROCEDURES ........................................................... 11-6411.7.1
Preliminary Check-out ................................................................................ 11-64
11.7.2 Shutdown System Check-out ..................................................................... 11-6511.7.3 Commissioning Nitrogen and Utility Air to the Process .............................. 11-6611.7.4 Commissioning Hydrogen to the Process .................................................. 11-7211.7.5 Leak Testing the Process Piping and Equipment ....................................... 11-7511.7.6 Washing the Quench Water System .......................................................... 11-7911.7.7 Washing the Amine System ....................................................................... 11-85
-
8/3/2019 Operating Guidelines
13/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page xii
11.7.8 Purging the Low Pressure TGCU Columns ................................................ 11-9711.8 STARTUP PROCEDURES .............................................................................. 11-102
11.8.1
Initial Startup of the TGCU ....................................................................... 11-102
11.8.2 Pre-Sulfiding the TGCU Catalyst .............................................................. 11-10711.8.3 Routing SRU Tailgas to the TGCU ........................................................... 11-11511.8.4 Quench Water and Amine Systems ......................................................... 11-12211.8.5 Process Gas Flow to the TGCU Columns ................................................ 11-12411.8.6 Normal Startup of the TGCU .................................................................... 11-128
11.9 SHUTDOWN PROCEDURES ......................................................................... 11-14411.9.1 Planned Shutdown - No Reactor Entry ..................................................... 11-14511.9.2 Planned Shutdown for Reactor Entry ....................................................... 11-15111.9.3 Shutting Down When Boiler Tubes Are Leaking ...................................... 11-15811.9.4 Special Precaution During Shutdowns ..................................................... 11-15911.9.5 Emergency Shutdown .............................................................................. 11-16311.9.6 Effects of Shutdowns and Outages in Other Systems .............................. 11-164
11.10 ANALYTICAL PROCEDURES ..................................................................... 11-16711.10.1 General Procedures for Analyzing TGCU Solvent, ............................... 11-16711.10.2 Determination of Amine Concentration in TGCU Solvent ..................... 11-17111.10.3 Determination of Total Acid Gas Loading in TGCU Solvent ................. 11-17311.10.4 Determination of H2S and CO2 Loading in TGCU Solvent .................... 11-17511.10.5 Determination of Foaming Tendency of TGCU Solvent ........................ 11-17911.10.6 H2S Conc. in TGCU Contactor Ovhd by the Tutweiler Method ............. 11-18111.10.7 H2S Conc. in TGCU Contactor Ovhd Using Gas Detector Tubes ......... 11-18211.10.8 Monitoring the Performance Level of TGCU Catalyst ........................... 11-185
12. TAILGAS THERMAL OXIDIZER ............................................................................ 12-212.1 PURPOSE OF SYSTEM ..................................................................................... 12-212.2 SAFETY ............................................................................................................... 12-212.3 PROCESS DESCRIPTION .................................................................................. 12-312.4 EQUIPMENT DESCRIPTION .............................................................................. 12-4
12.4.1 Thermal Oxidizer, A2-BA1570 ...................................................................... 12-412.4.2 Thermal Oxidizer Burner, A2-BA1571 .......................................................... 12-412.4.3 Steam Knock-out Drum, A2-FA1570 ............................................................ 12-412.4.4 Thermal Oxidizer Air Blower, A2-GB1570A/B .............................................. 12-412.4.5 Thermal Oxidizer Vent Stack, A2-ME1570 ................................................... 12-512.4.6 Refractory for Thermal Oxidizer, A2-MR1570 .............................................. 12-512.4.7 Thermal Oxidizer Waste Heat Boiler, A2-BF1570 ........................................ 12-5
12.5 INSTRUMENTATION AND CONTROL SYSTEMS ............................................. 12-712.5.1 Thermal Oxidizer Burner Management System ........................................... 12-7
-
8/3/2019 Operating Guidelines
14/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Table of Contents
Issued 30Aug11 Table of Contents Page xiii
12.5.2 Thermal Oxidizer Temperature Control ...................................................... 12-1012.5.3 Thermal Oxidizer Excess Oxygen Control .................................................. 12-1012.5.4
Boiler Low-Low Level S/D Transmitter Testing .......................................... 12-11
12.5.5 Thermal Oxidizer Shutdown System .......................................................... 12-13
12.6 PROCESS PRINCIPLES AND OPERATING TECHNIQUES ........................... 12-1812.6.1 Equipment Damage .................................................................................... 12-1812.6.2 Effect of Upstream Operations on the Thermal Oxidizer ............................ 12-2112.6.3 "Swapping" Air Blowers During Operation .................................................. 12-2312.6.4 Boiler Water Treatment .............................................................................. 12-24
12.7 PRECOMMISSIONING PROCEDURES ........................................................... 12-2612.7.1 Preliminary Check-out ................................................................................ 12-2612.7.2 Shutdown System Check-out ..................................................................... 12-2712.7.3 Commissioning Fuel Gas, Pilot Gas, and I/A to the Process ..................... 12-28
12.8 STARTUP PROCEDURES ................................................................................ 12-3312.8.1 Initial Firing / Refractory Cure-out ............................................................... 12-3312.8.2 Normal Startup ........................................................................................... 12-48
12.9 SHUTDOWN PROCEDURES ........................................................................... 12-5812.9.1 Planned Shutdown - No Entry .................................................................... 12-5912.9.2 Planned Shutdown for Entry ....................................................................... 12-6112.9.3 Shutting Down When Boiler Tubes Are Leaking ........................................ 12-6512.9.4 Emergency Shutdown ................................................................................ 12-6612.9.5 Effects of Shutdowns and Outages in Other Systems ................................ 12-69
-
8/3/2019 Operating Guidelines
15/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 Introduction Page 1-1
1. INTRODUCTION
THE INFORMATION IN THESE GUIDELINES IS CONFIDENTIAL. SOME OFTHE 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 withand 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
-
8/3/2019 Operating Guidelines
16/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 Introduction Page 1-2
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 theoperating 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.
-
8/3/2019 Operating Guidelines
17/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-i
Table of Contents
2. GENERAL SAFETY ..................................................................................................... 2-12.1 DEFINITION OF TERMS ....................................................................................... 2-12.2 HYDROGEN SULFIDE (H2S) ................................................................................ 2-3
2.2.1 Description and Properties ............................................................................. 2-32.2.1.1 General .................................................................................................... 2-32.2.1.2 Toxicity Information ................................................................................. 2-32.2.1.3 Permissible Exposure Limits ................................................................... 2-32.2.1.4 Odor ........................................................................................................ 2-32.2.1.5 Physical Data .......................................................................................... 2-32.2.1.6 Reactivity Data ........................................................................................ 2-42.2.1.7 Corrosivity Data ....................................................................................... 2-52.2.1.8 Water Solubility ....................................................................................... 2-52.2.1.9 Other Characteristics ............................................................................... 2-52.2.1.10 Fire and Explosion Hazard ...................................................................... 2-62.2.1.11 Life Hazard .............................................................................................. 2-6
2.2.2 First Aid .......................................................................................................... 2-72.2.3 Precautions (remember these facts) .............................................................. 2-82.2.4 Good Work Practices ...................................................................................... 2-9
2.3 SULFUR DIOXIDE (SO2) ..................................................................................... 2-102.3.1 Description and Properties ........................................................................... 2-10
2.3.1.1
General .................................................................................................. 2-10
2.3.1.2 Toxicity Information ............................................................................... 2-102.3.1.3 Permissible Exposure Limits ................................................................. 2-102.3.1.4 Odor ...................................................................................................... 2-112.3.1.5 Physical Data ........................................................................................ 2-112.3.1.6 Reactivity Data ...................................................................................... 2-112.3.1.7 Corrosivity Data ..................................................................................... 2-122.3.1.8 Water Solubility ..................................................................................... 2-122.3.1.9 Fire and Explosion Hazard .................................................................... 2-122.3.1.10 Life Hazard ............................................................................................ 2-12
2.3.2 First Aid ........................................................................................................ 2-132.3.3 Precautions ................................................................................................... 2-14
2.4 SULFUR .............................................................................................................. 2-152.4.1 Description and Properties ........................................................................... 2-15
2.4.1.1 General .................................................................................................. 2-152.4.1.2 Toxicity Information ............................................................................... 2-152.4.1.3 Permissible Exposure Limits ................................................................. 2-15
-
8/3/2019 Operating Guidelines
18/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-ii
2.4.1.4 Odor ...................................................................................................... 2-152.4.1.5 Physical Data ........................................................................................ 2-152.4.1.6 Reactivity Data ...................................................................................... 2-162.4.1.7 Corrosivity Data ..................................................................................... 2-192.4.1.8 Other Characteristics ............................................................................. 2-192.4.1.9 Fire and Explosion Hazard .................................................................... 2-192.4.1.10 Life Hazard ............................................................................................ 2-20
2.4.2 Precautions ................................................................................................... 2-202.4.3 Fire Fighting .................................................................................................. 2-21
2.5 AMMONIA (NH3) .................................................................................................. 2-222.5.1 Description and Properties ........................................................................... 2-22
2.5.1.1 General .................................................................................................. 2-222.5.1.2 Toxicity Information ............................................................................... 2-222.5.1.3 Permissible Exposure Limits ................................................................. 2-222.5.1.4 Odor ...................................................................................................... 2-222.5.1.5 Physical Data ........................................................................................ 2-232.5.1.6 Reactivity Data ...................................................................................... 2-232.5.1.7 Corrosivity Data ..................................................................................... 2-252.5.1.8 Water Solubility ..................................................................................... 2-252.5.1.9 Fire and Explosion Hazard .................................................................... 2-252.5.1.10 Life Hazard ............................................................................................ 2-25
2.5.2 First Aid ........................................................................................................ 2-262.5.3 Precautions ................................................................................................... 2-26
2.6 METHYLDIETHANOLAMINE (MDEA, CH3-N-(CH2-CH2-OH)2) ........................... 2-282.6.1 Description and Properties ........................................................................... 2-28
2.6.1.1 General .................................................................................................. 2-282.6.1.2 Toxicity Information ............................................................................... 2-282.6.1.3 Permissible Exposure Limits ................................................................. 2-282.6.1.4 Odor ...................................................................................................... 2-282.6.1.5 Physical Data ........................................................................................ 2-282.6.1.6 Reactivity Data ...................................................................................... 2-282.6.1.7 Corrosivity Data ..................................................................................... 2-292.6.1.8 Water Solubility ..................................................................................... 2-292.6.1.9 Fire and Explosion Hazard .................................................................... 2-292.6.1.10 Life Hazard ............................................................................................ 2-29
2.6.2 First Aid ........................................................................................................ 2-292.6.3 Precautions ................................................................................................... 2-30
2.7 SODIUM HYDROXIDE (CAUSTIC SODA, NAOH) ............................................. 2-312.7.1 Description and Properties ........................................................................... 2-31
2.7.1.1 General .................................................................................................. 2-31
-
8/3/2019 Operating Guidelines
19/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-iii
2.7.1.2 Toxicity Information ............................................................................... 2-312.7.1.3 Permissible Exposure Limits ................................................................. 2-312.7.1.4 Odor ...................................................................................................... 2-312.7.1.5 Physical Data ........................................................................................ 2-322.7.1.6 Reactivity Data ...................................................................................... 2-322.7.1.7 Corrosivity Data ..................................................................................... 2-342.7.1.8 Water Solubility ..................................................................................... 2-342.7.1.9 Fire and Explosion Hazard .................................................................... 2-342.7.1.10 Life Hazard ............................................................................................ 2-35
2.7.2 First Aid ........................................................................................................ 2-352.7.3 Precautions ................................................................................................... 2-36
2.8 SULFUR PLANT SAFETY ................................................................................... 2-372.8.1 Hydrogen Sulfide .......................................................................................... 2-372.8.2 Sulfur Dioxide ............................................................................................... 2-372.8.3 Sulfur Storage Tank ...................................................................................... 2-38
2.8.3.1 Poisonous Gases .................................................................................. 2-382.8.3.2 Explosion and Fire ................................................................................. 2-38
2.9 HOT WORK ......................................................................................................... 2-392.10 VESSEL ENTRY .................................................................................................. 2-392.11 PIPES AND LINES .............................................................................................. 2-41
2.11.1 General ......................................................................................................... 2-412.11.2 Before Breaking Lines .................................................................................. 2-422.11.3 When Breaking Lines ................................................................................... 2-42
2.12 ELECTRICAL EQUIPMENT ................................................................................ 2-422.12.1 Electrical Repairs .......................................................................................... 2-432.12.2 Grounding ..................................................................................................... 2-432.12.3 Conduit, Cables, and Wires .......................................................................... 2-432.12.4 Fuses ............................................................................................................ 2-432.12.5 Switching ...................................................................................................... 2-432.12.6 Hand Tools and Portable Equipment ............................................................ 2-442.12.7 Miscellaneous ............................................................................................... 2-44
2.13 BOILERS AND OTHER DIRECT-FIRED EQUIPMENT ...................................... 2-452.13.1 General ......................................................................................................... 2-452.13.2 Boilers ........................................................................................................... 2-45
2.13.2.1 Repair and Maintenance ....................................................................... 2-452.13.2.2 Operations ............................................................................................. 2-46
2.13.3 Direct-Fired Equipment ................................................................................. 2-462.14 LABORATORY SAFETY ..................................................................................... 2-47
2.14.1 Good Housekeeping ..................................................................................... 2-472.14.2 Equipment .................................................................................................... 2-47
-
8/3/2019 Operating Guidelines
20/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-iv
2.14.3 Chemical Sorting and Identification .............................................................. 2-472.14.4 Chemical Handling ....................................................................................... 2-48
2.15 MATERIAL SAFETY DATA SHEETS (MSDS) .................................................... 2-49A. 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
-
8/3/2019 Operating Guidelines
21/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-1
2. GENERAL SAFETYGeneral
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 minimumconcentration 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.
-
8/3/2019 Operating Guidelines
22/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-2
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 thanwater, 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.
-
8/3/2019 Operating Guidelines
23/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-3
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: -122F (-86C)
b. Boiling Point: -77F (-61C)
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: 500F (260C)
f. Vapor Specific Gravity: 1.2 (heavier than air)
-
8/3/2019 Operating Guidelines
24/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-4
2.2.1.6 Reactivity Data
Hydrogen sulfide is dangerously reactive with the following
substances:
Formula NameC2H4O 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, chromicacid)
Cu copper
Fe2O3nH2O 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 andcalcium oxide)
Na sodium
NaOH + CaO + air sodium hydroxide + calcium oxide (lime) in air
Na2O2 sodium peroxide
-
8/3/2019 Operating Guidelines
25/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-5
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 650F/343C), 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 60F (15C), 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 absorbhydrogen sulfide. Increased temperature or mechanical disturbance
tends to release the absorbed gas.
-
8/3/2019 Operating Guidelines
26/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-6
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 HazardHydrogen 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).
-
8/3/2019 Operating Guidelines
27/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-7
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
prolonged exposure
10 0.001
Slight symptoms after exposure of several
hours
70-150 0.007-0.015
Maximum concentration that can be inhaled
for one hour without serious consequences
170-300 0.017-0.03
Dangerous after exposure of thirty minutes
to one hour
400-500 0.04-0.05
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.
-
8/3/2019 Operating Guidelines
28/792
Operating Guidelines Samsung Total Petrochemicals Co., Ltd.Fall 2011 Daesan, Korea
SULFUR BLOCK
Issued 30 August 2011 General Safety Page 2-8
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).