Engineering Services related to Process Study

SRU Revamp

13 April 2018

Engineering Services Report ARL Pakistan (via Sulphur Experts B.V.)

 Engineering Services Report

Engineering Services related to Process Study for SRU Revamp

Attock Refinery Limited, Pakistan

Client Name:

Document No.:

Revision:

Revision Date: 13 April 2018

Prepared By:

Approved By:

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Contents

1. Introduction................................................................................................................................................ 4
2. Scope of Services...................................................................................................................................... 5
3. Process Equipment Modifications........................................................................................................... 6
3.1 Recommendations for Plugging Tubes of Waste Heat Boiler ..................................................................... 7
3.2 Electrical Heaters ........................................................................................................................................ 7
3.3 1st Claus Reactor R-001 .............................................................................................................................. 8
4. Instrument Modifications / Verifications ............................................................................................... 12
4.1 Flow Elements ........................................................................................................................................... 12
4.2 Control Valves ........................................................................................................................................... 14
4.3 Additional Instrument ................................................................................................................................. 16

Appendix A. Attachments ................................................................................................................................... 17

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3. Process Equipment Modifications

Below table summarized the Process Equipment modifications for the new operating capacity range of
2 to 7.5 TPD of sulfur:

Table 1: Summary of Process Equipment modifications

ARL Reference
Equipment Changes Implemented File Number
Document Number

Waste Heat Boiler • 35 out of 63 tubes remains open; 28 out VD-SRU-H-003-016

H-003 of 63 tubes to be plugged / covered.
• For additional information on
plugging/covering tubes refer to section
3.1

1st Sulfur Condenser • 22 out of 39 tubes remain open; 17 out of VD-SRU-E002-021

E-002 39 tubes to be plugged / covered VD-SRU-E002-050
• Effective demister area to be reduced to
0.1 m2 by partly covering demister.

2nd Sulfur Condenser • 22 out of 38 tubes remain open; 16 out of VD-SRU-E002-021

E-003 38 tubes to be plugged / covered VD-SRU-E002-050
• Effective demister area to be reduced to
0.1 m2 by partly covering demister

3rd Sulfur Condenser • 22 out of 39 tubes remain open; 17 out of VD-SRU-E004-021

E-004 39 tubes to be plugged / covered VD-SRU-E004-050
• Effective demister area to be reduced to
0.1 m2 by partly covering demister.

4th Sulfur Condenser • 22 out of 40 tubes remain open; 18 out of VD-SRU-E004-021

E-005 40 tubes to be plugged / covered VD-SRU-E004-050
• Effective demister area to be reduced to
0.1 m2 by partly covering demister.

Final Sulfur Condenser • 36 out of 66 tubes remain open; 30 out of VD-SRU-E006-021

E-006 66 tubes to be plugged / covered VD-SRU-E006-050
• Effective demister area to be reduced to
0.1 m2 by partly covering demister.

Steam Condenser • Louvres to be installed on top of steam PDS-PR-SRU-EA-001

EA-001 condenser to minimize heat losses.
• Steam coil to be installed below steam
condenser

Electrical Heaters • Software limiter to be incorporated / SRU-PID-104

E-001 / E-007 / E-008 / checked to prevent overheating. Remarks SRU-PID-107
E-009 / E-010 made on PID’s Rev 3B. For additional
SRU-PID-108
information refer to section 3.2
SRU-PID-109
SRU-PID-110

1st Claus Reactor • 0.5 m3 Titanium catalyst to be installed in See section 3.3 -
R-001 the bottom of the catalyst bed.
• Catalyst loading information.

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ARL Reference
Equipment Changes Implemented File Number
Document Number

Coalescer • Effective demister diameter to be reduced VD-SRU-V-005-007

V-005 to 400 mm.

Update P&ID Updated P&ID (Revision 3B) reflecting the SRU-PID-103

new AMU feed gas provided with dedicated SRU-PID-104
control line-up, consisting of:
• Flow orifice with double FT for control
and safeguarding.
• Flow control valve with TSO function
• Dedicated shut-down valve
• Pressure / temperature measurement for
flow compensation AMU control change

Update ABC process • Updated Cause and effect Diagram,

control deliverables to Logic Description and Process Control
reflect the AMU control Narrative
change.

3.1 Recommendations for Plugging Tubes of Waste Heat Boiler

XXXX has been requested to indicate the tubes that should be plugged/covered and the ones that
remain open in the Waste Heat Boiler. At the same time, ARL requested additional information on the
filling materials and the recommended methods to implement during plugging procedures.

The following method has been suggested by Industrial Ceramics Limited for temporary plugging of
tubes, where a custom made type of ferrules is advice. For this case, a bubble made alumina type
refractory castable inside the ferrule inner bore is used.

The plugging ferrules should be supplied either as straight or headed ferrules, depending on the style
and dimensions of the installed ones. For headed ferrules, the recommendation is to use a solid, one
piece headed ferrule, rather than two-piece headed ferrule.

Ferrules are supplied pre-fired with no special on site dry-out considerations required and should be
completely provided with ceramic fiber insulating sleeves and gaskets. The installation of the
Tubesheet protection system proceeds “as normal”; substituting “plugged” ferrules where required.

3.2 Electrical Heaters

During study phase XXXX evaluated, with the support of the electrical heater vendor, what kind of
modifications were required to obtain the correct outlet temperature with the reduced throughput. As in
the future the higher capacity could become in place, it was preferred that the modifications could be
easily reversed to gain the original duty back.

The vendor shared that currently the heating elements temperature signals are going directly to the
DCS, in which case the DCS vendor needs to set the new logic of high temperature limit or alarm
function. The temperature elements shall not exceed 650°C and the control signal of the Power
Switching Device (SCR) shall be off when the elements temperature reach to 650°C.

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Nevertheless, XXXX has determined that according to the current as built P&ID’s received from
client, the temperature elements measuring the electrical heater skin seems to be wired to the heater
control system, from where they are forwarded to the DCS for monitoring only. Vendor has been
requested to confirm if the current situation has this configuration.

If above configuration is correct, then the temperature protection is within the heater vendor scope and
no special specification is required at this stage of the design. If above configuration is not correct and
the temperature elements are wired to the DCS directly, vendor has been requested to provide
information on the action that should the taken by the DCS operator, weather is to limit the output to
the heater control when the temperature becomes too high (i.e. a protective controller with a setpoint
of 650°C which overrules the output of the normal TC) or if the electrical heater should be stopped
immediately.

Vendor has confirmed that the current control system doesn’t have an overheating protection and that
the overheating protection falls under Detailed Engineering Ccontractor’s scope.

3.3 1st Claus Reactor R-001

During the study phase the reactors efficiencies were evaluated for the new capacities. As a result, it
was determined that in order to reduce the increased slip of COS / CS2 due to co-firing, the installation
of a layer of titanium catalyst in the first reactor was necessary to increase the sulfur recovery
efficiency with respect to COS / CS2. In total, 0.5 m3 of new titanium catalyst CRS-31 needs to be
installed in the bottom of the catalyst bed. Table 2 indicates the distribution of the different layers of
catalyst and ceramic balls, together with the normal height per layer and the necessary loading height
during catalyst loading.

Table 2: Catalysts and Ceramic Balls for 1st Claus Reactor R-001

Normal Height Loading Height

Top of Size mm Shape
per layer mm mm
CR-3S 3-6 ball + 445 + 740
CRS-31 3-4 extrudate + 155 + 270
Ceramic balls 6 ball + 100 + 100
Grid -- -- 0 0

XXXX has been requested to elaborate on the catalyst loading procedure for the 1st Claus Reactor.
Below information is taken from the original project Operating Manual Doc. Number:
updated with the new configuration for the 1st Claus Reactor.

After the initial drying out and heating-up procedure, the unit is shut down for opening the equipment,
inspection of the refractory and loading of catalyst into the Reactor(s).

In order to prepare for the catalyst loading procedure, below steps should be followed:
1. Remove the pipe or bellow between the Reactor outlet and the Condenser inlet and place a
temporary blind at the Condenser inlet. In this way, no catalyst dust will come into the Condenser.
2. Check the interior of the Reactor for cleanliness, with particular attention to the area beneath the
support grid.
3. Check the mesh size of the gauge and check if the gauge is installed and fixed properly.

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4. Indicate on the wall the required heights for ceramic balls and catalyst. The height of the catalyst
bed is initially 5-10% higher than indicated on the data sheet. After some time of operation, the
bed height will be obtained as the catalyst density will increase to the normal bulk packed density.
5. With the addition of 0.5 m3 of titanium catalyst layer in the 1st Claus Reactor R-001 to be installed
in the bottom of the catalyst bed, from the top of the grid support the heights are applicable as per
table 2:
• Bottom layer (support balls): The bottom layer consists of 6 mm ceramic balls for support of
the catalyst bed.
• Bottom catalyst layer (CRS-31): The bottom catalyst layer consists of CRS-31 catalyst. Initially
the catalyst bed is 10% higher than indicated on the equipment drawing. The catalyst will
shrink to its normal height after some time of operation.
• Top catalyst layer (CR-3S): The top catalyst layer consists of CR-3S catalyst. Initially the
catalyst bed is 5% higher than indicated on the equipment drawing. The catalyst will shrink to
its normal height after some time of operation

Loading procedure for Claus Reactor(s)

Catalyst should be protected from contact with water (such as rain and condensate). It is
advisable to delay loading during rainfall. Ensure no rain water can enter the Reactor via the
manholes. If a deviation of following Reactor loading procedure is proposed, approval shall be
obtained from Licensor:

• Load the support balls to the specified and marked height.

• Load the catalyst via the manhole of the Reactor using a bucket or sock (see Figure 1). All
supplied catalyst shall be loaded.

• Load the catalyst in small layers to the specified and marked height. Level every layer. Use a
ventilator to discharge the catalyst dust to outside of the Reactor.

• Levelling of the catalyst is done gently using a rake. Do not tread, sit or lie down directly on
the catalyst. Use a "temporary work floor" of planks to move in the Reactor. Alternatively,
covers of catalyst drums can be used. Special care shall be taken when reaching a thermowell
to prevent damage.

• After the reactor has been loaded, catalyst dust and fines have to be removed by an air flow
from the blower through the Reactor. Then, close the Reactor.

• Reinstall the pipe or bellow between the Reactor and Condenser.

• Make a report of the catalyst loading, mention the number of drums and take samples of the
catalyst. Do the same for the ceramic balls.

• After catalyst loading and leak testing of the Reactors, the unit is heated up again.

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CATALYST BAG

RECEIVING HOPPER

Figure 1: Loading of Claus Reactor

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General Remarks

• Care must be taken to minimize the creation of catalyst fines during the loading of the Reactors.
Catalyst dust and fines are to be removed with the help of an air flow through the Reactor. For
this reason, the pipe between Reactor outlet and Condenser inlet should be removed and a
temporary blind at Condenser inlet should be installed. This procedure has to be followed for
each Reactor separately.
• During catalyst loading some dust is produced which should not be inhaled. Personnel who are
outside the Reactor during loading should wear dust masks. Inside the Reactor, a positive
pressure air mask or alternatively a full-face mask with filter should be worn. For the required type
of filter, the supplied catalyst safety datasheets should be consulted. Eye contact and prolonged
skin contact with the catalyst should be avoided by wearing the relevant protective clothing.
• The catalyst should be protected against water.

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4. Instrument Modifications / Verifications

The instrumentation scope is to evaluate the performance of the existing/installed instruments (Venturi
flow meters, Control Valves, Differential pressure transmitter) for the new process condition
established in the Instrument Process Data sheet, doc. No: and to
recommend necessary actions and modification to obtain proper accuracy for continuous operation at
lower capacity.

In addition, as part of new AMU feed gas line scope, new instruments have been specified.
Specifications for new Instruments have been included in Instruments Data Sheets Doc. No:

4.1 Flow Elements

Existing flow element (Venturi Type) have been sized considering the new operating conditions.
Tables 3 & 4 shows a summary of the results, analysis and conclusions for the existing/installed and
new proposed flow elements.

Table 3: Existing Flow Instruments

TAG Type of instrument Results Conclusion Ref. document/

number/ data sheet
subject

SRU-FE-001 Venturi-Machined • Reynold Number: The pipe Reynolds numbers

(Existing) @Min = 21484.398 obtained based on new process
@Nor = 56180.467 conditions for lower capacities
Manufacturer: are out of the recommended
@Max = 80257.811
SAMIL IND CO., LTD limit for Venturi -Machined as
per ISO 5167-4:2003 (2x105 -
106). As a consequence, the
Model No: SVT
uncertainty (%) increases.
Recommendation: Replace
existing flow element. See
Table 4

SRU-FE-003 Venturi-Machined • Reynold Number: The pipe Reynolds numbers

(Existing) @Min = 8809.553 obtained based on new process
@Nor = 11245.135 conditions for lower capacities
Manufacturer: are out of the recommended
@Max = 33683.586
SAMIL IND CO., LTD limit for Venturi -Machined as
per ISO 5167-4:2003 (2x105 -
106). As a consequence, the
Model No: SVT-J
uncertainty (%) increases.
Recommendation: Replace
existing flow element. See
Table 4

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TAG Type of instrument Results Conclusion Ref. document/

number/ data sheet
subject

SRU-FE-005 Venturi-Machined • Reynold Number The pipe Reynolds numbers

(Existing) @Min = 13482.800 obtained based on new process
@Nor = 51076.020 conditions for lower capacities
Manufacturer: are out of the recommended
@Max = 72965.744
SAMIL IND CO., LTD limit for Venturi -Machined as
per ISO 5167-4:2003 (2x105 -
106). As a consequence, the
Model No: SVT
uncertainty (%) increases.
Recommendation: Replace
existing flow element. See
Table 4

Table 4: New/suggested flow instruments

TAG Type of instrument Results Conclusion Ref. document/

number/ data sheet
subject

SRU-FE-001 Orifice Plate • β = 0.345 Orifice Plate suitable for lower NL850500-J.05-0001.
• FT-001 = 0-325 Kg/h capacity Pages 6 & 7
• FT-002 = 0-124 Kg/h

SRU-FE-003 Orifice Plate • β = 0.250 Orifice Plate suitable for lower NL850500-J.05-0001.
• FT-003 = 0-65 Kg/h capacity Pages 8 & 9
• FT-004 = 0-24 Kg/h

SRU-FE-005 Orifice Plate • β = 0.332 Orifice Plate suitable for lower NL850500-J.05-0001.
• FT-005 = 0-920 Kg/h capacity Pages 10 & 11
• FT-006 = 0-243 Kg/h

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4.2 Control Valves

Existing control valves (Globe Type) have been sized considering the new operation conditions.
Tables 5 & 6 show a summary of the results, analysis and conclusions for existing/installed and new
proposed control valves.

Table 5: Existing Control Valves

TAG Type of Results Conclusion Ref. document/

number/ instrument data sheet
subject

SRU-FV-001 Globe Valve • Cv req. (Min/Nor/Max) The travel percentage (%),

(Existing) = 2.81 / - / 11.89 based on the new low capacity
• % Travel for minimum condition, is below
Manufacturer: the recommended manufacturer
(Min/Nor/Max) = 9.43
KOMOTO Inc. value (minimum 10%).
/ - / 38.4
Operating continuously at a low
Rated Cv: 116 travel % could cause mechanical
damage in the valve and
unstable control.
Size: 4”x3”
Recommendation: Use a
different control valve to improve
the travel % and control
performance. See table 6

SRU-FV-003 Globe Valve • Cv req. (Min/Nor/Max) In general, the travel

(Existing) = 0.48/ - /1.98 percentages (%) based on the
• % Travel new low capacity are low, but
Manufacturer: within the Manufacturer
(Min/Nor/Max) =
KOMOTO Inc. recommended limit
13.48 / - /44.58
Recommendation: Use a
Rated Cv: 14 different control valve to improve
the travel % and control
performance. See table 6
Size: 2”x1”
(Flange = 3”)

SRU-FV-005 Globe Valve • Cv req. (Min/Nor/Max) The travel percentages (%),

(Existing) = 1.48/ - /8.45 based on the new low capacity
• % Travel are within the recommended
Manufacturer: manufacturer value.
(Min/Nor/Max) = 11.1
KOMOTO Inc. Nevertheless, the flow
/ - / 47.25
characteristic of existing valve
Rated Cv: 52 (Equal percentage) is not
according to Process Control
Requirement. The Flow
Size: 3”x2” characteristic shall be Linear.
Recommendation: Use a
different control valve with a flow
characteristic as per Process
Control requirement. See table 6

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TAG Type of Results Conclusion Ref. document/

number/ instrument data sheet
subject

SRU-ZV-006 Globe Valve • Cv req. (Min/Nor/Max) The travel percentage (%),

(Existing) = 5.175/ - /42.05 based on the new low capacity
• % Travel for minimum condition, is below
Manufacturer: the recommended manufacturer
(Min/Nor/Max) = 3.45/
KOMOTO Inc. value (minimum 10%). Operating
- / 23.52
continuously at a low travel %
Rated Cv: 240 could cause mechanical damage
in the valve and unstable control.
Recommendation: Use a
Size: 8”x 6”
different control valve to improve
the travel % and control
Low Noise Trim – performance. See table 6
1 Stage

Table 6: New/alternatives Control valves

TAG number/ Type of Results Conclusion Ref. document/

subject instrument data sheet
SRU-FV-001 Globe Valve • Cv req. (Min/Nor/Max) Recommendation: Use
= 2.809/ - /12.12 Globe valve, Size: 2”, rated
• % Travel Cv = 15. Flow Characteristic:
Manufacturer:
(Min/Nor/Max) = Linear
Masoneilan
20.97 / - / 83.22

Model No: 21115

Rated Cv: 15

Size: 2”
SRU-FV-003 Globe Valve • Cv req. (Min/Nor/Max) Recommendation: Use
ALTERNATIVE = 0.484/ - /2.004 Globe valve, Size: 1”, rated
• % Travel Cv = 3.8. Flow Characteristic:
Manufacturer:
(Min/Nor/Max) = Linear
Masoneilan
14.01 / - / 57.24

Model No: 21115

Rated Cv: 3.8

Size: 1”
(Flange = 3”)

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TAG number/ Type of Results Conclusion Ref. document/

subject instrument data sheet
SRU-FV-005 Globe Valve • Cv req. (Min/Nor/Max) Recommendation: Use NL850500-J.05-0002
= 1.48/ - /8.501 Globe valve, Size: 2”, rated Page 9
• % Travel Cv = 15. Flow Characteristic:
Manufacturer:
(Min/Nor/Max) = Linear
Masoneilan
10.85/ - / 61.01

Model No: 21115

Rated Cv: 15

Size: 2”
SRU-ZV-006 Globe Valve • Cv req. (Min/Nor/Max) Recommendation: Use NL850500-J.05-0002
= 5.176/ - /42.25 Globe valve, Size: 4”, rated Page 10
• % Travel Cv = 74. Flow Characteristic:
Manufacturer:
(Min/Nor/Max) = Equal percentage
Masoneilan
29.98/ - / 75.92

Model No: 21125

Rated Cv: 74

Size: 4”

4.3 Additional Instrument

Table 7: Summary of verification executed for SRU-PDT-037

TAG Type of instrument Results/Existing Conclusion Ref. document/data

number/ Inst. sheet
subject characteristics
SRU-PDT- Diff. Pressure The upper range The new process data is: NL850500-CL.4-0002
037 Transmitter. limit for 2051CD is: • Pinlet = 0.27 Kg/cm2g
• 62.3 mbar • Pdp min = 0.001 Kg/cm2
Manufacturer: (0.063 Kg/cm2) • PdP alarm Low = 0.002
EMERSON/Rosemount. with a minimum Kg/cm2
span of 1.2 • PdP max = 0.03 Kg/cm2
mbar.
Model No:
• Calibrated
2051CD1A02A1AH2S6 Recommendation: Re-
Range: 0 – 0.01
BCE1L calibrate range from 0 - 0.01
Kg/cm2
4M5D4CNP1Q4Q8. Kg/cm2 to 0 – 0.03 Kg/cm2.
Revised with EMERSON
Specialist for DP flow
High accuracy at support.
minimum pressure
difference

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Attachments

Licensor Doc No. Description Revision

NL850500/J.04/0001 Instrument Data Sheet - Orifice Plate Final Updated

NL850500/J.04/0002 Instrument Data Sheet - Control Valves Final Updated

NL850500/J.04/0003 Instrument Data Sheet - On-Off Valves (Ball Type) Final Updated

NL850500/J.04/0004 Instrument Data Sheet - Pressure Electronic Transmitters Final

NL850500/J.04/0005 Instrument Data Sheet - Temperature Wells, Elements & Final

Transmitters
NL850500/J.05/0001 Preliminary Flow Calculations Final (Updated for 7.5 TPD
Max.)
NL850500/J.05/0002 Preliminary Control Valve Calculations Final (Updated for 7.5 TPD
Max.)
NL850500/P.01/9653 PID: Acid / SWS / AMU Off Gas Control SRU Final

NL850500/P.01/9654 PID: Combustion Air Control SRU Final

NL850500/P.01/9657 PID: 1st Reactor Stage SRU Final

NL850500/P.01/9658 PID: 2nd Reactor Stage SRU Final

NL850500/P.01/9659 PID: 3rd Reactor Stage SRU Final

NL850500/P.01/9660 PID: Final Reactor Stage SRU Final

NL850500/P.04/0001 Instrument Process Data Sheet Final (Updated for 7.5 TPD
Max.)
NL850500/P.04/0002 Claus Waste Heat Boiler H-003 Final

NL850500/P.04/0003 1st / 2nd Sulfur Condenser E-002/003 Final (Updated for 7.5 TPD
Max.)
NL850500/P.04/0004 3rd / 4th Sulfur Condenser E-004/005 Final (Updated for 7.5 TPD
Max.)
NL850500/P.04/0005 Final Sulfur Condenser E-006 Final (Updated for 7.5 TPD
Max.)
NL850500/P.04/0006 Steam Condenser EA-001 Final (Updated for 7.5 TPD
Max.)
NL850500/P.04/0008 Coalescer V-005 Final (Updated for 7.5 TPD
Max.)
NL850500/P.06/0002 Cause and Effect diagram update Final (Updated for 7.5 TPD
Max.)
NL850500/P.06/0003 Logic Description Final (Updated for 7.5 TPD

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Max.)

NL850500/P.06/0004 Process Control Narrative Final (Updated for 7.5 TPD

Max.)

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