ADGAS Sulfur Recovery Units Reliability...
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ADGAS Sulfur Recovery Units – Reliability Improvement October 2015 2nd Annual Middle East Sulphur Plant Operations Network Forum
Transcript of ADGAS Sulfur Recovery Units Reliability...
ADGAS Sulfur Recovery Units – Reliability Improvement
October 2015
2nd Annual Middle East Sulphur
Plant Operations Network Forum
SRUs Reliability Analysis
ADGAS SRUs of Trains 1 ,2 and 3 are of similar design “Split Flow
Modified Claus Units”. SRU 1 & 2 were commissioned in 1993 (17
years after the LNG Trains). SRU 3 was commissioned in 1994.
All three SRUs have had number of failures since their
commissioning, causing Sulphur production loss, pollution to the
environment (high flare/emissions volumes) and safety incidents
(high risk exposure).
Reliability analysis is done using production capacity,
benchmarking with other LNG Plants, developing reliability block
diagram, review of various reports, modifications, repairs and
discussion with the concerned staff.
Reliability SRU, Rev3, February.2010
Previous Studies
• Bad Actors analyzed • Design deficiencies identified • Procedural gaps highlighted • Investigations initiated based on major opportunity losses • Around 50 recommendations
Outcomes
We have to identify the key factors leading to the main events
Sulphur production Controllable losses 2010-2014
Note:
Graph represents Total Sulphur losses Caused by SRUs and Train trips Vs Direst losses resulting from the loss of SRU function to the loss of the SRU units
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
2010
2011
2012
2013
2014
23,512
7,028
39,457
2,209
31,487
Direct losses in Tones
Total Loss in tones
SRU Controllable Direct and Indirect Losses 2010-2014
95.5%
88.6%
90.8%
92.8%
96.1%
88.8%
93.4%
91.3%
85%
87%
89%
91%
93%
95%
97%
99%
2007 2008 2009 2010 2011 2012 2013 2014
Average Trend GroupReliability is 98%
Reliability
SRU Reliability trend based on Total Sulphur losses from 2007-2014
SRUs – Main issues
SRUs – Main issues
SRUs – Main issues
SRUs – Main issues
SRUs – Main issues
1 Combustion
BFW Quality
Process Parameters Monitoring & Control
Modifications during SD
QA/QC (SD)
2
3
4
5
IOW
s
Actions: Focused List
Action
1. Combustion Control
• Advanced Control (Long Term)
• Tuning of Control Loops
Operation Training
• Burners Configuration
2. Integrity Operating Windows
• Corrosion Control Document
• Setting IOWs in SRUs (process & Water side)
3. Modifications
Sulfur Pit
• Flame Scanners
• Sight glasses
• Heat tracing set point change for Tail Gas Lines
4. QA/QC
• QA/QC & ITPs check
Thank you!
Any Questions?
