Sulphuric Acid Plant

8/6/2019 Sulphuric Acid Plant

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SULPHURIC ACID PLANTCriteria of erection of Equipments

to Built in Reliability


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CORRECTNESS IN CIVIL CONSTRUCTION

Proper layout to be done with proper

measurements.

Excavation of the Ground for EquipmentFoundations.

Proper mixing of Concrete to be used

Confirm the Concrete Temperature and itsproper setting.

Control of Measurements.


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CORRECTNESS IN CIVIL

CONSTRUCTION

Reference with other foundation orMeasurements.

Prepare template for foundation bolts to be kept

in position and check with vessel to be installed. Concrete surface leveling to be controlled.

Homogeneous Mixing to be done whileconcreting.

Surface finish to be considered for long life.

Proper leveling of Foundation to be taken care.


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CORRECTNESS IN CIVIL

FOUNDATIONS Proper curing to be done.

Honey combings should not be allowed.

Torrsteel rods should not be projected from the

surface of concrete. Proper care to be taken for Concrete Joints by

providing Rubber or PP Joint seal or Propersealant to be provided to avoid leakages.

After removing of centering, plastering to becompleted immediately. So that proper jointingto be possible to give extra strength.


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IMPORTANCE OF GOOD LAYOUT

Consider that the pressure drop in the systemshould not be effected while running of the plant.

Energy saving should be considered.

Heat loss should be avoided from the system. Generation of Heat to be converted into the

power generation.

Laying of Pipe lines and Ducts should not be

effected by layout. Pressure drop should not effected unless

otherwise stated.


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IMPORTANCE OF ERECTING

VESSELS

Check the Measurements of Foundation.

Check the elevation of Foundations.

Check the Equipment FoundationMeasurements, which is installing onFoundation.

Check the foundation bolts location and its

Measurements. Check the Foundation bolt holes on the Base

plate of the Equipments.


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Welding

1. Welding is the major role in the projects.

2. Weld Type of Arc, Tig and Mig

3. Arc welding is considered for ducting, Unpressurised

vessels, Structural, General etc.4. Tig. welding is for Pressure vessels, Pipe lines of Lowand High Lines. Ducting of Gas or Air flow.

5. Where the Expansion bellows are provided on DuctLines, there is a chance of Leakage of gasses during

sudden expansion. Tig welding is preferred.6. Arc welding may not give that much chance for

welding of ducts where the expansion joints areprovided.


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Welding

11.Provide curtains to reduce the joint failure.

12.Better to provide closed area like Tig welding tobe done with closed room.

13.Field joints are not possible to do like that, soyou have to provide close atmosphere for doingthe welding of joints of high or low pressurelines.

14. It is also important to take the welding joint intonormality by doing the Annealing process. Sothat joint failure will reduce.


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Plant Flooring, Position of Valves

and Flat forms

1. Valves should be provided in such a location to avoidloss of heat or Loss of Pressure etc.

2. Valves should be positioned in such a way for free

maintenance.3. Flat forms should be provided for opening and closing

of valves, maintenance of valves in that location.

4. Flat forms structural should not be effected for

movement of the plant operating people, movementof equipments like trolleys, Fork lifts etc.

5. Flat forms should be inter-connected, if possible withother supports or flat forms.


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and Flat Forms

9. Plant area to be covered with proper flooring tomaintain neat and clean.

10.Plant area to be provided walk ways, so that

visitors should follow the proper approach tothe plant area.

11.Name Plates are to be provided to identify theequipment name, Location of the plant area etc.

12.W

hile considering the flat forms you have tocare about the safety to the work force toescape from the position, if any suddenly unsafeconditions are generated.


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and Flat Forms

13. Considering of Gland leaks, which are common

from Gas Duct valves due to high gas

temperature at inside the ducts while running of

the plant.

14. You have to design properly about the glands,

which are to cooled with atmospheric air.

15. Gland cooling to be provided which is projectedfrom the Insulation to reduce the damage (or

burn) of Gland rope by high temperature.


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Plant Flooring, Position of Valves and

Gland Leaks

16. Proper gland ropes are to be used which aresuitable to the particular atmosphere to avoidthe gland leakages.

17. Plant area should be maintained neat andclean to avoid unwanted accidents.

18. Inside the plant, you have to earmark the

locations to keep the maintenanceequipments during the maintenance period.


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1. While circulation of Sulphuric Acid in Towers, some ofbroken saddle pieces are flow along with acid intowers and collected in to the Acid Circulation tank.

2. These are extracted by pump which are floated inliquid while running due to agitation in acid pumptank by returning acid from tower with velocity.

3. These ceramic pieces are pass though pump and willjam at inlet of the plate heat exchangers or shell andtube heat exchanger on shell side. There by reducethe flow of Sulphuric acid to the towers.

Plate Heat Exchangers & Towers


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Plate Heat Exchangers and Towers

5. If these are ceramic particles pass through Plate HeatExchanger, will get jam at acid distribution Headerthere by pressure drop will increase across the PlateHeat Exchangers and Distribution Headers.

To avoid, you have to provide mesh of lower the size ofthe Plate Heat Exchanger Openings and Lower size ofthe Acid Distribution holes.

6. Acid will flow across the openings and reduce thepressure drop in the circulation system.

7. Acid is highly corrosive at higher temperature, so thatsuitable material and proper shape to be required touse.


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Sulphur Gun for Spraying

1. Sulphur gun spraying is basically based on Air flow aswell as swirling motion of Sulphur flow.

2. Sulphur should not fall on furnace inside before

spraying. To avoid that falling of Sulphur Nozzleshould be Pressurized by flow and swirling motion tobe provided.

3. Sulphur Furnace inlet air flow is also required toprovide swirling flow along with Sulphur Gun nozzle.

4. Gun barrel pipe as well as supply jacketed pipe to bedesigned as required to provide sufficient flow to theGun nozzle.


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Instrument Erection and

PLC Positioning

a. PLC Control panel to be installed in Plantoperation control room.

b. Cable racks and Cable identification should be

properly earmarked by provided tags, likenumbers or letters.

c. Cable joints are not allowed for instrumentationsystem.

d. Cable junction boxes are to be provided in sucha location to avoid the damage of junction boxesby rain, sun rays etc.


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PLC Positioning

e. Local Indicators are to be provided with proper

cover.

f. Control valves and Controllers are to be provided

in proper direction to look locally by the

operating peoples.

g. Proper controlling system to be provided based

on the operational condition of the plant.h. Plant tripping is to be provided in proper way, it

should not deviate the system failure.


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PLC Positioning

i. Plant tripping should help us the Process

failure, System failure and to reduce the

damage of the plants.

j. Plant tripping will help us to control the

Environmental pollution based on the

settings of the plant with ventilations

through chimneys.


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CLOSEUP

a. Plants should run at clean atmosphere.

b. Plants should operate with in controlledenvironmental conditions.

c. Plants should operate with in the recommendedoperating condition.

d. Plant should be the unit, the Operating peopleas well as Management should feel happy to

run.e. Management should not feel burden to run theplants with in the controlled conditions.


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PREPARED BY

YALAMATI SATYANARAYANA

PROJECT MANAGER

M/S. HARIKA INDUSTRIES

HYDERABAD

INDIA

CELL: +919849963639 / +966590288534

[email protected]

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Sulphuric Acid Plant