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
Outcomes • Procedural gaps highlighted
• Investigations initiated based on major opportunity losses
• Around 50 recommendations

We have to identify the key factors leading to the main events

 Sulphur production Controllable losses 2010-2014
SRU Controllable Direct and Indirect Losses 2010-2014

45,000

40,000 39,457
35,000

30,000
23,512
25,000 31,487
20,000

15,000

10,000
7,028
5,000
0

2010
2,209
2011
2012
2013
2014
Direct losses in Tones

Total Loss in tones

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
SRU Reliability trend based on Total Sulphur losses from 2007-2014
99%
Average Trend Group
97% Reliability is 98%
96.1% Reliability
95.5%
95%

93.4%
93% 92.8%

91% 91.3%
90.8%

89% 88.8%
88.6%

87%

85%
2007 2008 2009 2010 2011 2012 2013 2014
SRUs – Main issues
SRUs – Main issues
SRUs – Main issues
SRUs – Main issues
SRUs – Main issues
1 Combustion

2 BFW Quality

IOWs
3 Process Parameters Monitoring & Control

4 Modifications during SD

5 QA/QC (SD)
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?