302 252 PDF

DOC CAT.
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ENGINEERING STANDARDS AND PRACTICES PROJECT: GCT Skhira
SPECIFICATION FOR JOB NO.: F134 DOC NO.: 302-252
GENERAL DOCUMENTS FOR ITEM NO.: N/A NO. REQ'D: N/A
SB PLANT WITH HRS OPERATING MANUAL REF.: ISSUE: DATED:
INSTRUCTIONS:
1. Initialing (BY/CHK’D/APP’D) required on cover sheet only. All other title block information must
be included on all pages.
2. Revisions are identified in the body of the Specification.
DESCRIPTION OF
REV. REVISION INCLUDING
NO. DATE BY CHK’D APP’D PAGE NUMBERS
0 5/9/12 ATG TC
0 9 May 2012
NO. DATE DESCRIPTION BY CHK'D APP'D APP'D
INFORMATION AND KNOW-HOW HEREON ARE CONFIDENTIAL AND PROPRIETARY PROPERTY OF DUPONT AND MAY NOT BE USED, REPRODUCED, OR REVEALED TO
OTHERS EXCEPT IN ACCORDANCE WITH THE TERMS OF A CONTRACT WITH OR OTHER WRITTEN PERMISSION OF DUPONT.
EC-94 (REV. 05/11)
Rev 0
30 May 11
GENERAL SB WITH HRS OPERATING DOCUMENTS
TABLE OF CONTENTS
APPENDIX 01 Pre-Startup Check Lists

APPENDIX 02 Plant Troubleshooting
2.1 Sulfur Burning Plant
2.2 HRS
APPENDIX 03 Safety Rules
3.1 General
3.2 Boiler Safety Rules
3.3 Acid Burns
3.4 Eye Protection
3.5 Hazards
3.6 Sulfuric Acid Storage, Pumping and Handling
3.7 Other Hazards
3.8 HRS Safety Considerations
APPENDIX 04 Material Safety Data Sheets
APPENDIX 05 Maintenance
5.1 Sulfur Burning Plant Maintenance
5.2 HRS Maintenance
APPENDIX 06 Procedure for Mothballing H2SO4 Plants
6.1 General
6.2 Recommended Preparation and Actions
APPENDIX 07 Plant Tests
7.1 Various Gas Tests
7.2 Drawing 10-6-8
7.3 Drawing 10-6-9
7.4 PeGASyS Updates
APPENDIX 08 Charts and Tables
APPENDIX 09 Plant Notebook and Operating Reports
This operating manual is the property of MECS, Inc. Information and know-how herein are confidential and proprietary and may not be used, reproduced, or revealed to others
except in accordance with the terms of a contract with or other written permission of MECS, Inc.
GEN DOCS - 1
Rev 0
30 May 11
APPENDIX 01
PRE START-UP CHECKLIST
Sheet No EQUIPMENT NAME Revision Date

CHK-02 Sulfur Burner 0 30 May 11
CHK-03 Waste Heat Boiler 0 30 May 11
CHK-04 Main Compressor 0 30 May 11
CHK-05 Inlet Air Filter 0 30 May 11
CHK-06 Converter 0 30 May 11
CHK-07 Hot Interpass Heat 0 30 May 11

Exchanger
CHK-08 Cold Interpass Heat 0 30 May 11

Exchanger
CHK-09 Economizer 3B 0 30 May 11
CHK-10 HP,IP Superheaters 4A 0 30 May 11

/ Economizers 4C,4A
CHK-11 Superheater 1B 0 30 May 11

CHK-12 Drying Tower 0 30 May 11
CHK-13 Final Tower 0 30 May 11
CHK-14 Combination Pump 0 30 May 11
Tank
CHK-15 Plant Stack 0 30 May 11
CHK-16 DT Acid Cooler 0 30 May 11
CHK-17 Product Acid Cooler 0 30 May 11
CHK-18 DT Acid Pump 0 30 May 11
CHK-19 FAT Acid Pump 0 30 May 11
CHK-20 Acid Drain Pump 0 30 May 11
CHK-21 Deaerator 0 30 May 11
CHK-22 Pressurized Blowdown 0 30 May 11
Tank
CHK-23 Atmospheric Blowdown 0 30 May 11
Tank
CHK-24 HP BFW Pump 0 30 May 11
CHK 01- 1
Rev 0
30 May 11
APPENDIX 01

CHK-25 Sulfur Feed Pump 0 30 May 11
CHK-26 Gas Duct 0 30 May 11
CHK-27 Acid Piping 0 30 May 11
CHK-28 Utility Piping 0 30 May 11
CHK-29 Steam and BFW Piping 0 30 May 11
CHK-30 Instrumentation 0 30 May 11
CHK-31 Heat Recovery Tower 0 30 May 11
CHK-32 HRS Diluter 0 30 May 11
CHK-33 HRS Acid Circulating 0 30 May 11
Pump
CHK-34 HRS Acid Drain Pump 0 30 May 11
CHK-35 HRS Boiler 0 30 May 11
CHK-36 HRS Heater 0 30 May 11
CHK-37 HRS Preheater 0 30 May 11
CHK-38 HRS Blowdown Tank 0 30 May 11
CHK-39 HRS BFW Pump 0 30 May 11
CHK-40 Interlock 0 30 May 11
CHK 01- 2
Rev 0
30 May 11
APPENDIX 01
SULFUR BURNER
Project Engineer
Location Date
MEN Equipment No.
MECS Dwg. / Required Actual

Condition Spec. Ref. Condition Condition
1. Inspect brick lining. Sat
2. Inspect baffle walls. Sat
3. Ensure peep holes (sight glasses) are
properly installed and aligned. Inspect Sat
castable lining.
4. Ensure thermocouples, PX connections,
and other instrumentation are properly Installed
installed and operational.
5. Remove debris from the sulfur burner. Clean
6. Inspect and clean the windbox. Clean
7. Plug and close the sulfur burner manway. Closed
8. Ensure the main gas damper is
Sat
operational.
9. Inspect sulfur guns, including the spray
Sat
nozzles.
10. Inspect the startup burner and fuel
Sat
system.
11. Prior to refractory cure, remove the plugs
Open/
in the burner shell. Replace the plugs
Closed
when the shell no longer steams.
12. A vendor should be present to
commission the startup burner. Verify
Complete
that all vendor pre-startup checks are
complete.
CHK 02- 1
Rev 0
30 May 11
APPENDIX 01
SULFUR BURNER
Project Engineer
Location Date
MEN Equipment No.
Remarks
1. Equipment Includes:
Sulfur Burner
Sulfur Spray Nozzles
Startup Burner
2.
3.
Punch List Items

Added to Master Punch
Item List
1.
2.
3.
CHK 02- 2
Rev 0
30 May 11
APPENDIX 01
WASTE HEAT BOILER
Project Engineer
Location Date
MEN Equipment No.

1. Inspect gas inlet refractory lining, if
Sat
required.
2. Inspect tube sheet castable and tube
Sat
ferrules, if required.
3. Ensure instrumentation in the inlet
vestibule is properly installed and Installed
operational.
4. Remove debris from the inlet vestibule. Clean
5. Inspect outlet vestibule metallizing, if
Sat
required.
6. Inspect outlet tube sheet. Sat
7. Ensure instrumentation in the outlet
Installed
vestibule is installed and operational.
8. Close the inlet and outlet vestibule
Closed
manways.
9. Inspect boiler saddles to ensure the boiler
Sat
is able to thermally expand.
10. Remove debris from shell side of boiler
Clean
and steam drum.
11. Inspect steam purifier. Sat
12. Ensure instrumentation, including level
sight glass is installed and operational (if
Installed
boil-out procedure is to be performed,
temporary sight glass may be installed).
13. Close the shell side of the boiler and
Closed
steam drum.
14. Ensure that the gas outlet and bypass or
Sat
jug valves are installed and operational.
CHK 03- 1
Rev 0
30 May 11
APPENDIX 01
WASTE HEAT BOILER
Project Engineer
Location Date
MEN Equipment No.
Remarks
1. The inlet vestibule is generally brick/castable lined for a boiler following a sulfur burner.
Boilers in other locations will be brick/castable lined as required.
Waste Heat Boiler
Waste Heat Boiler Steam Drum
3.
Punch List Items

Item List
1.
2.
3.
CHK 03- 2
Rev 0
30 May 11
APPENDIX 01
MAIN COMPRESSOR
Project Engineer
Location Date
MEN Equipment No.
MECS Dwg. Required Actual

Condition / Spec. Ref. Condition Condition
1. Generally the main compressor is
commissioned by a vendor representative.
Verify that the compressor vendor has Complete
performed any required pre-startup
checks.
2. Ensure lube oil system is full, and the lube
Sat
oil is warm and circulating.
3. Ensure vibration monitoring equipment is
Energized
4. Ensure all instrumentation for the
compressor and lube oil system is installed Installed
and operational.
5. Remove all debris from the compressor
Clean
casing and the inlet and outlet ducts.
6. For the motor drive, ensure cables are
Sat
properly terminated.
7. Ensure the motor is grounded. Sat
Remarks
2.
3.
CHK 04- 1
Rev 0
30 May 11
APPENDIX 01
MAIN COMPRESSOR
Project Engineer
Location Date
MEN Equipment No.
Punch List Items

Added to Master
Item Punch List
1.
2.
3.
CHK 04- 2
Rev 0
30 May 11
APPENDIX 01
INLET AIR FILTER
Project Engineer
Location Date
MEN Equipment No.

1. Ensure filter panels are installed. Installed
2. Ensure instrumentation is installed and
Installed
operational.
3. Remove debris from filter housing. Clean
4. Close the filter housing doors. Closed
Remarks
1.
2.
3.
Punch List Items

Item List
1.
2.
3.
CHK 05- 1
Rev 0
30 May 11
APPENDIX 01
CONVERTER
Project Engineer
Location Date
MEN Equipment No.

1. Ensure the type and depth of catalyst are
Correct
correct for each converter pass.
2. Ensure the proper depth of quartz (or
other material, as specified) is installed Sat
above and below each catalyst bed.
3. Ensure all instrumentation, including PX
connections and thermocouples, are
properly installed and operational. Installed
Ensure thermocouples are located at the
catalyst/quartz interface.
4. Ensure the bottom catalyst screen is
Installed
installed.
5. Remove debris from each converter pass.
Make sure to check as much of the Clean
nozzles as possible.
6. Close all converter manways. Closed
7. Ensure all duct valves around the
Installed
converter are installed and operational.
Remarks
1. Catalyst loads are made based on specific catalyst depths which are generally marked
on the inside shell of the converter. If possible, the startup engineer should verify the
marks on the converter prior to loading catalyst.
2.
3.
Punch List Items

Item List
CHK 06- 1
Rev 0
30 May 11
APPENDIX 01
CONVERTER
Project Engineer
Location Date
MEN Equipment No.
1.
2.
3.
CHK 06- 2
Rev 0
30 May 11
APPENDIX 01
HOT INTERPASS HEAT EXCHANGER
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the inlet and outlet tubesheets of
Sat
the heat exchanger.
2. Remove all debris from the inlet and
Clean
outlet vestibules.
3. Ensure all instrumentation in the inlet and
outlet vestibules is installed and Installed
operational.
4. Seal the tube side manways. Closed
5. Inspect the shell side of the heat
Sat
exchanger.
6. Remove all debris from the shell side of
Clean
the heat exchanger.
7. Ensure all instrumentation in the shell
side of the heat exchanger is installed Installed
and operational.
8. Seal the shell side manways. Closed
9. Check the operation of any bypass or
Sat
main duct valves for the heat exchanger.
10. Ensure any shell side or vestibule drains
Installed
are installed and closed or blinded.
11. Ensure drain pot is installed and
Installed
operational, if required.
Remarks
1.
2.
3.
CHK 07- 1
Rev 0
30 May 11
APPENDIX 01
HOT INTERPASS HEAT EXCHANGER
Project Engineer
Location Date
MEN Equipment No.
Punch List Items

Item List
1.
2.
3.
CHK 07- 2
Rev 0
30 May 11
APPENDIX 01
COLD INTERPASS HEAT EXCHANGER
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the inlet and outlet tubesheets of
Sat
the heat exchanger.
2. Remove all debris from the inlet and
Clean
outlet vestibules.
3. Ensure all instrumentation in the inlet and
outlet vestibules is installed and Installed
operational.
4. Seal the tube side manways. Closed
5. Inspect the shell side of the heat
Sat
exchanger.
6. Remove all debris from the shell side of
Clean
the heat exchanger.
7. Ensure all instrumentation in the shell
side of the heat exchanger is installed Installed
and operational.
8. Seal the shell side manways. Closed
9. Check the operation of any bypass or
Sat
main duct valves for the heat exchanger.
10. Ensure any shell side or vestibule drains
Installed
are installed and closed or blinded.
11. Ensure drain pot is installed and
Installed
operational, if required.
Remarks
1.
2.
3.
CHK 08- 1
Rev 0
30 May 11
APPENDIX 01
COLD INTERPASS HEAT EXCHANGER
Project Engineer
Location Date
MEN Equipment No.
Punch List Items

Item List
1.
2.
3.
CHK 08- 2
Rev 0
30 May 11
APPENDIX 01
ECONOMIZER 3B
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the economizer tubes, fins, and
Installed
tubesheet.
Installed
operational.
3. Remove debris from the inlet and outlet
Clean
vestibules.
Closed
manways.
5. Ensure the feedwater bypass is installed
Installed
and operational.
6. Ensure any casing drain valves are Installed
installed and closed.
Closed
7. Ensure water side vent and drain valves Installed
are installed and closed.
Closed
8. Ensure any relief valves are installed,
operational, and have been tested.
Installed
Ensure that the relief valves have not
been blocked shut.
9. Verify that anchors and sliding supports
Installed
are properly installed.
Remarks
1.
2.
3.
CHK 09- 1
Rev 0
30 May 11
APPENDIX 01
ECONOMIZER 3B
Project Engineer
Location Date
MEN Equipment No.
Punch List Items

Item List
1.
2.
3.
CHK 09- 2
Rev 0
30 May 11
APPENDIX 01
HP/IP SUPERHEATER 4A / ECONOMIZER 4C/4A
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the unit tubes, fins, and
Installed
tubesheet.
Installed
operational.
Clean
vestibules.
Closed
manways.
Closed
6. Ensure side vent and drain valves are Installed
Closed
Installed
Ensure that the relief valves have not
been blocked shut.
8. Verify that anchors and sliding supports
Installed
9. Ensure the bypasses are installed and
Installed
operational.
Remarks
1.
2.
3.
CHK 10- 1
Rev 0
30 May 11
APPENDIX 01
HP/IP SUPERHEATER 4A / ECONOMIZER 4C/4A
Project Engineer
Location Date
MEN Equipment No.
Punch List Items

Item List
1.
2.
3.
CHK 10- 2
Rev 0
30 May 11
APPENDIX 01
SUPERHEATER 1B
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the superheater tubes, fins, and
Sat
tubesheet.
Installed
operational.
Clean
vestibules.
Closed
manways.
5. Ensure the gas bypass is installed and
Installed
operational.
Closed
7. Ensure steam side vent and drain valves Installed
are installed and closed.
Closed
Installed
Ensure the relief valve has not been
blocked shut.
9. Verify that the slide plates and supports
Installed
10. Verify that the tie-bars are properly
Installed
installed and the gaps are set.
Remarks
1.
2.
3.
CHK 11- 1
Rev 0
30 May 11
APPENDIX 01
SUPERHEATER 1B
Project Engineer
Location Date
MEN Equipment No.
Punch List Items

Item List
1.
2.
3.
CHK 11- 2
Rev 0
30 May 11
APPENDIX 01
DRYING TOWER
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the chip strainer and vortex
breaker. Ensure that they are correctly Sat
installed.
2. Measure and record the chip strainer
662 mm
height up to the overflow.
3. Inspect brick lining and alloy grids. Sat
4. Inspect the packing from below. Ensure
the proper packing is installed in the Sat
bottom of the tower.
5. Inspect the nozzle(s) and lining(s).
Ensure that all inlet and outlet nozzles are Sat
free of obstructions.
6. Ensure any instrumentation in the bottom
of the tower is properly installed and Installed
operational.
7. Remove brick, mortar, packing chips, and
other debris from the bottom of the tower.
Clean
Sweep the brick on top of the piers for
loose packing chips.
8. Close the lower tower manway, but do not
Closed
bolt completely.
9. Inspect the brick lining at the distributor
Sat
level.
10. Ensure that the distributor hangers are
properly installed, have some load on Sat
them, and all fasteners are tight.
11. Ensure that the spray catcher packing is
Sat
the proper size and depth.
12. Randomly check to ensure that distributor
Sat
wall coverage is adequate.
CHK 12- 1
Rev 0
30 May 11
APPENDIX 01
DRYING TOWER
Project Engineer
Location Date
MEN Equipment No.
13. Ensure that the main packing is the

Sat
proper size and depth.
14. Ensure that the troughs are  1/8” of
level. Check the troughs from end to end, Level
side to side, and with adjacent troughs.
15. Measure and record the distance from the
bottom of the trough to the bottom of the X mm
downcomer slot.
16. Measure and record the distributor gate X mm
heights.
X mm
X mm
17. Measure and record the height from the
spray catcher packing to the bottom of the X mm
trough.
18. Ensure the distributor drain plugs are
Sat
properly installed.
19. Ensure the acid distributor and header
Tight
bolts are tight.
20. Ensure all instrumentation at the
distributor level of the tower is installed Installed
and operational.
21. Ensure the proper of mesh pad is
installed in the tower.
22. For a mesh pad, check to ensure there is
no gap between the mesh pad and the
tower wall or between the mesh pad
Sat
segments. A flashlight may aid in this
check with one person above the mesh
pad and one person below.
23. Ensure the mesh pad is adequately tied
Sat
down.
CHK 12- 2
Rev 0
30 May 11
APPENDIX 01
DRYING TOWER
Project Engineer
Location Date
MEN Equipment No.
24. If the tower contains seal cups, ensure

that they are full. The seal cups should
be checked as close to the startup as
Full
practical. If there is excess delay
between tower inspection and startup, the
seal cups should be rechecked.
25. Ensure all nozzle openings are free of
Sat
obstructions.
26. Close, but do not fully bolt, the distributor
Closed
level manway.
27. For a mesh pad, check the installation
along the walls and between the pad
Sat
segments. Ensure that the holds down
bars are installed.
Remarks
1. Prior to plant startup, the acid distribution must be checked.
2. After approximately 24 hours of acid circulation, the packing chips in the bottom of the
tower should be removed and the chip strainer should be cleaned.
3. Take stick tests starting after 24 hours of operation and several days after that. Suggest
that the client perform routine stick tests (monthly) after that.
Punch List Items

Item List
1.
2.
3.
CHK 12- 3
Rev 0
30 May 11
APPENDIX 01
FINAL ABSORBING TOWER
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the chip strainer and vortex
breaker. Ensure that they are correctly Sat
installed.
2. Measure and record the chip strainer
662 mm
height up to the overflow.
3. Inspect brick lining and alloy grids. Sat
4. Inspect the packing from below. Ensure
the proper packing is installed in the Sat
5. Inspect the nozzle(s) and lining(s).
Ensure that all inlet and outlet nozzles are Sat
free of obstructions.
6. Ensure any instrumentation in the bottom
of the tower is properly installed and Installed
operational.
7. Remove brick, mortar, packing chips, and
other debris from the bottom of the tower.
Clean
Sweep the brick on top of the piers for
loose packing chips.
Closed
bolt completely.
9. Inspect the brick lining at the distributor
Sat
level.
properly installed, have some load on Sat
them, and all fasteners are tight.
11. Ensure that the spray catcher packing is
Sat
the proper size and depth.
12. Randomly check to ensure that distributor
Sat
CHK 13- 1
Rev 0
30 May 11
APPENDIX 01
Project Engineer
Location Date
MEN Equipment No.
13. Ensure that the main packing is the

Sat
14. Ensure that the troughs are  1/8” of
level. Check the troughs from end to end, Level
side to side, and with adjacent troughs.
bottom of the trough to the bottom of the X mm
downcomer slot.
16. Measure and record the distributor gate X mm
heights.
X mm
X mm
spray catcher packing to the bottom of the X mm
trough.
18. Ensure the distributor drain plugs are
Sat
properly installed.
19. Ensure the acid distributor and header
Tight
bolts are tight.
20. Ensure all instrumentation at the
distributor level of the tower is installed Installed
and operational.
21. Ensure the proper type and number of
mist eliminators are installed in the tower.
22. Check the bottom of the mist eliminators. Sat
23. Ensure the mesh pad is adequately tied
Sat
down.
24. For mist eliminator elements, ensure the
mist eliminator drains and tube sheet
Sat
drains are properly terminated, either in
seal cups or in the troughs.
CHK 13- 2
Rev 0
30 May 11
APPENDIX 01
Project Engineer
Location Date
MEN Equipment No.
25. If the tower contains seal cups, ensure

that they are full. The seal cups should
be checked as close to the startup as
Full
practical. If there is excess delay
between tower inspection and startup, the
seal cups should be rechecked.
Sat
obstructions.
27. Remove all debris from the mist
Clean
eliminator level of the tower.
28. Close, but do not fully bolt, the distributor
Closed
level manway.
29. At the mist eliminator level, inspect the
mist eliminator installation. Ensure that Sat
the hold down bars are installed.
30. At the mist eliminator level, inspect the
mist eliminator installation. Ensure that Installed
all gaskets are installed correctly.
31. Ensure all mist eliminator bolts are tight. Tight
Sat
obstructions.
33. Ensure all instrumentation at the mist
eliminator level is installed and
Installed
operational, including any test ports
located in the outlet duct.
34. Remove all debris from the mist
eliminator level. For hang down mist
Clean
eliminators, take special care to check
down inside the mist eliminator.
35. Close the mist eliminator level manway. Closed
CHK 13- 3
Rev 0
30 May 11
APPENDIX 01
Project Engineer
Location Date
MEN Equipment No.
Remarks
Punch List Items

Item List
1.
2.
3.
CHK 13- 4
Rev 0
30 May 11
APPENDIX 01
COMBINATION PUMP TANK
Project Engineer
Location Date
MEN Equipment No.

1. Check the installation of the dilution water
line. Ensure the required check valve is
Sat
in the system and is in the proper
direction.
2. Ensure the acid pump motor power
cables are properly terminated. Ensure
Sat
the motors are properly grounded. Verify
correct motor rotation.
3. Ensure the acid pump(s) and motor(s) are
Coupled
coupled.
4. Ensure any recirculation, instrument loop,
or dilution water orifices are the proper Sat
size.
5. Ensure all sleeves are installed correctly,
Sat
and are the proper length and material.
6. Inspect the acid brick and mortar. Sat
7. Ensure splash pads are installed in the
Sat
proper locations.
8. Check the installation of the level
transmitter. If instrument air is available, Sat
ensure air is coming out of bubbler tube.
9. Ensure the acid pumps are free to rotate. Sat
10. Ensure the pump tank overflows, vents,
Clean
and drains are free of obstructions.
11. Ensure all pump tank nozzles are free of
Clean
obstructions.
12. Ensure the dilution water sparger
Sat
orientation is correct.
13. Ensure all pump tank instrumentation is
Installed
properly installed and operational.
CHK 14- 1
Rev 0
30 May 11
APPENDIX 01
COMBINATION PUMP TANK
Project Engineer
Location Date
MEN Equipment No.
14. Remove all debris from the bottom of the

Clean
pump tank.
Remarks
1.
2.
3.
Punch List Items

Item List
1.
2.
3.
CHK 14- 2
Rev 0
30 May 11
APPENDIX 01
PLANT STACK
Project Engineer
Location Date
MEN Equipment No.

1. Ensure instrumentation in the stack is
Installed
2. Remove any debris in the stack above the
Clean
false bottom.
3. Ensure drain valves are installed, if
Installed
required.
4. Close any stack manways. Closed
Remarks
1.
2.
3.
Punch List Items

Item List
1.
2.
3.
CHK 15- 1
Rev 0
30 May 11
APPENDIX 01
DT ACID COOLERS
Project Engineer
Location Date
MEN Equipment No.

1. Generally AP Shell and tube heat
exchangers are commissioned by a
vendor representative. Verify that the Complete
vendor has completed any required pre-
startup checks, if required.
2. Ensure all shell or tube side drains are
Installed
installed and shut.
3. Ensure all instrumentation is installed and
Installed
operational.
4. Inspect sliding support anchors for proper
Sat
installation.
5. Ensure that all water has been drained
Drained
from the acid side of the cooler.
6. Make sure any shipping gaskets have
Sat
been replaced with the proper material.
7. Inspect and clean the inlet and outlet
Clean
water boxes.
Remarks
1.
2.
3.
Punch List Items
Item List
1.
2.
CHK 16- 1
Rev 0
30 May 11
APPENDIX 01
PRODUCT ACID COOLER
Project Engineer
Location Date
MEN Equipment No.

1. Generally AP Shell and tube heat
exchangers are commissioned by a vendor
representative. Verify that the vendor has Complete
completed any required pre-startup checks,
if required.
Installed
installed and shut.
Installed
operational.
Sat
installation.
5. Ensure that all water has been drained from
Drained
the acid side of the cooler.
6. Make sure any shipping gaskets have been
Sat
replaced with the proper material.
7. Inspect and clean the inlet and outlet water
Clean
boxes.
Remarks
1.
2.
3.
Punch List Items
Item Added to Master Punch List
1.
2.
CHK 17- 1
Rev 0
30 May 11
APPENDIX 01
DT ACID CIRCULATING PUMP
Project Engineer
Location Date
MEN Equipment No.

1. Ensure that the pump motor power cables
are properly terminated. Verify correct Sat
motor rotation.
2. Ensure that the pump is grounded. Sat
Installed
operational.
4. Ensure that the pump and motor are
Coupled
coupled, and that the pump rotates freely.
5. Ensure all pipe connections are complete
and tight, including seal water and drain Complete
piping.
Sat
properly anchored.
Remarks
1.
2.
3.
Punch List Items

Item List
1.
2.
CHK 18- 1
Rev 0
30 May 11
APPENDIX 01
FAT ACID CIRCULATING PUMP
Project Engineer
Location Date
MEN Equipment No.

motor rotation.
Installed
operational.
Coupled
piping.
Sat
properly anchored.
Remarks
1.
2.
3.
Punch List Items

Item List
1.
2.
CHK 19- 1
Rev 0
30 May 11
APPENDIX 01
ACID DRAIN PUMP
Project Engineer
Location Date
MEN Equipment No.

motor rotation.-
Installed
operational.
Coupled
piping.
Sat
properly anchored.
Remarks
1.
2.
3.
Punch List Items

Item List
1.
2.
CHK 20- 1
Rev 0
30 May 11
APPENDIX 01
DEAERATOR
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the water storage section of the
deaerator. Remove all construction Clean
debris.
2. Ensure all inlet and outlet nozzles are free
Clean
of obstructions.
3. Ensure all trays are properly installed. Installed
4. Ensure spray nozzles are properly
Installed
installed and oriented.
5. Ensure the steam vent is free of Clean
obstructions and verify the orifice is the
correct size. Correct
6. Ensure any required relief valves are

installed, operational, and have been
Installed
tested. Ensure the valves are not blocked
shut.
7. Ensure the vacuum breaker is correctly
Installed
installed.
8. Ensure that all deaerator instrumentation
Installed
is installed and operational.
9. Ensure that the chemical feed pipe is
installed and supported in the storage Installed
tank.
10. Close all deaerator manways and
Closed
inspection ports.
Remarks
1.
2.
CHK 21- 1
Rev 0
30 May 11
APPENDIX 01
DEAERATOR
Project Engineer
Location Date
MEN Equipment No.
3.
Punch List Items

Item List
1.
2.
3.
CHK 21- 2
Rev 0
30 May 11
APPENDIX 01
PRESSURIZED BOILER BLOWDOWN FLASH TANK
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the interior of the tank. Remove all
Clean
debris.
2. Ensure all inlet and outlet nozzles are free of
Clean
obstructions.
3. Ensure all instrumentation and controls for
the blowdown tank are installed and Installed
operational.
4. Ensure the tank is insulated as required. Insulated
5. Verify that all required relief valves are
installed, operational, and have been tested. Installed
Ensure that the valves are not blocked shut.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 22- 1
Rev 0
30 May 11
APPENDIX 01
ATMOSPHERIC BOILER BLOWDOWN TANK
Project Engineer
Location Date
MEN Equipment No.

Clean
debris.
Clean
obstructions.
operational.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 23- 1
Rev 0
30 May 11
APPENDIX 01
HP BOILER FEEDWATER PUMP
Project Engineer
Location Date
MEN Equipment No.

Sat
are properly terminated.
2. Ensure that the pumps are grounded. Sat
Installed
operational.
4. Ensure that the pumps and motors are
Coupled
coupled, and that the pumps rotate freely.
and tight, including cooling water, seal Complete
water, and drain piping.
6. Ensure cooling water and seal water are
Available
available.
Sat
properly anchored.
8. Ensure any required startup strainers are
Installed
installed in the suction piping.
9. Ensure that the automatic recirculation
valves and piping are installed and Installed
operational.
10. Ensure that the warm-up line orifice is
Installed
installed.
Remarks
1.
2.
3.
CHK 24- 1
Rev 0
30 May 11
APPENDIX 01
HP BOILER FEEDWATER PUMP
Project Engineer
Location Date
MEN Equipment No.
Punch List Items

Item List
1.
2.
3.
CHK 24- 2
Rev 0
30 May 11
APPENDIX 01
SULFUR FEED PUMP
Project Engineer
Location Date
MEN Equipment No.

motor rotation.
Installed
operational.
Coupled
piping.
Sat
properly anchored.
Remarks
1.
2.
3.
Punch List Items

Item List
1.
2.
3.
CHK 25- 1
Rev 0
30 May 11
APPENDIX 01
GAS DUCTS
Project Engineer
Location Date
MEN Equipment No.

1. Ensure all gas ducts are installed in the
Sat
correct location in the process.
2. Ensure all duct instrumentation is installed Sat
and operational.
3. Ensure the correct insulation thickness is
Sat
installed on all ducts.
4. Ensure all duct supports are properly
Sat
installed.
5. Remove all debris from the ducts. Clean
6. Set all blinds and valves for startup
Positioned
conditions.
Remarks
1.
2.
3.
Punch List Items
Item List
CHK 26- 1
Rev 0
30 May 11
APPENDIX 01
ACID PIPING
Project Engineer
Location Date
MEN Equipment No.

1. Check acid pipe routing against the P&ID’s.
Ensure all piping is installed, and that it is the
Sat
correct size. Verify all orifice sizes are
correct.
2. Ensure gaskets are installed in all flange
connections, and that all flange connections Sat
are tight.
3. Ensure all acid piping instrumentation is
Installed
4. Ensure all required valves are installed.
Ensure there are no obstructions blocking Installed
valve operation.
5. Verify all valves are in the proper position for
Sat
startup.
6. Ensure all flange covers are installed. Installed
7. Verify all control valves are operational.
Verify their position indicators are properly Sat
aligned.
8. Ensure required piping supports are
Installed
installed.
9. Ensure the baskets are installed in in-line
Installed
acid strainers, if required.
10. Drain water from the acid lines. Blow lines
Complete
with compressed air as required.
CHK 27- 1
Rev 0
30 May 11
APPENDIX 01
ACID PIPING
Project Engineer
Location Date
MEN Equipment No.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 27- 2
Rev 0
30 May 11
APPENDIX 01
UTILITY PIPING
Project Engineer
Location Date
MEN Equipment No.

1. Check pipe routing against the P&ID’s.
Ensure all piping is installed, and that it is the
Sat
correct size. Verify all orifice sizes are
correct.
are tight.
3. Ensure all piping instrumentation is installed
Installed
and operational.
valve operation.
Sat
startup.
6. Ensure all flange covers are installed. Installed
aligned.
Installed
installed.
9. Ensure baskets are installed in any in-line
Installed
strainers, if required.
10. Ensure the lines have been flushed as
Complete
required to remove construction debris.
11. Ensure heat tracing and insulation are
Installed
installed and operational, if required.
Remarks
1. Utility piping covers all piping in the plant not covered by a separate checklist. The systems
may include: plant air, plant water, fire protection, potable water, fuel lines, etc.
CHK 28- 1
Rev 0
30 May 11
APPENDIX 01
UTILITY PIPING
Project Engineer
Location Date
MEN Equipment No.
2.
3.
Punch List Items

Item List
CHK 28- 2
Rev 0
30 May 11
APPENDIX 01
STEAM AND BFW PIPING
Project Engineer
Location Date
MEN Equipment No.

1. Check steam and BFW pipe routing against
the P&ID’s. Ensure all piping is installed,
Sat
and that it is the correct size. Verify all
orifice sizes are correct.
are tight.
3. Ensure all steam and BFW piping
Installed
instrumentation is installed and operational.
valve operation.
Sat
startup.
6. Verify all required relief valves are installed,
operational, and have been tested. Ensure Installed
the valves are not blocked shut.
aligned.
8. Ensure that all desuperheaters are installed
Sat
with the correct orientation.
Installed
installed.
10. Ensure baskets are installed in any in-line
Installed
strainers, if required.
11. Ensure heat tracing and insulation are
Installed
installed and operational, if required.
12. Ensure all lines are clean. Complete steam
Complete
blows, if required.
13. Ensure that the BFW line to the waste heat
Sat
boiler slopes up.
CHK 29- 1
Rev 0
30 May 11
APPENDIX 01
STEAM AND BFW PIPING
Project Engineer
Location Date
MEN Equipment No.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 29- 2
Rev 0
30 May 11
APPENDIX 01
INSTRUMENTATION
Project Engineer
Location Date
MEN Equipment No.

1. Generally, instrumentation loop checks are
completed by the instrument engineer.
Complete
Assist in the completion of the instrument
loop checks.
2. Review the instrument list. Ensure any
instrumentation that may have been missed
Installed
in the other checklists is installed and
operational.
3. Ensure the DCS displays accurately
Sat
represent the process.
4. Check to make sure the HRS acid analyzers
have been configured with MECS special Sat
procedures.
5. Verify that the client has a laboratory
conductivity meter and cell with a constant of Sat
K=10 for use in acid plant control room.
Remarks
1. Instrumentation checks are included with each individual equipment check list. This check
list is intended to encompass any that may have been missed as well as any
instrumentation tie-ins between separate systems.
2.
Punch List Items
Item List
CHK 30- 1
Rev 0
30 May 11
APPENDIX 01
HEAT RECOVERY TOWER AND PUMP BOOT
Project Engineer
Location Date
Equipment No.

1. Ensure the strainers for the pump boot and
Sat
the HRS drain pump suction are installed.
2. Inspect the tower shell. Ensure any weld
burns are removed.
3. Inspect the first stage packing from below.
Ensure the proper packing is installed in the Sat
4. Inspect the nozzle(s) and lining(s). Ensure
that all inlet and outlet nozzles are free of Sat
obstructions.
5. Ensure all instrumentation in the bottom of
Installed
the tower is installed and operational.
6. Inspect the HRS pump boot shell. Ensure
Sat
that all weld burns are removed.
7. Ensure the HRS pump is free to rotate by
Free
hand.
8. Ensure all nozzles in the pump boot are free
Sat
of obstructions.
9. Ensure all instrumentation in the pump boot
Installed
is installed and operational.
10. Remove packing chips and other debris from
Clean
the bottom of the tower and pump boot.
Closed
bolt completely.
12. Inspect the tower shell at the first stage
distributor level. Ensure any weld burns are Sat
removed.
properly installed, have some load on them, Sat
and all fasteners are tight.
CHK 31- 1
Rev 0
30 May 11
APPENDIX 01
Project Engineer
Location Date
Equipment No.
14. Check to ensure that first stage distributor

Sat
15. Ensure that the spray catcher packing is the
Sat
16. Ensure that the troughs are  1/8” of level.
Check the troughs from end to end, side to Level
side, and with adjacent troughs.
17. Observe and record the first stage distributor 13 mm
gate heights.
19 mm
13 mm
spray catcher packing to the bottom of the 100 mm
second stage trough.
19. Ensure the first stage distributor drain plugs
Sat
20. Ensure the first stage acid distributor and
Tight
header bolts are tight.
21. Ensure all instrumentation at the first stage
distributor level of the tower is installed and Installed
operational.
Sat
obstructions.
23. Remove all debris from the first stage
Clean
distributor level of the tower.
24. Close, but do not fully bolt, the first stage
Closed
distributor level manway.
25. Check that the stick test port is properly
Sat
installed and accessible from the platform.
26. Inspect the tower shell at the second stage
distributor level. Ensure any weld burns are Sat
removed.
CHK 31- 2
Rev 0
30 May 11
APPENDIX 01
Project Engineer
Location Date
Equipment No.
27. Ensure that the second stage distributor

hangers are properly installed, have some Sat
load on them, and all fasteners are tight.
28. Ensure that the second stage downcomers
are buried approximately 200 mm in the 200 mm
spray catcher packing.
29. Check to ensure that second stage
Sat
distributor wall coverage is adequate.
30. Ensure that the second stage packing is the 100 mm #1
proper size and depth. Super
intalox
31. Ensure that the troughs are  1/8” of level.
Check the troughs from end to end, side to Level
side, and with adjacent troughs.
bottom of the trough to the bottom of the 263 mm
downcomer slot.
33. Observe and record the second stage 33 mm
distributor orifice sizes. 39 mm
33 mm
34. Ensure the second stage distributor drain
Sat
plugs are properly installed.
35. Ensure the second stage acid distributor and
Tight
header bolts are tight.
36. Ensure the proper type and number of mist 28 EFF
eliminators are installed in the tower. ES212 G18
37. Ensure the mist eliminator drains and tube
sheet drains are properly terminated in the Sat
troughs.
Sat
obstructions.
CHK 31- 3
Rev 0
30 May 11
APPENDIX 01
Project Engineer
Location Date
Equipment No.
39. Ensure all instrumentation at the second

stage distributor level is properly installed Installed
and operational.
40. Remove all debris from the second stage
Clean
distributor level of the tower.
41. Close, but do not fully bolt, the second stage
Closed
distributor level manway.
42. At the mist eliminator level, inspect the mist
eliminator installation. Ensure that all Installed
gaskets are installed correctly.
43. Ensure all mist eliminator bolts are tight. Tight
Sat
obstructions.
45. Ensure all instrumentation at the mist
eliminator level is installed and operational,
Installed
including any test ports located in the outlet
duct.
46. Remove all debris from the mist eliminator
level. For hang down mist eliminators, take
Clean
special care to check down inside the mist
eliminator.
47. Close the mist eliminator level manway. Closed
48. Check that the stick test port is properly
Sat
installed and accessible from the platform.
Remarks
CHK 31- 4
Rev 0
30 May 11
APPENDIX 01
Project Engineer
Location Date
Equipment No.
Punch List Items

Item List
CHK 31- 5
Rev 0
30 May 11
APPENDIX 01
HRS ACID DILUTER
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the diluter foundation. Ensure there
is a 50 – 75 mm gap between the bottom of
Sat
the horizontal guide saddles and the top of
the foundation to allow for expansion.
2. Ensure that the vertical guide supports are in
Sat
place to minimize diluter vibration.
3. Ensure the dilution water piping is routed in a
Sat
manner to facilitate diluter removal.
4. Check that the correct gaskets are installed
on the vertical barrel. Ensure that the Teflon
Sat
liner is in place and sealed between the
flanges.
5. Ensure that the sparger orientation is
Sat
correct.
6. Check the flow direction on all check valves
Correct
to the diluter.
7. Ensure that weep holes fully penetrate the
steel shell.
8. Ensure that the weep hole drains are routed
Sat
away from equipment and personnel.
9. Check the inlet dilution water piping to permit
Sat
removal of the sparger.
10. Check the piping, flow restriction orifices and
valves for the acid concentration analyzer
Installed
and corrosion monitor at the outlet of the
diluter.
11. Close the sparger air block valve at the inlet
to the diluter. Close the sparger air manual
flow control valve. Blow the sparger air line Clean
through the drain on the inlet strainer, and
when it blows clean, close the drain.
CHK 32- 1
Rev 0
30 May 11
APPENDIX 01
HRS ACID DILUTER
Project Engineer
Location Date
MEN Equipment No.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 32- 2
Rev 0
30 May 11
APPENDIX 01
HRS ACID CIRCULATING PUMP
Project Engineer
Location Date
MEN Equipment No.

Sat
Installed
operational.
Coupled
Complete
and tight.
6. Ensure that the pump and motor are properly
Sat
anchored.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 33- 1
Rev 0
30 May 11
APPENDIX 01
HRS ACID DRAIN PUMP
Project Engineer
Location Date
MEN Equipment No.

Sat
321-124 Installed
operational.
Coupled
Complete
and tight.
6. Ensure that the pump and motor are properly
Sat
anchored.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 34- 1
Rev 0
30 May 11
APPENDIX 01
HRS BOILER
Project Engineer
Location Date
MEN Equipment No.

1. Inspect the shell side of the boiler and the
steam purifier. Remove any debris. Close Clean
the shell side and purifier manways.
2. Inspect the acid inlet and outlet; remove any
debris. Close the acid inlet and outlet Clean
inspection ports.
3. Ensure all required relief valves are installed,
operational, and have been tested. Check Installed
that the valves are not blocked shut.
4. Verify that the anchors and sliding supports
Sat
5. Ensure all instrumentation is properly
Installed
6. Ensure the BFW inlet and steam outlet
check valves are installed in the proper Sat
direction.
7. Check for obstructions in the tube pulling
Sat
space.
8. Check the accessibility to the intermittent
Sat
blowdown valves/
9. Check the operability of all block valves. Sat
10. Ensure that all water is drained from the acid
Sat
inlet line.
11. Check the clearances so that the boiler can
grow in both directions (from fixed support) Sat
when in operation.
12. Check the piping, flow restriction orifices,
and valves for the corrosion monitor at the Sat
outlet of the HRS boiler.
CHK 35- 1
Rev 0
30 May 11
APPENDIX 01
HRS BOILER
Project Engineer
Location Date
MEN Equipment No.
13. Check gasket installation and make sure any

shipping gaskets are replaced with the Sat
proper material.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 35- 2
Rev 0
30 May 11
APPENDIX 01
HRS HEATER
Project Engineer
Location Date
MEN Equipment No.

Installed
installed and shut.
Installed
operational.
Sat
installation.
Drained
Sat
Clean
boxes.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 36- 1
Rev 0
30 May 11
APPENDIX 01
HRS PREHEATER
Project Engineer
Location Date
MEN Equipment No.

Installed
installed and shut.
Installed
operational.
Sat
installation.
Drained
Sat
Clean
boxes.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 37- 1
Rev 0
30 May 11
APPENDIX 01
HRS BLOWDOWN TANK
Project Engineer
Location Date
MEN Equipment No.

Clean
debris.
Clean
obstructions.
operational.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 38- 1
Rev 0
30 May 11
APPENDIX 01
HRS BOILER FEEDWATER PUMP
Project Engineer
Location Date
MEN Equipment No.

Sat
2. Ensure that the pumps are grounded. Sat
Installed
operational.
4. Ensure that the pumps and motors are
Coupled
coupled, and that the pumps rotate freely.
and tight, including cooling water, seal Complete
water, and drain piping.
6. Ensure cooling water and seal water are
Available
available.
Sat
properly anchored.
8. Ensure any required startup strainers are
Installed
installed in the suction piping.
9. Ensure that the automatic recirculation
valves and piping are installed and Installed
operational.
10. Ensure that the warm-up line orifice is
Installed
installed.
Remarks
1.
2.
3.
CHK 39- 1
Rev 0
30 May 11
APPENDIX 01
HRS BOILER FEEDWATER PUMP
Project Engineer
Location Date
MEN Equipment No.
Punch List Items

Item List
1.
2.
3.
CHK 39- 2
Rev 0
30 May 11
APPENDIX 01
INTERLOCKS
Project Engineer
Location Date
MEN Equipment No.

1. Verify that all interlocks are operating
Sat
properly.
2. Verify that all bypasses that will be required
Installed
for startup have been installed.
Remarks
1.
2.
3.
Punch List Items

Item List
CHK 40- 1
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING
1. TROUBLESHOOTING GUIDE - SB
The instructions and actions given in the following table should only be used as a guideline for checking alarms and trips
within the acid plant. It does not cover every possible cause for the alarms and trips listed.
SYMPTOM INDICATION POSSIBLE CAUSE ACTION

Sulfur Sublimation 1. Milky acid. Insufficient oxygen: 1. Increase main compressor flow.
2. Change in plant pressure a. Low air flow. 2. If too severe, plant must be shut
drop. b. Sulfur flow change. down to clean system.
3. Sulfur furnace temperature c. Instrument malfunction. 3. Gas chromatography or Orsat
high-high. d. Shutdown with sulfur still in analysis to check O2.
burner. 4. Inspect sulfur burner regularly for
sulfur accumulation.
Loss of Strength in Strong Acid Acid analysis (instrument or 1. Boiler, economizer, or 1. Shut down plant and check for
laboratory) superheater leak. leaks and pluggage.
2. Malfunction in drying tower. 2. Check dilution valve and controller.
3. Malfunction in dilution water
system.
Steam Equipment Leaks 1. Loss of steam pressure. 1. Low water level causing 1. Shut down plant immediately.
2. Fluctuations in boiler water overheating. 2. Close steam valve on drum.
level. 2. Tower inlet gas temperatures 3. Drain water from steaming
3. Bad stack. too low (drip acid formation). equipment.
4. High superheated steam 3. Poor water treatment. 4. Maintain water level in boiler if
temperature. possible.
5. High level alarm in economizer 5. Locate leak and repair.
3B catchpot.
Low SO2 Concentration 1. Low temperature at burner 1. Poor sulfur atomization. 1. Shut down to check burner gun
exit. 2. Plugged sulfur guns. tips and instrumentation.
2. Poor converter reaction. 3. Compressor flow too high. 2. Verify gas concentrations by Orsat
3. Acid milky and strength 4. Low sulfur flow (plugged line, analysis or gas chromatography.
decreases. pump malfunction). 3. Adjust O2 and SO2 in gas steam to
5. Same causes as sulfur proper specs:
sublimation. - increase sulfur burning
- decrease compressor flow
4. Check sulfur line and pump.
This operating manual is the property of MECS, Inc. Information and know-how herein are confidential and proprietary and may not be used, reproduced, or revealed to others except in accordance with the terms of a contract with or other
written permission of MECS, Inc.
TRB 01 - 1
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

High SO2 Concentration 1. High temperature at burner 1. High sulfur rate. 1. Decrease sulfur rate and increase
exit. 2. Low compressor flow. compressor flow.
2. High stack emissions. 3. Air filter plugged. 2. Check air filter.
3. Poor converter reaction. 3. Check instrumentation.
Poor Converter Reaction 1. Inadequate temperature rise in 1. High or low SO2 concentration. 1. Confirm gas analysis by Orsat or
converter. 2. Low O2 concentration. gas chromatography.
2. High stack emissions. 3. Low converter passes inlet 2. Correct operating conditions so
temperatures. %SO2 and %O2 are in specs.
3. Preheat converter in startup to
approximately 450°C inlet to 1st
pass and 425°C to all other
passes.
Poor Stack Opacity 1. Visible plume. 1. Acid concentration or 1. Check acid flow through analyzers
2. High SO2. temperature. and immediately correct acid
3. High NO2. 2. Acid flow to final absorption concentration.
4. High or low 98.5% acid tower. 2. Check circulating rate of final
strength. 3. Excessive mist or poor mist absorption tower acid. Check the
5. High acid temperature to final eliminator efficiency. pump for vibration. If the pump is
absorption tower. 4. Poor converter operation. bad, shut down and replace it.
6. Low acid temperature to final 5. Excessive sulfur burner 3. Check the mist eliminator seals,
absorption tower. temperature. fiber, and gaskets (plant down).
6. High ash content in sulfur. 4. Correct temperatures in the
converter to get optimum
conversion.
5. Check acid cooler operation.
6. Check dilution water control valve.
7. Check composition of sulfur.
High Main Compressor Discharge Main compressor discharge 1. Blockage in catalyst. 1. Take pressure survey to determine
Pressure pressure indicator. 2. Main line damper closed. blockage point.
3. Tower blockage such as 2. Adjust main compressor flow to
frozen acid or mist eliminator lower air flow.
blockage. 3. Check all main line damper
4. High main compressor flow. positions.
5. Sulfur sublimation/MME 4. See above item regarding
pluggage. sublimation.
TRB 01 - 2
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

Gas Heat Exchanger Leaks 1. High SO2 in stack gas. Leaks in hot or cold interpass heat 1. PeGASyS to analyze leaks.
2. Temperature change in exchanger tubes. 2. Shut down to plug leaking tubes.
converter layers.
3. Inability to maintain 98.5%
acid concentration.
Malfunction of SO2 Stack Analyzer 1. Sudden change in reading. 1. Improper sample to analyzer. 1. Check sample flow and correct
2. Drift in reading. 2. Electrical problem. immediately.
3. Straight line recording. 3. Plugged sample line. 2. Check reading with gas
4. Analyzer is performing “auto- chromatography or Orsat analysis.
calibration” function. 3. Check converter temperature rise
to judge SO2 level.
Drip Acid in Economizer 4A 1. Low temperature to final 1. Economizer in clean condition 1. Open economizer 4A bypass and
absorption tower. (high heat transfer). close economizer 4A line valve to
2. Low water temperature to 2. Plant at reduced rate. force water through bypass.
economizer. 3. Low BFW temperature. 2. Check deaerator operation.
3. Poor stack opacity.
Drip Acid in Economizer 3B 1. Low temperature to interpass 1. Economizer in clean condition 1. Open economizer 3B bypass and
absorption /HRS tower. (high heat transfer). close economizer 3B line valve to
2. Low water temperature to 2. Plant at reduced rate. force water through bypass.
economizer. 2. Close economizer 4A bypass.
Steam Hammer at Outlet of 1. High water temperature. 1. Economizer in clean condition 1. Close economizer 3B bypass and
Economizer 3B 2. Pipe vibration. (high heat transfer). open its main line valve.
2. Plant at reduced rate. 2. Open economizer 4A bypass.
3. Economizer bypass open. 3. Increase plant rate.
Acid Condensing in Waste Heat 1. Steam temperature below 1. Sulfur burner outlet 1. Raise burner temperature to
Boiler 255 °C. temperature too low. 1,100 °C.
2. Gas temperature leaving 2. Boiler operating pressure too 2. Shut down if not immediately
boiler too low. low. corrected.
3. Condensation in boiler gas 3. Boiler leak.
exit vestibule (check drain).
Waste Heat Boiler Supply Water 1. Low level in boiler. 1. BFW pump failure. 1. Check operation of spare BFW
Failure 2. Low water supply pressure. 2. Instrument or valve pump.
malfunction. 2. Shut down immediately.
3. Check instrumentation and valve
functions.
TRB 01 - 3
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

Acid Cooler Leaks High cooling water conductivity. Leaks in acid coolers. Shut down to repair leak on cooler.
Oxygen Deficiency 1. Low % SO2 outlet sulfur 1. Poor sulfur atomization 1. Shut down to check tips and
burner. 2. Same causes as sulfur instruments
2. Low or high % SO2 to sublimation. 2. Verify all gas concentrations by
converter 3. Plugged sulfur guns. Orsat/ Reich analysis.
3. Low % O2. 3. Adjust oxygen and SO2 in gas
4. Acid milky and strength stream to proper specs (sulfur
decreases. furnace temperature)
5. Possible minor explosion or 4. Increase the compressor flow to put
fire when air enters system; more oxygen in converter
e.g. air inlet. 5. Converter temperature
6. Poor converter reaction.
TRB 01 - 4
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING
2. TYPICAL ALARM AND ACTION GUIDELINES - SB
The set points given below are typical and may not be exact for your plant.
The table below includes typical instrument and limit switches with either an alarm or interlock trip in the DCS associated with
its output. The values in your plant may vary slightly. Consult the detailed instrument list and material balance.
SETPOINT DESCRIPTION CAUSE ACTION

1. Fouled catalyst.
1. Check catalyst pressure drop and
2. Improper converter
screen.
temperatures.
Design -5 2. Check converter temperature and
High Stack SO2 Concentration 3. High SO2 concentration.
ppm optimize.
4. High gas flow / plant rate.
3. Lower gas strength and plant rate.
5. Transmitter or analyzer
4. Check instrument operation.
malfunction.
Design +5
High-High Stack SO2 Concentration See previous. See previous.
ppm
Design -0.5
Low Stack O2 Concentration See previous. See previous.
%O2
Design -1
Low-Low Stack O2 Concentration See previous. See previous.
%O2
1. Dilution water system 1. Check dilution water control valves.
malfunctions. 2. Verify acid concentration in
98.9% H2SO4 High Towers Acid Concentration
2. Transmitter or analyzer laboratory. Check analyzer
malfunction. function.
High-High Towers Acid
99.2% H2SO4 See previous. See previous.
Concentration
TRB 01 - 5
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

1. Check operation of drying tower
1. Drying tower malfunction.
and mesh pad.
2. Dilution water system
2. Check dilution water control valves.
98.0% H2SO4 Low Towers Acid Concentration malfunction.
3. Verify acid concentration in
3. Transmitter or analyzer
laboratory. Check analyzer
malfunction.
function.
1. See previous.
97.0% H2SO4 Low-Low Towers Acid Concentration See previous. 2. Dilution water system interlocked to
stop flow.
1. Acid cooler leak.
High Product Cooler Cooling Water Shut down and check acid coolers for
By Detail 2. Poor control of chemical
Return Conductivity leaks.
addition.
High-High Product Cooler Cooling
By Detail See previous. See previous.
Water Return Conductivity
1. Acid cooler leak.
High Common Cooler Cooling Water Shut down and check acid coolers for
By Detail 2. Poor control of chemical
Return Conductivity leaks.
addition.
High-High Common Cooler Cooling
Water Return Conductivity
1. BFW preheater acid leak. 1. Verify inlet and outlet water
High BFW Preheater Outlet Water 2. Poor water quality. conductivity at preheater.
3 S/cm
Conductivity 3. Transmitter or analyzer 2. Bypass preheater and check for
malfunction. leaks.
1. See previous.
High-High BFW Preheater Outlet 2. BFW preheater interlocked to be
5 S/cm See previous.
Water Conductivity bypassed on both acid and water
sides.
Common Acid Coolers Anodic
N/A See Cooler operating manual. See Cooler operating manual.
Protection Fault
Final Acid Cooler Anodic Protection
N/A See Cooler operating manual. See Cooler operating manual.
Fault
TRB 01 - 6
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

1. Check piping system for leaks.
1. Pipeline leak.
2. Check / clean coolers and acid lines
2. Plugged acid cooler or line.
for blockage.
3. Drain line open.
90% Design Low Drying Tower Acid Flow 3. Close acid drain valves.
4. High flow to interpass tower.
4. Check flow to interpass tower.
5. Throttling valve not sufficiently
5. Adjust throttling valve for correct
open.
flow.
Interpass Tower Acid Flow Interlock
N/A Startup bypass use only. None.
Bypass Alarm
1. Pipeline leak.
for blockage.
3. Drain line open.
85% Design Low Interpass Tower Acid Flow 3. Close acid drain valves.
4. High flow to drying tower.
4. Check flow to drying tower.
open.
flow.
1. See previous.
55% Design Low-Low Interpass Tower Acid Flow See previous. 2. Main compressor interlocked to
shut down.
Final Tower Acid Flow Interlock
N/A Startup bypass use only. None.
Bypass Alarm
1. Pipeline leak.
for blockage.
90% Design Low Final Tower Acid Flow 3. Drain line open.
3. Close acid drain valves.
open.
flow.
1. See previous.
85% Design Low-Low Final Tower Acid Flow See previous. 2. Main compressor interlocked to
shut down.
105% Design High Final Tower Acid Flow Controller tuning or malfunction. Check flow controller operation.
110% Design High-High Final Tower Acid Flow Controller tuning or malfunction. Check flow controller operation.
TRB 01 - 7
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

1. Malfunction in BFW supply from
1. Check BFW supply with Owner.
Owner.
2. Check BFW lines for blockage.
Low Boiler Feedwater Flow to 2. Blockage in line.
25% Design 3. Increase plant rate.
Economizers 3. Plant turndown.
4. Check boiler level and controller
4. Waste heat boiler level
operation.
controller malfunction.
Normal +5% High Acid Pump Tank Level Level valve malfunction. Check level controller operation.
Normal x2.75 High-High Acid Pump Tank Level See previous. See previous.
1. Acid system leak. 1. Check acid system for leaks.
2. Drain line open. 2. Close drain valves.
Normal -5% Low Acid Pump Tank Level 3. Level valve malfunction. 3. Check level controller operation.
4. Plugged packing or strainer in 4. Drain pump tank first. Check tower
acid towers (excess hold-up). strainers and packing for pluggage.
Normal -10% Low-Low Acid Pump Tank Level See previous. See previous.
1. Level controller malfunction. 1. Check level controller operation.
By Detail High Waste Heat Boiler Level
2. Instrument malfunction. 2. Verify level with local indicator.
By Detail High-High Waste Heat Boiler Level See previous. See previous.
1. Check blowdown valve position.
1. Blowdown valve open.
2. Check boiler for leaks (gas
2. Boiler leak.
dewpoint).
3. High sulfur burner outlet
By Detail Low Waste Heat Boiler Level 3. Reduce plant rate or SO2 gas
temperature (high heat duty).
concentration.
4. Instrument malfunction.
4. Verify level with local indicator.
5. BFW pump malfunction.
5. Check pump operation.
1. See previous.
2. Main compressor interlocked to
By Detail Low-Low Waste Heat Boiler Level See previous. shut down.
3. Clean sulfur pumps interlocked to
shut down.
Waste Heat Boiler Level Interlock
N/A Gauge blowdown bypass only. None.
Bypass
TRB 01 - 8
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

Low-Low Waste Heat Boiler Gauge
Level
1. Check level controller and valve
1. Level controller or instrument
High Pressurized Boiler Blowdown operation.
By Detail malfunction.
Flash Tank Level 2. Check that manual valves before
2. Discharge line blocked.
and after level valve are open.
By Detail High-High Deaerator Level 1. Level control malfunction. 1. Check level controller, level valve,
2. BFW pump malfunction. and overflow valve.
3. Control valve bypass open. 2. Check BFW pump operation.
3. Close level control bypass valve.
By Detail High Deaerator Level 1. Level control malfunction. 1. Check level controller, level valve,
2. BFW pump malfunction. and overflow valve.
3. Control valve bypass open. 2. Check BFW pump operation.
3. Close level control bypass valve.
By Detail Low Deaerator Level 1. Level control malfunction. 1. Check level controller and valve.
2. Tank or pipeline leak. 2. Check system for leaks.
3. Drain valve open. 3. Close drain valves.
By Detail Low-Low Deaerator Level See previous. See previous.
1.0 barg Low Deaerator Pressure 1. Low header pressure. Check header pressure and steam
2. Low steam supply flow. supply.
By Detail High Lube Oil Rundown Tank Level See Vendor operating manual. See Vendor operating manual.
By Detail Low Lube Oil Rundown Tank Level See Vendor operating manual. See Vendor operating manual.

1. Pump shutdown.
N/A Common Acid Pump Motor Fault 2. Dilution water system interlocked to
2. Pump malfunction.
stop flow.
2. Dilution water system interlocked to
1. Pump shutdown.
N/A Product Acid Pump Motor Fault stop flow.
3. Product acid storage valve
interlocked to close.
TRB 01 - 9
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

N/A Acid Drain Pump Motor Fault Check pump operation.
2. Pump shutdown.
N/A Auxiliary Lube Oil Pump Motor Fault Check pump operation.
2. Pump shutdown.
1. Check filter media and

1. Filter media plugged.
150 mm w.c. High Air Filter Pressure Drop clean/replace.
Low-Low Differential Pressure 1. Increase compressor flow.

145 mm w.c. across Sulfur Burner / Waste Heat Turndown condition. 2. Startup burner interlocked to shut
Boiler down.
High Main Compressor Discharge

Design +10% See Troubleshooting section. See Troubleshooting section.
Pressure
High-High Main Compressor
Design +20% See Troubleshooting section. See Troubleshooting section.
Discharge Pressure
Low Main Compressor Discharge 1. Turndown condition.
25% Design Increase plant rate.
Pressure 2. Low compressor flow.
1. See previous.
2. Clean sulfur pumps interlocked to
Low-Low Main Compressor
20% Design See previous. shut down.
Discharge Pressure
3. Main compressor discharge valve
1. High steam header pressure.
High Waste Heat Boiler Steam 1. Reduce steam header pressure.
By Detail 2. Pressure control or relief valve
Collecting Chamber Pressure 2. Check relief valve settings.
malfunction.
1. Check sulfur line, flowmeter, and
1. Sulfur line frozen or blocked. control valve. Check steam
Low Sulfur Pressure to Sulfur 2. Transmitter malfunction. jacketing.
7 kg/cm2 g
Burner 3. Pump malfunction. 2. Check transmitter operation.
4. Sulfur burner tip lost. 3. Check pump operation.
4. Check burner tips.
TRB 01 - 10
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

1. See Vendor operating manual.
Low Lube Oil Pressure to Main
By Detail See Vendor operating manual. 2. Auxiliary lube oil pump interlocked
Compressor
to start.

By Detail Low Lube Oil Pressure See Vendor operating manual.
2. Main compressor start permissive.

By Detail Low-Low Lube Oil Pressure See Vendor operating manual. 2. Main compressor interlocked to
shut down.
High Main Compressor Bearing
99 C See Vendor operating manual. See Vendor operating manual.
Temperature
High-High Main Compressor
116 C See Vendor operating manual. See Vendor operating manual.
Bearing Temperature
See Material Main Compressor Discharge
See Vendor operating manual. See Vendor operating manual.
Balances Temperature
1. Increase compressor flow and lower
1. High SO2 gas concentration.
sulfur flow.
Design +25 High Sulfur Burner Outlet 2. High inlet gas temperature.
2. Check compressor discharge
°C Temperature 3. High sulfur flow to burner.
temperature; lower pressure drop.
1. See previous.
Design +40 High-High Sulfur Burner Outlet 2. Clean sulfur pumps interlocked to
See previous.
°C Temperature shutdown and sulfur feed valve
1. Low SO2 gas concentration. 1. Decrease compressor flow and
Low Sulfur Burner Outlet 2. Low sulfur flow to burner. increase sulfur flow.
Design -50 °C
Temperature 3. High gas flow. 2. Check sulfur line and control valve.
4. Sulfur gun plugged. 3. Check and clean sulfur guns.
Design -250 Low-Low Sulfur Burner Outlet
See previous. See previous.
°C Temperature
TRB 01 - 11
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

1. Check cooling water conditions at
1. High cooling water temperature.
supply from Owner, and at cooler.
2. Low cooling water flow.
Design +5 °C High Towers Inlet Acid Temperature 2. Decrease plant rate.
3. High plant rate.
3. Shut down and clean common acid
4. Common acid cooler fouled.
cooler.
1. Economizer 4A and 3B 1. Open economizer 4A and 3B
bypasses closed. bypasses.
High Economizer 4C Outlet Water
By Detail 2. High SO2 gas concentration or 2. Reduce plant rate and gas strength.
Temperature
plant rate. 3. Lower steam header pressure. Be
3. High boiler pressure. aware of possible water hammer.
1. Superheater 4A bypass closed. 1. Check bypass position.
2. High 1st pass outlet 2. Lower 1st pass inlet temperature,
temperature, low 2nd pass inlet raise 2nd pass inlet temperature.
temperature. 3. Lower plant rate and SO2 gas
Design +20 High Superheated Steam
3. High plant rate or low SO2 gas concentration.
°C Temperature
concentration. 4. Increase steam production by
4. Plant turndown. closing economizer bypasses.
5. Temperature controller 5. Check temperature controller
malfunction. operation.
By Detail Low Lube Oil Temperature See Vendor operating manual.
By Detail High Lube Oil Temperature See Vendor operating manual. See Vendor operating manual.
By Detail High-High Lube Oil Temperature See Vendor operating manual. 2. Main compressor interlocked to
shut down.
High Common Main Compressor
By Detail See Vendor operating manual. See Vendor operating manual.
Vibration / Thrust
High-High Common Main
By Detail See Vendor operating manual. 2. Main compressor interlocked to
Compressor Vibration / Thrust
shut down.
N/A Startup Burner Flame On See Vendor operating manual. See Vendor operating manual.
N/A Startup Burner Panel Purge Failure See Vendor operating manual. See Vendor operating manual.
TRB 01 - 12
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING
N/A Startup Burner Common Alarm See Vendor operating manual. See Vendor operating manual.
1. Main compressor interlocked to
Main Compressor Discharge Valve
N/A Normal plant operation. shut down if not true.
Open
Main Compressor Discharge Valve
N/A Plant shutdown. Normal interlock function.
Closed
TRB 01 - 13
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING
1. TROUBLESHOOTING GUIDE – HRS
CONSEQUENCE ALARMS ACTION

Low Pressure Feedwater Supply Failure
 Loss of steam production  Low level alarm on boiler 1. Check BFW pumps and water supply to
 High acid temperatures  High acid temperature alarms (boiler inlet pumps
 High corrosion rates from high temperatures and outlet) 2. Check operation of HRS boiler level valve

st 3. Check feedwater inlet and outlet block
 SO3 and mist carryover High concentration alarm on 1 stage inlet
 Low dilution water pressure valves at HRS heater
4. Restart boiler feedwater flow. If HRS
feedwater cannot be restarted, shut down
acid plant
5. Flush dilution water inlet strainers
High Cl in Feedwater
Increased possibility for stress corrosion cracking Possible high conductivity in boiler blowdown 1. Increase boiler blowdown rate
in HRS boiler 2. Check water supply system and restore
water quality
HRS Boiler Acid Leak
Water will leak into the acid system, reduce acid  Low alarm on concentration controller 1. If a boiler leak is highly suspected, shut
concentration, and cause high corrosion rates  High temperature alarm boiler exit acid down the plant and rapidly evacuate the
 Reduced acid side temperature decrease boiler by activating emergency trip
through HRS boiler 2. Emergency shutdown procedure will be
 High boiler feedwater flow to dilution water automatically initiated by low-low acid
flow ratio concentration
 High deviation pump boot acid concentration
 Temperature cross alarm
TRB 02 - 1
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

High Pressure in Intermediate Steam Pressure Header
Open relief valves on header or on HRS boiler  HRS boiler column pressure 1. Open HRS boiler vent valve to temporarily
 Operator may either observe pressure relieve boiler pressure
increase or relief valves opening 2. Stop dilution water
3. Reduce plant rate
4. In emergency, trip the HRS pumps. This, in
turn, will trip the main compressor and shut
down the plant.
Main Compressor Trip
Loss of gas flow will cool down system and acid  Alarm on DCS 1. If main compressor cannot be restarted,
concentrations will dilute if second stage flow is  Interlocks will stop sparge air, dilution water, manually block in dilution water and sparge
not stopped and acid flow to the second stage air to diluter
2. Continue to circulate acid over the first stage
3. Check the main compressor interlocks
screen
Loss of Sulfur Flow
Loss of SO3 and heat input. System will cool  Alarm on DCS 1. Stop second stage acid flow and dilution
down and acid concentrations will dilute  Low sulfur furnace exit temperature water
2. If sulfur cannot be readily restored, the main
compressor should be stopped. Then follow
procedures for main compressor trip.
Steam / Water Leak into Gas Stream Ahead of HRS
 Acid mist and moisture entering HRS and  High boiler feed water flow to dilution water Shut down the plant per operating manual,
some dilution of acid. May or may not be flow rate depending on the size of the leak and how it was
detectable by concentration analyzers  Low concentration alarm detected
depending on size and location of leak
 Observe large increase in drip acid
occurring at existing economizer 3B and/or
cold I.P. heat exchanger hot side drain
during routine field inspections.
TRB 02 - 2
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

HRS Circulation Pump Failure
Loss of HRS steam production, bad stack, loss  Low-low flow alarm stage 1 1. Restart pumps and plant
of absorption  Interlocks will stop the main compressor, 2. If pump is damaged, remove and replace
dilution water, sparge air and second stage with spare pump. To minimize SO3 fuming
acid flow out from the open pump mounting nozzle,
take the following steps.
 Pump out the pump boot acid to the
final tower pump tank using the HRS
acid drain pump. Refill the pump boot
with fresh, cold acid from storage.
Continue this operation until the pump
boot acid temperature is < 70 °C.
 Purge the tower with dry air from the
main compressor (at minimum speed)
for at least 20 minutes while HRS acid is
being changed out. It is necessary to
bypass the low-low 1st stage flow
interlock. Stop purge before removing
pump.
Loss of Second Stage Flow
High gas temperature and mist and SO3  High gas temperature exit second stage 1. Restore flow, check flow valves and
carryover to the heat recovery tower mist  Low second stage acid flow strainers
eliminator, increased corrosion of mist eliminator, 2. If flow cannot be immediately restored, shut
duct, and downstream cold I.P. heat exchanger. down the plant
High acid drainage from catch pot before cold
I.P. heat exchanger inlet vestibule.
Loss of Dilution Water
HRS circulation acid concentration will increase,  Low HRS dilution water flow 1. Restore dilution water flow
steam production will fall off, and SO3 will not be  High boiler feedwater flow to dilution water 2. Check valve positions and dilution water
absorbed, causing overheating of the final tower flow ratio piping and strainer. Shut down the plant as
system and high stack SO3 and SO2 emissions  High concentration alarm required.
TRB 02 - 3
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

Low Acid Concentration in HRS
High corrosion of stainless steel equipment  Low concentration alarms 1. Check position of dilution water valves
 High corrosion rate alarms 2. Check dilution water flows and cut back as
required
3. Check and adjust second stage flow
4. Check common pump tank concentration
5. Verify acid concentration analyzer(s)
6. If necessary, shut down the plant. The plant
interlock system will shut down the plant and
drain the HRS boiler if the trip level of 97%
H2SO4 is reached
7. Check for drip acid in economizers 3B and
other economizers for indications of high
pressure steam or water leaks
High BFW Flow to Dilution Water Flow Ratio
Could be indication of HRS boiler leak or high High boiler feedwater flow to dilution water flow 1. Check pump tank acid concentration by
pressure boiler/superheater/economizer leak or ratio laboratory sample
low common pump tank acid concentration, or 2. Shut down plant and drain HRS boiler if
high HRS boiler blowdown rate. Recovering condition continues
from low HRS boiler level will have the same 3. Check vestibule drain of economizer 3B for
affect. This will be self-adjusting as level is excessive drip acid
established 4. Check HRS boiler blowdown valves
Leak in Tower Shell
Local hazards from acid and gas None 1. Observe leaks and shut down plant
2. Stop dilution water and sparge airflow to
diluter and second stage acid flow.
3. Shut down HRS pump
4. Drain as required and repair leak.
TRB 02 - 4
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

Poor SO3 Absorption
 Drip acid and SO3 plume in cold I.P. heat  High acid concentration in first stage 1. Check first stage acid concentration
exchanger cold gas catch pot drain  Plugged distributor in first or second stage 2. Inspect first and second stage distributors as
 Increased stack SO2 emissions  Low acid flow to second stage (plugged soon as possible
 Black stick test at exit of heat recovery tower strainer) 3. Check acid flow rate to first and second
 Low acid flow to first stage stage
 > 3 °C temperature rise across mist 4. Check second stage acid strainer for
eliminator elements pluggage with pressure gauge provided
Heat Recovery Tower Pump Boot Low Level
HRS pump cavitation, loss of acid flow to heat Low-low level alarm 1. Check level transmitter for malfunction
recover tower first stage 2. Manually raise level by throttling valve to get
to proper operating level
3. Shut down plant and check level with stick
4. Control level manually until level indicator is
corrected
5. Check emergency acid drain valve and
manual drain valves for tight shut-off
6. Check tower bottom and circulating pipes for
leaks
Heat Recovery Tower Pump Boot High Level
Acid level up into heat recovery tower gas inlet,  High pump boot level alarm 1. Check level transmitter for malfunction
may flood packing and surge compressor  High-high pump boot level alarm 2. Manually open valve to reduce level to
proper operating level
3. Shut down plant and check level with stick
after level has dropped below back-up level
alarm
Plant Power Failure
 System cool off  Main Compressor trip and others 1. Block and bleed dilution water and sparge
 Loss of steam pressure air
 Dilute acid 2. Stop continuous blowdown on HRS boiler
3. Block in boiler steam system
TRB 02 - 5
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

HRS Heater Water Leak
Water will leak into acid system, reducing acid  Low alarm on concentration indicator 1. Bypass the heater on the water side by
concentration and causing high corrosion rates.  High deviation from pump boot acid opening the water side bypass valve, and
Acid outlet temperature increases until it concentration then close the water side heater inlet and
becomes higher than the acid inlet temperature  Temperature cross alarm outlet valves. Open the water side drains.
2. If an HRS heater leak is highly suspected,
shut down the plant with emergency trip .
Fog Formation in Stage 2
H2SO4 vapor from stage 1 will normally  No instrument alarms. 1. Raise acid temperature at the bottom (gas
condense and be absorbed in stage 2. If the  Bad stick test after Stage 2 inlet area) of Stage 2 by reducing acid flow
condensation occurs too rapidly in the gas  Possible visible plume from plant stack. over tower, and increasing acid temperature
phase, fine mist (fog) may result. The high  Excessive drip acid from Cold IP HEX. into this tower.
efficiency mist eliminators will collect most of this
mist, but if too much, some will pass through.
TRB 02 - 6
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING
2. TYPICAL ALARM AND ACTION GUIDELINES – HRS
within the HRS. It does not cover every possible cause for the alarms and trips listed.
The set points given below are typical and may not be exact for your plant.
The table below includes typical instrument and limit switches with either an alarm or interlock trip in the DCS associated with
its output. The values in your plant may vary slightly. Consult the detailed instrument list and material balance.

High-High Heat Recovery Tower
99.8% H2SO4
Pump Boot Acid Concentration 1. Low 1st stage acid flow. 1. Increase acid flow to 1st stage.
High Heat Recovery Tower Pump malfunction. 3. Verify acid concentration in
99.7% H2SO4 3. Transmitter or analyzer laboratory. Check analyzer
Boot Acid Concentration
Low Heat Recovery Tower Pump
99.2% H2SO4 See Troubleshooting Guide See Troubleshooting Guide
Boot Acid Concentration
Low-Low Heat Recovery Tower See Troubleshooting Section 1 See Troubleshooting Section 1
99% H2SO4
Pump Boot Acid Concentration
0.2% H2SO4 High Concentration Difference See Troubleshooting Section 1 See Troubleshooting Section 1
Heat Recovery Tower Pump Boot See Troubleshooting Section 1 See Troubleshooting Section 1
N/A
Acid Concentration Analyzer Fault
Heat Recovery Tower Pump Boot
N/A See instrument operating manual. See instrument operating manual.
Acid Concentration Analyzer Hold
1. Low 1st stage acid flow. 1. Increase acid flow to 1st stage.
High 1st Stage HRS Acid
99.3% H2SO4 malfunction. 3. Verify acid concentration in
Concentration
3. Transmitter or analyzer laboratory. Check analyzer
TRB 02 - 7
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

st
Low 1 Stage HRS Acid See Troubleshooting Section 1 See Troubleshooting Section 1
98% H2SO4
Concentration
st
Low-Low 1 Stage HRS Acid See Troubleshooting Section 1 1. See Troubleshooting Section 1
97% H2SO4
Concentration 2. See interlock descriptions.
st
1 Stage HRS Acid Concentration
Analyzer Fault
st
1 Stage HRS Acid Concentration
Analyzer Hold
st
High 1 Stage HRS Acid See Troubleshooting Section 1 See Troubleshooting Section 1
99.3% H2SO4
Concentration
st
Low 1 Stage HRS Acid See Troubleshooting Section 1 See Troubleshooting Section 1
98% H2SO4
Concentration
st
Low-Low 1 Stage HRS Acid See Troubleshooting Section 1 See Troubleshooting Section 1
97% H2SO4
Concentration
0.2% H2SO4 High Concentration Difference Analyzer out of calibration See instrument operating manual.
0.3% H2SO4 High-High Concentration Difference
Low HRS Acid Concentration to See Troubleshooting Section 1
99.2% H2SO4 See operating manual
Final Tower Pumptank
Low-Low HRS Acid Concentration to See Troubleshooting Section 1 See Troubleshooting Section 1
99% H2SO4
Final Tower Pumptank
High HRS Boiler Feedwater 1. Poor treated water quality. 1. Verify treated water quality.
20 µS/cm
Conductivity 2. Transmitter or analyzer 2. Check transmitter operation.
malfunction. 3. Inspect heater and plant data for
High-High HRS Boiler Feedwater 3. HRS heater leak. potential leak.
30 µS/cm
Conductivity .
High HRS Blowdown Water 1. Improper boiler chemical 1. Check boiler chemical addition rate.
4,000 µS/cm
Conductivity addition 2. Increase continuous blowdown rate.
2. Low continuous blowdown rate. 3. Check plant data for potential leak.
High-High HRS Blowdown Water 3. Boiler or heater leak.
5,000 µS/cm
Conductivity
TRB 02 - 8
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

nd
Low Heat Recovery Tower 2 Stage See Troubleshooting Section 1 See Troubleshooting Section 1
80% Design
Flow
nd
Low-Low Heat Recovery Tower 2 See Troubleshooting Section 1 See Troubleshooting Section 1
50%Design
Stage Flow
500% Design High Water Flow to HRS Diluter Controller malfunction. Check controller functions.
80% Design Low Water Flow to HRS Diluter See Troubleshooting Section 1 See Troubleshooting Section 1
5.0 High BFW to Dilution Water Ratio See Troubleshooting Section 1 See Troubleshooting Section 1
1. Controller malfunction. 1. Check acid concentration controller.

2.0 Low BFW to Dilution Water Ratio
2. IP BFW supply failure. 2. Check IP BFW supply.
N/A 1st Stage Flow Interlock Bypassed Start-up bypass use only. None.
st
90% Design Low 1 Stage HRS Acid Flow 1. Pump malfunction. 1. Check pump operation.
2. Manual valve in line closed. 2. Check valve positions in system.
70% Design Low-Low 1st Stage HRS Acid Flow 3. Level controller malfunction. 3. Check level controller operation.
4. See interlock descriptions.
st
Low-Low 1 Stage HRS Acid
N/A Concentration Interlock Bypass Start-up condition. Start-up condition.
Alarm
N/A Interlock 82 Bypass Alarm Start-up condition. Start-up condition.
N/A HRS Emergency Trip Alarm HRS emergency trip activated. See interlock actions.
High HRS Acid Circulating Pump
By Vendor
Motor Current See vendor manual. See vendor manual.
High-High HRS Acid Circulating
By Vendor
Pump Motor Current
See drawing High-High Heat Recovery Tower See Troubleshooting Section 1 See Troubleshooting Section 1
(62%) Pump Boot Level
See drawing High Heat Recovery Tower Pump See Troubleshooting Section 1 See Troubleshooting Section 1
(61%) Boot Level
TRB 02 - 9
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

See drawing High-High Heat Recovery Tower See Troubleshooting Section 1 See Troubleshooting Section 1
(62%) Pump Boot Level
See drawing Low Heat Recovery Tower Pump See Troubleshooting Section 1 See Troubleshooting Section 1
(53%) Boot Level
See drawing Low-Low Heat Recovery Tower See Troubleshooting Section 1 See Troubleshooting Section 1
(51) Pump Boot Level
By Vendor 1. Level controller malfunction. 1. Check level controller operation.
High HRS Boiler Level
By Vendor Low HRS Boiler Level
1. Manual blowdown valve left 1. Check manual blowdown valve
By Vendor open. position.
2. Boiler leak. 2. Check boiler for leaks (See
3. Instrument malfunction. Troubleshooting Guide).
Low-Low HRS Boiler Level
4. BFW pump malfunction. 3. Check pump operation.
4. Verify level with local indicator.
By Vendor 1. Level controller malfunction. 1. Check level controller operation.
High-High HRS Boiler Level
N/A HRS Drain Pump Motor Fault Check pump operation.
2. Pump shutdown.
1. Pump shutdown. 1. Check pump operation.
HRS Acid Circulation Pump Motor
N/A 2. Pump malfunction. 2. Check interlock actions.
Fault
3. Result of interlock 85. 3. Both pumps interlocked to stop.
Design -1 Low Dilution Water Pressure to HRS See Troubleshooting Section 1 See Troubleshooting Section 1
barg Diluter Trip
Design -2 Low-Low Dilution Water Pressure to See Troubleshooting Section 1 1. See Troubleshooting Guide.
barg HRS Diluter 2. See interlock descriptions.
TRB 02 - 10
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING
1. Instrument / plant air system 1. Check instrument/plant air system.

Design -3 Low Plant Air Pressure to HRS failure. 2. Check line or strainer for blockage.
barg Diluter 2. Blockage in line. 3. Check instrument operation.
3. Instrument malfunction. 4. HRS Diluter air block valves
Design See Troubleshooting Section 1 See Troubleshooting Section 1
High HRS Boiler Level Column
Steam +
Pressure
0.2 barg
1. Start-up condition. 1. Check controller operation.
Design steam Low HRS Boiler Level Column 2. Back-pressure controller 2. Verify vent valve position.
-1.0 barg Pressure malfunction.
3. Vent valve open.
Design -3.0 Low Plant Air Pressure to HRS 1. Instrument / plant air system 1. Check instrument/plant air system.
barg Diluter down. 2. Check line or strainer for blockage.
2. Blockage in line. 3. Check instrument operation.
3. Instrument malfunction. 4. HRS Diluter air block valves
Design -1.0 Low Dilution Water Pressure to HRS See Troubleshooting Section 1 See Troubleshooting Section 1
barg Diluter
1. High acid flow to 2nd stage.
Low 2nd Stage Outlet Acid
150 °C 2. Low acid temperature to 2nd Check acid conditions to 2nd stage.
Temperature
stage.
1. Low or no 1st or 2nd stage acid 1. Check that 1st and 2nd stage acid
High Heat Recovery Tower Outlet flow. flows are at the design rate.
80 °C
Gas Temperature 2. Plugged distributor. 2. Inspect distributor performance.
1. High acid flow to 2nd stage.
Low Heat Recovery Tower Outlet
40 °C 2. Low acid temperature to 2nd Check acid conditions to 2nd stage.
Gas Temperature
stage.
1. Check for acid leak as described in
High HRS Boiler Inlet Acid 1. Water to acid leak in boiler.
Design +10°C operating manual.
Temperature 2. Low acid circulation flow.
2. Check 1st stage acid flow.
TRB 02 - 11
Rev 0
30 May 11
APPENDIX 02
TROUBLESHOOTING

Design High-High HRS Boiler Inlet Acid 1. Water to acid leak in boiler. 1. See TIH-
+20°C Temperature 2. Low acid circulation flow. 2. See interlock descriptions.
Design High HRS Boiler Outlet Acid 1. Water to acid leak in boiler.
operating manual.
+5°C Temperature 2. Low acid circulation flow.
2. Check 1st stage acid flow.
Design operating manual.
High-High HRS Boiler Outlet Acid 1. Water to acid leak in boiler.
+15 °C 2. Check 1st stage acid flow.
Temperature 2. Low acid circulation flow.
Low HRS Diluter Acid Bypass Unblock line to prevent vacuum in HRS
150 °C Line blocked.
Temperature diluter on shutdown.
Low HRS Drain Pump Acid Inlet
60 °C Pipe empty. Shutdown HRS drain pumps.
Temperature
HRS Temperature Cross Trip, I-5, I- 2. Check operating data for source of
See Interlock
51, I-61, I-81, I-82, I-83, I-84, I-85, I- Leak in HRS heat exchanger temperature cross.
Description
86, I-87, I-88, I-89, I-91, and I-92 3. Inspect HRS heat exchanger for
acid leak.
TRB 02 - 12
Rev 0
30 May 2011
APPENDIX 03
SAFETY RULES
1. GENERAL
The following safety procedures are supplied as a guideline for plant personnel. It is not
intended to replace or to be used in lieu of regular, established safety practices.
Operation of the sulfuric acid plant can be hazardous if the plant is not operated,
controlled, and maintained properly. All personnel must comply with all safety rules and
regulations normally required for any acid plant. Proper safety equipment must be
provided. The plant is designed and engineered with safety interlock shutdown facilities,
safety showers, and other necessary normal controls of hazards. The chemical safety
data sheets in Appendix 4 outline various hazards and safety requirements.
A sulfuric acid plant is as safe as the operating personnel make it. Hazards that
normally exist include:
 EXPLOSION
 THERMAL BURNS
 CHEMICAL BURNS
 ELECTRICAL SHOCK
 TOXIC SUBSTANCES
The time involved to develop and maintain a good safety program is not wasted. No one
enjoys being injured, and the expenses involved are much higher than might be obvious.
Learning and using proper safety practices and devices will make operating the acid
plant easier and safer.
2. BOILER SAFETY RULES
Each of the following rules is a direct result of an accident.
1. Trace every pipeline. Learn the location and purpose of every valve.
2. Never attempt to light an oil or gas burner with a torch until the fan or blower has
been operating long enough to thoroughly purge any unburned gases left in the
system. Always assume delayed ignition is going to cause an explosion. If the
burner does not stay lit on the first attempt, purge the system before making a
second attempt. The combustion gases exiting from the start-up stack must
always be almost invisible. If they are not (i.e.--dark, sooty), shut off the burner
at once.
3. Never heat the boiler without first checking and confirming adequate water level.
Always make sure the blowdown valves are closed and all vents and drip valves
are open. Check all valves in the system. Be sure that all pressure gauge cocks
are open.
This operating manual is the property of MECS, Inc. Information and know-how herein are confidential and proprietary and may not be used, reproduced, or revealed to
others except in accordance with the terms of a contract with or other written permission of MECS, Inc.
SAF 01- 1
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30 May 2011
APPENDIX 03
SAFETY RULES
4. Never open any valve under pressure quickly without specific instructions to the
contrary. The sudden changes in pressure or resulting waterhammer may cause
piping failure.
5. Never allow sediment to accumulate in the gauge glass or water column

connections. Always blow out each gauge glass and water column connection at
least once each day. Always check the water level in the gauge glass with the
gauge cocks at least once each day and also at any other time the accuracy of
the glass indicator is in doubt.
6. Never leave an open blowdown valve unattended.
7. Never tighten bolts, nuts, or pipe thread under steam pressure. Never strike any
object under steam pressure.
8. Always consult an authorized boiler inspector before proceeding with boiler

repairs. Never allow unauthorized persons to tamper with any steam plant
equipment. Never fail to report unusual behavior of a boiler or other equipment.
3. ACID BURNS
In case of an acid burn, the Operator should quickly get under a safety shower and use
the full flow of water; the more water the better. A small amount of water will increase
the severity of the burn. Water should be used until all traces of acid have been washed
from the burn, normally for a minimum of 15 minutes. Alkaline solutions are not needed.
If used at all, they should be used only after all the acid has been washed from the burn.
Once the acid has been washed from the burn, it may be treated in the same manner as
a heat burn.
Safety shower/eyewash stations are typically located as follows:
a. At the ground level near the combination pump tank.

b. At the combination pump tank platform.
c. One at each acid pipe inlet level of each acid tower.
d. Two at grade near the acid coolers and drain pump.
e. At the sulfur storage tank.
f. At the sulfur melting area.
g. At the boiler chemical feed systems.
h. At the cooling tower chemical feed system.
i. At the ground level near the HRS pump boot.
j. At the HRS pump boot platform.
SAF 01- 2
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APPENDIX 03
SAFETY RULES
k. One at grade near the HRS heater and HRS drain pump.
The showers should be regularly tested and maintained when necessary.
Before making any repair on a pipeline or on a flue or piece of equipment that may
contain acid, care should be taken to drain the equipment thoroughly. If a pump line is
involved, the pump should be stopped, the starting switch locked, and the valve suitably
closed. Any possible blockage of the line should be cleared. Maintenance personnel
should always have a water hose nearby, as many burns are avoided or made minor by
this simple precaution.
Rubber gloves designed for chemical plant service should be available to all personnel
working around acid plant equipment.
4. EYE PROTECTION
All operating personnel should wear goggles or eye shields when they are in an area
where acid is being circulated or pumped. This includes, in particular, the area around
the drying, absorbing, and HRS towers, acid coolers, all HRS equipment, acid storage
tanks, and loading platforms.
Goggles or shields must be worn when adjusting valves on acid lines, handling acid,
opening a line, or at any other time when there is even a remote chance of acid leakage
or splash. Always assume that an acid line is full.
A drinking fountain or eye-wash fountain with a liberal upward flow of water is desirable
and may be used to mitigate the severity of eye burns. If an Operator gets a drop of acid
in the eye, the Operator should position the eye directly over the fountain and thoroughly
flush it with water. Alkaline neutralizing agents should never be used for eye burns. It
cannot be emphasized too strongly that the best first aid measure for an acid burn is “A
LOT OF WATER AND QUICKLY!” (It is undesirable to use a drinking fountain that
supplies ice water. It is better to provide water that is not excessively cold.)
5. HAZARDS
1. Combustion of Fuels
The start-up burner furnished in this plant utilizes propane gas and diesel fuel as
fuel. The normal fire and explosion hazards associated with firing burners with
combustible fuel will exist if proper operation, control, and maintenance are not
maintained at all times. The possibility of equipment failures always exists.
2. Boiler and Steam Generation and Use
SAF 01- 3
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30 May 2011
APPENDIX 03
SAFETY RULES
Waste heat boilers together with accessories and steam handling facilities are
included in this plant. The normal explosion hazard and steam hazards
associated with boilers and steam handling equipment will exist if proper
operation, control, maintenance, and observance of safety rules are not
maintained at all times.
3. Gas Fumes
Sulfur dioxide, sulfur trioxide, sulfuric acid fumes, and oxides of nitrogen normally
are not a hazard in a well operated and maintained acid plant, but all gas fumes
can be hazardous to personnel when proper plant conditions are not maintained.
The possibility of equipment failures always exists.
Sulfur dioxide is a colorless gas having a characteristic odor and a strong irritant
action of the eyes, nose, throat, and upper respiratory tract. A concentration of 3
to 5 ppm is readily noticed and tasted, and one of 8 to 12 ppm causes irritation of
the nose and throat. Coughing and eye irritation are observed at about 20 ppm.
Higher concentrations are so irritating that voluntary exposure generally cannot
be endured. Proper respiratory devices should be available for entering areas of
high concentration and for emergency purposes.
Sulfur trioxide and sulfuric acid vapors or mists exist as a fog in the air and are
irritating to the mucous membranes of the eyes and the respiratory tract. Proper
respiratory devices should be available for emergencies.
The oxides of nitrogen primarily irritate the respiratory tract, which mainly affect
the deep portion of the lungs. Nitrogen dioxide is a dangerous substance. It has
a characteristic odor at concentrations as low as 5 ppm and mild irritation of the
eyes, nose, and upper respiratory tracts occurs at concentrations of 10 to 20
ppm. There is very little change in the intensity of irritation with increase in
concentration. Continuous exposure can be quite harmful and can result in
edema and asphyxiation. Because of the delayed action of nitrogen dioxide, rigid
controls and strict supervision should be enforced where there is potential
exposure. A high flame temperature in the sulfur burner due to poor air flow may
generate nitrogen oxides. Proper respiratory devices should be available for
entering areas where high concentrations may accumulate and for emergency
purposes.
4. Catalyst Dust
During plant operations, the exposure to vanadium catalyst is practically nil and
is not a hazard. During plant shutdown, when personnel are engaged in handling
or screening the catalyst, a serious hazard results. Exposure to vanadium
pentoxide dust produces irritation of the eyes and respiratory tract. Knowledge of
the toxicology of vanadium is incomplete, particularly as to the chronic and
systemic effects. In order to reduce this exposure, it is recommended that the
catalyst be removed pneumatically from the converter and screened externally.
SAF 01- 4
Rev 0
30 May 2011
APPENDIX 03
SAFETY RULES
In all cases, personnel should be protected throughout the exposure period with
approved respirators and eye protection. Instructions for screening catalyst are
given in Section 22.5.
6. SULFURIC ACID STORAGE, PUMPING, AND HANDLING
Sulfuric acid is classified as a corrosive liquid. Care must be exercised in all handling
operations because it reacts with most metals and with water. In concentrations below
77.7 wt% H2SO4 (60° Be), it is highly reactive to metals and evolves hydrogen gas on
contact. In concentrations above 77.7 wt%, it is a strong oxidizing agent, reactive with
many organic materials and inorganic reducing agents to evolve considerable heat.
Sulfuric acid has a high affinity for water (hygroscopic) and decomposes many oxygen-
containing organic materials by dehydration. Addition of water to concentrated acid will
produce violent steam explosions and splattering.
Sulfuric acid solutions, particularly the more concentrated ones, rapidly destroy all body
tissues, causing serious burns and may be accompanied by shock and collapse.
Repeated exposure to low concentrations may result in dermatitis. Contact with the
eyes is especially hazardous, often causing severe damage or loss of sight.
Inhalation of the concentrated vapor from hot acid may be harmful since it causes
chronic inflammation of the upper respiratory tract. Cough and chronic bronchitis may
result from repeated exposures. Severe exposures may cause pneumonitis.
In cases of contact with sulfuric acid, the most important treatment is immediate flushing
with copious amounts of water. No neutralizing substances should be used until all of
the acid has been thoroughly washed away with water as otherwise the heat of
neutralization may enhance the burn. Readily available safety showers and eye wash
fountains are provided in the plant and must be regularly inspected by the Owner to
ensure good working order at all times.
Sulfuric acid by itself is not flammable, but the higher concentrations may cause ignition
by contact with combustible materials. Sulfuric acid may generate hydrogen in metal
piping, vessels, or storage tanks. Hydrogen-air mixtures are very explosive in the range
of 4 to 75% hydrogen by volume. No open lights, flames, sparks, or spark producing
tools should be permitted near containers of sulfuric acid. All electrical fixtures in these
areas should be vapor tight.
Contact of strong sulfuric acid with metallic sulfides can cause evolution of hydrogen
sulfide and ignition.
Sulfuric acid spills should be neutralized with lime or soda ash where possible and
flushed with copious quantities of water after ventilating thoroughly if inside a building. A
supply of water for wash down purposes should be available in areas where acid is
stored or handled.
SAF 01- 5
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APPENDIX 03
SAFETY RULES
7. OTHER HAZARDS
Other hazards common to most chemical plants will also exist in this plant and should be
included in accident prevention plans. Some of the common regulations are outlined.
The proper tools for each job should be provided and used. Each Operator should wear
the proper safety equipment required for the job performed such as safety glasses,
safety goggles, face shields, acid hoods, hard shell hat, acid proof suit, rubber boots,
rubber hat, gloves, welding hood, respirators, etc. For welding, cutting, chipping,
grinding, jackhammering, etc., the Operator should use the proper applicable safety
equipment. Acetylene and oxygen gas cylinders should be safely stored and handled.
Fire extinguishers should be available in buildings, and periodically checked and ready
for use. All portable ladders should be secured at the upper end and blocked whenever
used. All workers including supervisors should be given a full understanding of the safe
job procedures and the requirements of the job. Hazard areas should be isolated by
barriers, screens, roping, and warning signs.
Workers should not blow dust or dirt from their clothing with oxygen or compressed air.
All electrical switches, starters, or disconnects should be locked out in the off position by
the worker performing the repair or adjustment to any piece of power-driven equipment.
All vessels or enclosed spaces should be drained, purged, ventilated, and checked for
safe entry before entering. Approved hand safety lamps should be used inside tanks
and in hazardous areas. Safety work and flame permits should be required. Rescue
and resuscitation equipment should be readily available. All power tools should be
adequately grounded.
A basic rule in sulfuric acid plant maintenance is that no work is to be performed on any
vessel, tank, pipeline, or other equipment which has contained acid without complete
draining, flushing, purging, and an explosiometer test on the gas indicating good
ventilation and a safe atmosphere.
Another cardinal safety rule in sulfuric acid plants is that all acid lines, even though they
have been drained, are considered to be full of acid and under pressure whenever
opened or flanges unbolted. This way all workers are wearing proper protective devices
and apparel and are above the piping in elevation so that acid pockets under hydrogen
pressure, if they exist, will drain out without contacting the workers. Any spills should
immediately be flushed with water from a readily available water hose. Some plants
require that acid valves be locked in the closed position when acid lines are un-bolted.
Other general rules may be added to these listed.
SAF 01- 6
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APPENDIX 03
SAFETY RULES
Specific measures to be taken to eliminate or control each hazard listed in the above
analysis depends upon the Owner’s or Operator’s attitude for safety and local existing
safety requirements in the acid plant. The Owner’s or Operator’s personnel will start-up
and operate the plant. MECS representatives will adhere to all local safety rules and
regulations in force for the Owner’s plant while in the plant.
Safe working procedures are generally developed by a joint venture of the plant workers
and the Owner’s safety department. The responsibility for a good safety program rests
with plant management. All workers, operations, and maintenance should perform their
respective duties in accordance with the established safety practices and good
housekeeping requirements existing at the plant site. The recommendations included in
the analysis of hazards are the result of past acid plant experience. One of the most
important factors in efficient plant operation is good maintenance of all operating and
control equipment. Annual inspection of all equipment is recommended. The use of
proper materials of construction in making repairs is emphasized in an acid plant for
good accident prevention. The MECS representative in attendance at the plant start-up
will be available to discuss any safety matters on which the Owner may desire additional
information.
8. HRS SAFETY CONSIDERATIONS
Hazards Identification
Listed below are a few additional personnel exposure items unique to the Heat
Recovery System.
1. HRS Acid – Hot and Concentrated:

Highly concentrated acid causes a lot of smoking when an acid leak
occurs and the acid is exposed to the atmosphere.
2. HRS Acid Lines are Hot:

Exposed acid lines can cause thermal burns.
3. HRS Pump Boot is Pressurized

Be aware that gas and possibly acid can shoot out of opened nozzles
on the HRS pump boot.
4. Boiler Blowdown Flash Discharge

Emergency blowdown discharge releases the entire content of the
water from the HRS boiler to he emergency blowdown separators.
5. Hydrogen Explosions
Large quantities of hydrogen (corrosion by-product) can be generated in
the stainless steel heat recovery tower if exposed to low acid
concentrations.
SAF 01- 7
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APPENDIX 03
SAFETY RULES
Protective Systems
Sample coolers are provided to cool the hot HRS acid prior to sampling.
An acid suit, acid boots, acid gloves, and safety shield with safety goggles
should be worn when taking acid samples, when level rodding the pump boot,
when draining strong acid from equipment, and when performing maintenance
on strong acid piping or equipment. In addition to the above safety equipment,
a respirator and safety harness must be worn when entering the heat recovery
tower.
SAF 01- 8
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APPENDIX 04
MATERIAL SAFETY DATA SHEET INDEX

MSD-02 Sulfuric Acid 1963
MSD-03 Sulfur Dioxide 1953
MSD-04 Sulfur Trioxide 18 Jan 91
MSD-05 Catalyst 2002
MSD-06 Sulfur 1959
MSD 01- 1
MONSANTO Company
Material Safety Data
____________________________________________________________________________________________
1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

____________________________________________________________________________________________
PRODUCT NAME: SULFURIC ACID CATALYST DATE: March 22, 2002

TYPE 516, TYPE 210, TYPE 11
TYPE LP-120, TYPE LP-110, TYPE LP-220
TYPE LP-1150
TYPE XLP-110, TYPE XLP-220
CHEMICAL NAME: Mixture of complex inorganic salts (oxosulfato vanadates) containing sodium, potassium and
vanadium salts on crystalline silica support
SYNONYMS: None
MONSANTO COMPANY, 800 N. LINDBERGH BLVD., ST. LOUIS, MO 63167
FOR CHEMICAL EMERGENCY, SPILL LEAK, FIRE, EXPOSURE, OR ACCIDENT

Call CHEMTREC - Day or Night - 1-800-424-9300 Toll free in the continental U.S., Hawaii, Puerto Rico, Canada,
Alaska, or Virgin Islands. For calls originating elsewhere: 703-527-3887 (collect calls accepted)
For additional non-emergency information, call: 314-694-6661

____________________________________________________________________________________________
2. COMPOSITION/INFORMATION ON INGREDIENTS
____________________________________________________________________________________________
COMPONENT CAS NO. % BY WEIGHT
vanadium salt complex * not available 39 - 45

crystalline silica * # 24 - 32
cristobalite 14464-46-1
quartz 14808-60-7
diatomaceous earth (amorphous silica) * 68855-54-9 26 - 28
* Hazardous chemical(s) under the criteria of the OSHA Hazard Communication Standard (29 CFR 1910.1200).
# National Toxicology Program (NTP) and International Agency for Research on Cancer (IARC) listed carcinogen.
____________________________________________________________________________________________
3. HAZARDS IDENTIFICATION
____________________________________________________________________________________________
EMERGENCY OVERVIEW
WARNING!
CAUSES EYE AND RESPIRATORY TRACT IRRITATION
MAY CAUSE SKIN IRRITATION
MAY BE HARMFUL IF SWALLOWED
REPEATED AND PROLONGED INHALATION CAN CAUSE DELAYED LUNG DAMAGE
CANCER HAZARD - CONTAINS CRYSTALLINE SILICA WHICH CAN CAUSE CANCER
MONSANTO Material Safety Data Page 2 of 7
Sulfuric Acid Catalyst TYPE 516, TYPE 210, TYPE 11
TYPE LP-120, TYPE LP-110, TYPE LP-220, TYPE LP-1150
TYPE XLP-110, TYPE XLP-220 March 22, 2002
_____________________________________________________________________________________________
APPEARANCE AND ODOR: yellow to light green pellets or rings
POTENTIAL HEALTH EFFECTS
LIKELY ROUTES OF EXPOSURE: skin contact and inhalation
EYE CONTACT: causes pain, redness and tearing based on toxicity studies on the components. Dust may cause
eye irritation as would any foreign material.
SKIN CONTACT: no more than slightly toxic or irritating based on toxicity studies. Dust grittiness may cause slight
irritation.
INHALATION: causes coughing, chest pain, runny nose and burning throat based on experience with the components.
Repeated and prolonged inhalation can cause delayed lung damage.
INGESTION: no more than slightly toxic. Significant adverse health effects are not expected to develop if only small
amounts (less than a mouthful) are swallowed.
MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE: pre-existing lung conditions
CARCINOGENICITY: can cause cancer
Refer to Section 11 for toxicological information.

____________________________________________________________________________________________
4. FIRST AID MEASURES

____________________________________________________________________________________________
IF IN EYES, immediately flush with plenty of water for at least 15 minutes. If easy to do, remove any contact lenses.
Get medical attention.
IF ON SKIN, immediately flush with plenty of water. Remove contaminated clothing. Get medical attention. Wash
clothing before reuse.
IF INHALED, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen.
IF SWALLOWED, rinse mouth thoroughly with water. NEVER GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS
PERSON. Get medical attention. Contact a Poison Control Center. Do NOT induce vomiting unless directed by
medical personnel.
____________________________________________________________________________________________
5. FIRE FIGHTING MEASURES

____________________________________________________________________________________________
FLASH POINT: not applicable
HAZARDOUS PRODUCTS OF COMBUSTION: Product may evolve small volumes of sulfur trioxide gas if heated
above 805 degrees F.
EXTINGUISHING MEDIA: In case of fire, use water, dry chemical, CO2, or foam.
UNUSUAL FIRE AND EXPLOSION HAZARDS: none known
FIRE FIGHTING EQUIPMENT: Fire fighters and others exposed to products of combustion should wear self-contained
breathing apparatus. Equipment should be thoroughly decontaminated after use.
_____________________________________________________________________________________________
6. ACCIDENTAL RELEASE MEASURES

____________________________________________________________________________________________
In case of spill, sweep, scoop or vacuum and remove. Flush residual spill area with water. Keep out of sewers,
watersheds and water systems.
Refer to Section 13 for disposal information and Sections 14 and 15 for reportable quantity information.
____________________________________________________________________________________________
7. HANDLING AND STORAGE

____________________________________________________________________________________________
Avoid contact with eyes, skin and clothing.

Do not taste or swallow.
Avoid breathing dust.
Keep container closed.
Use only with adequate ventilation.
Wash thoroughly after handling.
Emptied container retains vapor and product residue. Observe all labeled safeguards until container is cleaned,
reconditioned or destroyed.
STORAGE: Must keep dry to avoid degradation of product.

____________________________________________________________________________________________
8. EXPOSURE CONTROLS/PERSONAL PROTECTION

____________________________________________________________________________________________
Eye Protection: Where there is significant potential for eye contact, wear chemical goggles and have eye flushing
equipment available.
Skin Protection: Wear appropriate chemical resistant gloves and clothing to protect potentially exposed skin. Consult
glove manufacturer to determine appropriate type glove for given application. Wash contaminated skin promptly.
Launder contaminated clothing and clean protective equipment before reuse. Wash thoroughly after handling.
Respiratory Protection: Avoid breathing dust. Use NIOSH approved respiratory protection equipment when airborne
exposure limits are exceeded (see below). Consult respirator manufacturer to determine appropriate type equipment
for given application. Observe respirator use limitations specified by NIOSH or the manufacturer. Respiratory
protection programs must comply with 29 CFR 1910.134.
Ventilation: Provide natural or mechanical ventilation to control exposure levels below airborne exposure limits (see
below). If practical, use local mechanical exhaust ventilation at sources of air contamination such as open process
equipment.
Airborne Exposure Limits:
COMPONENT OSHA PEL ACGIH TLV

vanadium salts * not established not established
cristobalite 0.05 mg/m3 (respirable dust) 8-hr TWA 0.05 mg/m3 (respirable dust) 8-hr TWA
quartz + 0.1 mg/m3 (respirable dust) 8-hr TWA 0.05 mg/m3 (respirable dust) 8-hr TWA
diatomaceous earth % not established not established
(amorphous silica)
_____________________________________________________________________________________________
* OSHA and ACGIH have not established specific exposure limits for this material. OSHA has established the
following limits for vanadium pentoxide (V2O5) respirable dust and fume. ACGIH has established the following limits
for vanadium pentoxide (V2O5) respirable dust.
OSHA PEL ACGIH TLV
0.5 mg/m3 (respirable dust) ceiling 0.05 mg/m3 8-hr TWA
0.1 mg/m3 (fume) ceiling
+ A2: The ACGIH has designated this component as an “A2" substance, thereby including it among industrial
substances suspect of carcinogenic potential for man. Worker exposure by all routes should be carefully controlled.
% OSHA and ACGIH have not established specific exposure limits for this material. However, they have established
limits for particulates not otherwise regulated (PNOR) and particulates not otherwise classified, insoluble (PNOC)
respectively, which are the least stringent exposure limits applicable to dusts.
OSHA PEL ACGIH TLV
15 mg/m3 (total dust) 8-hr TWA 10 mg/m3 (inhalable) 8-hr TWA
5 mg/m3 (respirable) 8-hr TWA 3 mg/m3 (respirable) 8-hr TWA
____________________________________________________________________________________________
9. PHYSICAL AND CHEMICAL PROPERTIES

____________________________________________________________________________________________
Appearance: yellow to light green pellets

Size: Type 516, Type 210, Type 11: 7/32” or 5/16” in diameter by 3/8” average length
Type LP-120, Type LP-110, Type LP-220 1/2” or 3/8” in diameter by 1/2” average length
Type XLP-110, Type XLP-220 1/2” or 3/8” in diameter by 1/2” average length
Type LP-1150 1/2" diameter by 5/8" long Raschig Ring
Solubility: 65 - 75% SiO2 - insoluble ; 25 - 35% inorganic salts - partially soluble in water
Bulk Density: 1.24 lb./L (Type LP-220 and Type XLP-220)
Specific Gravity bulk (H2O = 1):
Type 516, Type 210, Type 11: 0.60 - 0.70
Type LP-120, Type LP-110, Type LP-1150 0.50 - 0.55
Type XLP-110, Type XLP-220 0.50 - 0.55
NOTE: These physical data are typical values based on material tested but may vary from sample to sample. Typical
values should not be construed as a guaranteed analysis of any specific lot or as specifications for the product.
____________________________________________________________________________________________
10. STABILITY AND REACTIVITY

____________________________________________________________________________________________
STABILITY: Product is stable under normal conditions of storage and handling
MATERIALS TO AVOID: none known
HAZARDOUS DECOMPOSITION PRODUCTS: none known
INCOMPATIBILITY: none known

____________________________________________________________________________________________
11. TOXICOLOGICAL INFORMATION

____________________________________________________________________________________________
Industrial experience indicates that vanadium compounds, such as vanadates and vanadium oxides, are irritating to the
eyes, skin and mucous membranes of the upper respiratory tract. Productive cough, wheezing, difficulty in breathing,
chest pains, bronchitis, inflammation of the mucous membranes of the nose, pneumonia, gastrointestinal tract
disturbances, kidney and heart effects have also been reported with excessive exposure to dust and fumes of
vanadium compounds.
_____________________________________________________________________________________________
Overexposure to dusts of the diatomaceous earth (silica) component of sulfuric acid catalyst may also cause
respiratory tract irritation. The diatomaceous earth contains crystalline forms of silica (quartz and cristobalite).
Repeated and prolonged inhalation of crystalline silica may cause a progressive pneumoconiosis (commonly known as
silicosis), a form of disabling lung disease (pulmonary fibrosis). Clinical signs and symptoms of silicosis include
cough, shortness of breath, wheezing and impairment of lung function. Impairment of lung function may be
progressive. In the usual case of silicosis, there is a slow deterioration of capacity for physical effort, decreased chest
expansion, and an increased susceptibility to tuberculosis and other respiratory infections. Studies have also shown
that quartz can cause cancer in animals, and there is some epidemiological evidence that quartz may be associated
with lung cancer observed in workers exposed to silica dust.
Toxicological Data
Monsanto has not conducted toxicity studies on these sulfuric acid catalysts. However, the following data were
developed on a similar sulfuric acid catalyst and are considered representative of these catalysts.
Single exposure (acute) studies indicate:
Oral - Slightly toxic (rat LD50 - 1,460 mg/kg)

Dermal - Practically nontoxic (rabbit LD50 - >5,010 mg/kg)
Eye Irritation - Slightly irritating (rabbit, 19.5/110.0)
Skin Irritation - Nonirritating (rabbit, 24-hr exposure, 0.0/8.0)
Components
Data from the scientific literature on the components of these sulfuric acid catalysts which have been identified as
hazardous chemicals under the criteria of the OSHA Hazard Communication Standard (29 CFR 1910.1200):
Amorphous and Crystalline Silica
Inhalation of silica dust may produce lung toxicity and adverse effects on the respiratory system. Data from the
available literature on crystalline forms of silica confirm the capacity of free crystalline silica to induce a fibrinogenic
response in lungs.
In addition to the adverse effects noted above, studies on a variety of laboratory animals (rats, guinea pigs, rabbits and
monkeys) using inhalation, as well as intratracheal, routes of exposure indicate the ability of crystalline silica to
produce silicosis similar to that seen in man, and confirm human experience that the presence of crystalline silica in
the lung increased susceptibility to infection. In laboratory studies, quartz produced malignant and benign tumors in
animals following inhalation exposure or placement in the lungs (pleural implants). Epidemiology studies in workers
exposed primarily to silica dust (predominantly the quartz form of silica) indicated excess mortality from lung cancers.
Crystalline forms of silica, which includes quartz and cristobalite, are classified as "carcinogenic to humans" by the
International Agency for Research on Cancer (IARC Monographs, Vol. 68). The IARC listing is based on their
determination that there is sufficient evidence for the carcinogenicity of crystalline forms of silica in humans and
sufficient evidence for the carcinogenicity of crystalline forms of silica in experimental animals. Epidemiology studies
cited by IARC give indications of increased risk for lung cancer in a working environment contaminated with crystalline
silica, particularly in combination with other exposures.
Vanadium Salts
Reduced weight gains, and effects on liver, kidney and lungs have been reported in laboratory animals following
repeated oral administration of vanadates. Vanadium is also reported to interfere with a number of biochemical
processes.
_____________________________________________________________________________________________
12. ECOLOGICAL INFORMATION

____________________________________________________________________________________________
Monsanto has not conducted environmental toxicity studies with this product.
____________________________________________________________________________________________
13. DISPOSAL CONSIDERATIONS

____________________________________________________________________________________________
Sulfuric acid catalyst is not a "hazardous waste" as that term is defined in the Resource Conservation and Recovery
Act (RCRA), 40 CFR 261, "Identification and Listing of Hazardous Waste”. Dispose of in accordance with local, state
and federal regulations. Consult your attorney or appropriate regulatory officials for information on such disposal.
Metal reclaimers are available to recover vanadium value from disposed material. This product should not be dumped,
spilled, rinsed or washed into sewers or public waterways.
____________________________________________________________________________________________
14. TRANSPORT INFORMATION

____________________________________________________________________________________________
The data provided in this section is for information only. Please apply the appropriate regulations to properly classify
your shipment for transportation.
This product is not hazardous under the applicable DOT, ICAO/IATA, or IMDG regulations.
____________________________________________________________________________________________
15. REGULATORY INFORMATION

____________________________________________________________________________________________
TSCA INVENTORY: All intentional components are listed.
SARA Title III Rules

Section 311/312 Hazard Categories
Immediate; Delayed
Section 302 Extremely Hazardous Substances
Not applicable.
Section 313 Toxic Chemical(s)
Vanadium compounds
CERCLA REPORTABLE QUANTITY: Not applicable
CALIFORNIA PROPOSITION 65: The state of California's Safe Drinking Water and Toxic Enforcement Act of 1986
requires the following label on this product. WARNING! This product contains chemicals known to the state of
California to cause cancer.
Refer to Section 2 for OSHA Hazardous Chemical(s) and Section 13 for RCRA classification.
_____________________________________________________________________________________________
16. OTHER INFORMATION

____________________________________________________________________________________________
REASON FOR REVISION: New product type Supersedes MSDS dated: February 20, 2001
Although the information and recommendations set forth herein (hereinafter "Information") are presented in good faith
and believed to be correct as of the date hereof, Monsanto Company makes no representations as to the
completeness or accuracy thereof. Information is supplied upon the condition that the persons receiving same will
make their own determination as to its suitability for their purposes prior to use. In no event will Monsanto Company
be responsible for damages of any nature whatsoever resulting from the use of or reliance upon Information. NO
REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED, OF MERCHANTABILITY, FITNESS
FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE ARE MADE HEREUNDER WITH RESPECT TO
INFORMATION OR THE PRODUCT TO WHICH INFORMATION REFERS.
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MISCELLANEOUS MAINTENANCE
1. WASHING PROCEDURES FOR MECS MIST ELIMINATOR ELEMENTS
1.1 General Instructions:
Make a record of the pressure drop across the mist eliminators before and after
the wash at the design flow conditions.
CAUTION: Wear safety goggles and take necessary safety precautions

during washing. Use acid proof clothing and face shields to wash
elements in sulfuric acid service.
Construct two or three tanks out of 4-foot (1,200 mm) ID pipe or equivalent
material. Install overflow and drain lines on the tanks. The tanks should be
longer than the elements with their seal cups attached. Construct a hanger for
drying the elements after washing.
Fill the first washing tank with water, solvent or detergent. Keep 1 to 2 feet
(approximately 0.5 meters) of freeboard for immersing each element. Fill the
second tank with water for rinsing. Arrange to keep water running at
approximately 10 gpm (2 m3/h) in the second tank. Wash one element at a time.
Take the element out of the vessel using a crane or a forklift and lower it into the
first washing tank. Move the element gently up and down to provide some
agitation, but avoid jerking the element. Soak the element for approximately 15
minutes or until it is clean. Move the element to the second tanks and rinse for
approximately 15 minutes. After washing, hang the element on the hanger for
one to two hours to dry.
1.2 Instruction for Sulfate Pluggage
Prepare three tanks in series as instructed above. Add 500 lb (225 kg) of sodium
carbonate (soda ash) to the first and second tanks to make a 5% solution. Add
clean water to all three tanks. Keep one to two feet (approximately 0.5 meters)
of freeboard for immersing each element. Arrange to keep water running at
approximately 10 gpm (2 m3/h) in the third tank for rinsing. Wash one element at
a time. Remove the element from the vessel and remove the seal cup. Remove
the accumulated sulfate and wash the seal cup with water.
Immerse the element in the first washing tank. Make sure the element is
completely covered with soda ash solution. The solution will bubble due to CO2
evolution from the acid neutralization. Soak the element until bubbling stops,
usually 5 to 10 minutes. Move the element to the second tank and soak it for two
to three minutes to neutralize any remaining acid. Move the element to the third
tank and rinse it with running water for approximately 15 minutes. Hang the
element on the hanger for one to two hours to dry.
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APPENDIX 05
Add soda ash to the first and the second tank as needed to keep the solution
alkaline. The first tank uses approximately 100 lb (50 kg) of soda ash per
element, and the second tank uses approximately 10 lb (5 kg) per element.
1.3 Instructions for Sublimed Sulfur Pluggage
Prepare four tanks in series as instructed above. Add 500 lb (225 kg) of soda
ash to the first tank to make a 5% solution, and 100 lb (50 kg) of sodium sulfide
to the third tank to make a 0.5% solution. Add clean water to all four tanks.
Keep one to two feet (approximately 0.5 meters) of freeboard for immersing each
element. Maintain water running at approximately 10 gpm (2 m3/h) in the second
and fourth tank for rinsing.
Wash one element at a time. Remove the element from the vessel and immerse
it in the first washing tank filled with approximately 5% soda ash solution. Make
sure the element is completely covered with soda ash solution. The solution will
bubble due to CO2 evolution from the acid neutralization. Soak the element until
bubbling stops, usually 5 to 10 minutes. Then move the element to the second
tank and rinse with running water for 5 minutes. If the element is not
completely neutralized, H2S (hydrogen sulfide) gas may evolve, posing a
serious hazard. Be sure that there is no residual acidity in the fiber bed at
this point.
Move the element to the third tank filled with approximately 0.5% sodium sulfide
solution. The solution should bubble due to reaction between sulfur and sodium
sulfide. Soak the element in the sodium sulfide solution for 30 minutes. Move
the element to the fourth tank and rinse with running water for approximately 15
minutes. Hang the element on the hanger one to two hours to dry.
Add soda ash to the first tank to keep the solution alkaline. It will use
approximately 100 lb (50 kg) of soda ash per element. Add sodium sulfide to the
third tank as needed. It will use approximately 50 lb (25 kg) of sodium sulfide per
element.
1.4 Reinstallation instructions
After drying, install the elements on a clean dry tube sheet. Use new full face
1/4" thick fiberglass cloth impregnated with Teflon gaskets. Lubricate the screws
before torquing them properly with a torque wrench, following the tightening
sequence as shown in the original installation and maintenance instructions.
Proper installation is very important.
2. INSTRUCTIONS FOR WASHING ABSORBING AND DRYING TOWERS

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2.1 General
Washing consists essentially of flushing the towers quickly with as large a

quantity of water as possible until the effluent is reasonably clear.
If repairs are made to the tower, it should be washed with water, neutralized with
a soda ash solution, and flushed again with water. (If the tower has a mist
eliminator installed, it will have to be washed and neutralized, to prevent acid
from dripping on the repair crew).
If no repairs are necessary, strong acid should be circulated through the system
as quickly as possible after the tower is washed to minimize possible corrosion
and deterioration of exposed metal and brickwork by water and weak acid.
2.2 Washing Procedures
a. Shut down the plant and allow the towers to drain as long as possible,
preferably for at least two hours.
b. Use the drain pump to drain the acid from the seal leg and base of the
tower back to the pump tank.
c. Disconnect the acid piping at the tower outlet and make a temporary
connection to the sewer for the effluent wash water. This may be done
by use of a 4" or 6" (100 or 150 mm) steel pipe, a section of flexible
hose, or a combination of flexible hose and pipe. A trough of sheet
metal, lined with roofing paper, has also been used for this job but is
much less desirable. A trough may also be constructed of wood.
CAUTION: There will still be some drainage of strong acid from

the tower packing even after two hours.
d. Open all manholes adjacent to the distributor.
CAUTION: No one should enter the tower unless adequately

protected (air mask, goggles, and rubber suit).
Residual fumes or acid drip may be present. In
unusual cases, the fumes could be toxic due to the
presence of oxides of nitrogen. It should also be
assumed that the gas left in the tower could be
flammable.
e. Flush the tower thoroughly from the manholes using one or more fire
hoses without nozzles, or the equivalent. It is important that the water
be directed downward against the packing as much as possible. The
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APPENDIX 05
packing under the distributors can best be flushed by attaching to the

fire hose a section of 2" (50 mm) pipe with an elbow and nipple on the
end.
The flushing should be done as quickly as possible. Discontinue the

flushing as soon as the effluent starts to become clear.
After flushing, inspect the packing to determine that it extends up to the

bottom of the distributor troughs. Add or rearrange packing if needed.
f. Remove the drain at the acid outlet. Reinstall the acid piping to the
pump tank and circulate strong acid as quickly as possible. In no event
should the tower be allowed to stand overnight before circulating strong
acid.
The first water to be flushed from the tower contains a lot of acid. It may be
necessary to run effluent water through a tank where an alkali, such as lime,
soda ash or caustic soda can be added.
CAUTION: If any welding is required on tower piping or ductwork,

purge the entire system thoroughly with air, and test vessel
and/or piping with an explosimeter before welding.
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3. INSTALLATION PROCEDURE - MECS MIST ELIMINATORS
3.1 Description of ES Series
The ES mist eliminators provided are high efficiency flanged forward flow units.
In a conventional fiber bed, liquid draining on the downstream face of the fiber
bed is sometimes re-entrained in the exiting gas. This entrainment becomes
worse with higher loadings of mist and/or higher flow velocities.
The ES units include a patented layer of coarse fibers downstream of the finer
collecting fiber. Liquid that would re-entrain from the finer fiber bed is recollected
and drained in the re-entrainment layer.
3.2 Description of CS Series
The CS Series of mist eliminators are flanged, reverse flow units. They perform
with moderate to high efficiency and pressure drop. When they are used as an
alternative to mesh pads, a tubesheet is usually retrofitted into an existing vessel.
The CS Series is designed to be repackable.
The newer CS-IP and CS-IIP mist eliminator elements include an integral
reentrainment control layer downstream of the collecting fiber. This layer is
constructed of a special wire mesh and collects any reentrainment from the fiber
bed. The “P” designation refers to the wire mesh pad.
The CS-IBP and CS-IIBP (and older CS-IB and CS-IIB) mist eliminator elements
include an optional baffle screen impaction separator. The “B” designation refers
to the baffle screen. In high loading situations this pre-separator removes many
of the larger particles and reduces the center core of the element or may hang
down underneath the element inlet. A separate dip pipe and seal cup is provided
for each baffle screen. (The dip pipe location may require that a specific
minimum hole diameter be available in the tubesheet. See the element drawing
for this minimum diameter.)
3.3 Storage
When the elements are received at the job site, the crated elements should be
stored in a warehouse, covered with a tarp or plastic sheet. This must be done to
prevent the fibers from being saturated with water and dirt. The crates should be
stacked in a horizontal position. The stack should be no more than four crates
high.
3.4 Installation
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APPENDIX 05
Refer to the drawing details of the element and housing during the following
description. The element cage has been ruggedly built with a protected fiber
bed, but reasonable care should be exercised in handling. Careless handling of
the mist eliminator can result in filtration media damage that would lead to poor
performance. Two lift lugs are located at the top end of the element for hoisting
into place. Remove any waterproof paper from the element before hoisting it into
place. Avoid piercing the mist eliminator with any sharp object, and avoid
compressing the fiber bed.
The element flange is to be bolted to the tubesheet in the tank housing or tower
top. A gasketed seal is required, and it is vitally important that the flange be
tightly sealed. Any gas leakage around the flange materially reduces the overall
collection efficiency.
Full face gaskets are normally required for these elements, but Goretex joint
sealant may be used. To obtain a gas-tight seal, the following installation
procedure should be used.
1. Clean the mating surfaces of the element flange and tubesheet. Dirt and
scale provide leakage paths.
2. Install three socket set screws into the element flange approximately 120
degrees apart, or install three drift pins through the tubesheet. This
simplifies the alignment of the bolt holes.
3. Place the full face gasket on the tubesheet, or cut the Goretex 1/4 " joint
sealant to the length specified for the element size:
Element Size Sealant Length

(Shell Diameter) Per Element
24” (610 mm) Metal 83” (2,110 mm)
26" (660 mm) Metal 89 1/2" (2,275 mm)
30" (760 mm) Metal 102" (2,600 mm)
The placement of the joint sealant is important because it makes a very thin
gasket that widens as the cap screws are torqued. The flanges bend appreciably
as the cap screws are torqued and might come together without adequately
compressing the joint sealant if it is improperly placed. Remove the protective
backing tape carefully without removing the adhesive tape as the joint sealant is
firmly pressed into place. The adhesive strip holds the joint sealant in position.
To complete the seal, cross the ends near a bolt hole as indicated in Figure 1.
Hand flatten the ends.
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APPENDIX 05
FIGURE 1
4. Lower the element into place. Care should be exercised to avoid

damaging the threads in the tubesheet or element. Do not allow the
element to contact the gasket until the bolt holes are aligned. Remove
the socket set screws or the drift pins. Lubricate the cap screws with a
heavy graphite-oil mixture or a suitable anti-galling compound such as
Molykote, carbon disulfide or Anti-seize.
5. Torque cap screws as follows:
 Run up all cap screws finger tight.
 Torque all cap screws to the level specified in Table 1 in a minimum

of three equal steps, following the tightening up sequence as shown
in Figure 2. Select torque based on element material of construction
and gasket material. Joint sealant is highly compressible, but has
little resilience so gradual tightening is required to form a gasket of
uniform thickness.
 Check the cap screws once more to be sure they are fully torqued.
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APPENDIX 05
FIGURE 2
TABLE 1
CAP SCREW TORQUE REQUIREMENTS
Bolt
Gasket Type Diameter Total Torque/Bolt Comments
Goretex ½" 45 Ft-Lbs (61 N-m) 1, 2, 5

Full Face ½" 60 Ft-Lbs (81 N-m) 3, 4, 5
Comments
1. Bring bolts up to specified torque in a minimum of three

graduated steps.
2. Note that joint sealant is highly resilient so gradual tightening is

required to form a gasket of uniform thickness.
3. Torque bolts to 45 ft-lbs. Then repeat sequence and torque to

60 ft-lbs. Wait a minimum of 2 hours (24 hours preferred) to
allow gasket/flange relaxation and retorque bolts to 60-70 ft-lbs.
4. NOTE: Bolt failure is 85-90 ft-lbs. and care must be taken on

the torquing sequence to prevent bolts from shearing off.
5. Use of an impact wrench is not recommended since it is less

likely that the bolts will be tightened in the graduated steps
required.
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APPENDIX 05
It is recommended that any dip pipes be installed after the elements

have been installed in the vessel. Install the dip pipe as follows:
Wrap the male threads with Teflon tape or a suitable thread sealant
(by customer). For CS-IBP and CS-IIBP elements, each element
must have a dip pipe and seal cup for the baffle drain. In addition,
the tubesheet must have at least one, but preferably several drains
with seal cups.
3.5 Start-Up
Before starting the plant, be sure that all dust and debris has been removed from
the equipment and ductwork. When everything is clean, fill the seal(s) with
process liquid. Each seal cup must be filled with process liquid before start-up
so that the process gas will not have a direct bypass through the dip pipe. All
seal cups MUST be filled prior to start-up. If they are not, all collected
liquid will be re-entrained into the clean gas.
IMPORTANT:
Failure to fill all the seal cups, the tank sump seal, or trough-type distributor, etc.
will result in “dirty” gas bypassing plus the bypassing gas will blow out the
collected liquid that is trying to drain. Many start-up problems are a result of the
failure to fill the liquid seal.
Connections should be provided for a differential pressure device, such as a

manometer. At start-up the pressure drop and gas should be recorded. The
pressure drop will gradually increase, perhaps for several days until the elements
become saturated. The pressure drop should stabilize once this saturation is
complete.
3.6 Operation
Upon starting, the pressure drop across the mist eliminator should be checked.
For the first few hours the pressure drop will be lower than normal until normal
liquid holdup is reached in the fiber bed. The time required depends on the
amount of mist present in the gas.
Once the unit is on-line, it should be observed from time to time to see that
performance is satisfactory. Pressure drop across the unit and the
corresponding gas flow rates should be recorded once a day until stable
conditions are obtained. Thereafter, that data should be recorded every week or
when rates change.
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APPENDIX 05
If, during continued operation, the pressure drop falls off appreciably, it may be
due to leaks across the gasket surfaces, erosion of the fiber bed in one or more
elements, or some other factor outside the equipment itself.
On the other hand, if the pressure drop increases during operation, it is a sign
that the fibers are becoming blinded. Such a condition can result from
entrainment in the gas of solids, tars or any foreign material that is not being
removed from the elements by natural irrigation.
If the problem is an excessive reduction in pressure drop, check whether there is

leakage of gas past the fiber beds. If so, the plant must be shut down for
inspection and possible repair.
If the pressure drop increases without leveling out at an acceptable value, the
unit should probably be cleaned. This decision can be made only after
inspection.
3.7 Maintenance
Element washing procedures are detailed elsewhere.
UNDER NO CIRCUMSTANCE SHOULD THE ELEMENT BE WASHED WITH A

HIGH VELOCITY STREAM FROM A HOSE.
If damage to the element is suspected, the element should be pulled out of the
tubesheet for external inspection. The wet element weight is much heavier than
the weight when installed dry.
After cleaning, the element should be drained for several hours before putting
back into service.
Be sure when reinstalling the element to use a new spare gasket of the proper
material (see "Installation").
3.8 Repacking and/or Replacement
MECS Mist Eliminator elements should be repacked, altered or changed by

MECS only. Return elements in separate crates (similar to original), with freight
prepaid, to our closest packing facility.
Elements and purchase orders are sent to different locations. Return elements
to the packing facility in the left-hand column below. Send correspondence and
purchase orders to the address on the right and include our MC-B number.
_____________________________________________________________________
Packing Facility Correspondence

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APPENDIX 05
MECS, Inc. MECS, Inc.

C/O Corrpak Inc. MECS Mist Eliminators
719 Spirit Forty Ct. Corporate Pointe Office Park
Chesterfield, Missouri 63005 P.O. Box 14547
St. Louis, Missouri 63178
Phone: 314/275-5700
4. INSTRUCTIONS FOR INSTALLATION OF MECS SULFURIC ACID CATALYST
Shipping containers for MECS Vanadium Sulfuric Acid Catalyst are tightly sealed when
received. The catalyst can be affected by moisture in the air or damaged by water;
therefore, the containers should never be opened until the converter is ready to be
packed.
The catalyst is sufficiently hard to withstand normal handling, and screening for dust
removal after shipment usually will not be required. However, if the catalyst has been
subjected to unusual shipping conditions, a small quantity of dust may be formed. Since
dust will tend to raise the resistance in the converter, the catalyst, if found necessary by
inspection, should be carefully screened before installation. This screening is best done
by passing the catalyst gently over a screen as the containers are opened for converter
packing. Workmen handling the catalyst should wear respirators and proper protective
equipment, as the dust may be irritating to the throat and lungs.
Screening of catalyst (if required) and packing of the converter should be done so far as
possible in dry weather and the operation should be completed expeditiously so as to
limit the duration of exposure to moist air.
In preparation for installation of catalyst, the inside of the converter, the converter cover
and all of the miscellaneous fittings used inside the converter should be brushed clean
of scale and dirt with a wire brush, and care should be taken that workmen clean their
shoes before entering the converter. All interior fittings should have been assembled in
the converter before beginning the installation of the catalyst to be sure that once begun,
the installation can proceed without undue delay for the fitting or parts.
After the slotted grids have all been installed, they should be pushed toward the center
of the converter and fitted together so that it is not possible for any of the ½” (13 mm)
quartz pebbles to fall through. Then two or three strands of pure fiberglass rope may be
used to caulk around the shell of the converter. No caulking should be used between
the slotted grid sections, as they must be placed to allow for some expansion.
Sometimes the converter shell is not truly cylindrical throughout or excessive openings
occur between the grids. In such cases, inserting a steel tee bar can close the
excessive opening between grids. Excessive openings around the shell may be closed
by spot welding and angle or bar to the shell immediately under the grid and then filling
the space with fiberglass rope. Depending on the detail design of the converter,
assurances need to be made to prevent gas bypassing.
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APPENDIX 05
The solid partition plates must be carefully caulked between each plate, and between
the plates and the converter shell with several strands of pure fiberglass rope. It is
extremely important that no gas be able to pass these solid partition plates. Gas leaks
past these solid partition plates will cause poor temperature control and result in loss of
conversion efficiency.
The catalyst supporting medium in each layer typically consists of ½” by 1” (13 m by 25

mm) milled quartz pebbles that should not spall by 630 °C. A 2” (50 mm) deep layer is
put on each set of slotted grids and after being leveled carefully is followed by the
specified volume of catalyst. A piece of 2” (50 mm) thick plank can be used as a depth
guide for the bottom layer of quartz. A similar layer of quartz pebbles is also placed on
top of each layer of catalyst.
Catalyst should be handled gently and not thrown in recklessly or dumped from a great
height. It is best handled in small containers or in the original containers (after re-
screening, if found necessary). After the specified amount of catalyst has been
placed, the layer should be carefully leveled to ensure uniform thickness in the
catalyst bed. Failure to level properly will cause excessive flow through “thin
spots” and may result in poor conversion. It is helpful to make three chalk marks
around the columns and around the wall of the converter at a uniform distance above the
grid. The bottom chalk mark represents the approximate top level of catalyst. The
second chalk mark, two inches above the first mark, represents the anticipated level of
the quartz pebbles over the catalyst. The third mark is placed two inches above the
second mark and serves as a reference if quartz pebbles cover the second mark.
Any of the bottom layers (except as noted for wet gas purification plants) may be packed
through access nozzles on the converter shell, without disturbing the others. Wide
boards or panels of plywood should be used as a working platform while leveling the
catalyst and installing the top layer of quartz. In no case should people be permitted to
step or lie directly on the catalyst. Care must be taken at all times that dirt, pieces of
wood, cloth, etc., do not get into the catalyst or the converter.
In cool, damp weather electric heat lamps or large size electric light bulbs can be used in
the converter to aid in keeping it dry while installing catalyst. Some types of heat lamps
will serve the dual purpose of supplying both heat and illumination. Before sealing on
the manhole covers, inspect to determine that all equipment has been removed and that
all parts of the converter are clean. Remove any dust that may have fallen through the
grids onto the division plates while installing the catalyst.
Any thermocouple protecting wells inside the converter must be located in their proper
places while the catalyst is being installed. They should be located exactly at the
dividing line between the catalyst and the quartz pebbles in each instance as shown on
the drawings. A handful of quartz may be placed under the end of the thermocouple well
to prevent the top of the thermocouple from being buried in the catalyst.
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5. INSTRUCTIONS FOR SCREENING OF CATALYST
It will be necessary to clean the catalyst in the converter because of increased pressure
drop due to dust and scale from various sources being carried in the gas stream to the
converter. An improper air filter or impurities in the sulfur will cause catalyst pluggage.
1. Cool the converter by blowing dried air though it until the temperature is low
enough to work safely. Normally 50-65 °C is sufficiently low, as the converter will
cool rapidly when it is opened to the point where it can be worked in comfortably.
If minimum shutdown time is desired, and if two manways are installed, both
manway covers may be removed and an exhaust fan installed in one while the
work is done through the other.
2. Prior to shutting down, erect a temporary platform, if required, at the converter

manway from which catalyst will be removed. Provide safe access to the
platform.
The thermocouples and wells should be removed or protected before removing

the catalyst so that they will not be damaged. Be sure that the thermocouples
are installed before the catalyst is replaced, being certain that they are replaced
at the proper locations.
3. In the U.S., most catalyst is removed from the converter by vacuum. The
catalyst is collected in a cyclone-like vessel and fed by feeder onto a two-layer
mechanical screen that separates the quartz from the catalyst and screens in
one operation. The quartz and catalyst are collected in plastic bags or other type
of water-tight containers and stored until ready to return to the converter.
Catalyst should be stored indoors or protected outdoors in unfavorable weather
conditions.
The rate of catalyst removal from the converter should be controlled at 2,000 -
3,000 liters per hour to keep catalyst breakage at a minimum.
4. Before the catalyst layer is repacked, thoroughly clean the division plate under
the grids. This may be done from the manways, if provided, or by removing an
occasional grid to reach this area. The use of a vacuum cleaner is desirable, but
brushing with a soft brush is satisfactory. Any dust or dirt left on the division
plate may blow into the next layer of catalyst. Observe the condition of the
screens and clean out if they are plugged with bits of quartz and catalyst.
Normally these screens will not require cleaning, but cases have occurred where
after several cleanings, rough handling of the quartz has caused small pieces to
become lodged in these slots, causing added pressure drop. It is recommended
that an inspection be made of the caulking between the grids and the shell and of
the spacing between the grids to make certain there are no openings large
enough to allow quartz and catalyst to fall through the grids. Some division
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APPENDIX 05
plates are covered with insulating brick. This insulation brick should be
inspected and repaired if necessary.
5. Normally, the catalyst cleaning is contracted, and the contractor will supply the
vacuum unit with hoses, screens, etc., and a crew to operate the unit. The plant
owner will then supply a crew, with a supervisor, to handle the catalyst removal
and placement in containers.
6. On re-installing the catalyst, be sure that a good 50 mm layer of quartz is

installed on the grids. Use wide boards or panels of plywood as a working
platform inside the converter. In no case should anyone be permitted to walk
directly on the quartz or catalyst, as this causes holes in the quartz supporting
the catalyst, and also breaks the catalyst rings.
RECOMMENDED SCREEN SIZES FOR MECS CATALYSTS

(Dimension of Openings in Inches)
To Separate Rock from Catalyst, Use:
 16 mm x 16 mm Square or 14 mm x 25 mm Slotted or 14 mm x 38 mm
Slotted
To Separate XLP-220 or LP-120 from Other Rings or Pellets, Use:
 9.5 mm x 9.5 mm Square (Retains essentially whole rings)
 9.5 mm x 50 mm Slotted (Retains essentially whole rings)
To Separate XLP-220, XLP-110, LP-110 and LP-120 from Smaller Ring or Pellet
Catalyst, Use One or More of the Following Sizes:
 7 mm x 50 mm Slotted (Retains whole rings)
 4 mm x 50 mm Slotted (Retains whole rings plus acceptable chips)
 6.4 mm x 50 mm Slotted
 5.6 mm x 50 mm Slotted (Alternate screen size to retain whole rings and

fewer chips)
 4.8 mm x 50 mm Slotted
To Separate Pieces of Ring Catalyst from Fines, Use:
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 3.2 mm x 50 mm Slotted Cloth (Retains minimum acceptable size rings

and chips for re-installation in any bed)
NOTE: Screening losses are normally made up by adding fresh, whole

ring catalyst on top of the screened material. Chipped ring
catalyst mixed with whole ring catalyst can be re-installed in all
converter beds with no measurable increase in “clean” plant
pressure drop. The quantity of chips retained by any screen size
is an indication of the quality of the entire vacuum screening
operation. The rate of subsequent pressure drop increase is
proportional to the size and quantity of the broken pieces. This
can be controlled by occasional screening with a larger screen
size opening.
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6. PROCEDURE FOR WASHING THE MAIN COMPRESSOR
From time to time, the main compressor in a typical sulfuric acid plant will accumulate
enough dust, dirt, and sulfate to cause balance or vibration problems with the wheel.
With the drying tower preceding the blower, the cause is normally a build-up of ferrous
sulfate. This is the corrosion product from the small amount of acid mist and vapor
condensation in the ducts that is carried through to the blower wheel. Most of this
material passes through the blower, but some of it clings to the wheel as a thin film.
As the film builds up, it becomes irregular and eventually causes imbalance to the
machine. This is frequently noticed after the plant has been down for a few hours
following a sustained operation period. A possible cause is that moist, ambient air
infiltrates the blower, allowing ferrous sulfate to partially hydrate and be thrown off when
the blower is restarted.
When washing the main compressor, the operators need to be aware of the precautions.
Whenever water is introduced into any part of a sulfuric acid plant, weak acid is created.
While materials of construction in the plant are very resistant to corrosion from strong
sulfuric acid, weak acid (below 90% H2SO4) is very corrosive. For blower washing, it is
important to complete the job as quickly as possible, minimize splashing, thoroughly
drain the equipment, and get the plant back to a dry condition as soon as possible so
that it can be restarted.
If the plant is in operation, it should be stopped, with a short blow-through to purge the
SO2 from the system. The blower should be washed, and the plant restarted as quickly
as possible. If the plant is down for other maintenance and the blower is to be washed,
this should be scheduled during the last few hours of the shutdown. This scheduling is
done to minimize the duration of exposure of the system to corrosive, weak sulfuric acid.
A typical procedure to wash the blower is to first prepare the wash solution of either
water or 2-5% soda ash solution. Open the scroll washing connection on the blower.
The drain in the containment sump surrounding the blower should be covered to prevent
the weak acid from draining to the oily water sewer system. A worker in protective
clothing can then spray the blower wheel with the hose provided. The wheel is rotated
by hand at the coupling. Most blowers also have an inspection port on the back side of
the casing, and the wheel can also be washed through that port. Typically, 15 to 20
minutes of washing on each side is enough to dislodge or dissolve all the scale and film
on the blower wheel. Rinse the blower with fresh water for a few minutes if a soda ash
wash solution is used. The blower casing is allowed to drain for the time taken to
replace the covers, and the unit is ready for restart.
The used wash solution, weak acid and dissolved ferrous sulfate is drained from the
blower through the drain connection. The containment sump can be emptied using a
portable sump pump. The portable sump pump should be connected to send the wash
solution to the effluent sump.
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7. PROCEDURE FOR WASHING A TANK THAT CONTAINED SULFURIC ACID
1. Pump the tank as dry as possible. If the tank contained oleum, rinse it with 98%
H2SO4 after initially draining the tank to remove any residual SO3 vapor.
2. Remove the blank from the outlet and drain the tank as thoroughly as possible.
3. Flush the tank with high pressure water (250 - 350 kPag) from a large hose (fire
hose). Direct the stream of water at any deposits of sludge in the bottom of the
tank to break them up and flush them to the drain. Once washing starts, it must
be continued without interruption as quickly as possible until complete.
4. After the sludge has been flushed out, replace the bottom outlet and start filling
the tank with water. Sift in, do not dump in, sufficient lime or soda ash to keep
the solution in the tank alkaline. Keep the solution well agitated by mixing with
air. Change the location of the air pipe frequently to ensure thorough mixing of
the entire contents of the tank.
5. After the tank has been filled to the top and neutralized, add an extra 10 to 25 kg
of lime or soda ash and continue to mix for two to three hours. At the end of this
time, test the solution for alkalinity. If it is alkaline, then drain the tank. If the
solution is acidic, more lime or soda ash must be added and the mixing repeated.
6. After draining the tank, inspect its interior for deposits of sludge. If any sludge is
found, repeat items 4 and 5.
7. After the tank has been thoroughly cleaned, the air in the tank should be tested
with a combustible gas tester. If no combustible gases are found, it should be
safe to weld or cut the metal of the tank.
CAUTION: All the lines entering and leaving the tank should be disconnected or
blanked off before any work is started on the tank.
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HRS MAINTENANCE
TABLE OF CONTENTS
SECTION DESCRIPTION
1. Introduction
2. Equipment Description and Recommended Maintenance
HRS Boiler
HRS Acid Circulating Pump
HRS Diluter
HRS Instrumentation
HRS Tower and Mist Eliminator
HRS Heater
HRS Acid Piping
3. Troubleshooting Guide
4. Appendix
Planned HRS Shutdown (for Boiler Leak)
Procedure for Cleaning HRS Boiler (Acid Side)
Procedure for Cleaning HRS Heat Exchangers (Acid and Water Side)
Procedure for Tube-Plugging in HRS Heat Exchangers
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1. INTRODUCTION
This section provides maintenance information for equipment in a new HRS (Heat
Recovery System) installation. This information should be supplemented by any vendor
maintenance instructions provided with each individual piece of equipment and
instrumentation included in the HRS.
All the equipment is important to efficient and reliable operation of the HRS, but some
components are more important than others. A list of the components, in order of their
importance, is as follows:
1. The HRS boiler is essential to operation of the HRS. Its failure will shut down both
the HRS and the entire plant until repairs or replacements are done.
2. The HRS acid circulating pump operation is essential to operation of the HRS. Its
failure will shut down both the HRS and the entire plant long enough to replace the
pump.
3. The HRS diluter vessel and water sparger are essential to operation of the HRS and
its failure will shut down both the HRS and the entire plant until it is repaired or
replaced.
4. Instrumentation reliability, especially acid conductivity (acid strength), is critical to

successful operation of the HRS. Failure of the acid strength control, alarm, or
interlock system could lead to major corrosion damage to HRS equipment and shut
down of the HRS and plant. Failure of the level control system could lead to
operation of the HRS pump with insufficient level, causing damage to the pump.
5. HRS tower acid distributors must provide uniform distribution of acid to ensure good
SO3 absorption efficiency and low acid mist carryover from the HRS tower. Failure
to maintain good acid distribution may result in high SO2 emissions from the stack
(due to poor conversion in the final converter pass) and, over time, corrosion of
downstream equipment (due to acid mist carryover).
6. HRS mist eliminator performance is important to prevent high acid mist carryover
from the HRS tower. Failure to maintain good performance will, over time, result in
corrosion of downstream equipment.
7. The HRS Heater is important to provide maximum energy recovery in the HRS, but
its operation is not essential to HRS operation, since it can be temporarily bypassed
in the event of failure while the plant continues to run at reduced rate.
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HRS MAINTENANCE
Section 2 describes each equipment item in the HRS and the recommended
maintenance actions for it (in the above order of importance). Maintenance actions are
divided into two categories--Routine Preventive Maintenance (during normal operation)
and Maintenance During Major Plant Shut-down (for periodic cleaning, maintenance,
catalyst screening, etc). Frequency intervals for Periodic Maintenance actions are at the
Owner’s discretion (unless noted). Section 3 summarizes troubleshooting actions
recommended to correct various operating problems in the HRS. The P & ID drawings
for the HRS are included in the back of the manual.
2. EQUIPMENT DESCRIPTION AND RECOMMENDED MAINTENANCE
2.1 HRS Boiler
Equipment Description
The boiler is a horizontal kettle type with U-tube removable tube bundle and separate
external steam purifier drum. Strong acid from the heat recovery tower pump is cooled
from in the tube side of the U-tube bundle by generating medium pressure steam in the
kettle drum. The boiler consists of a carbon steel shell and tubes fabricated of special
MECS grade ZeCor 310M stainless steel.
Routine Preventive Maintenance
 Test safety relief devices (monthly or at Owner’s direction).

 Monitor tube fouling by periodically evaluating heat transfer performance data (i.e.
acid inlet and outlet temperatures, acid flow rate, and steam boiling temperature).
 Monitor steam purifier performance by taking periodic steam samples from the steam
leaving the boiler, using the HRS steam sample cooler. The steam purifier should
maintain steam purity levels (dissolved solids content) as recommended by the
turbogenerator manufacturer.
 Maintain correct boiler water quality using blowdown and testing procedures as
outlined in Section 8 of the Operating Manual for the HRS system.
 Be vigilant for signs of a leak in the boiler tubes (normally of boiler water into
the acid). Since the leak will grow rapidly, early detection and shutdown of the
HRS (and plant) is imperative to prevent total destruction of the tube bundle. See
Appendix 2 (Troubleshooting) of this Manual for signs of boiler tube leakage. In the
event of loss of boiler tubes due to leakage/corrosion, the damaged tube(s) may be
plugged and the HRS operation resumed with somewhat less boiler capacity,
depending on the number of tubes plugged. See the Appendix of this Manual for a
tube plugging procedure.
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Major Plant Shut-down Maintenance
 Inspect safety relief valves.

 Open the inspection ports and manholes and check for signs of corrosion of
tubesheet and tubes. If the tubesheet area requires cleaning or exhibits non-uniform
corrosion, the channel should be removed for further inspection and cleaning.
Note: If there is severe localized corrosion of one or a few tubes, it may be

advisable to plug those tubes using the tube plugging procedure given in the
Appendix of this Manual. If there is generalized corrosion of most of the tubes, it
may be advisable to replace the entire tube bundle with the spare bundle.
If corrosion is suspected at the inlet of the tubesheet, the tube bundle may be rotated
180° to maximize the boiler’s service life.
Note: Prior to removing any inspection nozzles or the exchanger channel, ensure
spare gaskets are available to replace the existing gaskets. When removing the
HRS boiler channel, the tapped studs holding the backing gasket in place (about
every fifth stud) must remain in place. It is very difficult to replace the backing gasket
if these studs are removed.
 Inspect steam drum purifier. Clean if necessary.
 Inspect for any steam side or tube side fouling. A new set of heat transfer
performance data should be taken upon re-startup to establish baseline information.
Subsequent data will provided an indication of the fouling, if any.
Note: fouling on either side of the tubes should be negligible. If acid side fouling is
significant, it is a sign of poor dilution water treatment. See the Appendix of this
Manual for chemical cleaning of tubes (acid side only).
 Inspect blowdown valves. Repair or replace if necessary.

 Inspect and clean all level gauge glasses, water columns, and level controls.
 Check all pressure gauges and transmitters.
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2.2 HRS Acid Circulating Pump
Equipment Description
The pump is a vertical, submerged, Lewis pump made with special grade stainless steel
wetted parts and impeller. It circulates acid from the heat recovery tower pump boot
through the HRS boiler to the distributor of the heat recovery tower and crossflow to the
combination pump tank. The mechanical shaft seals are provided with dry air purge to
seal against operating process gas pressure. A water cooled bearing housing is used.
 Ensure water is flowing through the cooling jacket on the bearing housing (check
water flow from bearing housing cooling jacket to open funnel). Check bearing
temperature on local RTD (recommended range is up to 70 °C).
 Check for unusual noises or vibration.
 Lubricate top ball-bearing every 3-6 months (refer to vendor’s manual).
 Ensure purge air is flowing to the mechanical shaft seal (check local air flow meter).
 Check that carbon grounding brush on pump shaft is electrically grounded.
 Pull pump and inspect for erosion/corrosion of impeller. Replace impeller if

necessary.
Note: This may need to be done more frequently (between turn-arounds) if the pump
loses capacity or develops excessive vibration.
 Overhaul pump as per vendor’s equipment manual.
Note: The internal surface of the pump boot should be absolutely clean before the
pump is reinstalled—any small debris may jam the impeller due to tight clearances.
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2.3 HRS Diluter
The HRS acid diluter is an ASME B&PV Section VIII, Division I designed Teflon – lined
stainless steel vessel with a Teflon dilution water sparger. It is designed duty is to mix
99.6% sulfuric acid with dilution water (and 98.5% sulfuric acid crossflow during high
humidity operations) to produce sulfuric acid at 99.0% strength.
 Monitor the acid weep hole piping on the HRS diluter for any acid leakage. This
piping is connected to the diluter between the Teflon liner and stainless steel shell.
Acid leakage indicates a failure in the integrity of the Teflon liner; the stainless steel
shell is corrosion resistant and will prevent leakage to the outside for some period of
time. Plans should be made to replace the diluter with the uninstalled spare at the
next opportunity (probably the next major plant shutdown) and repair the leaking
lining.
 Blow-out the Y-strainer in the air supply piping to the sparger daily and verify
adequate air pressure at the pressure gauge (indicating adequate air flow).
 Blow-out the Y-strainer in the dilution water supply piping to the sparger daily.
 Check for severe vibration of the diluter. If this occurs, it may be due to inadequate
air flow mixing with dilution water to the sparger or to damage of the sparger.
Note: Do not drain the acid from the diluter unless the acid temperature is below
250 °F (121 °C), or the Teflon liner may be damaged.
 Remove and inspect the diluter sparger for distortion, damage, or pluggage.
Replace if necessary.
Note: Be sure the sparger is re-installed in the correct orientation—rotated so that

the V-notch on the sparger flange is on the top (sparger water injection holes are
on the bottom half of the sparger).
 Replace the diluter with the uninstalled spare if the Teflon lining has failed (i.e. acid
leakage from the weep hole piping).
 Ensure that the double block and bleed valves in the dilution water supply have
functioned properly.
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2.4 HRS Instrumentation
HRS instrumentation consists of the following:
a. 4 acid concentration analyzers, alarms, interlock, and concentration control valve in

dilution water supply.
b. Pump boot level transmitter, alarms, interlock, and level control valve in acid export
line to HRS heater.
c. Acid flowmeter, alarms, and interlock, in acid circulation line to HRS tower.
d. HRS boiler feedwater and HRS dilution water flow meters.
e. HRS boiler level transmitter, alarms, interlocks, and level control valve in boiler
feedwater supply.
f. HRS boiler steam pressure transmitter and control valve in steam export line.
g. HRS boiler steam vent valve and interlocked remote control.
h. Conductivity analyzer and alarm in HRS boiler continuous blowdown line.
i. Conductivity analyzer and alarm in boiler feedwater line from HRS heater to HRS
boiler.
j. Temperature transmitters with remote indication at following locations:
1.) Acid and water inlet and outlet of HRS Heater.
2.) Acid inlet and outlet (with alarms) of HRS boiler.
3.) Acid inlet to HRS diluter.
4.) Acid inlet to HRS tower.
5.) Gas inlet to HRS tower.
 Replace any faulty acid concentration conductivity analyzers as soon as possible.

 Note that the acid conductivity analyzer and sensor must be calibrated in matched
sets to ensure concentration measurement accuracy. Any analyzers should be
replaced as calibrated, matched sets.
 Ensure critical flow meters are working properly—these are: HRS boiler feedwater
flow and HRS dilution water flow.
 Check HRS boiler level transmitter reading against local level gauge reading.
 Check HRS pump boot level transmitter reading against level measurement using a
dip-stick in the sticking port.
Note: this should only be done when main compressor is down and there is no internal
pressure in the HRS tower, to prevent acid blow-out through the sticking port.
 Remove and inspect flow meter element for acid flow to HRS tower. Check for
pluggage and clean if necessary.
 Check operation of HRS dilution water double block and bleed valves to make sure
water is prevented from flowing into HRS during shutdown.
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 Verify all interlock actions relating to low-low acid strength are ready to function if
activated.
2.5 HRS Tower
The heat recovery tower is a vertical, cylindrical vessel, constructed of MECS ZeCor-
HRS alloy. The two packed sections (1st and 2nd stages) contain 76 mm chemical
porcelain saddles supported on a MECS ZeCor HRS alloy grid. A MECS distributor with
overflow downcomers is provided for acid distribution.
The bottom section of the tower and pump boot serve as the acid reservoir for the HRS
pump. One side drain and one bottom drain are provided.
Manways are provided for access to the tower base (from the pump boot platform), to
both distributor levels, and above the mist eliminator housing.
The Pump Boot Section is a horizontal, cylindrical tank, entirely constructed of special
MECS ZeCor HRS alloy. The boot has an eccentric flared section with a mounting
nozzle provided for the pump.
 Check the drain on the catch pot at the outlet of the HRS tower (cold interpass heat
exchanger inlet) daily. Refer to Appendix 2 (Troubleshooting) of this manual for
discussion of possible problems and corrective actions.
 Monitor pressure drop across the Y-strainer in the acid supply line to the HRS tower
2nd stage. Blow-out the strainer if pressure drop reaches 0.7 bar (should not exceed
this).
 Measure wall thickness of tower shell and monitor corrosion rates at selected points
around the bottom reservoir section, pump boot, and the 1st stage distribution section
(where there is platform access) starting from the first day of operation and once per
month afterwards. Use a "D" meter or similar sonic measuring device (Krautkramer-
Branson is a well known manufacturer of "D" meters). The measurements should be
repeated at the same locations, which should be permanently marked, with
removable insulation plugs, because plate thickness will vary slightly.
Note: Wall thickness checks are especially important following any period of
operation with excursions outside the recommended acid strength range for the
HRS. Report any changes observed to MECS Inc.
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HRS MAINTENANCE
 Inspect and clean HRS tower acid distributor troughs and downcomers. Repair
downcomer pipes and glass inserts if necessary.
 Inspect and clean base of tower (after complete drainage).
 Inspect, clean, and repair (if necessary) outlet screen at tower bottom inlet to pump
boot.
 Inspect Pump Boot internals including dip pipes and bubbler tubes. Access is
through the pump nozzle, while pump is removed for servicing.
Note: The internal surface of the pump boot should be absolutely clean before
reinstalling pump—any small debris may jam the impeller due to tight clearances.
 Observe acid distribution to distributors and ensure uniformity. Replace distributor

orifices if necessary to achieve uniformity (equal liquid level depth in all troughs).
2.6 HRS Mist Eliminator
 In this plant, the HRS Mist Eliminators are installed in the top of the existing
Interpass Absorbing Tower and their function should be considered as part of the
HRS system.
 Take a stick test at the HRS tower gas outlet weekly. Refer to Troubleshooting
Appendix 2 of this manual for discussion of possible problems and corrective
actions.
 Monitor gas pressure drop across the mist eliminators (using a portable manometer
or pressure gage). See Troubleshooting Appendix 2 of this manual for discussion of
possible problems and corrective actions.
2.7 HRS Heater
The HRS heater is a ZeCor-310M stainless steel shell and tube heat exchanger, which
receives hot acid from the exit of the HRS boiler (in the tubeside of the heater) and
discharges cooled acid to the existing acid plant The acid exchanges heat with boiler
feedwater from the deaerator to the HRS boiler.
 Be vigilant for signs of a leak in the exchanger tubes. This will normally be of boiler
water into the acid. Leakage is indicated by high conductivity of the exit water from
either heat exchanger and by drop in acid concentration between the acid inlet and
exit. Since the leak will grow rapidly, early detection is imperative to prevent
total destruction of the tube bundle. In the event of leakage, the exchanger can
be bypassed and drained on the acid and water side for repair while the HRS
continues to operate at reduced rate.
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Note: This requires installation of blanks in the acid inlet and outlet nozzles of the
heater to isolate it on the acid side. The reduced rate may be required to prevent
overheating of the common pump tank acid due to the increase in acid temperature from
the bypassed heater. Damaged tubes may be plugged using the plugging procedure.
 Record acid and water inlet and outlet temperatures to determine heat transfer rates.
If heat transfer rates fall significantly, it is a sign of fouling (which is very unlikely in
these heat exchangers due to the purity of both the water and acid streams).
 Check shell thickness with "D" meter or similar sonic measuring device
(Krautkramer-Branson is a well known manufacturer of "D" meters). It is
recommended that the location of the measurements be permanently marked on the
cooler, as plate thickness will vary slightly.
 Open inspection ports in the shell and check tube thickness with "D" meter or special
OD calipers.
 Open the inspection ports and manholes and check for signs of corrosion of
tubesheet and tubes. If the tubesheet area requires cleaning or exhibits non-uniform
corrosion, the channel should be removed for further inspection and cleaning.
 Look for solids build-up or scaling/fouling on inside and outside of tubes. Chemical
cleaning may be required to restore rate of heat transfer. Check for sediment build-
up on top of tubes and bottom of shell. See the Appendix of this manual for cleaning
procedure.
Note: fouling on either side of the tubes should be negligible--if significant on the
water side, it is a sign of inadequate boiler water treatment.
Note: Prior to removing any inspection nozzles or the exchanger channel, ensure
spare gaskets are available to replace the existing gaskets.
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2.8 HRS Acid Piping
The main HRS acid circulating piping is ZeCor HRS alloy. All acid piping is insulated
and smaller lines (sample, drain, etc) are electric traced and insulated. All low points
are provided with drain valves and drain piping either to the pump boot or the drain
pump.
Note: Carbon steel should not be allowed to contact any ZeCor-310M piping to avoid
galvanic corrosion. 304 SS “poison pads” should be welded to the piping between the
piping and the carbon steel part.
 Measure wall thickness of main circulation piping once per month at selected points
and monitor corrosion rates. Selected points should be in the sections between
pump and boiler and between dilutor and tower 1st stage. Use "D" meter or similar
sonic measuring device (Krautkramer-Branson is a well known manufacturer of "D"
meters). The measurements should be repeated at the same locations, which
should be permanently marked, with removable insulation plugs, because plate
thickness will vary slightly.
Note: Wall thickness checks are especially important following any period of
operation with excursions outside the recommended acid strength range for
the HRS.
 Ensure electric tracing is functioning on all small sample lines, etc (where there is
stagnant acid, as shown on the Piping and Instrument Diagrams) during cold
weather to prevent freezing of acid.
 Service and maintain all valves (packing glands, actuators) per vendor’s
recommended practice.
 Inspect the HRS sample coolers for corrosion and replace with the spare if
necessary.
 During plant shutdowns, the best way to ensure that weak acid is not being formed in
the piping (from atmospheric moisture) is to continue circulation of acid at or above
minimum strength (97% H2SO4). During periods of extended downtime when
circulation is stopped, be sure that all sections of piping are completely drained of
acid. Accumulation of weak acid in HRS alloy piping (and equipment) will result in
localized accelerated corrosion.
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3. EQUIPMENT TROUBLESHOOTING GUIDE
This section describes maintenance actions required to correct operating problems

caused by HRS equipment trouble.
A. HRS Acid Circulation Pump
Operating Problem: Low acid flow to HRS tower 1st stage.

Low pump motor current.
Pump boot level is OK or high and level control valve is full
open.
Maintenance Action: Inspect and repair HRS acid circulation pump.
Operating Problem: Severe noise/vibration of pump.
Maintenance Action:Verify pump boot level is not low (causing cavitation). Inspect
and repair HRS acid circulation pump.
Operating Problem: High temperature in HRS circulating pump bearing.
Bearing cooling water flow OK.
Maintenance Action: Repair/replace HRS pump bearing.
B. HRS Boiler
Operating Problem: Suspected acid leak in boiler, indicated by low dilution water
flow, drop in acid strength across boiler (between strength
analyzers at HRS pump and HRS heater outlet), high boiler
outlet acid temperature, and/or high conductivity of boiler
blowdown.
Maintenance Action: Verify that low dilution water flow is not caused by upstream
steam leak which would be indicated by below-normal acid
concentration at HRS pump discharge analyzer.
If analyzer indication is normal, initiate emergency shutdown of
HRS and plant and follow the procedure for Planned HRS
Shutdown (for boiler leak) included in the Appendix of this
manual.
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C. HRS Diluter
Operating Problem: Unusually severe vibration of the HRS diluter.
Maintenance Action: Blow-out Y-strainer in air supply to sparger and ensure

adequate air flow to sparger. Shut-down and inspect sparger
and replace if damaged.
D. HRS Tower and Mist Eliminator
Operating Problem: Excessive acid collection in HRS exit duct knock-out pot (>
four liters/day), or very spotty stick test in the duct following the
HRS tower.
Maintenance action: Verify HRS tower acid flows, concentrations, and temperatures
are correct.
At next opportunity, inspect HRS tower acid distributors and

clean/repair downcomers and ensure uniform acid flow (liquid
level) in all distributor troughs. Inspect mist eliminator
elements, flanges, drain pipes, and correct as necessary.
Operating Problem: Stick test gives generally discolored stick, indicating SO3
slippage.
Maintenance Action: Verify acid strength to HRS tower is not too high or acid flow to
HRS tower is not too low.
At next opportunity, inspect HRS tower acid distributors and

clean/repair downcomers and ensure uniform acid flow (liquid
level) in all distributor troughs.
Operating Problem: High pressure drop across HRS mist eliminator.
Maintenance Action: Inspect and clean elements if pressure drop > 750 mm wg.
Cause could be sublimed sulfur or iron sulfate from unusual
corrosion upstream. Refer to mist eliminator element washing
procedure in the Appendix of this manual.
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4. APPENDIX
4.1 Planned HRS Shutdown (for Boiler Leak)
Operation with an HRS boiler internal leak for even a short period of one hour can cause
severe damage to the boiler and associated equipment. The plant must be shut down
immediately upon a boiler leak or when conditions indicate that the boiler is leaking.
Under normal operating conditions, the leak will be from the water (high-pressure) to the
acid (low pressure) side. This may cause steam generation in the acid side due to heat
of dilution. Over-pressure due to this steam generation is not likely since the acid side
pressure eventually reaches the water side pressure, causing water leakage to stop.
Both sides of the boiler are designed to handle full steam pressure.
HRS emergency shutdown interlocks are provided to protect the HRS from damage due
to low acid concentration. If an internal boiler leak develops, it will create conditions
which will trip the HRS shutdown interlocks. However, by the time these conditions are
reached, the boiler internals will probably already be severely damaged.
In addition to the shutdown interlocks, the plant is equipped with several other alarms
and process indicators that might indicate a possible boiler leak. In general there is no
direct method, under normal operating conditions, to positively know that abnormal
conditions are caused by a boiler leak or a condition elsewhere in the plant.
The operator must be constantly vigilant and aware of alarms or abnormal conditions
and must take prudent action if a leak is suspected to minimize damage. The operator
must evaluate the operating information at hand and decide whether to continue to
operate or actuate the HRS emergency trip button on the HRS panel if the interlock
system has not already shut the plant down.
Once the plant is down, the operator must determine if the boiler is in fact leaking or if
the indications were a false alarm caused by some other conditions in the plant.
4.1.1 Boiler Leak Indications
The following alarms or indications could indicate a boiler leak before the
automatic shutdown interlocks are actuated:
 Low acid concentration returning from the HRS diluter or low concentration
alarm.
 High ratio of HRS boiler feedwater to HRS dilution water flow.
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 Note that this can also be an indication of low acid strength in the common
pump tank acid to the diluter, a leak in the high pressure steam system, or
rising water level in the HRS boiler.
 High acid temperature at the inlet to the HRS Boiler
 High acid temperature at the outlet of the HRS Boiler
 Decrease or reversal of boiler acid temperature differential.
 High conductivity HRS boiler blowdown. Extensive damage may already have
occurred when this indication is observed. This condition can occur when
the HRS Boiler is vented to atmosphere or at reduced pressure, permitting
acid flow to the water side of the boiler.
Based on the total operating conditions plus some of the above alarms, the
operator may determine that there is a high probability of a boiler internal leak. If
this situation occurs, the operator should actuate the HRS emergency trip button
on the HRS panel. Do not wait for an interlock trip condition to be reached.
4.1.2 HRS Shutdown Follow-up Activities
Verify that all of the HRS emergency shutdown actions have been taken:
 Main blower shut down

 Common pump tank dilution water blocked
 HRS dilution water blocked
 HRS boiler steam vent valve open
 HRS boiler steam outlet blocked at backpressure control valve
 HRS acid circulation pump shut down
 HRS boiler feedwater blocked at level control valve
 HRS boiler emergency blowdown valve open
 HRS boiler acid drain valve open
 HRS acid drain pump running
 IP boiler feedwater pumps stopped
 HRS heater acid bypass valve opened
 Common pump tank crossflow valve to HRS diluter closed
 HRS diluter purge air blocked
Note: If the HRS interlock is tripped due to low-low concentration to the

HRT, then these interlocks will have to be bypassed also to restart
the Main Blower.
At the common or final pump tank, close the manual dilution water block valve.
Verify that the dilution water bleed valve is open.
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 At the HRS diluter, close the dilution water and sparge air block valves.
Verify that the dilution water and sparge air bleed valves are open.
 Close the manual valve at the HRS boiler steam outlet.
 Close the manual valve in the acid line to the Diluter.
 Shut down the HRS boiler chemical feed pumps.
 Restart the main blower and purge the plant with air for several minutes (this
will require bypassing the low-low acid flow to the HRS interlock).
 In the event of an emergency HRS trip due to low-low concentration, check

the acid concentration in the heat recovery tower by local readout. Open the
heat recovery tower drain valve and use the HRS acid drain pump to pump
acid from the heat recovery tower base through the acid analyzer and back
into the tower. If the acid concentration is less than 96%, take a sample for
lab analysis from the drain pump casing drain. Do not open the heat
recovery tower drain valve until boiler leakage has been completely
drained.
Note: If weak acid (<96%) has formed in the HRS, steps should be
taken to vent hydrogen that may have formed as a corrosion product.
Open the manway at the top of the heat recovery tower to vent the tower
and pump boot as soon as possible after the main air blower has been
shutdown, using non-sparking tools. Check for residual hydrogen in
any vessel that is opened for maintenance or repair.
If the HRS tower acid concentration is below 97% but not below 90%, it
should be pumped to the owners combination or FAT pump tank using the
HRS drain pumps The HRS heater, and HRS pump boot should also be
drained, without cooling, using the HRS drain pumps. This is to stop
corrosion of the HRS by the hot, weak acid. The final, interpass, and drying
tower acid should be circulating in order to mix and cool the hot HRS acid
with the stronger, cooler, tower acid and prevent corrosion of the final,
interpass, and drying tower systems. The acid will eventually be
automatically pumped to product storage via the pump tank level controller.
If the HRS tower acid concentration is below 90%, it is even more

imperative that it be removed quickly (less than 8 hours) to prevent
accelerated corrosion of the tower, pump boot, and pump. However, the
concentration may be too low to pump into the owners combination or FAT
pump tank and may need to be drained by gravity to the HRS or strong acid
area sumps.
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Hoses used to transfer the acid should be Teflon-lined or other non-metallic

material suitable for the hot (204 °C) acid.
 Check the boiler blowdown pH and conductivity.
 Check acid concentration in the final tower pump tank and change out if it is
below 97%.
 Study the operating data to determine if the indication of a leak is from the
HRS boiler or another cause. Check the common pump tank and the HRS
acid concentration recorders and historical trends, dilution and boiler
feedwater rates, acid temperatures, and compare acid concentration to
corrosion indicator readings. Look for plant upsets (other than an HRS boiler
leak) that could cause low acid strength (i.e. dilution water valve stuck in
open position, waste heat boiler, economizer, or superheater steam or water
leak).
 Shut down the HRS drain pumps immediately after the boiler has been
completely drained on the water and acid side (as indicated by the pump
discharge pressure gage or sounds of pump cavitation).
4.1.3 Boiler Leak Verification
This procedure is used only to verify the condition of the HRS boiler when an
examination of plant data indicates no probable damage to equipment or if the
shutdown was caused by an unknown event. If any plant data indicates doubt
about the boiler condition, proceed to Section 4.1.4. To determine whether there
is a boiler internal leak, do the following tests:
 With the acid side completely drained, remove a section of acid drain line
adjacent to the main HRS boiler acid inlet line at the auto drain valve location.
 Fill the boiler shell with water to the normal operating level and look for water
leaking out the section of drain line removed in step 1 above. If water is
leaking, prepare to isolate the HRS and inspect the HRS boiler (see 4.1.4
below).
 If no water is leaking out the drain line in step 2 above, pressurize the boiler
shell with high pressure air by connecting a utility hose to the vent valve on the
steam separator. If water leakage appears, prepare to isolate the HRS and
inspect the HRS boiler (see Section 4.1.4 below).
 If no water is leaking out the drain line in step 3 above, vent the steam drum
and replace the section of acid drain line.
 Fill the HRS with 98.5% acid and restart the acid plant.
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 Do the Phase 1 and Phase 2 HRS boiler leak tests in section 8 of the operating
manual, during the restart of the plant. If leakage is found, follow steps listed in
Section 4.1.4 below. If no leakage is found, continue with the start-up and
return to normal operation.
4.1.4 In the Event a Boiler Leak is Verified
 Completely drain the HRS, then open up and inspect for damage to the heat
recovery tower and piping system.
 Remove the boiler tube bundle and inspect for damage.
 Replace the tube bundle with the spare bundle or repair it by plugging the
leaking tubes (using the tube plugging procedure in this Appendix).
4.2 Procedure for Cleaning HRS Boiler (Acid Side)
Thoroughly drain the acid side of the boiler and then remove the acid side inspection
ports on the boiler head.
4.2.1 Drain and vents the steam/water side of the boiler.
4.2.2 Verify that all tubes are open to fluid flow. Remove the channel and check tube
by tube by blowing compressed air through each tube.
CAUTION: IF A TUBE IS BLOCKED AND HOLDING ACID AND YOU

PROCEED BEYOND THIS STEP, SEVERE CORROSION OF
THE TUBE COULD OCCUR.
4.2.3 Reinstall the acid head.
4.2.4 Install fittings to mate with the chemical cleaning tank at the inspection ports.
4.2.5 Blind off the acid inlet and outlet to the boiler. Provide a drain at the acid inlet at
the low point to drain the cleaning solution when finished and a vent at a high
point to purge air from the system.
An alternate method used by one client is to blind the acid inlet line between the
pump and drain line. If this method is chosen, be sure to thoroughly drain the
acid line and disconnect the drain from the plant acid drain system.
4.2.6 Connect the chemical cleaning tank and pump to the fittings installed on the
boiler head.
4.2.7 Prepare a solution of soda ash or caustic in the chemical cleaning tank.
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HRS MAINTENANCE
One client started their wash with soda ash but switched to caustic as the
release of CO2 caused a lot of foaming in the cleaning pump tank. The
client reported that actual quantities of neutralizing chemical were
somewhat less than estimated below.
Quantities of neutralizing chemicals:
Basis: 1,050 STPD HRS boiler at 10,200 ft2 area – assume 1/16” film of
sulfate at the equivalent acid strength of 100% H2SO4. This volume of
acid equates to 3 tons of H2SO4.
Caustic equivalent as 100% NaOH = 2.5 tons

or
Soda ash equivalent as 100% Na2CO3 = 3.25 tons
Volume: The boiler head and tubes will hold about 1,000 gal (pipe run
not included)
4.2.8 Crack open the vent at the high point in the system. Start the chemical cleaning
pump and fill the system. Add additional quantities of neutralizing agents as
required to maintain the cleaning solution at a basic pH of about nine. Add
additional quantities of demineralized water to maintain the level in the chemical
cleaning tank. When all the air is purged from the system, close the vent valve.
Circulating pump capacity used at one client: 34 m3/h

Chemical pump tank capacity used at one client: 1.7 m3
Contract agent used at one client: Used in plant personnel
Note: If the volume of the chemical cleaning tank is less than the volume
of the boiler and piping, throttle the cleaning pump discharge valve
while filling the system to maintain a constant level in the cleaning
tank. Do not batch fill the system. If an acid / water interface is left
standing in the system, high localized corrosion could occur.
4.2.9 Circulate the solution through the boiler for about 2 hours. Maintain a small
purge stream of cleaning solution at an appropriate discharge point to purge
sulfate sludge from the system. Stop the circulating pump, drain the solution
from the boiler, and inspect the boiler to see if all sulfate is removed. If required,
reconnect the chemical tank to the boiler and circulate the cleaning solution until
the boiler is clean.
4.2.10 When the boiler is clean and drained of the cleaning solution, flush the boiler with
copious quantities of demineralized water. Continue the water flush until the
purge stream is clear and the pH approaches the pH of demineralized water.
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4.2.11 Thoroughly drain the water from the acid side of the boiler and any acid pipe
used in the circulation scheme.
4.2.12 Remove all blinds and cleaning connections and reconnect the acid pipe. Close
all vents and drains.
Flow Scheme, Acid Side Cleaning of HRS Boiler
TO HRS
DILUTER
VENT BLIND
HRS BOILER
FROM HRS
PUMP
DRAIN BLIND
PURGE
CHEMICALS
DEMIN WATER
CHEMICAL
TO HRS CLEANING
DRAIN PUMP TANK
4.2.13 Fill the HRS pump boot with strong 98.6% + H2SO4 and circulate the acid through
the boiler. Refer to the MECS HRS Operating Instructions and follow the
procedures for the Phase 1 and Phase 2 boiler leak checks.
4.3 Procedure for Cleaning HRS Heat Exchangers (Acid and Water Side)
The following is an accepted method of cleaning the HRS Heater.
4.3.1 Water side (shellside) of HRS Heater:
4.3.2 Remove debris from vestibules.
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4.3.3 Hydro-blast inside of tubes with high-pressure water
4.3.4 If calcium or phosphate scale is occurring, the tubes may be chemically cleaned
as follows:
 Blank off water-side inlet and outlet nozzles.
 Circulate inhibited formic acid solution of less than 12%
concentration at 65oC- 93oC.
 Monitor concentration of circulating solution. If concentration drops
below 5%, add more inhibited formic acid to boost to near original
strength.
 When acid strength stops diminishing, it is assumed that exchanger
is clean.
 Drain acid solution and flush clean with water. Sometimes loose
scale will remain in the tubes after the acid wash. This can be
removed by light hydro-blasting (with water in tubeside only).
4.3.5 Acid Side (tubeside HRS heater):
The acid side of the exchanger must be chemically cleaned, as follows:
4.3.6 Drain acid from cooler.
4.3.7 Blank acid inlet and outlet nozzles.
4.3.8 Circulate (pump) 2% sodium hydroxide (NaOH) solution through the cooler at
82oC- 93oC, using the nozzle N8A and the drain nozzle for connections.
4.3.9 Check pH of recycle and add concentrated solution as needed to maintain pH

above 8.
4.3.10 Circulate the NaOH solution for 1 to 2 hours.
4.3.11 Drain the NaOH solution.
4.3.12 Flush the cooler with hot soft (demineralized) water.
4.3.13 Refill with strong acid and return to service.
 Caution: It is extremely important that the NaOH solution be

circulated under pressure to avoid gas spaces in the cooler.
 Caution: It is also extremely important that the cooler be fully
flushed with water immediately after draining the NaOH solution.
Caustic stress corrosion cracking may occur if the above two guidelines are not
followed.
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4.4 Procedure for Tube-Plugging in HRS Heat Exchangers
In the event that the HRS boiler, or heater develops a leak in a tube, individual tubes can
be plugged (allowing operation with reduced surface area) using the following
procedure:
4.4.1 With channel cover plate removed, hydro-blast clean with de-mineralized water
all tube bore surfaces. Remove (blow dry) all residual hydro-blast water by use of
clean/dry compressed air. Mechanically clean (use only stainless steel wire
brush) tubes and face of tube-sheet to remove all remaining surface
contaminants (products of corrosion and any sulfate deposits).
4.4.2 Power-brush the entire face of tube-sheet, especially in weld repair locations, via
use of a powered rotary wire brush.
4.4.3 Wire brush clean bore of tube that is to be plugged, at least 600mm deep from
tube-sheet face.
4.4.4 Use rubbing alcohol to further clean tube end and tube-sheet in repair location.
Use cloth swabs to clean tube bore, same as wire brush depth. Suggest use of
shotgun type cleaning swabs.
4.4.5 Block repaired tube bore with “tampon”, approximately one foot from tube-sheet
face. This is to prevent liquid from entering backside during welding.
4.4.6 Use GTAW (TIG) welding process to weld plug(s). Avoid weld crater crack. Start
and stop arc on plug and not in weld seam or on tube-sheet. Weld repair is to be
done only when tube-sheet temperature is at least 21oC.
4.4.7 Recommended plug geometry is shown on the sketch below.
Note: Tack weld end of plug to piece of filler wire to hold in position during
weld out. Grind off to remove when finished. Liquid dye penetrant test and
visually inspect all repair welds. Any weld indication is to be totally ground out
and re-welded.
Hydro-test of repair welds is recommended. For this purpose, neutralize the shell
side of the heat exchanger and use de-mineralized, low chloride water on shell
side to conduct a hydro-test. Drain and blow- dry shell side completely. Hydro-
test pressure shall be same as that shown on the nameplate.
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APPENDIX 05
HRS MAINTENANCE
30°
30°
PLUG
310s DETAIL
Plug Detail USE
UseZECOR®-310N
ER310
filler wire
WIRE
Plugged Tube Detail
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APPENDIX 06
PROCEDURE FOR MOTHBALLING H2SO4 PLANTS
1. GENERAL
Occasionally there is a need for a sulfuric acid plant to be shut down or idled for long
periods of time, with the expectation that it will be restarted at some future date. If the
plant is simply stopped and all acid drained from the systems, severe corrosion is likely
to occur, which will cause major expenses for replacement or repairs before it can be
restarted. This is a brief discussion of the major points to consider in preparing a sulfuric
acid plant for extended outages, to minimize the damage from the idleness, and to
minimize the costs for restarting the plant.
There are two basic types of layaway, or “mothballing”, that can be considered:
1. Shutdown with regular, but limited operator attendance and actions, for an
expected duration of a few months up to as much as two or three years.
2. Shutdown with no planned attendance for long and/or indefinite periods of time.
The principles to be followed for these two types of layaway are distinctly different. In
the first case, the plant will be kept “dry”, in that ambient moisture will be excluded from
essentially all major plant equipment. Strong acid is maintained in the pump tanks and
circulated regularly to ensure dryness of any air ingress. In the second case, all acid
and acidic sulfates are drained, neutralized, and washed out, and moist ambient air is
not excluded from plant equipment.
2. RECOMMENDED PREPARATION AND ACTIONS
2.1 Case 1, Limited Duration:
When the plant is stopped, it should be purged of all SO2 and cooled down by
blowing through, with normal drying tower acid circulation, and with the drying
acid concentration kept at 90% or above at ambient temperatures. When the
plant is near ambient temperature, the blower is stopped, and the air inlet is
blanked. Some plants will also “cap” the stack to exclude rainwater ingress. This
is helpful, but not usually mandatory.
It is necessary that the plant be allowed to “breathe” in response to ambient

temperature changes. This must be done through either the drying tower or
absorbing tower, in order to absorb moisture from the air being drawn in as the
plant cools.
If there is accumulated sulfate in the base of the stack, it should be cleaned out,
and the stack drain left open. The stack drain should also be rerouted to the
sewer instead of left to the pump tank to reduce the dilution from this source.
For the duration of the shutdown, strong acid, i.e. 90% or above, is maintained in
the drying and absorbing tower pump tanks at ambient temperatures. Acid is
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APPENDIX 06
circulated at normal pumping rates through the piping system and over the
towers every second or third day (suggest three times per week as a workable
schedule). The acid concentration is checked regularly, and fresh 98.5% acid is
added as necessary to maintain 90% or above in all pump tanks.
1. Acid Coolers
Strong, cool acid exposure and a few hours’ circulation per week will not
cause undue corrosion to the stainless steel. The water side should be
drained, flushed with chloride-free water, and left open to drain.
2. Main Compressor
The main compressor rotor may be washed and removed from the casing
and stored in a dry warehouse, or it may be rotated by hand a few turns on
the same schedule as the acid pumping. It should not be “bumped”, or
power rotated unless the lubrication system has been kept warm and
running.
3. Converter
Catalyst in the converter may be screened and replaced, or it may be left as
is, depending on the status of the catalyst and the normal screening
schedule. Some owners have opted to keep a small dry air, or nitrogen
purge on the converter, but that is not required if the acid circulation
schedule is maintained as recommended above.
4. Steam System
The process side of the boiler, economizers, and superheaters will be kept
dry by the above procedures. The water, or steam side may be kept full of
cold boiler feedwater containing a suitable phosphate or other corrosion
inhibitor. Alternately, the water, or steam side of this equipment may be
allowed to “float” on the plant steam system. The level control system can
be reconfigured to blow down condensate that occurs as steam “backs” into
the system and condenses. This will keep this equipment relatively warm
and free from acid condensation on the process side.
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5. Gas-Gas Heat Exchangers

These will be kept dry by the above procedures, and no further action is
needed.
6. Miscellaneous
Major control valves and dampers should be stroked on a weekly basis to

assure they do not freeze up.
Space heaters in all electrical motors should be kept energized to keep the
motors dry. At the time of restart, all motors should be “meggered” on all
phases to assure no shorts, prior to being started for the first time.
Instrumentation air systems should be kept “live” and blown out about once
per month. Analyzers should be removed from the process environment,
and stored in a dry warehouse. Other instrumentation will generally not
degrade over this period.
2.2 Case 2, Unlimited Duration:
For this case, there is no planned continuing operator attendance or

maintenance. The costs of “mothballing”, or cleaning and neutralizing the plant
properly need to be considered against the probability of ever restarting if no
special steps are taken.
When the plant is stopped, it is cooled down by blowing through and maintaining
acid circulation in the strong acid towers, similar to case 1.
1. Converter
All catalyst and quartz is removed from the converter, screened, and stored
in plastic lined drums or sacks in a dry warehouse. The converter is swept
out and resealed.
2. Brick-lined absorbing and drying towers and pump tanks
It is nearly impossible to flush or neutralize all the acid in the pores of the
brick linings and ceramic packing materials; nevertheless, it is prudent to try
to do so. The best way is to fill the pump tank(s) with dilute caustic, or soda
ash solution (2 to 4%), and circulate for several days while monitoring and
maintaining the pH above 7.0. A hose can be hooked to the circulating
piping to provide a means for an operator (in proper protective gear) to
wash and neutralize surfaces above the normal irrigated zone. When no
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APPENDIX 06
pH change is noted for a day or two, the system is drained, and the drains
are left open. They will continue to drip for several weeks.
3. Mist Eliminators
Elements should be removed from the towers and neutralized by immersion

in dilute caustic (2 to 4% solution), then rinsed with clear water. They can
be stored in a warehouse, or outdoors under a dust cover.
4. Stainless steel Drying, Absorption, HRS Tower and Pumpboot
Due to the cost and vulnerability of stainless steel to weak acid corrosion,
complete removal of all ceramic materials, such as tower packings, support
beams, nozzle liners, etc. is recommended. These items can be
neutralized by immersion in dilute caustic and allowed to drain where the
acidic effluent is acceptable. The empty towers and pump tanks can be
hosed out vigorously with clean chloride-free water and allowed to drain.
Strong acid pumps should be thoroughly flushed, drained, and stored

vertically. They can be left in the pump tanks if desired.
5. Acid Coolers
These will be neutralized along with the tower circulating system.

Afterward, they should be flushed with chloride-free water on both the acid
and water sides, and allowed to drain.
6. Steam System
The water/steam side should be well flushed with a suitable corrosion

inhibitor, drained and sealed. The process side of this equipment should
be vigorously flushed, i.e. fire hose, drained and left with the drains open.
Any accumulated acid sulfates that are not washed out will absorb ambient
moisture to form weak, very corrosive acid, resulting in major corrosion in
those locations.
7. Gas-Gas Heat Exchangers
These are very difficult to protect. By their configuration and service, they
will normally collect acid sulfates on the lower tubesheets. If these sulfates
are not completely dissolved and removed, they will absorb ambient
moisture to form weak acid, and eventually dissolve the tubes just above
the tubesheet. The best way to remove the sulfates is to cut two large
“windows”, 1800 apart, each approximately ¼ circumference wide by 3’
high. These give the best access to this area for high pressure water
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APPENDIX 06
flushing, followed by neutralization with dilute caustic. Following drying, the

“windows” are welded back in place, and the drains are left open.
8. Sulfur System
Sulfur storage tanks and pits can be left full or empty of sulfur, so long as
the steam coils are either kept hot, or drained and dried to prevent damage
from freezing weather. The same is true of the sulfur pumps and piping.
Most owners will opt to pull and clean the sulfur pumps, and store them
vertically in a warehouse or outdoors.
9. Miscellaneous
Electric motors can be left de-energized, with the understanding they will
have to be “meggered” prior to restart. There will be a chance that they will
have to be oven dried prior to re-energizing.
Analyzers should be stored in a dry warehouse. Other instruments can be

removed from the process and stored indoors or can be left in place and
allowed to “take their chances” with the weather. All instruments will have
to be checked out as part of the recommissioning of the plant.
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GENERAL NOTE:
Throughout this section, there are references to chemical reagents and laboratory
equipment items by manufacturer and model number. Some of these may no longer be
available. If no longer available, substitutions of substantially equivalent chemicals or
lab equipment should be made.
1. SO2 GAS TESTS (REICH TEST)
Refer to MECS Standard Drawings 100-6-8 and 100-6-9 for the following gas tests.
1.1 Entrance Gas Test
1. The sample line should be flushed thoroughly with process gas before
proceeding with the test in order to obtain a sample representative of
operation at the time of the test.
2. Fill the shaker bottle approximately two-thirds full of water and add
about 5 ml of starch solution.
3. Bring the solution to a faint blue color by adding one or two drops of
N/10 iodine solution.
4. Add 10 ml of N/10 iodine to the bottle by means of the pipette.
Note: It is preferable to use the same water with starch indicator in

the shaker bottle for a number of determinations. New water
in the shaker bottle should either be acidified with two drops of
acid or the first determination should be repeated to obtain a
good reading.
5. With all clamps and stopcocks closed, place the rubber stopper in the
test bottle.
6. Adjust the water level in the 250 cc. burette to the “zero mark” by raising
the water bottle with the glass stopcocks at the top and bottom of the
burette open.
7. Close the top stopcock and place the water bottle back on the table.
Make sure that all connections in the apparatus are tight.
8. Open the clamp on the sampling tube, adjusting it so that the gas
bubbles pass slowly through the solution in the bottle. Shake the bottle
continuously when gas is bubbling in to ensure complete SO2
absorption. Continue until the solution has changed to the same faint
blue color in step 3 above. Be careful not to over-run the end point.
INFORMATION AND KNOW-HOW HEREON ARE CONFIDENTIAL AND PROPRIETARY PROPERTY OF MECS, INC. AND MAY NOT BE USED, REPRODUCED, OR
REVEALED TO OTHERS EXCEPT IN ACCORDANCE WITH THE TERMS OF A CONTRACT WITH OR OTHER WRITTEN PERMISSION OF MECS, INC.
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9. Close the clamp on the sampling line tightly when the end point has
been reached.
10. Raise the water bottle so that the water level in it is balanced against the
water level in the burette, and record the amount of air that has been
displaced in the burette.
11. Record the temperature on the thermometer.
12. Refer to the “Entrance Gas” section of Drawing 100-6-9 and to the
column headed by the temperature nearest that noted during the test.
Follow down this column until that number is found which is nearest to
the measured volume of air in the cylinder. Then read the
corresponding %SO2 from the table.
For example, if the temperature was 30 °C and the measured volume

was 145 ml, then the strength of the gas would be 8.0%.
1.2 Exit Gas Test
The water aspirator, which maintains a suction on the exit gas sampling line,
should be left running at all times in order to ensure a representative sample of
gas. If gas is flowing through the line, a slight suction will show on the
manometer.
In the Exit Gas Test apparatus, repeat the procedure listed in Section 1.1, but
use 1 ml of N/100 iodine solution instead of N/10 iodine solution in steps 3 and
4. Record the volume of air displaced and the temperature as before, and then
refer to the “Exit Gas” section of Drawing 100-6-9 for the %SO2.
1.3 Conversion Efficiency
For the percent conversion efficiency, refer to Drawing 100-6-8.
For example, if the entrance gas was 8.5% and the exit gas was 0.05%, the
conversion efficiency would be 99.5%.
1.4 Solutions
The solution of N/100 iodine solution may be prepared with sufficient accuracy
by measuring 100 ml of the standardized N/10 iodine solution in a graduated
cylinder and then diluting this with water to 1,000 ml in a 1,000 ml graduated
cylinder.
All iodine solutions should be kept in a brown bottle and in a cool place.
Always replace the glass stoppers as soon as possible.
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Starch solution sours quickly due to bacterial and mold growth, which turns the
iodine solution brown instead of blue so that a clear end-point is not obtained.
Fresh starch solutions should be prepared weekly or even more often in warm
weather. However, if the starch solution is prepared as follows, it will keep for
months without deterioration or sensitivity loss.
2% Stabilized Starch Indicator Solution
Ingredients:
 Soluble indicator starch, Mallinckrodt, Cat. No. 8188, or equivalent.
 Glycerine, AR, Mallinckrodt, Cat. No. 5100, or equivalent.
To a vigorously boiling mixture of 100 ml of distilled water and 100 ml of

glycerine, add a thick paste consisting of 4 grams of starch in a
minimum of distilled water. Boil for 3 minutes and allow to cool.
To prepare a smaller amount of indicator solution, reduce quantities in

proportion.
2. ORSAT GAS ANALYSIS
2.1 General Description
The Orsat gas analyzer is composed of a gas measuring burette with a leveling
bottle and three absorption pipettes for separate absorption of the gas
components (SO2, CO2, and O2). All glass joints and stopcocks should be
lubricated with a minimum amount of good stopcock grease to prevent gas
leakage. Mercury is normally used as a leveling fluid, but if its use is prohibited
by local plant regulations, manometer oil with a specific gravity of about 2 to 3
will give reasonably good results.
Orsat equipment having only one absorption pipette is frequently used at single
absorption sulfur burning plants to measure oxygen in the stack gas. The gas
sample actually used is the effluent from the Reich test that has had its SO2
content removed.
Single pipette Orsat equipment can be ordered from Fisher Scientific Co. as
No. 10-623, Type EF. Three pipette Orsat equipment should be ordered as
Fisher No. 10-605, Type B, but having the usual style pipettes replaced with
three No. 10-642 pipettes to eliminate contact with copper strips which will
otherwise be present.
2.2 Operation of Analyzer

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The sample burette should be flushed thoroughly with the process gas to
obtain a representative test sample. When drawing the sample to be analyzed,
fill the sample burette with the mercury level in the burette and bottle equal
before closing the stopcock, so that the measured volume of gas will be at
atmospheric pressure.
The gas is to be analyzed for SO2, CO2, and O2 in that order. It is necessary to
maintain proper order, since the absorbing solutions are not selective in any
other order. For example, if CO2 were analyzed first, all of the SO2 would be
absorbed along with the CO2 in the potassium hydroxide solution.
The gas should be “pumped” through each of the pipettes until a constant
reading is obtained in the measuring burette. Each time a reading is to be
taken, the absorbing solution should be drawn up into the neck of the pipette,
the stopcock closed, and the reading taken with the mercury in the burette and
bottle at the same level. Record the decrease in gas volume after absorption
of each of the components. If the original gas sample is 100 cc, the difference
in readings will be the percent of each gas component. The balance of the gas
remaining in the burette after absorption is nitrogen.
2.3 Absorption Solutions
1. Sulfur Dioxide
A 30% solution by weight of chromium trioxide, analytical reagent

grade, in distilled water. Can be obtained commercially (Fisher,
Scientific Co., No. A-100).
Alternate solution: 23.5% each by weight of (1) chromium trioxide, (2)

phosphoric acid (86-90% H3PO4 - 1.7 sp. gr.) in distilled water. Heat to
boiling and cool.
2. Carbon Dioxide
A 30-40% solution of potassium hydroxide. Can be obtained

commercially (Fisher Scientific Co., No. SO-P-226).
3. Oxygen
Potassium Pyrogallol Solution. Can be obtained commercially (Fisher

Scientific Co., P-395).
2.4 Cleaning and Maintenance
Periodic cleaning and replacement of the absorbing solutions is necessary to

obtain the best results. Frequency will be best determined by experience. It is
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advisable to have two Orsat units on hand so that one can be cleaned or
repaired while the other is in service.
Most of the Orsat analyzer can be cleaned with water. The measuring burette
sometimes requires a good washing with dilute nitric acid and/or detergent.
The SO2 absorption pipette generally has to be cleaned with aqua regia.
If the mercury used in the measuring burette becomes dirty, it can gradually be
cleaned by washing with water in a separating funnel. Sometimes a wash with
dilute nitric acid is necessary followed with water washes.
3. ACID MIST IN DRIED AIR OR GAS
Refer to the drawing “Apparatus for Determination of Acid Content of Acid-Dried Air or
Gas and Exit Gas in Contact Sulfuric Acid Plants” at the end of this section.
3.1 Extend a right-angle glass sample tube into the flue approximately one-third the
distance across it. The end of the tube should face into the gas stream. The
diameter of the tube, when sampling at the desired rate of 225 to 340 L/h,
should allow the same gas velocity entering the tube as the gas velocity in the
flue. The velocity in the flue may be calculated from the plant production rate
and the gas strength, or alternately determined by means of a Pitot tube. The
sampling connection may be made by welding a 25 mm coupling into the flue.
The sample tube may be held in place by means of a one-hole rubber stopper.
3.2 For removal of the acid particles from the sample, connect a series of filters
directly to the sample tube. Either of two types of filters may be used as
described below:
1. The preferred filter is the Buechner-type, medium porosity, fritted glass

filter with a capacity of 30 to 40 ml (E.H. Sargent and Co., Cat. No.
S355910). Connect the filter by one-holed rubber stoppers. Two filters
in series should be used for acid dried air or gas, and three filters in
series should be used for gas from the exit stack.
2. Gooch-type filtering funnels (E.H Sargent and Co., Cat. No. 6S-24485)
packed with acid washed, ignited, dry asbestos, supported in a
perforated porcelain plate in the bottom of the funnel may be used. The
asbestos should be packed tight enough to function efficiently but not
tight enough to seriously restrict gas flow. Two or three filters in series
should be used for dry air or gas, and four filters should be used for exit
stack gas. The end of the sample tube and the end of the stem of each
funnel should extend into the asbestos to the following funnel. A blank
acidity determination should be made on a portion of the asbestos
before using it.
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Glass filters are preferred because they are superior to asbestos filters for mist
removal, and they are simpler to use than asbestos filters. However, the
pressure drop through glass filters is usually great enough to require the use of
a vacuum pump or aspirator to draw sufficient gas flow through the testing
equipment.
3.3 To the end of the filter train, connect a flow meter. Also provide a thermometer
for measuring the temperature and a manometer for measuring the static
pressure of the gas passing through the meter. A gas meter (Sprague Type
175 laboratory test meter, Sprague Meter Company, Bridgeport, CT) or a
calibrated orifice flow meter may be used.
3.4 To draw the gas sample from the flue through the test apparatus, connect the
flow meter to either a vacuum pump or an aspirator operated with air or water.
A vacuum pump or aspirator is not required for tests on dry air or gas if the gas
pressure is great enough to force the sample through the apparatus.
3.5 The gas flow may be regulated by a screw clamp in the sampling line either
before or preferably after the filters. However, if a vacuum pump or aspirator is
used, the flow regulation screw clamp should be after the flow meter instead of
before or after the filters.
3.6 Allow the gas to flow through the apparatus at the calculated rate (225 to 340
L/h). Record the meter reading, temperature, and pressure periodically.
Maintain a steady flow.
3.7 The test on dry air should be continued for about 5 to 6 hours, or if the gas is
substantially acid-free, for 24 hours. The test on exit gas should be continued
for about 3 to 4 hours (700 to 1,150 liters).
3.8 At the end of the test, disconnect the flow meter. Carefully remove the sample
tube from the flue so that any acid that might have collected in the tube is not
lost.
3.9 Wash the acid from the inside of the sample tube.
3.10 Wash the filters, with suction, until the washings are acid free. Combine the
washings with the sample tube solution. To check whether the filter bulbs
caught all of the acid in the sample, the last bulb should be washed and titrated
separately.
3.11 If the gas tested contained any SO2, slowly boil the washings for 15 minutes to
remove any dissolved SO2.
3.12 Titrate the washings with standard NaOH (N/100 for dry air or gas, and N/20 for
exit gas) to a methyl red endpoint. Express the acidity as milligrams of H2SO4.
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3.13 Calculate the volume of the gas sample as cubic meters at standard conditions
(0 °C and 760 mm Hg).
3.14 Express the acid content of the gas as mg H2SO4 per cubic meter of dry gas at
standard conditions.
3.15 In order to interpret and compare test results, it is essential that any pertinent
operating data, including production rate and gas strength or the air or gas
volume, be reported along with the test results.
4. MOISTURE IN DRIED AIR OR GAS
Refer to the drawing “Apparatus for Determination of Moisture Content of Acid-Dried Air
or Gas in Contact Sulfuric Acid Plants” at the end of this section.
4.1 Choose a convenient sampling location on the discharge side of the drying
tower. A 6 mm steel pipe with an all-iron gate valve close to the flue may be
used for the sample connection. Before making a test, clean the line
thoroughly to remove any acid or acid sulfate that might have collected in it.
Another suitable type of sampling connection may be made by welding a 25
mm pipe coupling to the flue and extending a glass sample tube through it.
The sample tube may be held in place by means of a one-hole rubber stopper.
4.2 For removal of any acid particles or other foreign material from the sample,
connect a filter to the sample line. Either of two types of filters may be used as
described below:
1. A Gooch-type filtering funnel (E. H. Sargent and Co., Cat. No. 8S-
24485) packed with acid-washed, ignited, dry asbestos supported on a
perforated porcelain plate in the bottom of the funnel may be used. The
asbestos should be packed tight enough to function efficiently but not
tight enough to seriously restrict the gas flow. If the air or gas contains
an appreciable amount of acid, two filters in series should be used.
2. A Buechner-type, medium porosity, fritted glass filter with a capacity of

30 ml (E. H. Sargent and Co., Cat. No. S35591d) may be used. The
pressure drop through the glass filter may be too great to allow a
sufficient flow of gas through the testing equipment without the use of a
vacuum pump or aspirator.
The connection between the sample line and the filter should be made
with a minimum length of rubber tubing or preferably with no rubber at
all.
4.3 Allow several liters of gas to flow through the sample line and filter bulb to allow
the system to reach an equilibrium moisture condition with the gas sample.
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The gas flow may be regulated by the valve in the sample line and by a screw
clamp in the line after the filter. After blowing out the line and filter, close the
clamp at the end of the filter to keep the line and filter dry.
4.4 Connect to the filter two moisture absorption bulbs accurately weighed in
grams to four decimal places. Nesbitt bulbs (E. H. Sargent Co., Cat. No. S-
22025) are recommended because they can be closed easily and are large
enough in diameter to have a relatively low gas velocity through them during
the test. However, large, glass-stoppered U tubes may be used satisfactorily.
The bulbs may be packed as described below:
1. P2O5 is the preferred absorbent but has the disadvantage of “gas

channeling” unless packed properly. The following method is
recommended. First, place about 19 mm of glass wool in the bottom of
the Nesbitt bulbs. Then, cut some glass wool into lengths 6 mm or
shorter and mix with P2O5 to coat the glass fibers. This mixture is
packed in the bulbs, using first a 19 mm layer of the P2O5 alone, and so
on with alternate layers until the bulb is about ¾ full. The final layer
should be glass wool alone to prevent blowing P2O5 from the bulb.
Close the stopcocks as soon as possible.
2. The bulbs may also be packed with a mixture of P2O5 and a carrier such
as Drierite (anhydrous calcium sulfate). This mixture is easy to handle
and does not “channel” easily.
3. Anhydrone (pure anhydrous magnesium perchlorate) may be used as

an absorbent, but it is recommended that only the first bulb be packed
with Anhydrone and the second with P2O5.
Tightly packed areas might obstruct the flow of gas and are to be avoided.
Resistance through each bulb should be less than 250 mm w.c. when passing
140 liters per hour. The gas is drawn down the side tube and up through the
bulb. The stopcocks should be fastened with thin copper wire to prevent
blowing them out during the test. Use a minimum amount of stopcock grease
to prevent grease getting into the gas inlet and outlet arms. If a loss of weight
occurs in the second bulb, it is probably due to particles of the absorbing
material or of the glass wool being blown out of the bulb, and the glass wool
mat should be replaced.
If the moisture test is run on SO2 gas rather than air, several liters of the gas
to be sampled should be passed through the bulbs before weighing the first
time after being packed. The bulbs should be connected by a short piece of
rubber tubing that must fit snugly, be clean, and be free from cracks.
4.5 To the second moisture bulb, connect a flow meter. Also, provide a
thermometer for measuring the temperature and a manometer for measuring
the static pressure of the gas passing through the meter. A dry type gas meter
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(Sprague, Type 175, Laboratory Test Meter, Sprague Meter Company,

Bridgeport, CT) or a calibrated orifice flow meter may be used.
4.6 Very slightly open the gas flow screw clamp between the filter and bulbs, then
open the stopcocks on the moisture bulbs. This procedure keeps the bulbs
under a slight pressure so that they cannot absorb moisture from the exit line to
the flow meter.
Allow the gas to flow through the apparatus at about 140 L/h. The total sample
should be 425 to 575 liters. Record the meter reading, temperature, and
pressure periodically. Unless a vacuum pump or aspirator is used, the meter
pressure will be barometric pressure. Maintain a steady flow.
4.7 At the end of the test, close the moisture bulbs and then the flow rate regulation
screw clamp.
Reweigh the moisture bulbs. When weighing the bulbs before and after the
test, they should be cleaned carefully and desiccated. At least 90% of the total
increase in weight should occur in the first bulb. The bulbs can be used until it
is evident that the first bulb is not absorbing as much as 90% of the moisture.
Then, the second bulb can be used as the first bulb, and the first bulb can be
repacked for use as the second bulb. It is advisable to weigh the bulbs
immediately before and after the test.
4.8 Calculate the volume of the sample as cubic meters at standard conditions.
4.9 Express the moisture as milligrams of water per cubic meter of dry gas at
standard conditions.
4.10 In order to interpret and compare test results, it is essential that any pertinent
operating data, including production rate and gas strength or the air or gas
volume, be reported along with the test results.
5. STICK TEST FOR ACID SPRAY IN PROCESS GAS
This test is used as a quick, semi-quantitative measure of the number of acid particles
large than about 3 to 6 microns entrained in the air or gas leaving drying or absorbing
towers.
The test is conducted by inserting a clean, white, smooth surfaced, soft wood stick
across the full diameter of the gas duct for a period of one minute and visually observing
the number of black spots formed. Sticks are preferably White or Ponderosa Pine, 19
mm wide by 19 mm thick for rigidity, and approximately 1-½ to 2 times longer than the
duct diameter. In situations where only a few spots are found, it may be desirable to
increase the exposure time to 2 minutes. Longer times ordinarily should not be used
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because the stick will tend to darken or turn almost black, particularly if traces of SO3 or
extremely fine acid mist are present, or if gas temperatures are high.
Where internal gas pressures are low, such as at final absorbing tower and drying
towers under suction, the stick is inserted through a 50 mm schedule 80 coupling
provided for this purpose. At drying or interpass absorbing towers operate under
pressure, a 38 mm gate valve should be connected to the coupling to avoid excessive
release of air or gas and entrained acid. The stick is quickly inserted through the gate
valve after allowing air or gas to blow free for a few seconds to remove accumulated
scale and acid. (CAUTION: Stand upwind of the valve and wear a face shield or
goggle, long sleeved shirt, and gloves.)
Where the test nozzle is located at or near a duct elbow, it should be positioned so that
sticks are inserted along or parallel to the axis of the duct downstream of the elbow. If
the test nozzle is located perpendicular to this axis, representative results may not be
obtained because of uneven gas flow distribution at the elbow. If the test nozzle in an
existing plant is not properly located, then several stick tests should be made with the
sticks inserted at different angles to check for uneven spray patterns.
An acceptably small amount of entrained acid will be evidenced by a few spots about the
size of a pin head (in the range of 0 to about 3 or 4 spots). One or two spots are
considered normal even after MECS Mist Eliminators or mesh pads, since some re-
entrainment always seems to occur.
Extremely heavy entrainment is present when many dark spots of about 6 mm to 10 mm

diameter are noted, and the total black area is more than about 35% of the exposed
area. An alternate situation, which indicates the presence of fine mist or SO3 caused by
malfunctioning equipment or operating troubles, is complete blackening of the stick, or
the presence of a multitude of very small black spots. In either event, additional
diagnostic tests and/or appropriate corrective action should be undertaken promptly.
If the number of fair sized black spots is intermediate between the two situations
described above, corrective action should still be taken, but it may be possible to
continue operating the plant if other control points and emissions are normal.
If large black spots are noted, grouped all at the center or at one side of the exposed
stick, it frequently indicates that acid drainage or condensate is being re-entrained from
a particular portion of the duct. Alternatively, a mesh pad or MECS Mist Eliminator just
upstream may have developed a hole, or the sample point may be located too close to
the tower outlet and thus be subject to a jetting effect (vena contracta).
6. THE DEWPOINT METHOD FOR DETERMINATION OF MOISTURE IN AIR
Refer to the Lectrodryer Dewpoint Apparatus attachment at the end of this section.
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The Lectrodryer Dewpoint Apparatus is a simple means for determining the moisture
content of air and other non-corrosive gases at atmospheric pressure. The outer
container is a polished dense aluminum casing. The observation window is a two ply
safety glass. It is sealed in place with special cement. The polished cup is positioned
with a guide ring that insures that the cam locks on the cap will be properly engaged and
the cup assembly will be locked on an “O” ring.
6.1 Operation
1. The air or gas sample is introduced through the inlet by passing it

through metal tubing. The tubing should be butted against the inlet port
and held firm by slipping rubber tubing over the connection. Caution -
Do not use at pressure above 14 kPag.
2. Pass a sample flow of gas through the dewpoint apparatus. Adjust the
flow to about 140 L/h. This flow can be felt when blown against wetted
lips but is not readily felt by the hand.
3. Pour acetone (about 50 mm) into the cup. CAUTION: Acetone is

flammable.
4. After the sample has passed through the apparatus for about five
minutes in order to purge it completely, small amounts of crushed dry
ice should be added to the acetone while stirring constantly with the
thermometer.
5. At the first sign of dew or moisture on the polished surface, the

temperature is recorded from the thermometer. This reading is an
accurate indicator (within ±3 °C) of the dewpoint of the gas or air being
tested. The use of a mixture of acetone and dry ice in the dewpoint
apparatus makes possible the checking of dew points as low as -76 °C.
By careful practice and a little skill, dew points can be checked quite
closely by several different operators, and the results will tie in
satisfactorily with more expensive gravimetric methods for the
determination of the moisture content.
6. From the date chart included, the dewpoint temperature may be

converter to absolute moisture content. See Table 24-1.
6.2 Suggestions
A reasonably bright light, preferably equipped with a shade, should be used to

illuminate the polished cup so that the very first faint trace of dew can be
detected. The light should be held in such a position that there will be the least
glare from the polished surface.
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It is suggested that the temperature of the acetone / dry ice mixture should be
lowered slowly in order to minimize any error due to temperature lag.
In measuring dew points, the surface of the polished cup should be clean and
free from any grease or dirt. If the surface is not clean, the appearance of the
dew may not be as sharp as desired and may cause errors. Sulfuric acid
vapors will etch the original polish. A fiberglass filter may be installed upstream
of the instrument.
The proper technique is usually gained only after some practice in making
these dewpoint determinations.
When polishing the cup, it is suggested that a soft optical tissue is used to
prevent scratching the surface.
Lectrodryer®
P.O. Box 2500
Richmond, KY 40476
859-624-2091
Fax: 859-623-2436
www.lectrodryer.com
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Table 24-1
DEW POINT TEMPERATURE DATA AT 1 ATMOSPHERE
°C Vapor Pressure mg per m3 mg per kg air

mm Hg x 10-1
-56.7 0.127 16.96 10.37
-55.6 0.146 19.52 11.99
-54.4 0.169 22.36 13.81
-53.3 0.195 25.68 15.93
-52.2 0.224 29.41 18.33
-51.1 0.258 33.64 21.09
-50.0 0.295 38.38 24.19
-48.9 0.339 43.80 27.73
-47.8 0.389 49.98 31.81
-46.7 0.444 56.87 36.36
-45.6 0.508 64.67 41.56
-44.4 0.579 73.39 47.37
-43.3 0.659 83.14 53.94
-42.2 0.749 94.07 61.33
-41.1 0.852 106.41 69.70
-40.0 0.966 120.14 79.07
-38.9 1.095 135.52 89.66
-37.8 1.241 152.79 101.60
-36.7 1.403 172.02 114.90
-35.6 1.584 193.30 129.70
-34.4 1.781 216.23 145.80
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7. MECS CONTRACTED GAS ANALYSIS SERVICE (PEGASYS)
MECS has a testing service available to determine SO2 and O2 in gas streams. The
scope of this service is described in the attached brochure at the end of this section.
8. TYNDALL BEAM TEST
The Tyndall beam test may be used to detect the presence of water vapor in the SO3
gas streams and to locate the source of water such as a leaking superheater.
8.1 Dry the sampling flask or bottle in an oven for 2 hours at 200 °C. The flask or
bottle should be stoppered when allowed to cool in the atmosphere.
8.2 Connect the bottle to the sample point with a minimum length of tygon tubing.
The sample point can be at the outlet of the waste heat boiler, inlet and outlet of
the first pass, or the economizer outlets. Each piece of equipment may be
checked individually in this manner.
8.3 Purge the sample flask with SO2/SO3 gas for approximately 5 minutes. Stopper
the outlet and then the inlet of the sample flask.
8.4 Take the sample flask to a darkened room as quickly as possible and shine a
flashlight through the sample flask. If any moisture is present in the gas, the
light will reflect off the moisture particles showing a light beam (or fog) through
the bottle (Tyndall beam effect). This phenomenon may be likened to sunlight
shining through a darkened room that has dust particles floating in the air.
The above test is qualitative only and is not to be used as a quantitative determination of
moisture content.
If a darkened room is not readily available, a coat or blanket draped over the head of the
analyst can make an effective “hood” in which to check the sample. This usually
requires the assistance of another person.
If a 500 ml suction flask is not available, any convenient size glass bottle may be used,
but a two hole rubber stopper will have to be used as well as another glass tube for the
gas outlet.
If tygon tubing is unavailable, then rubber or neoprene may be substituted, but they are
quickly attacked by the SO3 and will have a relatively short life.
TST 01 - 14
Rev 0
30 May 11
APPENDIX 07
PLANT TESTS
TEST FOR H2O VAPOR IN SO3 GAS STREAMS
Equipment Required
1 - Laboratory Oven for drying glassware.

1 - 500 ml Glass Suction Flask
2 - Laboratory Hose Clamps
1 - 1.2 m Piece of Tygon Laboratory Hose
1 - 150 mm Piece of Tygon Laboratory Hose
1 - Piece of Glass Tubing about 9 mm O.D., Thick Wall
1 - One-Hole Rubber Stopper for 500 ml Suction Flask
1 - Flashlight
TST 01 - 15
Rev 0
30 May 11
APPENDIX 07
PLANT TESTS
9. ATTACHMENTS
The following attachments are included after this page.
 Acid Mist Test Apparatus Sketch
 Moisture Test Apparatus
 Lectrodryer® Dew Point Apparatus
 Drawing Number 100-6-9: Reich Test for SO2
 Drawing Number 100-6-8: SO2 Conversion Chart
 MECS Gas Analysis Service
TST 01 - 16
Rev 0
30 May 11
APPENDIX 07
PLANT TESTS
APPARATUS FOR DETERMINATION OF MOISTURE CONTENT OF

ACID-DRIED AIR OR GAS IN CONTACT SULFURIC ACID PLANTS
B C D E E I
G F
LEGEND
A - AIR OR GAS FLUE

B - ALL-IRON GATE VALVE
C - FILTER
D - FLOW REGULATION SCREW CLAMP
E - MOISTURE BULB
F - GAS METER
G - MANOMETER
H - THERMOMETER
I - ASPIRATOR OR VACUUM PUMP USED WHEN GRP
GAS BEING SAMPLED IS UNDER VACUUM 20-AUG-02
INFORMATION AND KNOW-HOW HEREON ARE CONFIDENTIAL AND PROPRIETARY PROPERTY OF MECS, INC. AND MAY NOT BE USED, REPRODUCED, OR REVEALED TO OTHERS EXCEPT IN ACCORDANCE WITH THE
TERMS OF A CONTRACT WITH OR OTHER WRITTEN PERMISSION OF MECS, INC.
TST 01 - 17
Rev 0
30 May 11
APPENDIX 07
PLANT TESTS
APPARATUS FOR DETERMINATION OF ACID CONTENT OF

ACID-DRIED AIR OR GAS IN CONTACT SULFURIC ACID PLANTS
B C C C G H
E D
LEGEND
A - GAS FLOW IN FLUE

B - SAMPLE TUBE
C - FILTER
D - GAS METER
E - MANOMETER
F - THERMOMETER
G - FLOW REGULATION SCREW CLAMP
GRP
H - ASPIRATOR OR VACUUM PUMP 20-AUG-02
INFORMATION AND KNOW-HOW HEREON ARE CONFIDENTIAL AND PROPRIETARY PROPERTY OF MECS, INC. AND MAY NOT BE USED, REPRODUCED, OR REVEALED TO OTHERS EXCEPT IN ACCORDANCE WITH THE
TERMS OF A CONTRACT WITH OR OTHER WRITTEN PERMISSION OF MECS, INC.
TST 01 - 18
Rev 0
30 May 11
APPENDIX 07
PLANT TESTS
TST 01 - 19
SO2 CONVERSION CHART
PERCENT OF SO2 CONVERTED TO SO3

% SO2 IN % SO2 IN EXIT GASES % SO2 IN
ENTRANCE ENTRANCE
GAS GAS
0.05 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.22 0.24 0.25 0.26 0.28 0.30 0.32 0.34 0.35 0.36 0.38 0.40 0.45 0.50 0.60 0.70 0.80 0.90 1.00
3.5 98.6 97.3 97.0 96.7 96.5 96.2 95.9 95.7 95.4 95.1 94.8 94.6 94.0 93.5 93.2 92.9 92.4 91.8 91.3 90.7 90.5 90.2 89.7 89.1 87.7 86.4 83.6 80.8 78.1 75.3 72.5 3.5
4.0 98.8 97.6 97.4 97.2 96.9 96.7 96.5 96.2 96.0 95.8 95.5 95.3 94.8 94.3 94.1 93.9 93.4 92.9 92.4 92.0 91.7 91.5 91.0 90.5 89.4 88.2 85.8 83.4 81.0 78.6 76.1 4.0
4.1 98.9 97.7 97.5 97.2 97.0 96.8 96.6 96.3 96.1 95.9 95.6 95.4 94.9 94.5 94.3 94.0 93.6 93.1 92.6 92.2 91.9 91.7 91.3 90.8 89.6 88.5 86.1 83.8 81.5 79.1 76.8 4.1
4.2 98.9 97.8 97.5 97.3 97.1 96.9 96.6 96.4 96.2 96.0 95.7 95.5 95.1 94.6 94.4 94.2 93.7 93.3 92.8 92.4 92.2 91.9 91.5 91.0 89.9 88.8 86.5 84.2 81.9 79.6 77.4 4.2
4.3 98.9 97.8 97.6 97.4 97.2 96.9 96.7 96.5 96.3 96.1 95.9 95.6 95.2 94.8 94.5 94.3 93.9 93.4 93.0 92.6 92.3 92.1 91.7 91.2 90.1 89.0 86.8 84.6 82.4 80.2 77.9 4.3
4.4 98.9 97.9 97.7 97.4 97.2 97.0 96.8 96.6 96.4 96.2 96.0 95.7 95.3 94.9 94.7 94.5 94.0 93.6 93.2 92.7 92.5 92.3 91.9 91.5 90.4 89.3 87.1 85.0 82.8 80.6 78.4 4.4
4.5 99.0 97.9 97.7 97.5 97.3 97.1 96.9 96.7 96.5 96.3 96.1 95.8 95.4 95.0 94.8 94.6 94.2 93.8 93.3 92.9 92.7 92.5 92.1 91.7 90.6 89.6 87.5 85.3 83.2 81.1 79.0 4.5
4.6 99.0 98.0 97.8 97.6 97.4 97.2 97.0 96.8 96.6 96.3 96.1 95.9 95.5 95.1 94.9 94.7 94.3 93.9 93.5 93.1 92.9 92.7 92.3 91.9 90.8 89.8 87.7 85.7 83.6 81.5 79.5 4.6
4.7 99.0 98.0 97.8 97.6 97.4 97.2 97.0 96.8 96.6 96.4 96.2 96.0 95.6 95.2 95.0 94.8 94.4 94.0 93.6 93.2 93.0 92.8 92.4 92.0 91.0 90.0 88.0 86.0 84.0 82.0 79.9 4.7
4.8 99.0 98.1 97.9 97.7 97.5 97.3 97.1 96.9 96.7 96.5 96.3 96.1 95.7 95.3 95.1 95.0 94.6 94.2 93.8 93.4 93.2 93.0 92.6 92.2 91.2 90.3 88.3 86.3 84.3 82.4 80.4 4.8
4.9 99.1 98.1 97.9 97.7 97.5 97.3 97.2 97.0 96.8 96.6 96.4 96.2 95.8 95.4 95.3 95.1 94.7 94.3 93.9 93.5 93.3 93.2 92.8 92.4 91.4 90.5 88.6 86.6 84.7 82.7 80.8 4.9
5.0 99.1 98.1 98.0 97.8 97.6 97.4 97.2 97.0 96.8 96.7 96.5 96.3 95.9 95.5 95.4 95.2 94.8 94.4 94.1 93.7 93.5 93.3 92.9 92.6 91.6 90.7 88.8 86.9 85.0 83.1 81.2 5.0
5.1 99.1 98.2 98.0 97.8 97.6 97.5 97.3 97.1 96.9 96.7 96.5 96.4 96.0 95.6 95.5 95.3 94.9 94.5 94.2 93.8 93.6 93.4 93.1 92.7 91.8 90.9 89.0 87.2 85.3 83.5 81.6 5.1
5.2 99.1 98.2 98.0 97.9 97.7 97.5 97.3 97.2 97.0 96.8 96.6 96.4 96.1 95.7 95.6 95.4 95.0 94.7 94.3 93.9 93.8 93.6 93.2 92.9 92.0 91.1 89.3 87.5 85.6 83.8 82.0 5.2
5.3 99.1 98.3 98.1 97.9 97.7 97.6 97.4 97.2 97.0 96.9 96.7 96.5 96.2 95.8 95.6 95.5 95.1 94.8 94.4 94.1 93.9 93.7 93.4 93.0 92.1 91.3 89.5 87.7 85.9 84.2 82.4 5.3
5.4 99.1 98.3 98.1 98.0 97.8 97.6 97.4 97.3 97.1 96.9 96.8 96.6 96.2 95.9 95.7 95.6 95.2 94.9 94.5 94.2 94.0 93.8 93.5 93.2 92.3 91.4 89.7 88.0 86.2 84.5 82.7 5.4
5.5 99.2 98.3 98.2 98.0 97.8 97.7 97.5 97.3 97.2 97.0 96.8 96.7 96.3 96.0 95.8 95.6 95.3 95.0 94.6 94.3 94.1 94.0 93.6 93.3 92.4 91.6 89.9 88.2 86.5 84.8 83.1 5.5
5.6 99.2 98.4 98.2 98.0 97.9 97.7 97.5 97.4 97.2 97.0 96.9 96.7 96.4 96.1 95.9 95.7 95.4 95.1 94.7 94.4 94.2 94.1 93.7 93.4 92.6 91.8 90.1 88.4 86.8 85.1 83.4 5.6
5.7 99.2 98.4 98.2 98.1 97.9 97.7 97.6 97.4 97.3 97.1 96.9 96.8 96.5 96.1 96.0 95.8 95.5 95.2 94.8 94.5 94.4 94.2 93.9 93.5 92.7 91.9 90.3 88.7 87.0 85.4 83.7 5.7
5.8 99.2 98.4 98.3 98.1 97.9 97.8 97.6 97.5 97.3 97.2 97.0 96.8 96.5 96.2 96.0 95.9 95.6 95.3 94.9 94.6 94.5 94.3 94.0 93.7 92.9 92.1 90.5 88.9 87.3 85.6 84.0 5.8
5.9 99.2 98.5 98.3 98.1 98.0 97.8 97.7 97.5 97.4 97.2 97.1 96.9 96.6 96.3 96.1 96.0 95.7 95.3 95.0 94.7 94.6 94.4 94.1 93.8 93.0 92.2 90.6 89.1 87.5 85.9 84.3 5.9
6.0 99.2 98.5 98.3 98.2 98.0 97.9 97.7 97.6 97.4 97.3 97.1 97.0 96.7 96.3 96.2 96.0 95.7 95.4 95.1 94.8 94.7 94.5 94.2 93.9 93.1 92.4 90.8 89.3 87.7 86.2 84.6 6.0
6.1 99.3 98.5 98.4 98.2 98.1 97.9 97.8 97.6 97.5 97.3 97.2 97.0 96.7 96.4 96.3 96.1 95.8 95.5 95.2 94.9 94.8 94.6 94.3 94.0 93.3 92.5 91.0 89.5 87.9 86.4 84.9 6.1
6.2 99.3 98.5 98.4 98.2 98.1 97.9 97.8 97.7 97.5 97.4 97.2 97.1 96.8 96.5 96.3 96.2 95.9 95.6 95.3 95.0 94.9 94.7 94.4 94.1 93.4 92.6 91.1 89.7 88.2 86.7 85.1 6.2
6.3 99.3 98.6 98.4 98.3 98.1 98.0 97.8 97.7 97.6 97.4 97.3 97.1 96.8 96.5 96.4 96.2 96.0 95.7 95.4 95.1 94.9 94.8 94.5 94.2 93.5 92.8 91.3 89.8 88.4 86.9 85.4 6.3
6.4 99.3 98.6 98.4 98.3 98.2 98.0 97.9 97.7 97.6 97.5 97.3 97.2 96.9 96.6 96.5 96.3 96.0 95.7 95.5 95.2 95.0 94.9 94.6 94.3 93.6 92.9 91.4 90.0 88.6 87.1 85.7 6.4
6.5 99.3 98.6 98.5 98.3 98.2 98.1 97.9 97.8 97.6 97.5 97.4 97.2 96.9 96.7 96.5 96.4 96.1 95.8 95.5 95.3 95.1 95.0 94.7 94.4 93.7 93.0 91.6 90.2 88.8 87.3 85.9 6.5
6.6 99.3 98.6 98.5 98.4 98.2 98.1 97.9 97.8 97.7 97.5 97.4 97.3 97.0 96.7 96.6 96.4 96.2 95.9 95.6 95.3 95.2 95.1 94.8 94.5 93.8 93.1 91.7 90.3 88.9 87.5 86.1 6.6
6.7 99.3 98.7 98.5 98.4 98.3 98.1 98.0 97.8 97.7 97.6 97.4 97.3 97.0 96.8 96.6 96.5 96.2 96.0 95.7 95.4 95.3 95.1 94.9 94.6 93.9 93.2 91.9 90.5 89.1 87.8 86.4 6.7
6.8 99.3 98.7 98.5 98.4 98.3 98.1 98.0 97.9 97.7 97.6 97.5 97.4 97.1 96.8 96.7 96.6 96.3 96.0 95.8 95.5 95.4 95.2 95.0 94.7 94.0 93.3 92.0 90.7 89.3 88.0 86.6 6.8
6.9 99.3 98.7 98.6 98.4 98.3 98.2 98.0 97.9 97.8 97.7 97.5 97.4 97.1 96.9 96.7 96.6 96.3 96.1 95.8 95.6 95.4 95.3 95.0 94.8 94.1 93.5 92.1 90.8 89.5 88.1 86.8 6.9
7.0 99.4 98.7 98.6 98.5 98.3 98.2 98.1 97.9 97.8 97.7 97.6 97.4 97.2 96.9 96.8 96.7 96.4 96.1 95.9 95.6 95.5 95.4 95.1 94.9 94.2 93.6 92.3 91.0 89.6 88.3 87.0 7.0
7.1 99.4 98.7 98.6 98.5 98.4 98.2 98.1 98.0 97.9 97.7 97.6 97.5 97.2 97.0 96.8 96.7 96.5 96.2 96.0 95.7 95.6 95.4 95.2 94.9 94.3 93.7 92.4 91.1 89.8 88.5 87.2 7.1
7.2 99.4 98.8 98.6 98.5 98.4 98.3 98.1 98.0 97.9 97.8 97.6 97.5 97.3 97.0 96.9 96.8 96.5 96.3 96.0 95.8 95.6 95.5 95.3 95.0 94.4 93.8 92.5 91.2 90.0 88.7 87.4 7.2
7.3 99.4 98.8 98.7 98.5 98.4 98.3 98.2 98.0 97.9 97.8 97.7 97.6 97.3 97.1 96.9 96.8 96.6 96.3 96.1 95.8 95.7 95.6 95.3 95.1 94.5 93.9 92.6 91.4 90.1 88.9 87.6 7.3
7.4 99.4 98.8 98.7 98.6 98.4 98.3 98.2 98.1 98.0 97.8 97.7 97.6 97.3 97.1 97.0 96.9 96.6 96.4 96.1 95.9 95.8 95.7 95.4 95.2 94.6 93.9 92.7 91.5 90.3 89.0 87.8 7.4
7.5 99.4 98.8 98.7 98.6 98.5 98.3 98.2 98.1 98.0 97.9 97.7 97.6 97.4 97.1 97.0 96.9 96.7 96.4 96.2 96.0 95.8 95.7 95.5 95.2 94.6 94.0 92.8 91.6 90.4 89.2 88.0 7.5
7.6 99.4 98.8 98.7 98.6 98.5 98.4 98.2 98.1 98.0 97.9 97.8 97.7 97.4 97.2 97.1 97.0 96.7 96.5 96.3 96.0 95.9 95.8 95.5 95.3 94.7 94.1 92.9 91.8 90.6 89.4 88.2 7.6
7.7 99.4 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.0 97.9 97.8 97.7 97.5 97.2 97.1 97.0 96.8 96.5 96.3 96.1 96.0 95.8 95.6 95.4 94.8 94.2 93.0 91.9 90.7 89.5 88.3 7.7
7.8 99.4 98.9 98.8 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.8 97.7 97.5 97.3 97.2 97.0 96.8 96.6 96.4 96.1 96.0 95.9 95.7 95.4 94.9 94.3 93.1 92.0 90.8 89.7 88.5 7.8
7.9 99.4 98.9 98.8 98.7 98.5 98.4 98.3 98.2 98.1 98.0 97.9 97.8 97.5 97.3 97.2 97.1 96.9 96.6 96.4 96.2 96.1 96.0 95.7 95.5 94.9 94.4 93.2 92.1 91.0 89.8 88.7 7.9
8.0 99.4 98.9 98.8 98.7 98.6 98.5 98.3 98.2 98.1 98.0 97.9 97.8 97.6 97.4 97.2 97.1 96.9 96.7 96.5 96.2 96.1 96.0 95.8 95.6 95.0 94.5 93.3 92.2 91.1 90.0 88.8 8.0
8.1 99.5 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.0 97.9 97.8 97.6 97.4 97.3 97.2 97.0 96.7 96.5 96.3 96.2 96.1 95.9 95.6 95.1 94.5 93.4 92.3 91.2 90.1 89.0 8.1
8.2 99.5 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.9 97.6 97.4 97.3 97.2 97.0 96.8 96.6 96.3 96.2 96.1 95.9 95.7 95.2 94.6 93.5 92.4 91.3 90.2 89.1 8.2
8.3 99.5 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.9 97.7 97.5 97.4 97.2 97.0 96.8 96.6 96.4 96.3 96.2 96.0 95.8 95.2 94.7 93.6 92.5 91.5 90.4 89.3 8.3
8.4 99.5 99.0 98.9 98.7 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.9 97.7 97.5 97.4 97.3 97.1 96.9 96.7 96.4 96.3 96.2 96.0 95.8 95.3 94.8 93.7 92.6 91.6 90.5 89.4 8.4
8.5 99.5 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.1 98.0 97.9 97.7 97.5 97.4 97.3 97.1 96.9 96.7 96.5 96.4 96.3 96.1 95.9 95.3 94.8 93.8 92.7 91.7 90.6 89.6 8.5
8.6 99.5 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.8 97.6 97.5 97.4 97.2 96.9 96.7 96.5 96.4 96.3 96.1 95.9 95.4 94.9 93.9 92.8 91.8 90.8 89.7 8.6
8.7 99.5 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.8 97.6 97.5 97.4 97.2 97.0 96.8 96.6 96.5 96.4 96.2 96.0 95.5 95.0 93.9 92.9 91.9 90.9 89.9 8.7
8.8 99.5 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.8 97.6 97.5 97.4 97.2 97.0 96.8 96.6 96.5 96.4 96.2 96.0 95.5 95.0 94.0 93.0 92.0 91.0 90.0 8.8
8.9 99.5 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.9 97.7 97.6 97.5 97.3 97.1 96.9 96.7 96.6 96.5 96.3 96.1 95.6 95.1 94.1 93.1 92.1 91.1 90.1 8.9
9.0 99.5 99.0 98.9 98.8 98.7 98.7 98.6 98.5 98.4 98.3 98.2 98.1 97.9 97.7 97.6 97.5 97.3 97.1 96.9 96.7 96.6 96.5 96.3 96.1 95.6 95.2 94.2 93.2 92.2 91.2 90.2 9.0
9.1 99.5 99.0 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 97.9 97.7 97.6 97.5 97.3 97.1 96.9 96.8 96.7 96.6 96.4 96.2 95.7 95.2 94.3 93.3 92.3 91.3 90.4 9.1
9.2 99.5 99.1 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 97.9 97.7 97.6 97.6 97.4 97.2 97.0 96.8 96.7 96.6 96.4 96.2 95.8 95.3 94.3 93.4 92.4 91.5 90.5 9.2
9.3 99.5 99.1 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 98.0 97.8 97.7 97.6 97.4 97.2 97.0 96.8 96.7 96.7 96.5 96.3 95.8 95.3 94.4 93.5 92.5 91.6 90.6 9.3
9.4 99.5 99.1 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.4 98.3 98.2 98.0 97.8 97.7 97.6 97.4 97.2 97.1 96.9 96.8 96.7 96.5 96.3 95.9 95.4 94.5 93.5 92.6 91.7 90.7 9.4 X = % CONVERSION OF SO2 TO SO3
9.5 99.5 99.1 99.0 98.9 98.8 98.7 98.6 98.6 98.5 98.4 98.3 98.2 98.0 97.8 97.7 97.6 97.5 97.3 97.1 96.9 96.8 96.7 96.6 96.4 95.9 95.5 94.5 93.6 92.7 91.8 90.8 9.5
9.6 99.6 99.1 99.0 98.9 98.8 98.7 98.7 98.6 98.5 98.4 98.3 98.2 98.0 97.9 97.8 97.7 97.5 97.3 97.1 97.0 96.9 96.8 96.6 96.4 96.0 95.5 94.6 93.7 92.8 91.9 90.9 9.6 a = % SO2 IN ENTRANCE GAS
9.7 99.6 99.1 99.0 98.9 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.2 98.1 97.9 97.8 97.7 97.5 97.3 97.2 97.0 96.9 96.8 96.6 96.5 96.0 95.6 94.7 93.8 92.9 92.0 91.1 9.7
9.8 99.6 99.1 99.0 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.3 98.3 98.1 97.9 97.8 97.7 97.6 97.4 97.2 97.0 96.9 96.8 96.7 96.5 96.1 95.6 94.7 93.8 93.0 92.1 91.2 9.8 b = % SO2 IN EXIT GAS
9.9 99.6 99.1 99.1 99.0 98.9 98.8 98.7 98.6 98.5 98.4 98.4 98.3 98.1 97.9 97.8 97.8 97.6 97.4 97.2 97.1 97.0 96.9 96.7 96.5 96.1 95.7 94.8 93.9 93.0 92.2 91.3 9.9
10.0 99.6 99.1 99.1 99.0 98.9 98.8 98.7 98.6 98.6 98.5 98.4 98.3 98.1 98.0 97.9 97.8 97.6 97.4 97.3 97.1 97.0 96.9 96.8 96.6 96.1 95.7 94.9 94.0 93.1 92.2 91.4 10.0
2a - 2b
10.1
10.2
99.6
99.6
99.2
99.2
99.1
99.1
99.0
99.0
98.9
98.9
98.8
98.8
98.7
98.8
98.7
98.7
98.6
98.6
98.5
98.5
98.4
98.4
98.3
98.3
98.1
98.2
98.0
98.0
97.9
97.9
97.8
97.8
97.6
97.7
97.5
97.5
97.3
97.3
97.1
97.2
97.0
97.1
97.0
97.0
96.8
96.8
96.6
96.7
96.2
96.2
95.8
95.8
94.9
95.0
94.1
94.1
93.2
93.3
92.3
92.4
91.5
91.6
10.1
10.2
X
3ab
10.3
10.4
99.6
99.6
99.2
99.2
99.1
99.1
99.0
99.0
98.9
98.9
98.8
98.9
98.8
98.8
98.7
98.7
98.6
98.6
98.5
98.5
98.4
98.5
98.4
98.4
98.2
98.2
98.0
98.0
97.9
98.0
97.9
97.9
97.7
97.7
97.5
97.6
97.4
97.4
97.2
97.2
97.1
97.1
97.0
97.1
96.9
96.9
96.7
96.7
96.3
96.3
95.9
95.9
95.0
95.1
94.2
94.3
93.4
93.4
92.5
92.6
91.7
91.8
10.3
10.4
2a -
10.5 99.6 99.2 99.1 99.0 99.0 98.9 98.8 98.7 98.6 98.6 98.5 98.4 98.2 98.1 98.0 97.9 97.7 97.6 97.4 97.3 97.2 97.1 96.9 96.8 96.4 96.0 95.1 94.3 93.5 92.7 91.9 10.5
100
10.6 99.6 99.2 99.1 99.0 99.0 98.9 98.8 98.7 98.6 98.6 98.5 98.4 98.2 98.1 98.0 97.9 97.8 97.6 97.4 97.3 97.2 97.1 97.0 96.8 96.4 96.0 95.2 94.4 93.6 92.8 91.9 10.6
10.7 99.6 99.2 99.1 99.1 99.0 98.9 98.8 98.7 98.7 98.6 98.5 98.4 98.3 98.1 98.0 98.0 97.8 97.6 97.5 97.3 97.2 97.2 97.0 96.8 96.4 96.0 95.2 94.4 93.6 92.8 92.0 10.7
10.8 99.6 99.2 99.1 99.1 99.0 98.9 98.8 98.8 98.7 98.6 98.5 98.4 98.3 98.1 98.1 98.0 97.8 97.7 97.5 97.3 97.3 97.2 97.0 96.9 96.5 96.1 95.3 94.5 93.7 92.9 92.1 10.8
10.9 99.6 99.2 99.2 99.1 99.0 98.9 98.8 98.8 98.7 98.6 98.5 98.5 98.3 98.2 98.1 98.0 97.8 97.7 97.5 97.4 97.3 97.2 97.1 96.9 96.5 96.1 95.4 94.6 93.8 93.0 92.2 10.9
11.0 99.6 99.2 99.2 99.1 99.0 98.9 98.9 98.8 98.7 98.6 98.6 98.5 98.3 98.2 98.1 98.0 97.9 97.7 97.6 97.4 97.3 97.3 97.1 96.9 96.6 96.2 95.4 94.6 93.9 93.1 92.3 11.0
11.1 99.6 99.2 99.2 99.1 99.0 98.9 98.9 98.8 98.7 98.6 98.6 98.5 98.3 98.2 98.1 98.0 97.9 97.7 97.6 97.4 97.4 97.3 97.1 97.0 96.6 96.2 95.5 94.7 93.9 93.1 92.4 11.1
11.2 99.6 99.3 99.2 99.1 99.0 99.0 98.9 98.8 98.7 98.7 98.6 98.5 98.4 98.2 98.1 98.1 97.9 97.8 97.6 97.5 97.4 97.3 97.2 97.0 96.6 96.3 95.5 94.7 94.0 93.2 92.5 11.2
11.3 99.6 99.3 99.2 99.1 99.0 99.0 98.9 98.8 98.7 98.7 98.6 98.5 98.4 98.2 98.2 98.1 97.9 97.8 97.6 97.5 97.4 97.3 97.2 97.0 96.7 96.3 95.6 94.8 94.0 93.3 92.5 11.3
11.4 99.6 99.3 99.2 99.1 99.1 99.0 98.9 98.8 98.8 98.7 98.6 98.5 98.4 98.2 98.2 98.1 98.0 97.8 97.7 97.5 97.4 97.4 97.2 97.1 96.7 96.3 95.6 94.9 94.1 93.4 92.6 11.4
11.5 99.6 99.3 99.2 99.1 99.1 99.0 98.9 98.8 98.8 98.7 98.6 98.6 98.4 98.3 98.2 98.1 98.0 97.8 97.7 97.5 97.5 97.4 97.2 97.1 96.7 96.4 95.6 94.9 94.2 93.4 92.7 11.5
11.6 99.6 99.3 99.2 99.1 99.1 99.0 98.9 98.9 98.8 98.7 98.6 98.6 98.4 98.3 98.2 98.1 98.0 97.9 97.7 97.6 97.5 97.4 97.3 97.1 96.8 96.4 95.7 95.0 94.2 93.5 92.8 11.6
11.7 99.6 99.3 99.2 99.2 99.1 99.0 98.9 98.9 98.8 98.7 98.7 98.6 98.4 98.3 98.2 98.2 98.0 97.9 97.7 97.6 97.5 97.4 97.3 97.2 96.8 96.4 95.7 95.0 94.3 93.6 92.8 11.7
11.8 99.7 99.3 99.2 99.2 99.1 99.0 99.0 98.9 98.8 98.7 98.7 98.6 98.5 98.3 98.2 98.2 98.0 97.9 97.8 97.6 97.5 97.5 97.3 97.2 96.8 96.5 95.8 95.1 94.4 93.6 92.9 11.8
11.9 99.7 99.3 99.2 99.2 99.1 99.0 99.0 98.9 98.8 98.8 98.7 98.6 98.5 98.3 98.3 98.2 98.1 97.9 97.8 97.6 97.6 97.5 97.4 97.2 96.9 96.5 95.8 95.1 94.4 93.7 93.0 11.9
Drawing 100.6.8
REICH TEST FOR SO2
BAROMETRIC CORRECTION FACTOR

TABLE No. 1 ENTRANCE GAS TABLE No. 2 EXIT GAS TABLE No. 3 TABLE No. 4
PERCENT SO2 CORRESPONDING TO GAS VOLUME AT T °C NORMAL BAROMETER
PERCENT SO2 CORRESPONDING TO GAS VOLUME AT T °C USING 10 CC N/10 I SOLUTION TEMPERATURE, °C
USING 10 CC N/100 I SOLUTION READING FOR VARIOUS
ALTITUDES
% SO2\°C 5 10 15 20 25 30 35 40 % SO2\°C 5 10 15 20 25 30 35 40 % SO2\°C 5 10 15 20 25 30 35 40 mm Hg 5 10 15 20 25 30 35 40
1.0 1113 1137 1162 1190 1221 1255 1294 1340 6.5 162 165 169 173 177 182 188 195 0.05 2247 2296 2347 2403 2465 2534 2613 2705 760 0.974 0.953 0.932 0.910 0.887 0.863 0.837 0.809 ALTITUDES BAROMETER
1.1 1011 1032 1056 1081 1109 1140 1175 1217 6.6 159 163 166 170 174 179 185 191 0.10 1123 1147 1173 1201 1232 1266 1306 1352 750 0.961 0.940 0.919 0.898 0.875 0.831 0.825 0.797 FEET M.M. Hg
1.2 926 945 967 990 1015 1044 1076 1114 6.7 157 160 164 167 172 177 182 188 0.11 1021 1043 1066 1092 1120 1151 1187 1229 740 0.958 0.928 0.907 0.886 0.863 0.840 0.814 0.786 0 760
1.3 853 872 892 913 936 962 992 1027 6.8 154 157 161 165 169 174 179 185 0.12 936 956 977 1001 1026 1055 1088 1126 730 0.935 0.915 0.895 0.873 0.851 0.828 0.802 0.774 500 746
1.4 792 809 827 847 868 893 921 953 6.9 152 155 158 162 166 171 176 183 0.13 864 882 902 924 947 974 1004 1040 720 0.922 0.902 0.882 0.861 0.839 0.816 0.790 0.763 1000 733
1.5 738 754 771 789 810 832 858 889 7.0 149 153 156 160 164 168 174 180 0.14 802 819 838 858 880 904 932 965 710 0.909 0.890 0.870 0.849 0.827 0.804 0.779 0.751 1500 720
1.6 691 706 722 739 758 780 804 832 7.1 147 150 154 157 161 166 171 177 0.15 748 764 782 800 821 844 870 901 700 0.897 0.877 0.857 0.837 0.815 0.792 0.767 0.740 2000 707
1.7 650 664 679 695 713 733 756 782 7.2 145 148 151 155 159 163 168 174 0.16 701 717 733 750 769 791 816 844 690 0.882 0.864 0.845 0.825 0.803 0.780 0.756 0.728 2500 694
1.8 613 626 641 656 673 692 713 738 7.3 143 146 149 153 157 161 166 172 0.17 660 674 690 706 724 744 768 795 680 0.870 0.852 0.832 0.812 0.791 0.769 0.744 0.717 3000 681
1.9 580 593 606 621 637 655 675 699 7.4 141 144 147 150 154 159 164 169 0.18 623 637 651 667 684 703 725 750 670 0.857 0.839 0.820 0.800 0.779 0.757 0.732 0.706 3500 669
2.0 551 563 575 589 604 621 640 663 7.5 139 142 145 148 152 156 161 167 0.19 591 603 617 632 648 666 687 711 660 0.844 0.826 0.807 0.788 0.767 0.745 0.721 0.694 4000 656
2.1 524 535 547 560 575 591 609 631 7.6 137 140 143 146 150 154 159 165 0.20 561 573 586 600 615 633 652 675 650 0.832 0.813 0.795 0.775 0.755 0.733 0.709 0.683 4500 644
2.2 500 511 522 534 548 564 581 602 7.7 135 138 141 144 148 152 157 162 0.22 510 521 533 545 559 575 593 614 640 0.819 0.801 0.782 0.763 0.743 0.721 0.697 0.671 5000 632
2.3 478 488 499 511 524 538 555 575 7.8 133 136 139 142 146 150 155 160 0.24 467 477 488 500 513 527 543 562 630 0.806 0.788 0.770 0.751 0.731 0.709 0.686 0.660 5500 621
2.4 457 467 478 489 501 516 532 550 7.9 131 134 137 140 144 148 152 158 0.25 449 458 469 480 492 506 522 540 620 0.793 0.775 0.757 0.739 0.719 0.697 0.674 0.648 6000 609
2.5 438 448 458 469 481 494 510 528 8.0 129 132 135 138 142 146 150 156 0.26 431 441 450 461 473 486 501 519 610 0.776 0.762 0.745 0.726 0.707 0.686 0.662 0.637 6500 598
2.6 421 430 440 450 462 475 490 507 8.1 128 130 133 136 140 144 148 154 0.28 400 409 418 428 439 451 466 482 600 0.767 0.750 0.732 0.714 0.695 0.674 0.651 0.625 7000 586
2.7 405 414 423 433 444 457 471 488 8.2 126 129 131 135 138 142 146 151 0.30 374 382 390 400 410 421 434 450 590 0.754 0.737 0.720 0.702 0.683 0.662 0.639 0.614 7500 575
2.8 390 399 408 417 428 440 454 470 8.3 124 127 130 133 136 140 144 149 0.32 350 358 366 375 384 395 407 421 580 0.741 0.725 0.707 0.690 0.670 0.650 0.627 0.602 8000 564
2.9 376 385 393 403 413 424 438 453 8.4 123 125 128 131 134 138 143 148 0.34 329 337 344 352 361 372 383 397 570 0.728 0.712 0.695 0.677 0.658 0.638 0.616 0.591 8500 554
3.0 363 371 380 389 399 410 423 438 8.5 121 124 126 129 133 136 141 146 0.35 320 327 334 342 351 361 372 385 560 0.715 0.699 0.683 0.665 0.646 0.626 0.604 0.579 9000 543
3.1 351 359 367 376 385 396 409 423 8.6 119 122 125 128 131 135 139 144 0.36 311 318 325 333 341 351 362 375 550 0.702 0.686 0.670 0.653 0.634 0.614 0.592 0.568 9500 533
3.2 340 347 355 364 373 383 395 409 8.7 118 121 123 126 129 133 137 142 0.38 295 301 308 315 323 332 343 355 540 0.689 0.674 0.658 0.641 0.622 0.603 0.581 0.556 10000 523
3.3 329 337 344 352 361 371 383 397 8.8 116 119 122 125 128 131 135 140 0.40 280 286 292 299 307 316 325 337 530 0.676 0.661 0.645 0.628 0.610 0.591 0.569 0.545
3.4 319 326 334 342 350 360 371 384 8.9 115 118 120 123 126 130 134 139 0.45 249 254 260 266 273 280 289 299 520 0.664 0.648 0.633 0.616 0.598 0.579 0.557 0.533
3.5 310 317 324 331 340 350 360 373 9.0 114 116 119 122 125 128 132 137 0.50 224 229 234 239 245 252 260 269 510 0.651 0.636 0.620 0.604 0.586 0.567 0.546 0.522
3.6 301 308 314 322 330 339 350 362 9.1 112 115 117 120 123 127 131 135 0.55 203 208 212 217 223 229 236 245 TABLES NOS. 1 AND 2 WERE CALCULATED FOR A BAROMETERIC PRESSURE
3.7 293 299 306 313 321 330 340 352 9.2 111 113 116 119 122 125 129 134 0.60 186 190 195 199 204 210 217 224 OF 760 MM.
3.8 285 291 297 304 312 321 331 343 9.3 110 112 115 117 120 124 127 132 0.65 172 176 179 184 188 194 200 207 IF A CORRECTION FOR BAROMETRIC PRESSURE IS DESIRED, FIND THE
3.9 277 283 289 296 304 312 322 333 9.4 108 111 113 116 119 122 126 130 0.70 159 163 167 171 175 180 185 192 FACTOR IN TABLE NO. 3 CORRESPONDING TO THE TEMPERATURE AND
BAROMETRIC PRESSURE OF THE TEST UNDER CONSIDERATION; CHOOSE THE
4.0 270 276 282 289 296 304 314 325 9.5 107 109 112 115 117 121 125 129 0.75 149 152 155 159 163 168 173 179 FACTOR IN THE 760 MM LINE CLOSEST TO IT NUMERICALLY AND FIND THE
4.1 263 269 275 281 288 297 306 316 9.6 106 108 111 113 116 119 123 127 0.80 139 142 146 149 153 157 162 168 CORRECT % SO2 IN TABLES NO. 1 AND 2, USING AS THE TEMPERATURE OF THE
4.2 256 262 268 274 281 289 298 309 9.7 105 107 109 112 115 118 122 126 0.85 131 134 137 140 144 148 152 158 TEST, THE TEMPERATURE CORRESPONDING TO THE FACTOR IN THE 760 MM
4.3 250 256 261 268 274 282 291 301 9.8 103 106 108 111 113 117 120 125 0.90 124 126 129 132 136 140 144 149 LINE.
4.4 244 250 255 261 268 275 284 294 9.9 102 105 107 109 112 115 119 123 0.95 117 120 122 125 129 132 136 141 BAROMETER, MM = BAROMETER, INCHES X 25.4
4.5 239 244 249 255 262 269 277 287 10.0 101 103 106 108 111 114 118 122 1.00 111 114 116 119 122 125 129 134 IF PERCENTAGES OF SO2 ARE DESIRED, WHICH ARE NOT LISTED IN TABLES
4.6 233 238 244 249 256 263 271 281 10.1 100 102 105 107 110 113 116 120 NO. 1 AND 2, THEY MAY BE EASILY CALCULATED BY USING THE FACTOR (K)
4.7 228 233 238 244 250 257 265 274 10.2 99 101 103 106 109 112 115 119 FORMULA USED IN MAKING CALCULATIONS USING 10 CCN/10 I SOLUTION
GIVEN IN TABLE NO.3 IN THE FORMULA.
4.8 223 228 233 238 245 251 259 268 10.3 98 100 102 105 107 110 114 118 1094.4 WHEN 10 CC'S N/10 I ARE USED
4.9 218 223 228 233 239 246 254 263 10.4 97 99 101 104 106 109 113 117 X
 B-W  1094.4
5.0 214 218 223 228 234 241 248 257 10.5 96 98 100 102 105 108 111 115 C  X
5.1 209 214 219 224 229 236 243 252 10.6 95 97 99 101 104 107 110 114  7601  0.00366T   10. 944  CK  10.944
5.2 205 209 214 219 225 231 238 247 10.7 94 96 98 100 103 106 109 113 FORMULA USED IN MAKING CALCULATIONS USING 10 CCN/100 I SOLUTION WHEN 10 CC'S N/100 I ARE USED
5.3 201 205 210 215 220 227 234 242 10.8 93 95 97 99 102 105 108 112 109 .44 109.44
5.4 197 201 206 211 216 222 229 237 10.9 92 94 96 98 101 104 107 111 X X
 B-W  CK  1.0944
5.5 193 197 202 207 212 218 225 232 11.0 91 93 95 97 100 103 106 109 C 
5.6 189 194 198 203 208 214 220 228 11.1 90 92 94 96 99 102 105 108  760 1  0.00366T   1 . 0944  IN THESE FORMULAE:
5.7 186 190 194 199 204 210 216 224 11.2 89 91 93 95 98 101 104 107 IN THESE FORMULAE: X = % SO2
5.8 183 187 191 195 200 206 212 220 11.3 88 90 92 94 97 100 103 106 B = BAROMETER MM Hg C = CC GAS COLLECTED
5.9 179 183 187 192 197 202 208 216 11.4 87 89 91 93 96 99 102 105 C = CC GAS COLLECTED K = FACTOR TO BE USED FROM TABLE NO. 3
6.0 176 180 184 188 193 199 205 212 11.5 87 88 90 93 95 98 101 104 T = TEMPERATURE OF GAS ºC
6.1 173 177 181 185 190 195 201 208 11.6 86 88 89 92 94 97 100 103 W = AQUEOUS VAPOR PRESSURE AT TEMPERATURE T (MM HG) WHERE MORE ACCURATE RESULTS ARE DESIRED FOR THE VALUE OF (K) TO
6.2 170 174 178 182 187 192 198 205 11.7 85 87 89 91 93 96 99 102 X = % SO2 IN GAS THE NEAREST 10 MM BAROMETRIC PRESSURE AND NEAREST 5 °C,
INTERPOLATE IN TABLE NO. 3.
6.3 167 171 175 179 183 189 194 201 11.8 84 86 88 90 92 95 98 101
6.4 164 168 172 176 180 185 191 198 11.9 83 85 87 89 91 94 97 100
Drawing 100.6.9
MECS, INC.
PeGASyS
PORTABLE GAS ANALYZER SYSTEM UPDATE
The MECS, INC. Portable Gas Analysis System (PeGASyS) was developed in the late 1980’s to
provide sulfuric acid producers with the means to fully characterize their plant operations. This
state-of-the-art gas analysis system was custom designed and fabricated in the MECS St. Louis
laboratories and has been widely applied in a variety of situations. Nearly 600 plants have been
evaluated with the use of the PeGASyS equipment, with numerous repeat tests. This analyzer
can be used to determine the SO2 and O2 levels in any available gas stream, whether the gas is
from the converter or a gas-gas heat exchanger. The inlet and outlet gas compositions for each
catalyst bed can be accurately determined and the results can assist in precisely modeling the
converter conditions. Then, the MECS Conventional and/or Cesium Catalyst requirements can
be determined based on the known operating conditions in the plant. The PeGASyS method for
characterizing the plant is much more reliable than thermocouple and Reich test information.
Experience shows that the system can provide an exceptional amount of information with little
time investment; it takes approximately 1 day to fully analyze one 4-pass converter. Heat
exchanger analyses are also a common application of the PeGASyS service; leaks on the order of
0.2% of the high pressure gas flow have been determined. The PeGASyS service has been
effectively applied to custom design numerous applications of MECSs Conventional and Cesium
Catalyst in plants worldwide. Optimum performance from the LP and Cs catalysts can be
obtained when the program is designed around the accurate and comprehensive data supplied by
the PeGASyS system.
The PeGASyS system consists of a highly specialized gas sampling system and the gas analyzer.
The analyzer equipment is generally set up near a control room or laboratory and occupies a
desk-sized space. A gas sample is taken from a slip stream of gas at a converter, heat exchanger,
or absorbing tower pressure tap (or any available sampling port). The gas sample is then
injected into the analyzer which accurately measures SO2 and O2 levels.
The generated results consist of an analysis report of the SO2 and O2 levels in each sample and a
conversion calculation for each specific converter sample based on the inlet gas to the first bed.
The custom software also calculates gas flow rates based on given production rates. Specialized
programs have also been designed to evaluate gas - gas heat exchangers, giving an estimate of
the amount of gas bypassing if the exchanger is leaking. Overall, the final report presents the
measured conversion through each pass, plus an evaluation of the stack SO2 emissions. These
results are then incorporated in a converter performance simulation using the MECS, Inc.
proprietary modeling software. Using both the PeGASyS results and the computer simulations,
it is possible to determine specific problems in the catalyst beds and/or heat exchangers. This
evaluation process represents a “step change” in converter performance determination and
provides the most accurate and reliable converter monitoring program available in the sulfuric
acid industry.
CT-004
- Page 2 -
MECS has also developed a semi-quantitative method for determining heat exchanger leaks
when the SO2 level is the same on both the shell and tube sides of the exchanger (a condition
which cannot be analyzed using PeGASyS). This gravimetric method determines the SO3 level
in the appropriate gas streams and generates a report which indicates the amount of SO3 leakage
in the exchanger. This method can also be utilized to determine the amount of SO3 slippage in
absorbing towers.
The PeGASyS service is available to all sulfuric acid producers worldwide. The service is
charged to the customer on a per diem basis plus travel expenses. Ideally, considering the high
cost of traveling outside of the U.S.A., it is desirable to coordinate PeGASyS visits to the various
plant sites in a single country or area during a 2-3 week period such that the equipment and
technical support could remain in the country and avoid multiple airline flights and customs
clearances. The PeGASyS equipment consists of an analyzer case and two (2) cartons
containing the calibration and chromatograph carrier gas cylinders. The cost for providing this
service is approximately $3000 (U.S.) per day plus travel and shipping/handling expenses.
Sulfuric acid plant personnel can take advantage of this unique service in order to optimize
current operations and accurately explore the use of the MECS Conventional and Cesium
Catalyst in their efforts to improve conversion and/or reduce SO2 emissions.
Attached please find several supporting documents of information regarding the MECS
PeGASyS analyzer system. These items are:
1. PeGASyS INFORMATION SHEET: A single page containing information utilized in

preparing for a PeGASyS test.
2. EXAMPLES OF PeGASyS RESULTS: These five (5) examples show PeGASyS data
for a variety of different plants and a typical heat exchanger. These data sheets are
produced automatically upon completion of the analysis work and provided to the
customer. A final summary report is prepared and submitted to the customer a few
weeks following the plant visit.
Please contact MECS if you require any further information on the PeGASyS service.
Phone: (314) 694-4482 (or 275-5802) FAX: (314) 275-2911
Attachments follow 2001
CT-004
MECS, INC.
PORTABLE GAS ANALYSIS SYSTEM (PeGASyS)
GAS SAMPLING INFORMATION
Gas sampling points for the Portable Gas Analysis System (PeGASyS) testing are shown in the attached figure and
are described as follows:
(1) INLET TO EACH CATALYST BED:
A gas sampling point (pressure tap) should be located at the inlet to each catalyst bed. If possible, the sample lines
should be at or near ground level to allow for the safest possible gas sampling procedures. Ideal sample lines
should be approximately 10 mm O.D. stainless steel with a ball valve shut off .
(2) INLET AND OUTLET OF HEAT EXCHANGERS (LOW PRESSURE SIDE):
Sample taps should be located at the inlet and outlet of the low-pressure side of any GAS-GAS heat exchangers.
The sample points may be at absorbing tower outlets or converter bed inlets. Sample tube sizes are specified in (1)
above. The inlet samples to the heat exchangers should be taken as close to the exchanger inlet as possible to insure
maximum gas mixing. Again, the sample valve positions should be at or near ground level to allow for the safest
possible gas sampling procedures.
(3) GAS INLET AND OUTLET - FINAL ABSORBING TOWER:
Sample taps should be available for the final absorbing tower gas inlets and outlets. Ideally, the final absorbing
tower outlet sample should be taken upstream of the mist eliminators to insure positive pressure in the sample line.
(4) MISCELLANEOUS INFORMATION:
Other important information for proper gas sampling is provided below:
a) The sulfuric acid plant should ideally be operating at the highest possible production rate in order to minimize
the effective catalyst loading in each bed. This situation allows for the most accurate determination of the actual
catalyst conversion efficiency in each pass.
b) Outside temperature should be above 32oF (0oC ) to insure that sample lines will remain free of frozen oleum.
c) In certain instances, a specialized SO3 absorption test is utilized to characterize a GAS-GAS heat exchanger
(usually a Cold Interpass Exchanger). An analytical balance (reading to 0.0001 gm) is required for this test.
d) A space the size of a large desk is required for the PeGASyS equipment setup. Power requirements call for
110 V or 240 V.
e) Plant operating data will also be required during the PeGASyS testing period. Catalyst bed inlet and outlet
temperatures, acid production rate (metric tons/day or short tons/day), stack analyzer SO2 level (if available), feed
gas SO2 level (if available), catalyst volumes in each bed, gas flow rate (Nm3/hr or SCFM; if available), sulfur
burner temperature (where applicable), sulfur burner feed air temperature (where applicable), converter diameter (m
or ft.), and any special dilution air situations (where applicable).
CT-004
MECS, INC.
CONVERTER PERFORMANCE SUMMARY
CUSTOMER NAME: EXAMPLE # 1 DATA FILE: EXAM01.SAM
PLANT LOCATION: EX - U. S. A.
PLANT NUMBER: 1
PLANT TYPE: SULFUR BURNER SINGLE ABSORPTION AIR DILUTION
SAMPLE SAMPLE DATE / TIME

NO. IDENTIFICATION OF SAMPLE % SO2 % O2 % CONV.
-------------------------------------------------------------------------------
5 FIRST PASS INLET 01 APR 95 1515 8.926 11.195 7.231

4 FIRST PASS OUTLET 01 APR 95 1515 3.024 9.039 71.241
3 SECOND PASS OUTLET 01 APR 95 1515 0.938 10.771 89.253
2 THIRD PASS OUTLET 01 APR 95 1515 0.486 10.826 94.356
1 FOURTH PASS OUTLET 01 APR 95 1515 0.167 10.850 98.045
SULFUR BURNER GAS 9.476 11.470
SAMPLE NO. SAMPLING POINT

-----------------------------------------------------------
1 FINAL TOWER OUTLET BEFORE MIST ELIMINATORS

2 PASS 4 INLET AT CONVERTER
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
X X X
X KG/HR. LBS./HR. X CATALYST BED X
X ---------------------- X TEMPERATURES X
X SULFUR FEED RATE 3781.25 8336.27 X ------------ X
X SO2 EMISSIONS 147.73 325.69 X L/STPD BED F C X
X X ------ --- - - X
X LBS.SO2/STPD = 26.05 KG SO2/MTPD = 13.02 X 1 IN 799 426 X
X X 49.0 1 OUT 1114 601 X
X NM3/HR SCFM X RISE 315 175 X
X ---------------------- X 2 IN 838 448 X
X AIR TO SULFUR BURNER 27876.63 16405.74 X 35.9 2 OUT 932 500 X
X CONVERTER INLET GAS 27876.63 16405.74 X RISE 94 52 X
X CONVERTER OUTLET GAS 30931.09 18203.32 X 3 IN 828 442 X
X DILUTION AIR 6939.34 4083.88 X 42.5 3 OUT 847 453 X
X TOTAL AIR TO PLANT 34815.96 20489.62 X RISE 19 11 X
X X 4 IN 824 440 X
X PRODUCTION RATE = 300.00 SHORT TONS PER DAY X 48.4 4 OUT 837 447 X
X GAS COMPOSITION (UNCONVERTED BASIS) = X RISE 13 7 X
X 7.59% SO2, 13.36% O2 X 5 IN X
X X 0.0 5 OUT X
X NOTE: ALL GAS VOLUMES ARE BASED ON X RISE X
X DRY, SO3-FREE GAS. X X
X X 175.8 TOTAL 441 245 X
X X X
CATALYST VOLUMES: 1- 15000 2- 11000 3- 13000 4- 14800 5- 0 LITERS
CT-004
MECS, INC.
PLANT LOCATION: EX - U.S.A
PLANT NUMBER: 2
PLANT TYPE: SULFUR BURNER DOUBLE ABSORPTION

-------------------------------------------------------------------------------

SULFUR BURNER GAS 10.409 10.537

-----------------------------------------------------------
1 FINAL TOWER OUTLET BELOW MIST ELIMINATORS

X X X
X X ------ --- - - X
X X 33.4 1 OUT 1101 594 X
X ---------------------- X 2 IN 885 474 X
X AIR TO SULFUR BURNER 164995.88 97102.09 X 39.2 2 OUT 1017 547 X
X X 4 IN 788 420 X
X PRODUCTION RATE = 1800.00 METRIC TONS PER DAY X 55.0 4 OUT 829 443 X
X X RISE 41 23 X
X X X
X X X
X NOTE: ALL GAS VOLUMES ARE BASED ON X X
X DRY, SO3-FREE GAS. X TOTAL X
X X 171.3 RISE 551 306 X
X X X
CATALYST VOLUMES: 1- 66400 2- 78000 3- 86800 4-109400 LITERS
CT-004
MECS, INC.
PLANT LOCATION: U. S. A.
PLANT NUMBER: 1
PLANT TYPE: SPENT ACID DOUBLE ABSORPTION

-------------------------------------------------------------------------------


-----------------------------------------------------------

X X X
X X ------ --- - - X
X X 36.3 1 OUT 1108 598 X
X ---------------------- X 2 IN 799 426 X
X X 58.1 2 OUT 932 500 X
X X 4 IN 801 427 X
X X RISE 46 26 X
X X 5 IN X
X X 0.0 5 OUT X
X X 200.1 TOTAL 555 309 X
X X X
CATALYST VOLUMES: 1- 14700 2- 23500 3- 15800 4- 27000 LITERS
CT-004
MECS, INC.
PLANT LOCATION: U. S. A.
PLANT NUMBER: 2
PLANT TYPE: METALLURGICAL DOUBLE ABSORPTION

-------------------------------------------------------------------------------


-----------------------------------------------------------

X X X
X X ------ --- - - X
X X 40.4 1 OUT 1029 554 X
X ---------------------- X 2 IN 847 453 X
X X 44.9 2 OUT 925 496 X
X X 4 IN 815 435 X
X X RISE 43 24 X
X X 5 IN X
X X 0.0 5 OUT X
X X 174.9 TOTAL 354 196 X
X X X
CATALYST VOLUMES: 1- 16200 2- 18000 3- 18000 4- 18000 5- 0 LITERS
CT-004
MECS, INC.
HEAT EXCHANGER EVALUATION
DATE / TIME: O1 APR 95 1430
FILE: EXAMHIP1.HEX
CUSTOMER: EXAMPLE # 5
PLANT LOCATION: EX - U.S.A.
PLANT NUMBER: 1
PLANT TYPE: SULFUR BURNER 3X1 DOUBLE ABSORPTION
HEAT EXCHANGER: HOT INTERPASS (# 1)
_____________________
| |
| |<===== 1.762 % SO2
| HIGH PRESS. | 7.346 % O2
|-------------------|
| | | | | |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
0.651 % SO2 <=====| | | | | |<===== 0.550 % SO2
6.862 % O2 | | | | | | 6.808 % O2
| | | | | |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
|-------------------|
| |
| |
1.762 % SO2 <=====| |
7.346 % O2 |___________________|
9.1 % OF TUBE SIDE GAS IS LEAKING INTO SHELL SIDE
SHELL SIDE INLET GAS WAS SAMPLED AT:

HOT INTERPASS HEX (# 1) SHELL SIDE INLET TAP
SHELL SIDE OUTLET GAS WAS SAMPLED AT:

PASS 4 INLET AT CONVERTER
TUBE SIDE GAS WAS SAMPLED AT:

PASS 3 INLET AT CONVERTER
CT-004
Rev 0
30 May 11
APPENDIX 08
CHARTS AND TABLES
 Conductivity Over 80 to 120% H2SO4 (Typical Variations)
 Sulfuric Acid Conductivity, Low Temperature Range
 Sulfuric Acid Conductivity, High Temperature Range
 Sulfur Burner Temperature Rise
 Equilibrium Conversion 6 - 11% SO2
 Density of H2SO4 0 - 93.2%
 Density of H2SO4 94 - 100%
..
CHT 01 - 1
Rev 0
30 May 11
APPENDIX 08
CHARTS AND TABLES
CHT 01 - 2
Rev 0
30 May 11
APPENDIX 08
CHARTS AND TABLES
Sulfuric Acid Conductivity (mS/cm), Low Temperature Range

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 45 50 °C
Wt% H2SO4 68 70 72 73 75 77 79 81 82 84 86 88 90 91 93 95 97 99 100 102 104 113 122 °F
90.0% 111 115 119 123 127 130 134 138 142 146 150 154 158 162 167 171 175 179 184 188 192 215 238
91.0% 114 117 121 125 128 132 136 139 143 147 151 155 159 163 167 171 175 180 184 188 192 215 237
92.0% 115 119 122 126 129 133 136 140 143 147 150 154 158 162 167 171 175 179 183 187 191 213 235
93.0% 115 119 122 125 129 132 136 139 142 146 149 153 157 161 165 169 173 177 182 186 190 211 232
94.0% 114 118 121 124 127 131 134 137 140 143 147 151 155 158 162 166 170 174 178 182 186 207 228
95.0% 111 114 117 120 123 126 129 132 135 138 141 145 149 153 156 160 164 168 171 175 179 199 219
95.5% 109 111 114 117 120 123 126 129 132 135 138 141 145 148 152 156 159 163 167 170 174 193 212
96.0% 105 108 111 114 116 119 122 125 128 130 133 137 140 144 147 151 154 158 161 165 168 186 204
96.5% 101 104 106 109 112 115 117 120 123 125 128 131 135 138 141 144 148 151 154 157 161 177 194
97.0% 96 99 101 104 106 109 112 114 117 119 122 125 128 131 134 137 140 143 146 149 152 168 183
97.1% 95 97 100 102 105 108 110 113 115 118 120 123 126 129 132 135 138 141 144 147 150 165 181
97.2% 93 96 99 101 104 106 109 111 114 116 119 122 124 127 130 133 136 139 142 145 148 163 178
97.3% 92 95 97 100 102 105 107 110 112 115 117 120 123 126 128 131 134 137 140 143 145 161 176
97.4% 91 93 96 98 101 103 106 108 111 113 115 118 121 124 127 129 132 135 138 140 143 158 173
97.5% 90 92 94 97 99 102 104 107 109 111 114 117 119 122 125 127 130 133 136 138 141 156 171
97.6% 88 90 93 95 97 100 102 105 107 109 112 114 117 120 123 125 128 131 133 136 139 153 168
97.7% 86 89 91 93 96 98 100 103 105 107 110 112 115 118 120 123 126 128 131 134 136 151 166
97.8% 85 87 89 91 94 96 98 101 103 105 108 110 113 116 118 121 124 126 129 131 134 148 163
97.9% 83 85 87 90 92 94 96 99 101 103 106 108 111 113 116 119 121 124 127 129 132 146 160
98.0% 81 83 86 88 90 92 95 97 99 101 104 106 109 111 114 117 119 122 124 127 130 143 157
98.1% 79 81 83 86 88 90 92 94 97 99 101 103 106 108 111 114 116 119 121 124 126 140 154
98.2% 77 79 81 83 86 88 90 92 94 96 98 101 103 106 108 111 113 116 118 121 123 137 150
98.3% 75 77 79 81 83 85 87 89 91 94 96 98 100 103 105 108 110 113 115 117 120 133 146
98.4% 73 75 77 79 81 83 85 87 89 91 93 95 98 100 102 105 107 109 112 114 117 130 143
98.5% 71 73 75 77 79 81 83 84 86 88 90 93 95 97 100 102 104 106 109 111 113 126 139
98.6% 68 70 72 74 76 77 79 81 83 85 86 88 91 93 95 97 99 102 104 106 108 120 133
98.7% 66 67 69 71 72 74 76 77 79 81 82 84 86 88 90 93 95 97 99 101 103 114 126
98.8% 63 65 66 68 69 71 72 74 75 77 78 80 82 84 86 88 90 92 94 96 97 109 120
98.9% 61 62 63 65 66 67 69 70 72 73 74 76 78 80 81 83 85 87 89 90 92 103 113
99.0% 58 59 60 62 63 64 65 67 68 69 70 72 74 75 77 79 80 82 84 85 87 97 107
99.1% 54 55 56 57 58 59 61 62 63 64 65 66 68 69 71 72 74 75 77 79 80 89 98
99.2% 50 51 52 53 54 55 56 57 58 58 59 61 62 64 65 66 68 69 70 72 73 82 90
99.3% 46 47 48 49 49 50 51 52 52 53 54 55 56 58 59 60 61 63 64 65 66 74 82
99.4% 42 43 44 44 45 45 46 47 47 48 49 50 51 52 53 54 55 56 57 58 59 67 74
99.5% 38 39 39 40 40 41 41 42 42 43 43 44 45 46 47 48 49 50 51 52 53 59 65
99.6% 32 33 33 34 34 35 35 36 36 37 37 38 39 40 40 41 42 43 44 45 46 51 57
99.7% 26 27 27 28 28 29 29 30 30 30 31 32 32 33 34 35 35 36 37 38 38 43 48
99.8% 20 21 21 22 22 23 23 23 24 24 25 25 26 27 27 28 29 29 30 31 31 35 39
99.9% 14 15 15 16 16 17 17 17 18 18 19 19 20 20 21 21 22 23 23 24 24 27 31
100.0% 9 9 9 10 10 11 11 11 12 12 13 13 13 14 14 15 15 16 16 17 17 20 22
CHT 01 - 3
Rev 0
30 May 11
APPENDIX 08
CHARTS AND TABLES
Sulfuric Acid Conductivity (mS/cm), High Temperature Range

60 70 80 90 100 120 140 160 180 190 200 210 220 °C
Wt% H2SO4 140 158 176 194 212 248 284 320 356 374 392 410 428 °F
85.0% 292 353 416 482 549 690 838 986 1133 1207 1281 1355 1429
90.0% 288 346 406 473 526 643 772 901 1030 1095 1159 1224 1288
91.0% 286 341 400 463 516 631 755 880 1005 1067 1129 1192 1254
92.0% 283 336 392 451 504 617 737 857 976 1036 1096 1156 1216
93.0% 279 328 383 439 491 601 715 830 945 1002 1059 1117 1174
94.0% 272 320 371 425 476 581 690 799 907 962 1016 1071 1125
95.0% 260 307 355 405 455 556 657 759 861 912 963 1014 1065
95.5% 253 297 345 392 441 540 637 735 833 882 931 980 1029
96.0% 244 286 333 378 425 520 613 706 800 846 893 940 986
96.5% 233 273 319 361 406 495 582 670 758 802 846 890 933
97.0% 219 260 301 341 382 463 544 625 706 747 788 828 869
97.1% 217 257 297 337 377 457 538 618 698 738 778 818 858
97.2% 214 253 293 333 372 451 531 610 689 729 768 808 847
97.3% 211 250 289 328 367 445 523 602 680 719 758 797 836
97.4% 208 247 285 324 362 439 516 593 670 709 747 786 824
97.5% 205 243 281 319 357 433 508 584 660 698 736 774 812
97.6% 202 239 276 314 351 426 500 575 650 687 724 762 799
97.7% 198 235 272 309 345 419 492 566 639 676 712 749 786
97.8% 195 231 267 303 339 411 483 556 628 664 700 736 772
97.9% 191 227 262 297 333 404 474 545 616 651 687 722 758
98.0% 187 222 257 291 326 395 465 534 604 638 673 708 742
98.1% 183 217 251 285 319 387 455 523 590 624 658 692 726
98.2% 179 212 245 278 312 378 444 510 577 610 643 676 709
98.3% 174 207 239 271 304 368 433 497 562 594 626 659 691
98.4% 170 201 232 264 295 358 421 483 546 577 609 640 672
98.5% 164 195 225 255 286 346 407 468 529 559 590 620 650
98.6% 158 187 216 246 275 333 392 450 508 538 567 596 625
98.7% 151 179 207 235 263 319 375 431 487 515 543 571 599
98.8% 144 170 197 224 250 303 357 410 463 490 516 543 569
98.9% 136 161 186 211 236 286 337 387 437 462 487 513 538
99.0% 127 150 174 197 221 267 314 361 408 432 455 479 502
99.1% 118 140 162 184 206 249 293 337 381 402 424 446 468
99.2% 109 129 150 170 190 230 271 311 352 372 392 412 433
99.3% 100 118 137 155 174 211 248 285 322 340 359 377 396
99.4% 90 107 124 140 157 190 224 257 291 307 324 341 358
99.5% 80 95 110 125 140 169 199 229 259 274 288 303 318
99.6% 70 83 96 109 122 148 174 200 226 239 252 265 278
99.7% 60 71 82 93 104 126 148 171 193 204 215 226 237
99.8% 49 59 68 77 86 104 123 141 159 169 178 187 196
99.9% 39 46 54 61 68 83 97 112 126 133 141 148 155
100.0% 29 34 40 45 51 61 72 83 94 99 104 110 115
100.1% 43 51 59 67 75 91 106 122 138 146 154 162 170
100.2% 49 57 66 75 84 102 120 138 156 165 174 183 192
100.3% 52 62 71 81 91 110 129 149 168 178 187 197 207
100.4% 55 65 75 86 96 116 137 157 177 188 198 208 218
100.6% 60 71 82 93 104 126 148 170 192 203 214 225 236
100.8% 63 75 86 98 110 133 156 179 203 214 226 238 249
101.0% 66 78 90 102 115 139 163 188 212 224 236 249 261
CHT 01 - 4
Rev 0
30 May 11
APPENDIX 08
CHARTS AND TABLES
Sulfur Burner Temperature Rise

13.00
12.00
11.00
10.00
Vol % SO2
9.00
8.00
7.00
6.00 120 F Inlet Air 160 F Inlet Air
220 F Inlet Air 400 F Inlet Air

5.00
1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Temp Deg F
CHT 01 - 5
Rev 0
30 May 11
APPENDIX 08
CHARTS AND TABLES
CHT 01 - 6
Manual
Manufacturing Chemists' Association Sheet
T-7
OF THE UNITED STATES

TABLE -- SULPHURIC ACID
STANDARD
ADOPTED 1904 CHT 02
Per Cent Weight of 1 cu. Per Cent Pounds O. V. *Freezing
Bé Sp. Gr. Tw.° APPROXIMATE BOILING POINTS
H2SO4 ft. in lbs. Av. O. V. in 1 cu. ft. (Melting) Point
0 1.0000 0.0 0.00 62.37 0.00 0.00 32.0° F. 50° Bé, 295 °F
1 1.0069 1.4 1.02 62.80 1.09 0.69 31.2° F. 60° Bé, 386° F
2 1.0140 2.8 2.08 63.24 2.23 1.41 30.5° F. 61° Bé, 400° F
3 1.0211 4.2 3.13 63.69 3.36 2.14 29.8° F. 62° Bé, 415° F
4 1.0284 5.7 4.21 64.14 4.52 2.90 28.9° F. 63° Bé, 432° F
5 1.0357 7.1 5.28 64.60 5.67 3.66 28.1° F. 64° Bé, 451° F
6 1.0432 8.6 6.37 65.06 6.84 4.45 27.2° F. 65° Bé, 485° F
7 1.0507 10.1 7.45 65.53 7.99 5.24 26.3° F. 66° Bé, 538° F
8 1.0584 11.7 8.55 66.01 9.17 6.06 25.1° F.
9 1.0662 13.2 9.66 66.50 10.37 6.89 24.0° F. FIXED POINTS
10 1.0741 14.8 10.77 66.99 11.56 7.74 22.8° F.
Sp. Gr. Per Cent H 2SO4 Sp. Gr. Per Cent H 2SO4
11 1.0821 16.4 11.89 67.49 12.76 8.61 21.5° F.
12 1.0902 18.0 13.01 68.00 13.96 9.49 20.0° F. 1.0000 0.00 1.5281 62.34
13 1.0985 19.7 14.13 68.51 15.16 10.39 18.3° F. 1.0048 0.71 1.5440 63.79
14 1.1069 21.4 15.25 69.04 16.36 11.30 16.6° F. 1.0347 5.14 1.5748 66.51
15 1.1154 23.1 16.38 69.57 17.58 12.23 14.7° F. 1.0649 9.48 1.6272 71.00
16 1.1240 24.8 17.53 70.11 18.81 13.19 12.6° F. 1.0992 14.22 1.6679 74.46
17 1.1328 26.6 18.71 70.65 20.08 14.19 10.2° F. 1.1353 19.04 1.7044 77.54
18 1.1417 28.3 19.89 71.21 21.34 15.20 7.7° F. 1.1736 23.94 1.7258 79.40
19 1.1508 30.2 21.07 71.78 22.61 16.23 4.8° F. 1.2105 28.55 1.7472 81.32
20 1.1600 32.0 22.25 72.35 23.88 17.27 1.6° F. 1.2513 33.49 1.7700 83.47
21 1.1694 33.9 23.43 72.93 25.14 18.34 -1.8° F. 1.2951 38.64 1.7959 86.36
22 1.1789 35.8 24.61 73.53 26.41 19.42 -6° F. 1.3441 44.15 1.8117 88.53
23 1.1885 37.7 25.81 74.13 27.70 20.53 -11° F. 1.3947 49.52 1.8194 89.75
24 1.1983 39.7 27.03 74.74 29.01 21.68 -16° F. 1.4307 53.17 1.8275 91.32
25 1.2083 41.7 28.28 75.36 30.35 22.87 -23° F. 1.4667 56.68 1.8354 93.19
26 1.2185 43.7 29.53 76.00 31.69 24.08 -30° F. 1.1822 58.14
27 1.2288 45.8 30.79 76.64 33.04 25.32 -39° F.
28 1.2393 47.9 32.05 77.30 34.39 26.58 -49° F. ALLOWANCE FOR TEMPERATURE
29 1.2500 50.0 33.33 77.96 35.77 27.88 -61° F. At 10° Bé, .029° Bé or .00023 Sp. Gr.=1°F.
30 1.2609 52.2 34.63 78.64 37.16 29.22 -74° F. At 20° Bé, .036° Bé or .00034 Sp. Gr.=1°F.
31 1.2719 54.4 35.93 79.33 38.56 30.59 -82° F. At 30° Bé, .035° Bé or .00039 Sp. Gr.=1°F.
32 1.2832 56.6 37.26 80.03 39.98 32.00 -96° F. At 40° Bé, .031° Bé or .00041 Sp. Gr.=1°F.
33 1.2946 58.9 38.58 80.75 41.40 33.43 -97° F. At 50° Bé, .028° Bé or .00045 Sp. Gr.=1°F.
34 1.3063 61.3 39.92 81.47 42.84 34.90 -91° F. At 60° Bé, .026° Bé or .00053 Sp. Gr.=1°F.
35 1.3182 63.6 41.27 82.22 44.29 36.41 -81° F. At 63° Bé, .026° Bé or .00057 Sp. Gr.=1°F.
36 1.3303 66.1 42.63 82.97 45.75 37.95 -70° F. At 66° Bé, .0235° Bé or .00054 Sp. Gr.=1°F.
37 1.3426 68.5 43.99 83.74 47.20 39.53 -60° F.
38 1.3551 71.0 45.35 84.52 48.66 41.13 -53° F. Per Cent Pounds 60° in Per Cent Pounds 50° in
39 1.3679 73.6 46.72 85.32 50.13 42.77 -47° F. 60° 1 cu. ft. 50° 1 cu. Ft.
40 1.3810 76.2 48.10 86.13 51.61 44.46 -41° F. 61.93 53.34 77.36 66.63
41 1.3942 78.8 49.47 86.96 53.09 46.16 -35° F. 63.69 55.39 79.56 69.19
42 1.4078 81.6 50.87 87.80 54.59 47.93 -31° F. 65.50 57.50 81.81 71.83
43 1.4216 84.3 52.26 88.66 56.08 49.72 -27° F. 67.28 59.66 84.05 74.53
44 1.4356 87.1 53.66 89.54 57.58 51.56 -23° F. 69.09 61.86 86.30 77.27
45 1.4500 90.0 53.07 90.44 56.95 51.50 -20° F. 70.90 64.12 88.58 80.10
46 1.4646 92.9 56.48 91.35 60.61 55.36 -14° F. 72.72 66.43 90.83 82.98
47 1.4796 95.9 57.90 92.28 62.13 57.34 -15° F. 74.55 68.79 93.12 85.93
48 1.4948 99.0 59.32 93.23 63.65 59.35 -18° F. 76.37 71.20 95.40 88.94
49 1.5104 102.1 60.75 94.20 65.19 61.41 -22° F. 78.22 73.68 97.70 92.03
50 1.5263 105.3 62.18 95.20 66.72 63.52 -27° F. 80.06 76.21 100.00 95.20
51 1.5426 108.5 63.66 96.21 68.31 65.72 -33° F. 81.96 78.85 102.38 98.50
52 1.5591 111.8 65.13 97.24 69.89 67.96 -39° F. 83.86 81.54 104.74 101.85
53 1.5761 115.2 66.63 98.30 71.50 70.28 -49° F. 85.79 84.33 107.15 105.33
54 1.5934 118.7 68.13 99.38 73.11 72.66 -59° F. 87.72 87.17 109.57 108.89
55 1.6111 122.2 69.65 100.49 74.74 75.10 Below -40 89.67 90.10 112.01 112.55
56 1.6292 125.8 71.17 101.61 76.37 77.60 Below -40 91.63 93.11 114.46 116.30
57 1.6477 129.5 72.75 102.77 78.07 80.23 Below -40 93.67 96.26 117.00 120.24
58 1.6667 133.3 74.36 103.95 79.79 82.95 Below -40 95.74 99.52 119.59 124.31
59 1.6860 137.2 75.99 105.16 81.54 85.75 -7° F. 97.84 102.89 122.21 128.52
60 1.7059 141.2 77.67 106.40 83.35 88.68 12.6° F. 100.00 106.40 124.91 132.91
61 1.7262 145.2 79.43 107.66 85.23 91.77 27.3° F. 102.27 110.10 127.74 137.52
62 1.7470 149.4 81.30 108.96 87.24 95.06 39.1° F. 104.67 114.05 130.75 142.47
63 1.7683 153.7 83.34 110.29 89.43 98.63 46.1° F. 107.30 118.34 134.03 147.82
64 1.7901 158.0 85.66 111.65 91.92 102.63 46.4° F. 110.29 123.14 137.76 153.81
64 ¼ 1.7957 159.1 86.33 112.00 92.64 103.75 43.6° F. 111.15 124.49 138.84 155.50
64 ½ 1.8012 160.2 87.04 112.34 93.40 104.93 41.1° F. 112.06 125.89 139.98 157.25
64 ¾ 1.8069 161.4 87.81 112.69 94.23 106.19 37.9° F. 113.05 127.40 141.22 159.14
65 1.8125 162.5 88.66 113.05 95.13 107.55 33.1° F. 114.14 129.03 142.57 161.17
65 ¼ 1.8182 163.6 89.53 113.40 96.07 108.95 24.6° F. 115.30 130.75 144.02 63.32
65 ½ 1.8239 164.8 90.60 113.76 97.22 110.60 13.4° F. 116.65 132.70 145.71 165.76
65 ¾ 1.8297 165.9 91.80 114.12 98.51 112.41 -1° F. 118.19 134.88 147.63 168.48
66 1.8354 167.1 93.19 114.48 100.00 114.48 -29° F. 119.98 137.34 149.87 171.56
Specific Gravity determinations were made at 60° F., compared with water at 60° F.
From the Specific Gravities, the corresponding degrees Baumé were calculated by the following formula:
Baumé = 145 - 145 / Sp. Gr.
Baumé Hydrometers for use with this table must be graduated by the above formula, which formula should always be printed on the scale.
66° Baumé = Sp. Gr. 1.8354
1 cu. Ft. water at 60° F. weighs 62.37 lbs. avoirdupois.
Atomic weights from F.W. Clarke's table of 1901. O = 16.
H2SO4 = 100 per cent
H2SO4 O.V. 60°
O.V. 93.19 100.00 119.98
60° 77.67 83.35 100.00
50° 62.18 66.72 80.06
Acids stronger than 66° Bé should have their percentage compositions determined by chemical analysis.
* Calculated from Pickering's results, Journal of London Chemical Society, vol. 57, p. 363
Authorities - W.C. Ferguson; H.P. Talbot.
MANUFACTURING CHEMIST' ASSOCIATION
1825 Connecticut Avenue, N.W.
Washington 9, D.C.
Rev 0
30 May 11
APPENDIX 09
PLANT NOTEBOOK AND OPERATING REPORTS
1. OPERATING LOG SHEET
Operating data may be recorded on log sheets confined either to each operator’s duties
or to the physical division of the plant. The amount of data recorded will depend on the
owner’s specific requirements.
All essential data should be recorded at least every two hours, even if it is continuously
recorded on the DCS. All DCS values should be read more frequently, however, even
though the data recordings are only made at two hour intervals. Field instruments
should be recorded at least once per shift or after any major change in the process
conditions.
2. DAILY OPERATING REPORT
The important information from the operating log sheets is typically summarized in a
daily operating report. This report typically includes major plant utility and export
quantities, plant capacity, plant emissions, and product quality. Hardcopy forms for the
daily operating report should be initially prepared using a computer, printer, and copying
machine. The electronic version of the report may prove beneficial later as a timesaving
device, as additional or fewer data points than those suggested may be desired. Higher
quality printed forms can be made after it is determined exactly what data is to be
recorded.
3. MONTHLY SURVEY REPORT
At a minimum of once a month, the supervisor or plant engineer should take a detailed
pressure and temperature survey throughout the plant at all points where connections
have been provided. These readings should be carefully studied and compared with
pressure/temperature trends and with design setpoints.
The survey report should contain all operating data collected on the operating log sheets
and daily operating report, all additional temperatures and pressures throughout the
plant, total production rate, equivalent SO2 gas concentration, conversion efficiency,
setting of gas bypass valves, etc. All data should be obtained within a short period of
time to give a true simultaneous picture of plant operation. Also listed should be any
shutdowns, major repairs, unusual operating difficulties, rate changes, etc. The survey
data should be clearly marked with the plant rate and best estimate of the gas flow to the
information can be properly compared with other data sets.
REP 01 - 1
Rev 0
30 May 11
APPENDIX 09
PLANT NOTEBOOK AND OPERATING REPORTS
Availability of detailed manometer readings, taken periodically throughout the plant,

enables the supervisor to determine when, if, and how fast dirt is accumulated in the
various pieces of equipment and enables the supervisor to determine which pieces of
equipment require maintenance or cleaning and when it should be performed.
As the total pressure drop through the plant increases with time, the maximum volume
that the blower delivers will decrease. Eventually, the plant will have to be shut down
and certain equipment cleaned if production is to be maintained at a maximum.
4. OPERATING LOG BOOK
A continuous day-to-day and shift-to-shift operating log book should be available in the
control room wherein the operators keep a written log of daily operations and events,
and the supervisor enters all written instructions.
REP 01 - 2

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2. Revisions are identified in the body of the Specification.

GENERAL SB WITH HRS OPERATING DOCUMENTS

APPENDIX 01 Pre-Startup Check Lists

Sheet No EQUIPMENT NAME Revision Date

CHK-03 Waste Heat Boiler 0 30 May 11

CHK-04 Main Compressor 0 30 May 11

CHK-05 Inlet Air Filter 0 30 May 11

CHK-06 Converter 0 30 May 11

CHK-07 Hot Interpass Heat 0 30 May 11

CHK-08 Cold Interpass Heat 0 30 May 11

CHK-09 Economizer 3B 0 30 May 11

CHK-10 HP,IP Superheaters 4A 0 30 May 11

CHK-11 Superheater 1B 0 30 May 11

Sheet No EQUIPMENT NAME Revision Date

MECS Dwg. / Required Actual

Punch List Items

WASTE HEAT BOILER

MECS Dwg. / Required Actual

WASTE HEAT BOILER

Punch List Items

MECS Dwg. Required Actual

Punch List Items

INLET AIR FILTER

MECS Dwg. / Required Actual

Punch List Items

MECS Dwg. / Required Actual

Punch List Items

HOT INTERPASS HEAT EXCHANGER

MECS Dwg. / Required Actual

HOT INTERPASS HEAT EXCHANGER

Punch List Items

COLD INTERPASS HEAT EXCHANGER

MECS Dwg. / Required Actual

COLD INTERPASS HEAT EXCHANGER

Punch List Items

MECS Dwg. / Required Actual

Punch List Items

HP/IP SUPERHEATER 4A / ECONOMIZER 4C/4A

MECS Dwg. / Required Actual

HP/IP SUPERHEATER 4A / ECONOMIZER 4C/4A

Punch List Items

MECS Dwg. / Required Actual

Punch List Items

MECS Dwg. / Required Actual

13. Ensure that the main packing is the

24. If the tower contains seal cups, ensure

Punch List Items

FINAL ABSORBING TOWER

MECS Dwg. / Required Actual

FINAL ABSORBING TOWER

13. Ensure that the main packing is the

FINAL ABSORBING TOWER

25. If the tower contains seal cups, ensure

FINAL ABSORBING TOWER

Punch List Items

COMBINATION PUMP TANK

MECS Dwg. / Required Actual

COMBINATION PUMP TANK