Process Functional Job No.

:PR10371
Description
Rev. 2
Docu.-No. 41375-5020 Sheet: 1 of: 7

Sulphur Soldification Plant

Process Functional Description

Dakhni Expansion Project

Sulphur Solidification Plant

Presson Decson International

Lahore – Pakistan

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 Process Functional Job No.:PR10371
Description
Rev. 2
Docu.-No. 41375-5020 Sheet: 2 of: 7

1. PURPOSE

2. REFERENCE DOCUMENTS

3. DESCRIPTION OF PROCESS

4. ABBREVIATIONS

5. PROCESS CONTROL NARATIVES

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 Process Functional Job No.:PR10371
Description
Rev. 2
Docu.-No. 41375-5020 Sheet: 3 of: 7

1. PURPOSE

This document describes the Control and Instrument Protective Function of the
Sulphur Solidification Plant at Dakhni Expansion Project

2. REFERENCE DOCUMENTS

41375-0020 P & I Diagram Sulphur Pastillation Unit

3. DESCRIPTION OF PROCESS

The complete Sulphur Pastillation Plant consists of 3 Rotoformers, one liquid Sulphur Pit
(TK-1902, by client), two Liquid Sulphur Pumps (1 in operation, 1 in stand by), one
Release Agent System, consists of one release Agent Tank (TK-1903) with an Release
Agent Mixer and two Release Agent Pumps (1 in operation, 1 in stand by). In normal
operation 2 Rotoformer Units are running, on in standby or maintenance

The liquid sulphur will be supplied from clients sulphur pit by pumps via heated pipelines
through a double filter to the Rotoform Units.

The required feed pressure at the inlet of each Rotoformer is maintained by a pressure
controlled recirculation line with a pressure transmitter and a pressure control valve (PT-
0010, PCV-0010) Excess sulphur is returned to liquid sulphur pit.
Each Rotoform unit consists of a ROTOFORM 3000, a steel belt cooler with internal water
spray and collecting basins and hood assemply. The ROTOFORM 3000 continuously
forms small pastilles of liquid sulphur and deposits them on the moving steel belt. The
pastilles are cooled and solidified by indirect contact with cooled water, sprayed onto the
underside of the belt. Water is recirculated and cool down in a cooling water system. (by
client)

To ensure good release of the pastilles from the stainless steel belt, a water soluble,
silicone-based release agent is continuously applied as a very thin film on the belt just prior
to the ROTOFORM 3000. Excess release agent is returned to the sump by squeegee.

The solid pastilles are collected on a collecting conveyor (by client) and transferred to the
solid sulphur storage area (by client)

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 Process Functional Job No.:PR10371
Description
Rev. 2
Docu.-No. 41375-5020 Sheet: 4 of: 7

4. ABBREVIATIONS

PLC: Programmable logic controller

DCS: Distributed control system
LOP: Local operator panel
FISL: Flow Indicator Switch
ZSO: Limit Switch open indication
ZSL: Limit Switch close indication
PDAH: Difference Pressure Alarm High
PDAHH: Difference Pressure Alarm High/High

5. PROCESS CONTROL NARRATIVE

5.1 Overall Description

The sulphur solidication plant has to control by a PLC based control system or DCS (by
client) and associated local operator panels (by Sandvik). The PLC-system or DCS controls
the Rotoform units, sulphur pumps, sulphur pressure control, release agent system and
exhaust fans.

5.1.1 Rotoform Units Operation (for example just Rotoform Unit SBC-1901)
Operation of the other Rotoform Units are identical

For the Rotoform units there are 2 operating modes, selected by a selector key switch at
each Rotoform local operator panel (LOP). Operating mode is indicated by indication lamp.
- production mode
- service mode
Usually the Rotoform units are running in production mode. The service mode shall be
use only for service, maintenance and cleaning of the Rotoform units.

5.1.2 Production mode

5.1.2.1 Start up sequence (operated at local control panel only)

Conditions:
- downstream equipment e.g. sulphur collecting conveyor is running
- cooling water flow is ok (FISL- 0100)
- sulphur pressure at circulation line (PT-0010) is ok
- start permission from client ok

Start Rotoform unit by push buttons at LOP

- Start exhaust fan by push button at LOP

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 Process Functional Job No.:PR10371
Description
Rev. 2
Docu.-No. 41375-5020 Sheet: 5 of: 7

- When cooling belt is running and Rotoformer temperature is high enough,

(indicated by temperature element TIS-0100) start Rotoformer by push button at
LOP.
- When the steel belt cooler, Rotoformer and exhaust fan are running, open
product valve XV-0100 by push button at LOP.
- Production is now running automatically.
- During production it is not possible to stop the Rotoformer, cooling belt or exhaust
fan, while the product valve is open, indicated by XZSH-0100. (except emergency
stop) Product valve closed is indicated by XZSL-0100

5.1.2.2 Shut down sequence

- Shut down sequence start by push button at LOP

- Product valve XV-0100 closed immediately.
- After a time delay of 10 minutes, when product valve is closed, (indicated by
XZSL-0100) the Rotoformer stops.
- After additional time delay of 10 minutes, when the Rotoformer has stopped, the
steel belt cooler stops too.
- After additional time delay of 10 minutes, when the steel belt cooler has stopped,
the exhaust fan stops too.
- Shut down sequence is finished.
- The shut down sequence can be interrupt, by starting again the steel belt cooler,
Rotoformer, Exhaust fan, or open product valve.

5.1.3 Failure handling

- Failure of down stream equipment e.g. sulphur collecting conveyor >>> shut
down sequence of each Rotoform unit starts.
- Cooling water flow or Rotoformer temperature are low, >>> shut down sequence
of the corresponding Rotoform unit starts.
- sulphur pressure is high or low >>> shut down sequence of each Rotoform unit
starts.
- Failure steel belt cooler >>> product valve closed and Rotoformer of the
corresponding Rotoform unit stopped immediately.

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Description
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5.1.4 Service Mode

- In service mode it is possible to run steel belt cooler, Rotoformer and exhaust fan
or open the product valve independent of each other and independent of down
stream equipment e.g. collecting conveyor running and sulphur pressure.
- only 2 interlockings are active. Cooling water flow min, (FISL-0100) to avoid
damage of the steel belt and emergency stop for safety of the whole plant.

5.2 Liquid sulphur supply

5.2.1 Sulphur Pumps

Liquid sulphur supply to the Rotoform Units will be done by two submerged pumps (P-1904
A/B) installed in clients sulphur pit TK-1902. One in operation, one in standby. Pumps will
be started by push button at LOP

5.2.2 Sulphur pressure control system

To supply the Rotoformer units with a constant sulphur pressure, a pressure controled
sulphur circulating system is used. This system consists of a sulphur recirculating line, a
pressure control valve (PCV-0010) and a pressure transmitter (PT-0010). The pressure will
be controled by a software controler included in clients PLC or DCS
Start and Stop of pressure control operation will be done by clients HMI.

5.2.3 Sulphur filter (C-1904A/B)

To protect the Rotoform units against pollution, a double filter station is installed in the
sulphur recirculation line.
This sulphur filter will be monitored by a difference pressure transmitter. (PDT-0010) If the
difference pressure is too high, an alarm will be create in clients PLC or DCS (PDIH-0010)
sulphur filter dirty, and the operator has to clean the filter.

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 Process Functional Job No.:PR10371
Description
Rev. 2
Docu.-No. 41375-5020 Sheet: 7 of: 7

5.3 Release agent system

In order to avoid any damage to the pastilles when being discharged from the steel belt,
one release agent system is installed.
This system consists of:
- Release agent tank TK-1903 with a level switch (LSL-0400 for low level
monitoring.
- Release agent mixer to mix up the release agent.
- Release agent pump P-1905A/B
- Release agent pan with a level switch (LSL0-100) for low level monitoring, a
level switch (LSH-0100) for high level monitoring and a ball valve (XY-0110)
to fill up the pan, at each Rotoform Unit. At low level the refill valve opens, at
high level the refill valve close automatically.

5.4 Cooling Water System

Cooling water supply and return will done by client.

5.5 Indication system

- All running and common failures of drives and positions of product valves are
indicated by indication lamps at the local operator panels (LOP)
- All temperatures, pressure, set points, drive status, running and failure signals will be
indicated at clients HMI.

5.6 Emergency stop system

- For the whole plant the client hav eto install an emergency stop system, controlled by
special emergency stop relais or .
- 2 pull rope switches are installed at each Rotoform unit and at the sulphur collecting
conveyor. 1 mushroom head pushbutton is installed at each local operator panel (LOP).
- In case of an emergency stop, each product valve closed, each Rotoformer, steel
belt cooler and sulphur collecting conveyor stopped.
- for safety reasons it is necessary to stop all Rotoformer units and the sulphur collecting
conveyor.
-To restart the plant, the pull rope switches and EM-stop pushbuttons has to be
unlocked and the EM-stop relay must be reset by operation of the reset button at LOP.

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