Story of an HRS Sulfuric Acid Unit

Operational transformation gives us an opportunity to review our operation methods in a way to measure our performance and focus on a rational strategy to improve the PS3 plant productivity and reduce SO2 emissions.This paper will detail specific process methodologies such as nondestructive process inspection (for example stick test provides operators with information about acid carryover in acid towers, operators can adjust acid and gas parameters depending on the result of the test and also to prepare spare parts for the next shutdown, another example is the pegasys test: pressure drop and conversion rate measurement of each catalyst bed helps operators optimizing the converter by adjusting the inlet temperature of each bed of catalyst). Other methodologies like process hazard analysis which addressed a cultural change into the team and also reinforced the relationship between operation and maintenance that's what leads us to reach a high level of performance.We will present after how preventive maintenance has helped us to predict future failures in some strategic equipment such as gas heat exchanger, turbine, blower…etc. An intelligent design modification was also a key factor to improve the reliability of the entire PSIII sulfuric unit.Our history can’t be concluded without talking about overhaul schedules and planning. The capitalization of all best practices and procedures allows us to adapt and standardize our maintenance tasks and activities, in way to create our own systemic overhaul process, that includes mainly safety instructions and CND inspections and controls(vibration, thermography, Oil Analysis, Foucault current measurement, check-list controls for major and risky tasks…etc) adapted for each equipment with specific and detailed reports, and done by experienced and certified OCP Staff (for example ISO certification on vibration and thermography).