I am facing challenges disassembling my Horizontal Sulfur Loading Pump in my Sulfur Recovery Unit for maintenance due to the solidification of sulfur jamming the internal parts, especially the Mechanical Seal. Can you recommend safe and effective techniques for dismantling the pump? This will ensure smooth maintenance processes and prevent any damage to the pump components.
Swapnil, have you attempted cleaning the pump with solvent right after turning it off? This quick maintenance step can help prevent clogs and ensure the pump continues working efficiently.
What is the best solvent to clean a pump with? Is it better to clean the pump while it is still mounted in its position or should it be removed from the casing first? The process of removing the pump from the casing can be time-consuming due to the solidification of Sulfur.
It is essential for seals to have a quench connection in accordance with API 682 in order to effectively remove sulfur buildup in the seal area. Look for the 'Q' marking and plug on the seal housing when the connection is not in use. This is crucial for maintaining the performance and longevity of the seal. Keep your equipment running smoothly with proper quench connections as recommended by industry standards. Don't forget to check for the marked 'Q' and plug when inspecting your seal housing.
The steam quenching connection in the seal is currently operational and not blocked. This seal is equipped with a steam connection for jacketing and quenching (according to API plan 62). However, I'm facing difficulty in loosening the Grub screws that secure the locking sleeve on the shaft. Should I consider using a gas cutting set to heat the seal and melt away the sulfur? It's important to note that sulfur is flammable and handling it in this manner can be hazardous and unsafe.
Swapnil, you are correct in recognizing that you are handling a potentially dangerous product. Have you discussed this issue with the pump vendor? It is essential to check if the pump has the necessary connections for a solvent or steam hookup at the inlet and outlet. Both the solvent and the effluent can pose health risks due to their toxicity and flammability. Therefore, it is crucial to carefully consider the design and follow your Plant Change Procedure, which should include a thorough risk analysis, including a HAZOP study. In laboratory settings, Carbon disulphide was commonly used as a solvent, but its industrial applications should be verified. There are commercially available products like Paratene S700 (a toxic product manufactured by Woodrising Resources Ltd., Canada) or organic disulfide-polysulfide sulfur solvents used in sour gas production. It is advisable to conduct further research on these options to determine their suitability for your specific needs. It is important to remember that finding a solution may take time, and there is no quick fix. Stay in close communication with the pump vendor and seek their technical expertise. As a short-term measure, avoid using a gas torch and opt for a steam lance to melt the sulfur instead. A steam flush through the pump could also be a safe alternative to using a solvent, if feasible.
You may want to try warming up the pump slightly to loosen the solidified sulfur content. Since sulfur has a relatively low melting point of about 115°C (239°F), a gradual and controlled heat application could be helpful. This technique could help to melt the sulfur and make it easier to disassemble the pump. However, you should use caution during this process to avoid overheating as it could damage your mechanical seal. Always remember, safety first!
I would suggest using a diluted solution of Sodium Carbonate to dissolve the solidified sulfur. Be cautious and protective while handling this solution and assure that it doesn't damage the seals. Further, apply a uniform heat that's within the seal's temperature bearing capacity to soften the sulfur, making disassembly easier. Also, ensure all safety measures and process guidelines are followed strictly to prevent any damage to pump components.
Have you tried using steam or heat jackets at a controlled temperature to gradually melt the solid sulfur? This method can help loosen the internal parts, making disassembly easier. Just be sure to maintain the temperature below the sulfur’s flash point to prevent fires. Once you're done with the heat application, you should be able to disassemble the pump and clean the parts with a recommended solvent that's sulfur-compatible. Also, consider incorporating regular preventive maintenance to avoid sulfur solidification in the future.
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Answer: 1. Q: What are the common challenges faced when disassembling a Sulfur Loading Pump for maintenance? One common challenge is the solidification of sulfur, which can jam internal parts such as the Mechanical Seal, making disassembly difficult.
Answer: To safely disassemble a pump with solidified sulfur jamming internal parts, it is recommended to heat the pump gently to liquefy the sulfur, allowing for easier dismantling without causing damage to the components.
Answer: Utilizing safe and effective techniques is crucial to ensure a smooth maintenance process and prevent damage to the pump components. Proper disassembly methods can also extend the lifespan of the pump.
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