th

V International Symposium on “Fusion of Science & Technology”,

New Delhi, India, January 18-22, 2016

ID: 2016-ISFT-259

Efficient Energy Transfer and Importance of

Jacketed Piping in Sulfur Transportation
B. Vinoth1, T. Vivek2, E. Siva Kumar3
1,2,3
Fluor India Pvt. Ltd., Infinity tower B, 6th floor, DLF Cyber City, Phase II, Gurgaon, Haryana, India. 122002
1
[email protected]

Abstract: In natural gas, sulfur is present mainly as coma [1]. For environmental and safety reasons, venting or
hydrogen sulfide (H2 S), while in crude oil it is present in flaring H2S to the surroundings is unacceptable. Therefore,
sulfur-containing organic compounds which are converted its conversion to the harmless elemental sulfur is necessary.
into hydrocarbons and H2 S during the removal process Elemental sulfur can be stored, handled and transported in
(hydrodesulphurization). In both cases, corrosive, highly- bulk. The primary use of sulfur is for the production of
toxic H2 S gas must be converted into elemental sulfur. This sulfuric acid and the minor uses include manufacturer of
elemental sulfur is received from the sulfur recovery process pesticide, fertilizer, bactericide in food preservation and
in a liquid or molten form .Heating and maintaining other fine chemicals.
temperature in process piping is very important to the
operation of sulfur in oil & gas industry. Hence, several 2. SULFUR RECOVERY
different technologies are used to transport the sulfur. In Sulfur is recovered through various types of processes. One
this several technologies, jacketed piping is one of the of the type is Straight through Claus process. This process is
common types which maintain a process temperature or it used when the acid gas containing more than 50% of H2S.
may be considered as a system of single tube heat This process consist of a thermal stage( Combustion
exchangers. This application is to prevent heat loss from a chamber, waste heat boiler) and two or three catalytic
fluid which it gets cooled by even a couple of degrees below reaction stages (reheater, reactor and condenser).In thermal
its freezing point. This paper will discuss about the types of stage, Acid gas combines with air passes through the
jacketed piping, efficiency of heat transfer in jacketed reaction furnace, where the amount of heat generated in the
piping, limits of calculated stresses due to sustained loads reaction furnace depends on the amount of H2S available in
and displacement strain for core as well as jacket pipe and the burner.
limits of calculated stresses due to occasional loads as per
ASME B31.3. It also explains external pressure applying on The furnace normally operates at combustion chamber,
the inner pipe wall, checking of buckling stress and distance temperatures ranging from 980 degC to 1300 degC with
of spacer calculated for each size, checking of welding pressure higher than 70 Kg/cm2.[2]. Before entering a sulfur
strength between jacket and core pipe. Finally this paper condenser, hot gas from the reaction furnace is cooled in a
deals with prevention and quality control during waste heat boiler that generated high to medium pressure
fabrication, erection and installation of jacketed piping. steam. About 80 % of heat released could be recovered as
useful energy. Liquid sulfur is removed in a separator
Keywords: Sulfur, Claus Process, Jacketed Piping, Stress section of the condenser and flows by gravity to a sulfur
analysis storage tank. The cooled gas exiting the condenser is sent to
the catalyst beds. The catalytic reactor operate at lower
1. INTRODUCTION temperatures, ranging from 200 to 315 deg C . Alumina or
Sulfur is one of the most important element in oil & gas bauxite is sometimes used as a catalyst. Because this
industry. The vast majority of sulfur is recovered from reaction represents an equilibrium chemical reaction, it is
natural gas and oil, which contain hydrogen sulfide and a not possible for a Claus plant to convert all the incoming
wide variety of organic compounds that contains sulfur. It sulfur compounds to elemental sulfur [2]. Therefore two or
has to be removed before the natural gas and oil can be used more stages are used in series to recover the sulfur. Almost
as feed stock for the chemical industry as they poison the 95 to 98% overall recovery of sulfur can be achieved
catalyst that are used in the various process to make depending in the number of catalytic reaction stages and the
chemicals.H2S is a flammable gas with a wide limit of type of reheating method used.
flammability and unlike elemental sulfur it is extremely For lean acid gases that contain 5-30% H2S, the straight
toxic. In fact 5min exposure to only 800 ppm results in through Claus process is not workable without additional
death and a single breath of 1000 -2000 ppm may cause

ISBN: 978-93-84935-64-1 ♦ 300 ♦

 Efficient Energy Transfer and Importance of Jacketed Piping in Sulfur Transportation

equipment. The alternative is to replace the thermal section However, straight through Claus process is commonly used
of the modified Claus process by a direct oxygen process. in oil & gas industry since sulfur recovery will be higher.

Fig. 1. (Straight Through Claus Process) [1]

3. TRANSPORTATION OF SULFUR that heat will be generated along a conductor according to

the losses in the conducting element.
The elemental sulfur is received from the recovery process
in a liquid or molten form. Melting point is between 112 Q= f( I2 R)
degC and 121 degC depending on the crystalline form. The
flash point of liquid sulfur –the temperature at which it ‘I’ is the current applied to the conductor and it is constant
vaporizes to form an ignitable mixture in the air. The along its entire length. ‘R’ is the resistance of the conductor
ignition temperature of liquid sulfur is the point at which it and varies with the average temperature along the
will auto ignite without an external spark is between 248 conductor. Thus the heat is generated uniformly along the
deg C and 261degC.[2].These properties mean it is vital that entire length of the conductor. A problem occurs when a
liquid sulfur can be stored and transported at carefully line is not uniformly insulated. In areas where insulation is
maintained temperatures, typically above 130 degC. Sulfur less, heat losses will be greater but there will not be a
undergoes a sudden increase in viscosity that makes it corresponding increase in heat generated in this area to
impossible to pump. Thus the challenge is to maintain the compensate. This is the major problem with traditional
temperature of sulfur within the acceptable temperature electric heat tracing systems. [3].
range in all equipments and pipe lines. The challenge is
even greater when sulfur is transported long distance in pipe 3.2 CONTRO TRACING
lines. Contro tracing element is a rectangular tube with one
surface curved to match the outside diameter of the pipe to
This is achieved by transferring liquid sulfur through pipe
be heated. It is strapped onto the outside of the pipe with a
lines heated in one of the three ways.
layer of heat transfer cement between the pipe and the trace.
1. Electrical Tracing Piping System Heating fluid typically steam, runs through the tube. The
number of elements used on a pipe is adjusted to match the
2. Contro tracing Piping thermal requirements.
3. Jacketed Piping System 3.3 JACKETED PIPING
3.1 ELECTRICAL TRACING PIPING Steam jacketed piping is the traditional method for
conveying the molten sulfur throughout the plant. Jacketed
Electrical heat tracing is used to maintain or raise
piping is basically a pipe within a pipe. Inner pipe is
temperature of pipes and vessels. It is based on the principle
commonly referred to as core pipe whereas outer pipe is
known as jacketed pipe. Molten sulfur flows in the central

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18-22, 2016 ♦ 301 ♦
 Efficient Energy Transfer and Importance of Jacketed Piping in Sulfur Transportation

or core pipe which is heated by a fluid, typically steam, Key successful for jacketed piping system installation is the
flowing in the annular space formed between the core and location of steam supplies and condensate removal points.
jacketed pipe. It maintains a very uniform temperature on The steam supply to each jacketed circuit shall be taken
the process pipe wall. Jacketed piping is of two types. from the main header or sub headers and condensate from
Continuous Jacketed and Discontinuous Jacketed piping. the steam trap shall be returned to a condensate sub header/
All straight lengths, flanges, fittings, valves and branch main header. In principle, the steam inlet pipe must be
connection are fully jacketed. In discontinuous jacketed connected to the uppermost point of the circuit. The steam
piping, only straight length of pipes is jacketed. Other supply line to jacketing system and steam/ condensate line
fittings are not jacketed. from jacketing system shall have block valve located near
nozzle of jacketing pipe.
3.3.1 CORE AND STEAM JACKETED SYSTEM

Fig. 2. Discontinuous Jacketed Piping [5].

3.3.2 CENTERING GUIDES fabricated to provide a fully concentric core pipe and even
annular space. For molten sulfur lines, crosses with open
Centering guide is used to support the core pipe for long ends with blind flange at direction changes are used to allow
span. Centering guide shall be place for 3m between the roding out of each run of pipe from two directions.
core pipes(Spacing is depends upon the project guide lines).
Guides are similar to the plates which will be welded in the
core pipe. A gap of 1.5mm to be provided between the guide
plates and Jacketed pipe.

Fig. 3. Centering Guide [5].

3.3.2 TEES AND CROSS TEES

It is desirable to use a tee or cross tee instead of 90 deg Fig. 4. Cross Tee [5].
elbow due to change in direction. Tees and crosses can be

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18-22, 2016 ♦ 302 ♦
 Efficient Energy Transfer and Importance of Jacketed Piping in Sulfur Transportation

4. PREVENTIONS FOR JACKETED PIPING 5. STRESS ANALYSIS FOR JACKETED PIPING

During fabrication of a jacketed piping system, close A pipe system is jacketed to ensure that flow medium inside
monitoring and quality control to be taken to prevent the core pipe is maintained at a certain temperature, by
problems. Failure of a core pipe will lead to mixing of using a low pressure steam between core and jacketed pipe.
molten sulfur and steam. Failure can be the results of poor This results in temperature differential between the core and
welding, faulty fabrication and incorrect design. The core jacket pipe.
pipe can develop a crack in the heat affected zone of a butt
weld. When the sulfur pressure is higher than the steam Modeling the core and jacketed pipe in analysis software is
pressure, sulfur will enter the steam / condensate system. little complicated for jacketed piping. Initially core pipe to
The sulfur in the core pipe will be freeze and process will be be modeled along with spacer as per the design guidelines,
stopped. Hence proper care to be taken while fabrication then the jacketed piping to be modeled above the core pipe.
and erection of the core and jacketed pipe. When the core Normally jacketed pipe is one size higher than core pipe. As
fabrication is completed, it should be hydraulically tested. per process requirement, parameters to be updated and
Any defect should be repaired prior to the fabrication of the supports shall be provided on jacketed pipe as per pipe span.
jacket. When the jacket piping is completed it should be
hydraulically tested as well [4].

Fig. 5. Modeling of Jacketed Piping in Caesar Model

5.1 MAJOR STRESS CHECK FOR PERFORMING 5.2 CHECKING OF BUCKLING LOAD
STRESS ANALYSIS
Computer program does not check compliance for the
Limits of calculated stress due to sustained loads and buckling load. Hence manual calculation to be made for the
displacement strain due to expansion stress to be evaluated same. Computer program gives the value of ‘P’ calculated at
separately for core and jacket piping as per clause 302.3.5 of the junction point between core and jacket. This calculated
ASME B31.3 and Limits of calculated stress due to value is to be less than critical force (Pcr).[4]
occasional loads to be evaluated as per clause 302.3.6 of
ASME B31.3 [6]. Other than computer analysis manual Pcr= (4π2 x E x IC ) / L2 for Core pipe
stress checks to be performed for jacketed piping. i.e. Pcr= (4π2 x E x Ij ) / L2 for Jacketed pipe
Buckling load and weld strength between core and jacket to Where,
be checked. P is calculated by computer program

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18-22, 2016 ♦ 303 ♦
 Efficient Energy Transfer and Importance of Jacketed Piping in Sulfur Transportation

Pcr = critical force Additional care to be taken for piping stress analysis,
E= Modulus of elasticity fabrication and erection of jacketed piping, since leakage
Ic = Moment of inertia for core may take place due to improper welding and faulty
Ij = Moment of inertia for jacket fabrication. This will allow refinery to maximize SRU
L= Length of pipe between the junction of core/ jacket. capability, improve emission performance to meet the latest
If P ≤ Pcr, then no buckling failure. stringent environmental standards.
5.3 CHECKING OF WELDING STRENGTH ACKNOWLEDGEMENT
BETWEEN JACKET AND CORE PIPE
The authors would like to acknowledge Fluor Corporation
‘P’ calculated at the junction point between core & jacket is for its consistent encouragement and motivation to its
compared with allowable load at weld point. employees for professional presentation and publication of

Area of weld = π x D x root of weld

Pall – Area of weld x 60% of allowable stress papers in industry and academic forums.

D = diameter of core pipe REFERENCES

Root of weld = 0.707 x weld size [1] Handbook of natural gas Transmission and
Load calculated at the junction point,P ≤ Pall. [4]. processing by Saied Mokhatab.
6. CONCLUSIONS [2] www.sulfurrecovery.com,
www.processsystems.com.
Our discussion shows that the how Sulfur plays an [3] Handbook of sulfuric acid manufacturing by Douglas
important role in oil and gas industry with straight through K.Louie, P.Eng.
Claus process and transferring the liquid or molten sulfur [4] Stress analysis of discontinuous jacketed
from recovery process through jacketing piping. Holistic system,P.S.Bandyopadhyaa.
piping design for in the jacketed piping, transfer heat more
[5] Jacketed Pipe fabrication details [CSI Jacketed
efficient than other process with their double barrier
piping / Control Southeast.inc].
between the heating medium and the process, this is one of
the best methods for transferring the high viscous fluid. [6] ASME B31.3., Process Piping.

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