I recall one particular case involving repeated near misses on exceeding emissions limits from a sulfur plant. At random intervals, the Tail Gas pressure control valve would jump open, releasing Tail Gas to an incinerator and bumping up against the permitted SO2 emissions limits. At the beginning of the investigations, the list of potential causes was practically endless. Was it a problem in the Tail Gas Recycle Compressor? Maybe there was a plug in a Condenser Seal Leg? Was the pressure spike even real at all, or was the pressure control valve responding to a phantom instrument anomaly?
Starting at the scene of the crime and painstakingly checking every instrument and detail back to the source, after 4 hours I discovered a faulty connection on a temperature transmitter used in the temperature-pressure compensation for the oxygen flow meter feeding the Claus Furnace. This caused a spike in oxygen flow, upsetting the stoichiometric ratio for the catalyst beds downstream, leading to poor conversion and overwhelming the Tail Gas Recycle Compressor.
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