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NFL Nangal is operating urea reactor since its inception in 1978. During its 32 years of operation, the thickness of lining of the reactor has undergone constant reduction and reached below minimum acceptable limit. NFL reviewed various options of repair and replacement and finally decided to replace the reactor with the one available with the closed plant of FCIL at Sindri as it was the most economical option. The paper describes the activities undertaken by NFL Nangal to replace the reactor with the one available with FCI Sindri, without compromising on the reliability of the plant. The replacement was completed in March 2013 and since then urea plant is operating at more than its installed capacity.