Assuring Safe and Reliable High Pressure Urea Equipment

Details: Published: 23 February 2018; Hits: 2804

On February 22, 2018, UreaKnowHow.com and KEY-TECH Engineering did present at the FAI Training Programme for Senior Maintenance Engineers in Fertilizer Industry organised from 18-23 February 2018 in Surat, Gujarat, India. The Training Program was well attended by more than 35 participants from most ammonia/urea complexes in India. The topic of the presentation was “Assuring Safe and Reliable High Pressure Urea Equipment”. For an existing urea reactor this can be achieved by:...click here for more information.

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What is reason #2 to choose for a vacuum system?

This question 7 is in continuation of question 6 in which we started explaining why an active vacuum leak detection system is superior over an active pressurized system. Active leak detection systems can be either a pressurized system, in which an inert carrier gas stream flows through the leak detection circuits most probably only via the machined leak detection grooves present in the carbon steel and a vacuum system, where one pulls vacuum pressure underneath the liner.

We recommend a vacuum based leak detection system for several reasons:

Reason #2: Direct detection of the complete carbon steel surface

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The State-Of-The-Art Ammonia Terminal

Since 100 years ago the industrial production of ammonia began for the widespread agricultural and industrial application. Safety hazards and risks have been identiﬁed and for a large extend resolved.

Nowadays ammonia is used more and more as a very eﬃcient hydrogen energy storage, carrier and carbon free fuel. This means that more and more people will get involved with this potentially toxic substance. How will the public and the authorities react?

Are the previously known safety regulations suﬃcient for the storage / bunkering of ammonia?

We say no, it can be better, more safe and reliable.

What is reason #1 to choose for a vacuum system?

We recommend a vacuum based leak detection system for several reasons:

Reason #1: No risk of liner bulging

A first reason is that when using a vacuum system there will be no risk for liner bulging and damage due a to too high pressure in the leak detection system behind the liner. Be aware that the relatively large liner compartments are welded to the carbon steel pressure bearing wall. These large areas allow only a very limited pressure difference between each side of the liner.

Some vendors try to avoid this risk of bulging by switching off the leak detection system when the pressure in the synthesis section is below a certain value. In our view this is not a good solution because...

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Which kind of active leak detection systems exist ?

High pressure urea equipment consist of a heavy carbon steel pressure bearing wall, which is protected against corrosion by a thin corrosion resistant layer; this layer is in the most cases made out of stainless steel or a duplex. This protective layer can be an overlay welding, an explosive cladded layer but is in most cases a loose liner.

Any leak in a loose liner will lead to a dangerous situation because a potentially corrosive fluid can be spread and trapped in the gap between the carbon steel pressure bearing wall and the loose liner. This area will then be exposed to the extremely corrosive ammonium-carbamate.

Real situations have proven that ammonium-carbamate can corrode carbon steels with very high corrosion rates up to 1,000 mm (40 inch) per year. But also stainless steels will show accelerated corrosion because of lack of oxygen. That means that it is an absolute must to have a detection system present that already warns for al leak in an early stage. Then one can only conclude that an active leak detection system is required...

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Why flushing with steam or condensate is NOT a good practice ?

To check if a leak detection system is not facing any clogging or to unclog a leak detection system, some plants practice a flushing procedure with steam or water.

This is not recommended and even dangerous! Introducing water can lead to corrosion. Corrosion, as known, is an electrochemical reaction so corrosion can only take place when water is present.

Without water no corrosion.

The corrosion product will block the passage ways and can also block the leak detection holes.

A more threatening form of corrosion that can occur is stress corrosion cracking of the carbon steel pressure vessel wall.

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UreaKnowHow.com will present at CRU's Nitrogen+Syngas 2021 Virtual Conference

For 33 years, CRU's Nitrogen + Syngas conference has provided an annual platform for the global industry to meet, network, and learn. Every year, 740+ producers, licensors, and materials and equipment providers attend to ensure they have knowledge, understanding and professional connections required to improve their production, maximise profitability, and maintain safe, reliable, and environmentally responsible operations.
In 2021, due to the pandemic, Nitrogen + Syngas will go ahead - as a virtual event. The tried and tested virtual platform allow CRU to deliver an interactive environment for all participants to meet, learn and network. The only virtual element of the conference is the venue - the conference still offers real insight, real networking, and real business opportunities.
UreaKnowHow.com will present a paper with the title: How to Improve Safety and Reliability of the High Pressure Synthesis Section of Urea Plants. The paper draws conclusions from a detailed analysis of the more than 130 serious incidents of the UreaKnowHow.com Urea Incident Database.

In Memoriam Jan van der Werf

Jan van der Werf died peacefully Monday morning November 30, 2020 at an age of 76 in his hometown Sittard-Geleen.

With a career of 55 years at Stamicarbon, Jan was enjoying his work with whole his heart. Jan did know where he was talking about, he knew what was urea as he was involved in numerous commissioning and start-up projects. Jan started up one of the first CO2 stripping plants under difficult circumstances in the former DDR, the first PoolCondenser plant in Bangladesh and left his footprint in many other countries like North Korea, Thailand, Romania, USSR, Japan, USA, Myanmar, China, Mexico and Alaska. Jan also worked at several high level management positions in Stamicarbon, always pushing forward innovations and breakthroughs in our industry; amongst many others Safurex^® and Full Life Cycle support.

Everywhere we came, people asked how Jan was doing. Jan was open, friendly, flexible and always in a good mood, Jan was really a great manager and colleague, with both feet on the ground, one between his colleagues, his door was always open, Jan was always striving for cooperation and teambuilding. We and we believe many other colleagues owe Jan a lot. Jan was always in to discuss technical issues, strategical topics and life in general, preferably with a pint of beer.

Jan, we will miss you.

We send condolences to Wilma, Guido and Petra and the entire van der Werf family.

Jo Eijkenboom

Mark Brouwer

Why is a passive leak detection system not acceptable anymore?

In a passive leak detection system an indication of a leak in the liner only shows up when the leak emerges from the leak detection hole. Or, in case the leak detection hole is connected via tubing to for example a bottle with a phenolphthalein solution, when the colour of the liquid in the bottle changes. The detection occurs at a later moment then when the leak occurs in the liner. Time passes (dwell time) between the moment the leak occurred and the moment the leak emerges at the leak detector or when a field operator notifies the leak. The latter case is even worse as the dwell time can be much larger. During that dwell time the risk that the leak detection path gets clogged is realistic. That means that there will be a serious threat to the integrity of the carbon steel pressure bearing wall... Click here to Read more.

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FERTILIZER INDUSTRIAL SERVICES Owner's Engineer

As experienced professionals in fertilizer industry, we discovered a necessity to ﬁll the gaps in technology knowhow required in various fertilizer industry projects. This is Fertilizer Industrial Services' foundational business strategy.
We are specialized in fertilizer production technologies covering process, mechanical, instrumentation, process safety and project management disciplines. Our services include design review, plant commissioning and startup, operation support, ammonia tank de-commissioning for inspection, plant revamp support and project management consultancy.
We have the unique ability to seamlessly link design, completions, commissioning and operations. That seamless link is provided by our people, an unrivalled group of independent experts. This team supported customers in the industry for new and existing fertilizer plants for more than 15 years.
We work with fertilizer manufacturers, operators, technology licensors, EPC companies and PMC consultants covering short term or long-term projects.

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Brochure Owner's Engineer

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When does one need a proper Leak Detection System ?

AMMO LASER Leak Detection System -
The #1 Safety Measure with a Guaranteed Pay Back
We are pleased to inform you about all the details via our Frequently Asked Questions
Question #2: When does one need a proper Leak Detection System ?
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The State-of-the-Art Urea Reactor

“Highest Safety and Reliability Standards ; Minimum Maintenance and Repair Efforts”

The heart of every urea plant is the urea reactor. The high pressures, high temperatures and the presence of very corrosive ammonium carbamate puts high demands on its reliability and safety during its typical lifetime of 40-50 years. UreaKnowHow.com has established a Urea Incident Database containing numerous serious incidents with urea reactors and a Urea Reactor Risk Register containing fifty risks and failure modes of a traditional design urea reactor.

Based on the above information plus by applying our extensive experience and knowledge, we can offer you the complete detailed design specification of a State-of-The-Art Urea Reactor with optimum design details of the carbon steel pressure bearing wall, the protective layers and all the internals. This will realise the highest reliability and safety standards and minimize maintenance and repair efforts.

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UreaKnowHow.com welcomes GRANDPERSPECTIVE as our new Sponsor

We make visible the invisible hazard. Stepping back is essential to overview.

Remote monitoring provides maximum coverage day and night.

Broaden your view. Get the Grandperspective.

Grandperspective is a solution provider for industrial monitoring of gas leaks and gas detection, based in Berlin, Germany. We provide Early Warning Monitoring Solutions for the fertilizer, ammonia urea, and petrochemical industry.

Our team of experts designs innovative Remote Monitoring solutions, that combine of high-tech hardware and intelligent software. Our spectroscopic monitoring technology identifies, locates, and tracks moving gas clouds at up to 4 km distance to cover large terrains, on the ground and for the airspace above. We identify and quantify from large distances hundreds of hazardous gases, including: Ammonia, Natural Gas, Methanol, CO and N2O.

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UreaKnowHow.com welcomes SDS SEPARATIONS as our Sponsor

Revolutionizing Separation & Scrubbing Solutions

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“SDSμ Separators and SDSμ Scrubbers reduce Total Cost of Ownership (CAPEX and OPEX, no consumables & negligible maintenance).”

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Our team is currently based in Europe and North-East Asia. Our expertise, know-how and IP-protected solutions deliver customers: Increased Production Rate, Higher Efficiencies, Less Fouling, Lower Emissions, Lean Designs and Short Pay Back Times.

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Why does one need a proper Leak Detection System ?

AMMO LASER Leak Detection System -

The #1 Safety Measure with a Guaranteed Pay Back
We are pleased to inform you about all the details via our Frequently Asked Questions
Question #1: Why does one need a proper Leak Detection System ?
Click here for the answer

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UreaKnowHow.com prepares a Risk Register Leak Detection System for Loose Liners of High Pressure Equipment

Clogging in the leak detection system is by far the most serious risk to cause high corrosion rates of the carbon steel pressure bearing wall of high pressure urea equipment. A state of the art leak detection system should safeguard first and for all warn before clogging occurs. Key words to avoid the aforementioned situations are early detection and high reliability.
This is the reason that passive leak detection systems, where one waits for the leak to show up at the analyzer are unsafe and not acceptable anymore today. This has been proven through trial and error in numerous incidents, for example Urea Incident 18-005 (FIORDA Urea Case #5).
The next question is: What are the requirements for a state of the art active and reliable leak detection system?
Find the Risk Register of a Leak Detection System including the lessons learned from related incidents via the following link: Risk Register Leak Detection System.pdf

UreaKnowHow.com welcomes FLUITEC as our Sponsor

Fluitec, a world leader in intelligent maintenance and lubrication

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UreaKnowHow.com starts up UAN Incident Database

After establishing the largest Urea Incident Database with 130+ incidents, now UreaKnowHow.com starts up a UAN Incident Database. UAN seems a safe, non hazardous, colourless liquid but several serious hazards and risks are to considered when designing, operating and maintaining UAN plants. Experience has proven that HAZOPs only do not provide sufficient assurance that all risks are properly take care (background reference). Learning lessons from earlier incidents is in our opinion a very effective way to increase safety and reliability of your plant. Click here to go to our UAN Incident Database

UreaKnowHow.com welcomes GEXCON as our Sponsor

Gexcon is a world-leading company in the field of safety and risk management and advanced dispersion, explosion and fire modelling.

Our experience arises from detailed knowledge of explosion phenomena built up through years of extensive research projects, carrying out safety assessments, performing accident investigations and conducting physical testing at the company’s facilities. Headquartered in Bergen, Norway, Gexcon has offices in Australia (Perth), China (Shanghai), France (Paris), India (Pune and Mumbai), Indonesia (Jakarta), the Netherlands (Utrecht), Sweden (Borås), the UAE (Dubai), the UK (Manchester) and USA (Houston, Bethesda, and Boston). Our team of experienced engineers and specialists can assist in identifying hazards, understanding risks and contribute to improving your company’s overall safety performance. We believe in a tailor-made and individual approach for each client, and by working together, we will find the most optimal process to identify the company’s needs to manage your most critical risks. Due to our commitment and passion within process safety and risk management,... Click here to read more

SAIPEM approves AMMO LASER Leak Detection System

Urea incident databases and risk registers clearly prove the need for a proper leak detection system for loose liners of high-pressure urea equipment as the #1 Safeguard for Any Urea Plant. UreaKnowHow.com and KeyTech Engineering Company have developed an active vacuum-based leak detection system with the most accurate and reliable ammonia analyzer: The AMMO LASER Leak Detection System. This leak detection system is the most reliable leak detection system over all existing leak detection systems in operation so far.

UreaKnowHow.com starts up an E-MarketPlace

UreaKnowHow.com introduces a new initiative for the nitrogen fertilizer industry: An E-MarketPlace for revamps, upgrades, equipment supply, diagnostics, audits, repairs, etcetera. Post your equipment / project and/or services requests or offers (excluding confidential information) in our E-MarketPlace. Click here for posting your inquiries and click here for posting your offers.

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Assuring Safe and Reliable High Pressure Urea Equipment

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