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16 - CHM - Chemical and Process Engineering

CHM 113 - Maintenance in Urea Plants

Code	Start Date	Duration	Venue
CHM 113	04 November 2024	5 Days	Istanbul	Registration Form Link
CHM 113	09 December 2024	5 Days	Istanbul	Registration Form Link
CHM 113	13 January 2025	5 Days	Istanbul	Registration Form Link
CHM 113	10 March 2025	5 Days	Istanbul	Registration Form Link
CHM 113	05 May 2025	5 Days	Istanbul	Registration Form Link
CHM 113	30 June 2025	5 Days	Istanbul	Registration Form Link
CHM 113	25 August 2025	5 Days	Istanbul	Registration Form Link
CHM 113	20 October 2025	5 Days	Istanbul	Registration Form Link
CHM 113	15 December 2025	5 Days	Istanbul	Registration Form Link

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Course Description

Growing prosperity worldwide demands six times more fertilizer than required for rice or grain. This all adds up to increased pressure on our agricultural resources as well as on the Fertilizer technology and plant operations.

The Maintenance in Urea Plants for Engineers training will be dedicated for all urea process technologies like Conventional Total Recycle, Stamicarbon, Saipem and TEC urea plants.

Participants will learn the background of the material selection criteria for urea equipment; learn all technical maintenance aspects of static urea equipment and high pressure piping. They will learn what the integrity risks of static urea equipment are and how to avoid these risks and how to limit its consequences. Furthermore, they will learn in detail how to ensure repairs. Many practical cases and numerous troubleshoot and other corrosion / reliability cases will be discussed.

Course Objectives

Recognizing Urea Process Technologies
Ensuring safe operation of Urea processes.
Realizing the background of the material selection criteria for urea equipment.
Identify all technical maintenance aspects of static urea equipment and high-pressure piping.
Recognizing the integrity risks of static urea equipment.
Identifying techniques to avoid the integrity risks.
Applying techniques to limit the consequences of the integrity risks of equipment.
Describing in detail how to ensure repairs urea equipment and high-pressure piping.

Who Should Attend?

Mechanical and Maintenance Engineers
Mechanical and Maintenance Supervisors
Inspection Engineers and Supervisors
Process and Operational Engineers
Mechanical and Maintenance Supervisors
Instrumentation and Process Control Engineers
Safety and Reliability Engineers and Supervisors

Course Details/Schedule

Day 1

Introduction Urea process technologies
Various process technologies currently in operation (Conventional, Stamicarbon, Saipem, TEC, UCSA)
Challenges in urea plants(thermodynamics, corrosion, emissions, urea efficiency)
Corrosion in carbamate solutions
Theory of corrosion in ammonium carbamate solutions
Parameters influencing corrosion in carbamate solutions
Overview of various corrosion phenomena in urea plants
Corrosion aspects utilities
Corrosion control in boiler (feed-) water and steam systems
Corrosion in cooling water systems

Day 2

Materials of construction in urea plants
Austenitic, duplex
Safurex®
Titanium, Zirconium, Tantalum
Bimetallic, OmegaBond
DP12 and DP28W ®
Operational aspects
Control philosophy
Key performance indicators
Key analysis for process control & corrosion control

Day 3

Corrosion inspection techniques
High Pressure Equipment
High Pressure Piping
Inspection techniques
Risk Based Inspection
Life time studies
Setting up Inspection Programs
Doing repairs
Finding a leak
Repair procedures of various materials of construction
Plugging heat exchanger tubes (POP-A-PLUG)
Relining projects

Day 4

High Pressure Synthesis equipment
Process aspects (liquid divider, fouling)
Mechanical aspects (liners, overlay welding, chlorides, nitrates)
Leak detection systems for loose liners and tube failures
Corrosion cases caused by failing leak detection systems
Safety, health & environmental aspects
Reliability aspects
Safety and health concerns
Emission sources (continuous and discontinuous)
Flare systems, containment systems
Explosion diagrams
Atmospheric Corrosion (CUI)
Forms of atmospheric corrosion
Preventive measures
Casuistry in urea plants

Day 5

HP piping & valves
Features HP Control and Manual Valves
Maintenance practices
Typical failure modes HP Piping
CO2 compressors
Phase and Mollier Diagram CO2
Revamping CO2 Compressors
Operating problems in CO2 Compressor
Troubleshooting Compressor problems
Revamp technologies
Capacity increase
Energy conservation & emission reduction
Solid heat exchanger revamp opportunities

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SAHARA Group Training and Consultancy INC (in Turkish: SAHARA Group Eğitim ve Danışmanlık AŞ)

Tax Office: Beyoğlu (Istanbul/Turkiye,Tax No: 7390525151 (Vergi Dairesi: Beyoğlu (İstanbul), Vergi No: 7390525151)

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16 - CHM - Chemical and Process Engineering

CHM 113 - Maintenance in Urea Plants

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