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16 - CHM - Chemical and Process Engineering

CHM 113 - Maintenance in Urea Plants

Code Start Date Duration Venue
CHM 113 20 November 2023 5 Days Istanbul Registration Form Link
CHM 113 11 December 2023 5 Days Istanbul Registration Form Link
Please contact us for fees


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