Training Program for Urea Engineers - Ureaknowhow.com
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Transcript of Training Program for Urea Engineers - Ureaknowhow.com
Choose the Modules of Your Interest and Compose your Preferred Training Program
ü Highly awarded by all previous participants ü Covering Stamicarbon, Saipem, TEC and UCSA technologies ü Dedicated to process, mechanical, instrumentation, process
control, operational, reliability, corrosion, inspection, SHE engineers and managers
ü Highly experienced trainers involved ü Each module takes some 3-4 hours ü Parallel sessions are possible ü Recommended group size: max 40 participants ü Hand out and Corrosion Engineering Guide will be included ü Examination, evaluation and certificates will be included ü Choose your preferred location, if you prefer we can also
organize the training facilities ü Send your preferences to [email protected]
and we will make you an attractive offer
“Excellent course !”
“One of a kind!”
“Nothing was missing in this course”
“Completely meets our expectations”
“The Best ever training,
I have ever attend in the industrial field”
“There is not enough support for urea plants training,
and you made the difference !”
“A very comprehensive and specialized training!”
“Thanks a million times!”
“Urea Expertise to feed the world”
“Almost Perfect”
Testimonials
Common topics
C1 Overview Urea Process Technologies
C2 Overview of various corrosion phenomena in urea plants
C3 Overview of Materials of Construction in urea plants
C4 High Pressure Equipment
C5 Troubleshoot and Corrosion / Reliability Cases
Training Topics
Process & Operational topics
P1 Thermodynamics and Phase diagrams
P2 Urea Prill Quality aspects
P3 Fluid Bed Granulation
P4 Operational aspects and Troubleshooting techniques
P5 Safety, Health & Environmental aspects
P6 Revamp and debottlenecking technologies
P7 CO2 Compressors design and operational issues
Training Topics
Mechanical & Maintenance topics
M1 Failure Modes of the various High Pressure Synthesis equipment
M2 High Pressure Piping & Valves
M3 Corrosion Inspection Techniques and Inspection Program
M4 Atmospheric corrosion; Corrosion Under Insulation (CUI)
M5 Corrosion in steam and cooling water systems
M6 Doing Repairs
Training Topics
Module C1: Overview Urea Process Technologies • Urea product • Urea market information • History of process technologies • Various process technologies currently in operation
(Conventional, Stamicarbon, Saipem, TEC, UCSA) • Challenges in urea plants
Module C2: Corrosion in carbamate solutions • Theory of corrosion in ammonium carbamate solutions • Overview of various corrosion phenomena in urea plants • Cases of various types of corrosion such as passive,
active, crevice, condensation corrosion, stress corrosion cracking, erosion corrosion
• Effect of oxygen, temperature, carbamate, N/C ratio, pressure, temperature on corrosion rates
• How to detect active corrosion ?
Module C3: Materials of construction in urea plants • Historical overview of applied materials • The typical properties of materials applied in urea plants (Austenitic
stainless steels in high pressure and low pressure sections, Duplex stainless steels (DP12, DP28W®, Safurex®) as well as Titanium, Zirconium, Tantalum.
• Which materials to apply in specific process conditions ? Module C4: High Pressure Synthesis equipment • Process aspects • Mechanical aspects • Multi layer or solid wall, Low or high strength steels • Leak Detection Systems for vessels and heat exchangers • Tube failures • Gaskets and Bolting • How to assure a high reliability of critical equipment • Corrosion cases caused by failing leak detection systems
Module C5: Cases • Nitrate SCC in pressure bearing part of reactor • High Pressure Flange connections • Failure of a High Pressure Weldolet • How to find a leak ? • LESER Safety Valves • Catastrophic failures • NH3 storage tank inspection • Atmospheric and Utility Corrosion cases You are welcome to bring up for discussion your own cases and Experiences.
Module P1: Thermodynamics and Phase diagrams • Thermodynamics & Phase diagrams • Parameters (CO2 conversion, alfa, N/C, H/C, H/U) • System pressure, inert pressure • Liquid isotherms • Top ridge line • Fraction approach to equilibrium • CO2 versus NH3 strippers Module P2: Urea Prill Quality Aspects • What is caking and how it can be avoided ? • Crushing strength, impact strength • Segregation • How to influence moisture content • Bulk flow coolers • Revamping prilling towers
Module P3: Fluid Bed Granulation • Principles of granulation • Critical operating parameters and its control • Operational problems • Troubleshooting • Urea granule quality issues Module P4: Operational aspects of urea plants • Control philosophy of various sections • Key performance indicators • Main calculations • Key analysis for process control • Key analysis for corrosion control • Explosion diagrams • What to do when … • Troubleshooting
Module P5: Safety, Health & Environmental aspects • Reliability aspects • Safety and Health concerns • Emission sources (continuous and discontinuous) • Flare systems, containment systems • Safety valves Module P6: Revamp technologies • Capacity increase • Energy conservation • Emission reduction • New developments • Solid heat exchanger revamp opportunities • Energy reduction management • References • Examples
Module P7: CO2 Compressors • Phase and Mollier Diagram CO2 • Different Type of CO2 compressors • Revamping CO2 Compressors • Operating problems in CO2 Compressor • Troubleshooting Compressor problems • SCC in CO2 coolers
Module M1: Failure modes High Pressure Equipment • Reactor failure modes • Heating up / cooling down, stop – starts and blocking in • Condenser failure modes • Baffle hammering problems and effects of different loads • Stripper failure modes • Effect of temperature and partial oxygen pressure • Effect of liquid distribution
Module M2: HP Piping & Valves • Typical corrosion failure modes HP Piping • Features HP Control and Manual Valves • Maintenance practices • Safety Incidents • Safety Valves in Urea Plants
Connection weld Tube
Module M3: Corrosion Inspection in urea plants • Inspection techniques • Life Time Extension studies • Setting up Inspection Programs; Risk Based Inspection Module M4: Atmospheric Corrosion (CUI) • Forms of atmospheric corrosion • Preventive measures • Casuistry in urea and ammonia plants Module M5: Corrosion/fouling aspects utilities • Corrosion control in boiler feed water and steam systems - Root cause of typical failure modes and preventive measures • Corrosion and fouling control in cooling water systems - Overview of inhibitor systems - Cases of typical failure modes and preventive measures
Connection weld Tube
Module M6: Doing repairs • Finding a leak • Basic philosophies • Best Repair is No Repair … and when to do Repair ? • Repair procedures of various materials of construction • Plugging heat exchanger tubes (POP-A-PLUG) • Relining projects • Chloride SCC => what to do …
Examination and Certificate Evaluation Hand out and reference documents • All presentations will be prepared in Microsoft Powerpoint and distributed as hand outs in
digital form (acrobat format). • Several topics will be elaborated by means of technical papers, which will also be
distributed in digital form (acrobat format). • Corrosion Engineering Guide, written by Mr. Giel Notten.
Deliverables