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S Raghava Chari

The author shared the problems developed during commissioning and the author’s 17 years of service in a South Indian Ammonia, Urea, and NPK complex fertilizers plant.
Boiler Feed Water Heater Shell Flange Leaks

Boiler Feed Water Heater Shell Flange Leaks

Boiler Feed Water Heater Shell Flange leaks and causes ammonia plant trips. This root cause analysis (RCA) eliminated the problems.

Induced Draft Cooling Tower

Cooling Tower fan FRP fan blades saves and saves

Root Cause Analysis (RCA): Cooling tower fan FRP fan blades saves and saves.

repairs of welding cast refractory lined box over the hot spots

Primary Reformer RFG main Hot Spots threaten Indefinite Outage

Root Cause Analysis (RCA) related to primary reformer RFG main hot spots threaten indefinite outage eliminated.

repairs of welding cast refractory lined box over the hot spots

Too often done riskily repaired Roof Hot Spots eliminated forever

Root Cause Analysis (RCA) related to the roof hot spots repairs and their problem eliminated forever.

Inlet Pigtail

Primary Reformer – Each Turnaround done expensive Tubes Repairs

Primary Reformer – Each Turnaround done massive and expensive Tubes Repairs eliminated.

butt weld end Plug Valves Leaks Stopped

PTFE lined 6” 300# butt weld end Plug Valves Leaks Stopped Forever

Root Cause Analysis (RCA): Urea Plant tight shut off impossible PTFE liner 6” 300# butt weld end Plug Valves leaks stopped.

Rupture Disc

Rupture Discs bursts caused too many Urea Plant Shutdowns

Root Cause Analysis (RCA): Repeat Rupture Discs (RD) bursts shutdowns a Urea Plant each time.

Repeat Safety Valve Popping

Repeat Safety Valve Popping caused Urea Plant Shutdown

A urea plant lost 10 days within a month from Repeat Safety Valve Popping stopped & recurrence eliminated.

Turbine to Gearbox Alignment Drifts Caused Pump Transfers Problems

RCA Related to Trip Throttle Valve (TTV)

Root Cause Analysis (RCA) related to the Steam Turbine Stubborn Dissemble defying 12” 2500 # Trip Throttle Valve.

Jacket Added Seawater Pipe Spool

Seawater Pipeline Spools from day-1 leaks threaten Plant Shutdown

Root Cause Analysis (RCA): Seawater pipeline spools from day-1 leaks threaten NH3 plant indefinite shutdown.

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