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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.
Refrigeration Compressor Turbine Not-tripping when needed Trip

Refrigeration Compressor Turbine Not-tripping when needed Trip

[RCA] Refrigeration Compressor Turbine Not-tripping when needed Trip Throttle Valve threatened potential compressor wrecks eliminated.

Process Air Compressor Overhauls Eliminated

Process Air Compressor too Frequent & too Lengthy Overhauls Eliminated

Root Cause Analysis: K-602 Process Air Compressor too frequent & too lengthy overhauls Eliminated. RCA problem and solution provided.

Compressor IP Case Discharge Temperature Gradually Increases

Compressor IP Case Discharge Temperature Gradually Increases

Steam Turbine Driven centrifugal compressors K-601’s IP case discharge temperatures gradually increases & lead to plant shutdown.

Steam Turbine Driven Centrifugal Compressors Leak due to Broken Instrument

Discharge Head 3‑monthly leaks of Steam Turbine Driven Centrifugal Compressors

Root Cause Analysis (RCA): Persisting K-601 steam turbine driven centrifugal compressors Discharge Head 3‑monthly leaks.

Steam Turbine Driven Centrifugal Compressors Leak due to Broken Instrument

Steam Turbine Driven Centrifugal Compressors Leak due to Broken Instrument

Root Cause Analysis (RCA): Yearly production reduced due to the steam turbine driven centrifugal compressors leak due to broken instrument.

Totally Enclosed Fan Cooled (TEFC) Motor

Totally Enclosed Fan Cooled (TEFC) Motors Rampant Winding Burnouts

Root Cause Analysis (RCA): Totally enclosed fan cooled (TEFC) electrical motors rampant winding burnouts. RCA solution provided.

Transformers Coolers Weld Joints Oil

Transformers Coolers Weld Joints Oil Oozes Were Eye Sores

Root Cause Analysis (RCA): Transformers Coolers Weld Joints Oil Oozes Were Eye Sores. RCA solution provided.

Burst Transformers Root Cause Analysis

Root Cause Analysis – Burst Transformers and 11 kV Input Breakers

Root Cause Analysis (RCA): An 11000/400V electrical transformer and its 11 kV input breaker burst on an occasion incident.

Weigh Feeder Drive

Failing Weigh Feeders and Mechanical Variable Speed Drives (VSD)

Root Cause Analysis (RCA): Within few weeks failing weigh feeders mechanical variable speed drives (VSD).

Heat Exchanger Root Cause Analysis

Heat Exchanger Root Cause Analysis (RCA)

Root Cause Analysis (RCA): 50% only heat transferring from Heat Exchanger threatens urea plant commissioning indefinite halt.

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