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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.
Control Valve Plug Stem and Gland Leaks

Repeat Control Valve Plug Stem and Gland Leaks

Instrumentation engineering root cause analysis (RCA) of repeat control valve plug stem and gland leaks problem.

Control Valves - Repeat Actuator Diaphragm Bursts

Control Valves – Repeat Actuator Diaphragm Bursts

Instrumentation engineering root cause analysis (RCA) of repeat failures of actuator diaphragm bursts in control valves.

Butterfly Valve Failure caused Fire

Butterfly Valve Failure Caused Serious vicinity Heavy Fire

Instrumentation engineering root cause analysis (RCA) of butterfly control valve failure caused serious vicinity heavy fire in a plant.

Control Valves Leak Tightness

Control Valves Leak Tightness Restoration Pose Difficulties

Instrumentation engineering root cause analysis (RCA) of control valves leak tightness restoration pose difficulties in the plant.

Passing Control Valves Cause Yearly Losses

Passing Control Valves Cause Yearly Losses in Production Plant

Instrumentation engineering root cause analysis (RCA) of control valves passing and they cause yearly losses in a production plant.

Under and Over-Capacity Control Valve

Under and Over-Capacity Control Valve Pose Poor Controllability

Instrumentation engineering root cause analysis (RCA) of under and over-capacity control valves pose poor controllability.

Purpose of Isolation valve

Repeat Failures of Letdown Valves

Instrumentation engineering root cause analysis (RCA) of letdown valves repeat failures in industrial plant.

Failed Letdown Valve

Failed Letdown Valve Shuts down a Urea Plant Several Hours

Instrumentation engineering root cause analysis (RCA) of failed letdown valve as it leads to urea plant shut down for several hours.

Valve Positioner Torn apart

Pipeline Shakes Torn apart Valve Positioners

Instrumentation root cause analysis of control valve positioner as it is torn apart when pipeline shakes during plant commissioning.

Steam Pressure Taps Primary Block Valves Glands and Bonnets Leaks

Instrument Steam Pressure Taps Primary Block Valves Glands and Bonnets Leaks

Instrument Steam Pressure Taps Primary Block Valves (PBV) Glands and Bonnets too soon leaks and this delays the commissioning of a plant.

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