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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.
Problems with Demister Pads – Root Cause Analysis (RCA)
Gas Cooler Re-tubing Done Successfully (Root Cause Analysis)
Boiler Feed Water Heater Shell Flange Leaks
Cooling Tower fan FRP fan blades saves and saves
Primary Reformer RFG main Hot Spots threaten Indefinite Outage
Too often done riskily repaired Roof Hot Spots eliminated forever
Primary Reformer – Each Turnaround done expensive Tubes Repairs
PTFE lined 6” 300# butt weld end Plug Valves Leaks Stopped Forever
Rupture Discs bursts caused too many Urea Plant Shutdowns
Repeat Safety Valve Popping caused Urea Plant Shutdown
RCA Related to Trip Throttle Valve (TTV)
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