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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.
Chemical Reactor Vessel P and ID

Wrong Operation Internals Destroyed Demineralization Mixed Bed Vessel

Root Cause Analysis (RCA): Ruined Demineralization (Demin) vessel internals threaten indefinite Ammonia plant shutdown.

Supplied Screen Vibrators Perennial Problems

Supplied Screen Vibrators Perennial Problems

Home developed motor vibrators lot better than provided vibrators boost safety and production.

Rotary Drier Shell to Split Gear drive

Rotary Drier Shell to Split Gear drive eliminates too frequent drive failures

Home-made Rotary Drier Shell to Split Gear drive eliminates too frequent drive failures.

Rotary Granulator Drive

Rotary Granulator Drive Root Cause Analysis (RCA)

Root Cause Analysis (RCA): Too noisy & too maintenance intensive granulator drive silenced and made maintenance free.

Improved Sprocket Segment Bolting to body

A Plant Bucket Elevators chains too short chain lives problem eliminated

Root Cause Analysis (RCA) related to a Plant Bucket Elevators chains too short chain lives problem eliminated.

Sprocket Assembly and Bolting Segments

Bucket elevators Chain and teeth wear Problems

Root Cause Analysis (RCA) related to Bucket elevators chains lives too short and teeth wear too rapid – both perennial.

Bucket Elevator Wrecks

Many Bucket Elevator Wrecks rob crew morale

This article listed excellent features to eliminate the elevator chain wrecks long shutdowns forever.

Finned Heater Leaks Sealed

Finned Tube Steam Leaks – Root Cause Analysis

Finned tube steam leaks rendered drying ineffective within 3 months of use. Study the root cause analysis (RCA) and detailed solution.

Demister Pads Problem

Problems with Demister Pads – Root Cause Analysis (RCA)

Demister pads contained in a flanged spool removes the air carried over dust and moisture. Study problems and Root Cause Analysis (RCA).

Rolled & Seal Welded Tube to Tube sheet joints

Gas Cooler Re-tubing Done Successfully (Root Cause Analysis)

Root Cause Analysis (RCA) related to heat exchangers cool the ammonia, and gas cooler re-tubing work problems.

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