Training Program for Urea Engineers. Tailor Made to Your Wishes

Transcription

1 Training Program for Urea Engineers Tailor Made to Your Wishes v6

2 Choose the Modules of Your Interest and Compose your Preferred Training Program ü Highly awarded by all previous participants ü Covering Stamicarbon, Saipem, TEC and UCSA technologies ü Dedicated to process, mechanical, instrumentation, process control, operational, reliability, corrosion, inspection, SHE engineers and managers ü Highly experienced trainers involved ü Each module takes some 3-4 hours ü Parallel sessions are possible ü Recommended group size: max 40 participants ü Hand out and Corrosion Engineering Guide will be included ü Examination, evaluation and certificates will be included ü Choose your preferred location, if you prefer we can also organize the training facilities ü Send your preferences to and we will make you an attractive offer

3 Testimonials Excellent course! One of a kind! Nothing was missing in this course Completely meets our expectations The Best ever training, I have ever attend in the industrial field There is not enough support for urea plants training, and you made the difference! A very comprehensive and specialized training! Thanks a million times! Urea Expertise to feed the world Almost Perfect

4 References Open Training Programs 5-day Training Program for Urea Engineers January 2013 in Abu Dhabi

5 In House Training Programs References

6 Half Open Training Programs References

7 Training Topics Common topics C1 Overview Urea Process Technologies C2 Overview of various corrosion phenomena in urea plants C3 Overview of Materials of Construction in urea plants C4 High Pressure Equipment C5 Troubleshoot and Corrosion / Reliability Cases C6 The Fertilizer and Urea Market C7 Nitric Acid C8 Centrifugal CO 2 Compressors NEW

8 Training Topics Process & Operational topics P1 Thermodynamics and Phase diagrams P2 Urea Prill Quality aspects P3 Fluid Bed Granulation P4 Operational aspects and Troubleshooting techniques P5 Safety, Health & Environmental aspects P6 Revamp and debottlenecking technologies P7 CO 2 Compressors design and operational issues

9 Training Topics Mechanical & Maintenance topics M1 Failure Modes of the various High Pressure Synthesis equipment M2 High Pressure Piping & Valves M3 Corrosion Inspection Techniques and Inspection Program M4 Atmospheric corrosion; Corrosion Under Insulation (CUI) M5 Corrosion in steam and cooling water systems M6 Doing Repairs M7 Manufacturing of HP equipment M8 High Pressure Reciprocating Pumps

10 Module C1: Overview Urea Process Technologies Urea product Urea market information History of process technologies Various process technologies currently in operation (Conventional, Stamicarbon, Saipem, TEC, UCSA) Challenges in urea plants Module C2: Corrosion in carbamate solutions Theory of corrosion in ammonium carbamate solutions Overview of various corrosion phenomena in urea plants Cases of various types of corrosion such as passive, active, crevice, condensation corrosion, stress corrosion cracking, erosion corrosion Effect of oxygen, temperature, carbamate, N/C ratio, pressure, temperature on corrosion rates How to detect active corrosion?

11 Module C3: Materials of construction in urea plants Historical overview of applied materials The typical properties of materials applied in urea plants (Austenitic stainless steels in high pressure and low pressure sections, Duplex stainless steels (DP12, DP28W, Safurex ) as well as Titanium, Zirconium, Tantalum. Which materials to apply in specific process conditions? Module C4: High Pressure Synthesis equipment Process aspects Mechanical aspects Multi layer or solid wall, Low or high strength steels Leak Detection Systems for vessels and heat exchangers Tube failures Gaskets and Bolting How to assure a high reliability of critical equipment Corrosion cases caused by failing leak detection systems

12 Module C5: Cases Nitrate SCC in pressure bearing part of reactor High Pressure Flange connections Failure of a High Pressure Weldolet How to find a leak? LESER Safety Valves Catastrophic failures NH 3 storage tank inspection Atmospheric and Utility Corrosion cases You are welcome to bring up for discussion your own cases and Experiences.

13 Module C6: Fertilizer and Urea Market Fertilizer: How it began Urea applications Drivers for fertilizer / urea consumption Urea trading trends Trends of major countries / areas Value Chain Key players: licensors, contractors, suppliers Module C7: Nitric Acid Applications Process schemes Key players: licensors, contractors, suppliers Corrosion phenomena Failure modes and cases Materials of construction

14 Module C8: Centrifugal CO 2 Compressors Design Challenges covering supercritical CO 2 compression challenges, design features and considerations CO 2 Compressor types focusing on Integrally Gear and Single shaft design, advantage, disadvantages Maintenance covering Corrosion and reverse rotation as highlights CO 2 compressor driver turbine including condensing/vacuum system Review of some Case studies on CO 2 compressors Lube oil system design, commissioning, start up Commissioning, start-up and normal operation and required operational checking during the normal operation Condition monitoring

15 Module P1: Thermodynamics and Phase diagrams Thermodynamics & Phase diagrams Parameters (CO 2 conversion, alfa, N/C, H/C, H/U) System pressure, inert pressure Liquid isotherms Top ridge line Fraction approach to equilibrium CO 2 versus NH 3 strippers Module P2: Urea Prill Quality Aspects What is caking and how it can be avoided? Crushing strength, impact strength Segregation How to influence moisture content Bulk flow coolers Revamping prilling towers

16 Module P3: Fluid Bed Granulation Principles of granulation Critical operating parameters and its control Operational problems Troubleshooting Urea granule quality issues Module P4: Operational aspects of urea plants Control philosophy of various sections Key performance indicators Main calculations Key analysis for process control Key analysis for corrosion control Explosion diagrams What to do when Troubleshooting

17 Module P5: Safety, Health & Environmental aspects Reliability aspects Safety and Health concerns Emission sources (continuous and discontinuous) Flare systems, containment systems Safety valves Module P6: Revamp technologies Capacity increase Energy conservation Emission reduction New developments Solid heat exchanger revamp opportunities Energy reduction management References Examples

18 Module P7: CO 2 Compressors Phase and Mollier Diagram CO 2 Different Type of CO 2 compressors Revamping CO 2 Compressors Operating problems in CO 2 Compressor Troubleshooting Compressor problems SCC in CO 2 coolers

19 Module M1: Failure modes High Pressure Equipment Reactor failure modes Heating up / cooling down, stop starts and blocking in Condenser failure modes Baffle hammering problems and effects of different loads Stripper failure modes Effect of temperature and partial oxygen pressure Effect of liquid distribution Connection weld Tube Module M2: HP Piping & Valves Typical corrosion failure modes HP Piping Features HP Control and Manual Valves Maintenance practices Safety Incidents Safety Valves in Urea Plants

20 Module M3: Corrosion Inspection in urea plants Inspection techniques Life Time Extension studies Setting up Inspection Programs; Risk Based Inspection Connection weld Tube Module M4: Atmospheric Corrosion (CUI) Forms of atmospheric corrosion Preventive measures Casuistry in urea and ammonia plants Module M5: Corrosion/fouling aspects utilities Corrosion control in boiler feed water and steam systems - Root cause of typical failure modes and preventive measures Corrosion and fouling control in cooling water systems - Overview of inhibitor systems - Cases of typical failure modes and preventive measures

21 Module M6: Doing repairs Finding a leak Basic philosophies Best Repair is No Repair and when to do Repair? Repair procedures of various materials of construction Plugging heat exchanger tubes (POP-A-PLUG) Relining projects Chloride SCC => what to do Module M7: Manufacturing of HP equipment Design aspects HP reactors and HP heat exchangers Which codes and standards Fabrication sequence, post weld heat treatments Selection criteria of fabricator Expediting and Inspection aspects Quality assurance HP equipment & HP piping components :

22 Module M8: HP reciprocating Pumps Principles Design stuffing box Materials of Construction Vibration issues

23 Deliverables Examination and Certificate Evaluation Hand out and reference documents All presentations will be prepared in Microsoft Powerpoint and distributed as hand outs in digital form (acrobat format). Several topics will be elaborated by means of technical papers, which will also be distributed in digital form (acrobat format). Corrosion Engineering Guide, written by Mr. Giel Notten.