Training Program for Urea Engineers. Complete 10-Day Detailed Urea Training
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1 Training Program for Urea Engineers Complete 10-Day Detailed Urea Training v0
2 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 A jump start for new engineers
3 References 5-day Training Program for Urea Engineers January 2013 in Abu Dhabi
4 Training Program for Urea Engineers Designed for Process, Operational, Mechanical, Maintenance, Instrumentation, Process Control and Inspection Engineers, Managers and Supervisors working in any kind of Urea Plant. For New and Experienced Engineers. Covers All Topics a Urea Engineer needs to know. Detailed discussions of numerous Troubleshoot and other Corrosion / Reliability Cases. Private sessions to discuss your problems with these Industry Experts. Including a Certificate of Completion. Previous Participants say: Rating is Very Good / Excellent and Nothing was missing in this course
5 UreaKnowHow.com An internet platform to exchange technical information within the urea industry with the target to improve the performance and safety of urea plants E-library Partnerships >2900 Members representing >98% of all urea plants worldwide Round Tables Largest network in urea industry Biweekly a Technical paper
6 Mr. Jo Eijkenboom Mechanical Engineer 39 Years Stamicarbon Maintenance, HP equipment, materials, corrosion, repair, welding. Vice President Jo Eijkenboom Consultancy BV Director UreaKnowHow.com
7 Mr. Giel Notten Mechanical Engineer 38 Years DSM Corrosion and Materials 8 Years NTT Consultancy Co-founder of Safurex Author of the Corrosion Engineering Guide
8 Mr. Mark Brouwer Process Engineer, University of Technology Eindhoven, The Netherlands 7 years ethylene plant DSM (revamp projects) 14 years Stamicarbon (revamp projects, services, hardware supply) Founder of UreaKnowHow.com (March 2009)
9 Day 1 Module: 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: 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
10 Day 1 Module: 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 Day 2 Module: 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: Corrosion Inspection in urea plants Inspection techniques Life Time Extension studies Setting up Inspection Programs; Risk Based Inspection
12 Day 3 Module: 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: 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
13 Day 4 Module: 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 Module: Troubleshooting Urea Plants General troubleshooting techniques Corrosion and failure cases Process upset cases Fouling cases
14 Day 5 Module: Safety, Health & Environmental aspects Reliability aspects Safety and Health concerns Emission sources (continuous and discontinuous) Flare systems, containment systems Safety valves Module: Revamp technologies Capacity increase Energy conservation Emission reduction New developments Solid heat exchanger revamp opportunities Energy reduction management References Examples
15 Day 6 Module: 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 Module: Failure modes High Pressure Equipment Reactor, condenser and stripper failure modes Heating up / cooling down, stop starts and blocking in Baffle hammering problems and effects of different loads Effect of temperature and partial oxygen pressure Effect of liquid distribution
16 Day 7 Module: 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 Module: HP reciprocating Pumps Design stuffing box Materials of Construction Vibration issues Module: HP Piping & Valves Typical corrosion failure modes HP Piping Features HP Control and Manual Valves Maintenance practices Safety Valves in Urea Plants
17 Day 8 Module: Atmospheric Corrosion (CUI) Forms of atmospheric corrosion Preventive measures Casuistry in urea and ammonia plants Connection weld Tube Module: 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
18 Day 9 Module: 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: 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 :
19 Day 10 Module: Cases Nitrate SCC in pressure bearing part of reactor Gaskets & Bolting Failure of a High Pressure Weldolet How to find a leak? High Pressure 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.
20 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.
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