Prevention of a Potential Catastrophic Failure of a High Pressure Condenser in a Urea Plant

摘要

This paper describes the findings of a High Pressure Carbamate Condenser installed in 1997 andrnoperating in a Urea Plant located in Russia. Frequent leakages from the overlay welding in tubesrnligament area were reported and Urea Casale was requested to inspect and provide solutions. Thernfollowing inspection revealed improper repair attempts and corrosion related issue that could have ledrnto potential catastrophic failure due to prolonged exposure of the tube-sheet Carbon Steel forging tornthe high corrosive Carbamate solution. Temporary specific repair procedure was agreed andrnimplemented to allow plant operation to continue prior to equipment replacement. The lesson learnedrnis, the importance of proper repair procedures that have to be implemented in the specific field ofrnUrea production plants and the necessity of implementing preventive inspection and maintenancernapproach. The lack of these precautions may lead to catastrophic consequences.