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 and operating in a Urea Plant located in Russia. Frequent leakages from the overlay welding in tubes ligament area were reported and Urea Casale was requested to inspect and provide solutions. The following inspection revealed improper repair attempts and corrosion related issue that could have led to potential catastrophic failure due to prolonged exposure of the tube-sheet Carbon Steel forging to the high corrosive Carbamate solution. Temporary specific repair procedure was agreed and implemented to allow plant operation to continue prior to equipment replacement. The lesson learned is, the importance of proper repair procedures that have to be implemented in the specific field of Urea production plants and the necessity of implementing preventive inspection and maintenance approach. The lack of these precautions may lead to catastrophic consequences.