Safety of plant and personnel is accorded the highest priority in fertilizer plants due to nature of operation. Manufacturing of fertilizers involves processing of hazardous chemicals at high temperature and pressure. Another factor that makes plant vulnerable to accidents is its age. There is possibility of accidental release of harmful chemicals, fire and explosion which pose danger not only to plant and personnel inside the plant battery limit but also to surrounding population and environment. Therefore, plant and equipments have to be maintained in excellent condition and all operating parameters have to be kept in safe limits. There is a need for continuous investment in ageing plants by way of revamp and replacement.
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