Training Program for Urea Engineers - Program for Urea Engineers Designed for Process, Operational, Mechanical, Maintenance, Instrumentation, Process Control and Inspection Engineers,

  • View

  • Download

Embed Size (px)

Text of Training Program for Urea Engineers - Program for Urea Engineers Designed for Process, Operational,...

  • Training Program for Urea Engineers Complete 10-Day Detailed Urea Training


  • 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


  • 5-day Training Program for Urea Engineers

    21-25 January 2013 in Abu Dhabi


  • 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

  • An internet platform to exchange technical information within the urea industry

    with the target to improve the performance and safety of urea plants



    >2900 Members representing >98% of all urea plants worldwide

    Largest network in urea industry Biweekly a

    Technical paper Round Tables

  • Mr. Jo Eijkenboom Mechanical Engineer 39 Years Stamicarbon Maintenance, HP equipment , materials, corrosion, repair, welding. Vice President Jo Eijkenboom Consultancy BV Director

  • 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

  • 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 (March 2009)

  • 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

    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 ?

    Day 1

  • 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

    Day 2

  • Module: Thermodynamics and Phase diagrams Thermodynamics & Phase diagrams Parameters (CO2 conversion, alfa, N/C, H/C, H/U) System pressure, inert pressure Liquid isotherms Top ridge line Fraction approach to equilibrium CO2 versus NH3 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

    Day 3

  • 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

    Day 4

  • 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

    Day 5

  • 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

    Day 6

  • Module: CO2 Compressors Phase and Mollier Diagram CO2 Different Type of CO2 compressors Revamping CO2 Compressors Operating problems in CO2 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

    Day 7

  • Module: Atmospheric Corrosion (CUI) Forms of atmospheric corrosion Preventive measures Casuistry in urea and ammonia plants 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

    Connection weld Tube

    Day 8

  • 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 :

    Day 9

  • 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 NH3 storage tank inspection Atmospheric and Utility Corrosion cases You are welcome to bring up for discussion your own cases and Experiences.

    Day 10

  • 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.