See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/321972215

Urea Reactor Liner Leakage (A Case Study)

Article  in  International Journal of Engineering and Technical Research · December 2017

DOI: 10.17577/IJERTV6IS120079

CITATIONS READS

0 1,380

2 authors, including:

Prem Baboo
National Fertilizers Ltd.,India
54 PUBLICATIONS   3 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Silo (UREA) level measurement View project

Industrial Process View project

All content following this page was uploaded by Prem Baboo on 21 December 2017.

The user has requested enhancement of the downloaded file.

 Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

Urea Reactor Liner Leakage

(A Case Study)

Prem Baboo
Sr. Manager (Prod)
National Fertilizers Ltd. India
Sr. Advisor & Expert for www.ureaknowhow.com

Abstract - This paper covers background information on the 30 Urea-I urea –II is 3030 & 3231 TPD respectively. The raw
years old revamped plant; problems experienced at the plant material used includes natural gas, water and power. Three
after many years of continuous operation, e.g., leaks in the SS Numbers Captive power plant of capacity 17 X 3 MW are
316 L (mod) lining due to the combined action of erosion and
used in this complex. Both the plants have consistently
corrosion; basis of the revamp work on the design information
achieved high levels of capacity utilization.
provided by M/S. Saipem a leader in urea production
technology. The urea reactor of Urea line 1 of 11 unit recently REACTORS DETAIL
suffered liner leakage from weep hole Number 34 on dated The all four reactors(R-1) of Urea line 1 &2 plants are 40
28/11/217.This was the second chance of liner leakage meters Height (tan to tan) and ID of the reactor is 2.04
1stleakage was occurred on dated 28th Jan 2006.The line-1 Plant meter. The liner of all reactors has SS 316 L (mod) while
was commissioned in 1988.A total number of 95 weep hole shell of line 1 & line 2 are differing. The line -1 both
provided in 11/21 Reactors. In any segments four number weep reactors are coil layered vessel while 31 unit has multi
hole are interconnected. This paper intended how to detect layered and that of 41 is mono block reactor. Detail as
leakage and repairing of the weld joint and further precaution following tableNo-1.The passivation of reactor liner is done
to prevent the corrosion/erosion. by air which is introduced in CO2 compressor in 1st stage.
The all four Urea reactor have 15 number of high efficiency
Key Words - Urea Reactor, Weep hole, liner, Detection, Helium. sieve trays. These have been provided to prevent the escape
of gaseous CO2, which must react with NH3 in the lower
INTRODUCTION portion of the reactor. These trays also help in preventing
National Fertilizers Limited, a Govt. of India Undertaking, the internal recycling of the reaction products with higher
was incorporated on 23rd August 1974. It is the second specific gravity products formed in the upper part of the
largest producer of nitrogenous fertilizer in the country and reactor. Reactor shell is made of CS with a 7mm liner of
has four operating fertilizer units located at Nangal, SS316L (mod) on the inner surface. Liner of the reactor is
Bhatinda, Panipat and Vijaipur with a total installed capacity cladded to the CS shell and longitudinal seams and
of 32.083 lakh tones Urea.NFL, a Schedule ‘A’ & a Mini circumferential seams are differing in line-1and line-2 urea
reactors. For detecting any leakage in the liner a weep hole
Ratna (Category-I) CompanyThe Vijaipur unit, which is an
monitoring system has been provided. The line-1 urea
ISO 9001:2000 & 14001 certified, comprises of two reactors have 95 numbers of weep holes. And Urea line-2 of
streams.The Vijaipur have two ammonia plant M/S. Haldor 31-Urea reactors has 77 numbers weep holes and 41
Topsoe Technology, Denmark capacity 1750 & 1864 TPD reactorhas 98 numbers weep holes. In the weep hole
for Line-I & line-II respectively and four urea plant of M/S. monitoring system there are two loops of weep holes
Saipem ammonia stripping process, Italy. The Line-I plant covering the entire reactor. Data are following in Table No.-
installed in 1988 and that of line –II in 1997.The capacity of 1, 2 & 3.

Table No.-1
Reactors Specifications
Sr. No. Parameters units Value
1 Working Pressure Kg/cm2 159
Kg/cm2 169 at top
2 Design Pressure
Kg/cm2 169 +full of liquid at Bottom
Kg/cm2 219.7 (Vertical)
3 Hydro Test Pressure
Kg/cm2 224 (Horizontal)
4 Working Temperature 0C 188
0
5 Design Temperature C 200
6 Liner Material SS 316 L (mod)
7 Shell Material CS
8 Internals & Trays 2 RE 9(25/22/2)

IJERTV6IS120079 www.ijert.org 155

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

Table No. 2
LINE 1 & 2 REACTOR DETAIL
Sr. No. Specifications 11/21 -Reactor (R-1) 31-Reactor(R-1) 41 Reactor(R-1)
1 Type of vessel Coil Layered Vessel Multi Layered vessel Mono wall Vessel
2 Manufactures M.H.I Japan BHPV(Vizag) L&T
3 Liner, MOC SS 316 L (mod) SS 316 L (mod) SS 316 L (mod)
4 Liner Thickness 7 mm 7 mm 7 mm
SPV 46 Q A 516 GR 70
5 Shell MOC A 516 GR 70
MY56 A 724 GR A
SPV 46 Q=16 Inner A 516 GR 70=10+3
A 516 GR 70=67
6 Shell Thickness, mm MY56=4.5 X 8 LYR A 724 GR A=6X12
SPV 46 Q=8 outer
7 Total THK, mm 67 92 74
8 No. of weep Hole 95 77 98
9 Weight, Ton 190 225 195

Table No. 3
Urea Reactors Trays Detail
Trays No. Material No. of Holes Pitch
1 to 5 (top) 2 RE 69 641 Triangular
6 to 10 (middle) 2 RE 69 1282 Triangular
11 to 15 (Bottom) 2 RE 69 1923 Triangular

Fig. No. 1

IJERTV6IS120079 www.ijert.org 156

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
 Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

REACTORS LEAKAGE DETECTION AND REPAIRING

Reactor Liner Leakage on 28/01/2006.

In Urea Line-I and 2 plant all the weep holes are connected to conductivity meter based monitoring system. on dated 28/01/2006
the leakage alarm appeared in weep hole number 23 of 11 stream.The weep hole was checked physically and vapour analysed in
laboratory found ammonia vapour and CO2.Immedially shut down was taken and leakage detected with instrument air and soap
solution the leakage easily detected. For find out the leakage the liner plate behind the weep hole was pressurized with instrument
air at the pressure of 0.5 kg/cm2 and other three interconnected weep holes were plugged. Soap solution applied on opposite side
of liner. The pin hole leakage easily detected. The pin hole repaired by welding. The repaired portion was passivate with 10 %
HNO3 solution and rinse with Demineralized water. The repaired portion was further checked with instrument air and soap
solution no leakage was found. The shutdown duration was only 69hrs. Feed cut to feed in.

Reactor Liner Leakage on 28/11/2017.

On dated 28/11/2017, a weep hole leakage alarm from Weep Hole No. 34 was appeared on lectrotek system. Immediately checked
the weep hole No.-34 and vapour analysed in laboratory found ammonia & CO 2 vapour and leakage was confirmed. Immediately
shut down was taken at 11.15 hrs on dated 28/11/2017.draining of the H.P loop started at 11.15 hrs. For air purging 11 PT-05 A/B
cover open for air purging. Man entry permitted at 18.15 hrs on dated 29/11/2017 after confirming ammonia contents less than 25
ppm and Oxygen contents more than 20 %. Four Numbers man ways were opened for detecting leakage the leakage above 5 th
tray. So the 4 man ways opened. first of all, leakage detection tried with instrument air & soap solution. For detecting the leakage,
the instrument air introduced at the pressure of 0.5 kg/cm2and other three interconnected weep hole plugged so that the pressure
retains inside the liner and shell. Soap solution applied on liner for detecting the leakage. Four hour tried to leakage but success
did not get. After that our further step to detect the leakage with ammonia and phenolphthalein indicator. But leakage could not
have detected. Timing tabulated in Table No-4.

As the weep hole leakage was not clear, the exact location the leak could not be found out with Soap solution and ammonia
test.Finally, the DP check and number of the spot, pin point found. All the circumferential Seam and longitudinal seam opposite of
weep hole No. 34 between 4th& 5th trays welding done. After that ammonia is introduced at the pressure of 0.4 kg/cm 2in weep
hole No. 34 and hold up for 10 hrs. and liner and all welding seam checked by phenolphthalein indicator. No leakage was found
and man hole cover boxed up. Start-up activities started and feed in done on dated 01/12/2017 at 11.15 hrs. Total time taken for
this shut down was 72 hrs (3 days) feed cut to feed in. Typical lifetime of the 316L Urea Grade protective layer of a urea reactor is
20-30 years depending upon passivation and plant load number of the tripping of the plant process variations etc. Typical lifetime
of a urea plant is 40-50 years. Every urea reactor will finally operate close to the end of lifetime conditions of the protective layer
meaning that at a certain moment a leak in the protective layer is nearly unavoidable.

WEEP HOLE MONITORING

Urea line-1 weep hole monitoring with lectrotek system (Pune). In Urea line-2 Masibus weep hole monitoring system is
incorporated. The Micro genie scan is a microprocessor based scanner which has been specially designed for resistance input to
monitor reactor leakage easy and very simple in installation low pricing equipment’s and easy in maintenance.

Table No. 4
DETAIL OF SHUT DOWN TIMING AND ACTIVITIES
Sr. No. Activities Date Duration Time Parallel Jobs
1 11 Reactor Feed Cut 11.15 0

2 H.P. Loop draining started 11.15 hrs. to 17.15 6

hrs Weep hole cleaning
28-11-2017 with steam
17.15 hrs to 21.15
3 L.S. Purging 4
hrs
21.15 hrs to 00.15
4 H.W filling 3 Instrument air
hrs
connection provided
00.15 hrs to 04.15 with pressure regulator
5 H.W overflowing at the pressure 30 kg/cm2 4
hrs with P.G
04.15 hrs to 12.15 Reactor man hole
6 H.W Draining 29-11-2017 8
hrs cover opening

7 Air cooling 6 Air sampling

12.15 hr to 18.15 hrs

IJERTV6IS120079 www.ijert.org 157

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

18.15 hrs. to 21.15 PT-5 A/B opening for

8 3
hrs air purging
Man entry permitted for Reactor trays man
ways opening up to 34 Number weep hole.

9 Leakage checking with Inst air and soap 21.15 hrs to 01.15 4 No Leakage found
solution hrs
Leakage checking with Ammonia &
phenolphthalein indicator solution 01.15 hrs to 08.15
10 7 No Leakage found
hrs

30-11-2017
08.15 hrs to 13.15
11 Finally welding by hit and trial on opposite 5
hrs
of W.H. No34, based on DP pin points
Further checking with ammonia &
phenolphthalein indicator solution 13.15 hrs to 23.15
12 10 No Leakage found
hrs

13 Man hole cover boxed up 23.15 hrs to 03.15 4 Bottom PT-5 A/B
hrs boxed up

14 L.S Heating for H.P. loop 3

03.15 to 06.15 hrs
01-12-2017
15 K.W.Heating, up to 140-1500C 06.15 hrs to 08.15 2
hrs

16 Ammoniation 08.15 hrs to 11.15 3

hrs
17 Reactor Feed In 11.15 Hrs.

Total Time 72

Fig. No. 2

IJERTV6IS120079 www.ijert.org 158

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
 Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

This programme containing non-volatile memory for setup data, 4 duals and 4 digit display and LED bar for information RS -232
–C serial port

The instrument is housed in a ½ DIN extruded Aluminum rack suitable for control room mounting. A small but highly functional
Keyboard consisting of 4 membrane keys is provided as the as the instrument operator interface electrical and I/O temperature are
instruments rear Via Screw type terminals. The electronics is located on modularly designed board for easy field trouble shooting
and maintenance. All cards are plug in type and segregated by their function Viz –including power supply CPU, A/D display.

All the weep holes have to be checked by passing instrument air every week/fortnight for any leakage and blockage & the
pressure of the testing medium should not be more than 0.5 kg/cm 2

SAFETY RISKS OF UREA HIGH PRESSURE EQUIPMENT

1. High pressures
2. High Temperatures
3. Various kinds of corrosion phenomena (inside and outside)
4. Crystallization risks.
5. Large volumes
6. Release of toxic ammonia in case of a leak

Integrity of carbon steel pressure bearing wall can be threatened by:

1. Carbamate corrosion due to damage of protective layer with (corrosion rate 1000 mm/year):
2. An early and reliable detection is a must.
3. Stress corrosion cracking behind loose liner when water and contaminants are present.
4. Stress corrosion cracking from outside when water and contaminants are present

Fig No.-3

IJERTV6IS120079 www.ijert.org 159

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
 Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

Other methods of Leak detection

Number of methods are available in market as following.

1. Instrument air & soap solution

2. Ammonia with phenolphthalein indicator.
3. Helium leak detection.
4. Vacuum testing method.
5. Ultrasonic flaw detection
6. DP Test method.

PRESSURE VESSEL
Pressure vessels are leak proof containers which contain media under pressure and temperature May be of any shape milk bottles,
shaving cream, tires, tanks, reactors etc. The term pressure vessel referred to those reservoirs or containers, which are subjected to
internal or external pressures.For higher operating pressures and higher temperature, new technologies have been developed to
handle the present day specialized requirements. Multilayer Pressure Vessels have extended the art of pressure vessel construction
and presented the process designer with a reliable piece of equipment useful in a wide range of operating conditions for the
problems generated by the urea processes.

Classification of Pressure Vessel

High Pressure Vessel

Mono wall Layered Vessel

Multi wall Coil Layered Multi Layered

Multi wall Vessel Coil Layer vessel Multi-layer vessel

Required thickness is calculated as per

They are the proprietary construction of Required thickness is calculated as per solid solid wall construction formulas
STRUTHERS WELLS CORPORATION wall construction formulas subsequently no. of subsequently no. of layers and their
U.S.A layers and their thickness is determined thickness is determined

Unit cylinders consist of an Inner shells, steel Inner shells of suitable material are used
Designed to various international codes hoop (3 – 6 mm thk ) coiled around the inner as per process requirement
shell in volute and split outer shell of 6-to 12
mm thickness

Required thickness is calculated as per solid Then thin plates of high T.S. are wrapped
Uninformative priestess can be obtained by
wall construction formulas subsequently no. of on outside of inner shell to obtain required
coiling of hoop around inner shell
layers and their thickness is determined thk.

Vent holes are provided in all layered sections Vent holes are provided in all layered
Cylindrical shells are rolled to desired Dia and
except for inner shell lining sections except for inner shell lining.
welded ( plates THK in the range of 1” to
21/2”)

IJERTV6IS120079 www.ijert.org 160

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
 Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

Higher the operational pressure or

Cylindrical shells are consecutively shrink
pressure vessel diameter or length the
fitted over each other to obtain total wall
more favourable the weight ratio between
thickness
multilayered and monowall design.

Heating rate for shrink fitting is as per ASME

SEC. VIII Cooling after shrink fitting is done in
still air

ADVANTAGES

Multi wall Vessel Coil Layer vessel Multi-layer vessel

Layers of different material can be Does not suffer from lack of Does not suffer from lack of
used as per process requirement. uniformity of material. uniformity of material.

Can be provided with innermost

Unlimited size of the vessel Can be provided with innermost layer layer in cladding or corrosion
in cladding orcorrosion resistant resistant material as per
material as per requirement. requirement
Lighter in weight due to use of high
Lighter in weight due to use of
T.S. steel plates. Vent holes are
Does not involve any full depth heavy high tensile strength steel plates.
provided for leak detection in welds.
longitudinal weld

No PWHT is required except in

These are also profitable in the point
Vent holes are provided for leak special cases.Vent holes are
of anti-hydrogen attack .Unlimited
detection in welds provided for leak detection in
size of the vessel
welds.

Normally uneven corrosion in reactor occurs due to poor feed rate and quality, N/C ratio; high inert; chloride and sulphides and
also iron precipitated water. Lack of passivation. 316 L Urea Grade needs a continuous oxygen supply to assure a passive layer
builds up. Sulphides cause stress cracking in stainless steel. Chlorides are somewhat corrosive to stainless steel. The combination
is not good. It sounds like you might be getting a lot of impurities in there from somewhere. Very small quantities of these things
(other than halides) are not likely to be very much of a problem, but you need to have an analysis made of the sludge you are
getting to determine what all you have in there. Then it will be easier to judge how bad the situation is. With this kind of mix (if
you are getting all of those things) you can get a lot of side reactions. If you have that many anions, you will need to get cautions
from something. It is possible for it to find them in the stainless steel. Passivation air must not be less than 0.3% in compressor
house in third stage. Following points to avoid corrosion/erosion.

1. Chloride in passivation air-seldom present in atmosphere.

2. N/C ratio should be proper.(In M/S. Saipem C/N ratio is 3.5 and in M/S. Stami is 2.8
3. Prevent iron precipitated water.
4. Check CO2 purity - 99.3%, Hydrogen and Iron present in carbon dioxide.
5. Oil content in liquid ammonia feed, as few grades of oil contains sulphur.
6. Holding of solution in shut down must be less than 48 hrs. However M/S. Saipem recommended 72 hrs. Initially, but
after some cases of corrosion/erosion was observed further recommended for 48 hrs.
7. Ammonia liquid feed in reactor must be more than 132.6 0C(critical temp. of ammonia)
8. During holding of solution liquid ammonia to be given to reactor for 10 minutes and during start up ammonia feed 10
minutes prior to carbon dioxide feed.
9. Pay attention to depletion of oxygen due to dead spots.

IJERTV6IS120079 www.ijert.org 161

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

Fig. No. 4

Fig. No. 5

IJERTV6IS120079 www.ijert.org 162

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
 Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

Fig. No. 6
CONCLUSION combined to produce an estimation of risk. The results show
My experience says that reactors always leak from the weld that the lining leakage is the most severe risk and the SCC of
joints of liner initially. However, if the leak is not attended layer shells risk is the second. Keep weep holes always open
and carbamate comes in contact with shell. The damages are and inspect for leaks periodically. Urea reactors should be
far beyond imagination. Weld joints are always more shut down immediately when a leakage is detected. Don't
vulnerable to fail. The probability and consequence are use vapour to detect the leakage of urea reactor vessel, in

IJERTV6IS120079 www.ijert.org 163

(This work is licensed under a Creative Commons Attribution 4.0 International License.)
 Published by : International Journal of Engineering Research & Technology (IJERT)
http://www.ijert.org ISSN: 2278-0181
Vol. 6 Issue 12, December - 2017

case it should be used, the vapour quality should be ensured. manufacturer and operator. The legislation and standard
The risk of highly corrosive urea-carbamate solution leaking must be such that these requirements are met.
through these liners always exists in this equipment which
might eventually damage the carbon steel walls. The places LEGENDS
having notches like corners of support cleats or crevices in CS-carbon steel, TPD-ton per hour, MW-Megawatt.
the weld joints are more prone for SCC.The reactor liner SS-stainless steel. SCC –stress corrosion cracking, DP-
leakage is the serious phenomenon. As and when urea Dye penetrating Test. Circ.-Circumferences, Long.-
reactor liner leakage started shut down must be taken as longitudinal. HP-High Pressure, L.S -low pressure
soon as possible otherwise carbon steel corrosion rate is Steam, K.W-High Pressure flushing water. H.W-about
high. The subject of pressure vessel technology is central to Medium pressure flushing water.ID-inner dia.
industries as a whole. The balance of safety with a sound P.W.H.T.-Post weld heat treatment. T.S. -Tensile
economic approach is a major consideration to the designer, strength

IJERTV6IS120079 www.ijert.org 164

(This work is licensed under a Creative Commons Attribution 4.0 International License.)

View publication stats