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Safety and HSE Training Programs for all ammonia and urea plants

Safety and HSE Training Programs for all ammonia and urea plants

Serious incidents continue to take place in the nitrogen fertilizer industry. UreaKnowHow.com together with its Partner Tech Safety Group start up a new initiative to improve the safety standards in ammonia and urea plants. Dedicated Safety and HSE Training Programs will discuss the specific safety and HSE aspects valid in ammonia and urea plants. Numerous safety incidents, which occurred in the past in ammonia and urea plants, form the basis of these training programs. The Lessons Learned will be discussed targeting a higher safety standard in our industry. For more information click here for Safety and HSE Training Programs in Urea Plants and for Safety Training Programs in Ammonia Plants. Also feel free to contact UreaKnowHow.com via This email address is being protected from spambots. You need JavaScript enabled to view it..

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Corrosion Inspection Services of High Pressure Piping in Urea Plants

Corrosion Inspection Services of High Pressure Piping in Urea Plants

High-pressure piping is often an area that receives almost no attention during the lifetime of a urea plant; there is no logical reason for this. Paying not enough attention or wrong inspection/repair procedures can lead to catastrophic incidents...

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BHDT Zero Dead Volume High Pressure Sampling Valve

BHDT Zero Dead Volume High Pressure Sampling Valve

UreaKnowHow.com together with BHDT developed The BHDT “Zero Dead Volume“ High Pressure Sampling Valve, which makes taking samples from the High Pressure Synthesis section in a Urea Plant much more Safe, more Reliable and lot Easier. And is now available for all urea technologies. The solution will flash whereby ammonia gas releases. During sampling no gasses are allowed to escape in order to obtain a reliable and representative sample. The sample needs to be caught in a balloon in which it is dissolved in a pre-weighted amount of water. The sample flow needs to be controlled accurately in order that the sample has time to dissolve in the water and to avoid that the balloon will burst. The sampling valve and inlet line need to be pre-heated and flushed through to remove the old solution. Proper personal protection equipment is needed to avoid any risks. It is time to solve these safety hazards…

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The KAPP CO2 CHILLER

The KAPP CO2 CHILLER

KAPP Heat Transfer Engineers, together with UreaKnowHow.com developed The KAPP CO2 Chiller, which cools the feed CO2 temperature without using cold energy sources from the existing ammonia and urea plant. This paper will describe and evaluate three options for The KAPP CO2 CHILLER. All three options lead to extreme short pay back times as will be demonstrated in the paper.

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UreaKnowHow.com & Tech Safety Group join forces to improve Your Safety and Reliability

UreaKnowHow.com & Tech Safety Group join forces to improve Your Safety and Reliability

UreaKnowHow.com and Tech Safety Group (UKH-TSG JV) joint venture provide operational safety and reliability engineering expertise specifically to operators in the nitrogen fertiliser industry.
Our services include, but not limited to:
- Technical Safety and Risk Management,
- Process Safety Documentation compliance with EU and International regulators,
- Reliability, availability and maintainability studies,
- Revamp support for Ammonia and Urea technologies,
- Operation and Process support.
 
 
Key benefits of using our services:

 

Maintain your operational license

One of the common key requirements of EU Seveso III, UK HSE, OHSAS 18001 or national environmental legislation is to demonstrate that your company risks have been reduced to As Low As Reasonably Practicable (ALARP) level. Your operational license depends on this commitment. We adopted a dedicated IT platform – Risk Track that will help you to provide a clear ALARP demonstration report to government regulators. It will also save significant time by cutting down the efforts required to prepare the approval documentation. Risk Track is coming with an integrated risk register developed specifically for the fertilizer industry and is free to use for all our clients.

Identify and mitigate the risks specific to the fertilizer industry

Safety studies that are developed by our Ammonia and Urea specialists will reduce the gap between already assessed Major Accident Hazards within your plant and those specific risks associated with fertilizer technologies to a minimum by using a systematic approach to identify and mitigate the Nitrogen Fertilizer technologies specific process risks.

Clear Investment Strategy

As a company that operates for a number of years, with perhaps several revamps completed and others to come in the future, a complete Safety Case* will act as a “road map” pointing the management to investments that really counts in terms of securing plant operability and safety.

Reduced insurance premium and risk profile

With a Safety Case* in place that demonstrate that your Company has a clear risk management system and make use of it in a daily basis, there will be a beneficial financial impact on insurance rates and bank's risk profile for the company. Nowadays financial institutions use safety & risk engineers to evaluate industrial client's risk profile based on safety documentation and daily operation.

*Definition: A Safety Case is a structured argument, supported by evidence, intended to justify that a system is acceptably safe for a specific application in a specific operating environment.

 

Our Capabilities Statement

Risk Track Brochure

 
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Turnaround Support Services

Turnaround Support Services

Yara invited UreaKnowHow.com to be present during a major turnaround of Yara Canada in Belle Plaine, Canada. UreaKnowHow.com provided consultancy services related to the replacement of some HP Urea Equipment items and the inspection and possible repair of equipment and piping. Before the turnaround UreaKnowHow.com visited the site to discuss in detail the relevant maintenance projects in the urea plant. During this first visit an extensive study was performed to look at how the high pressure equipment items could be replaced in the most efficient way...Click here for more details. Contact us for more information or our offer for support of your turnaround: This email address is being protected from spambots. You need JavaScript enabled to view it.

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The Off-Spec Urea Product Upgrader: From Off-Spec to Premium Product

The Off-Spec Urea Product Upgrader: From Off-Spec to Premium Product

The OFF-SPEC UREA PRODUCT UPGRADER converts off-spec urea product (lumps, fines and dust) into a premium quality urea product, namely Urea Super Granules. Urea Super Granules are part of the Urea Deep Placement technology developed by the International Fertilizer Development Company (www.ifdc.org) in the US with the target to increase rice yields with reduced nitrogen-fertilizer application and reduced nitrogen losses.

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Perform a regular Health Check on Your Urea Plant !

Perform a regular Health Check on Your Urea Plant !

How to keep your urea plant in optimum shape ?

-• Is your plant running at optimum process conditions and what about realizing maximum output, minimum ammonia losses, minimum energy consumption and optimum product quality ?
•- And how to realize a maximize reliability and on stream figures minimizing unplanned shut downs and keep safety standards up to date?
•- And what about future debottlenecking possibilities ?

UreaKnowHow.com offers now Health Check services covering all these aspects !
 
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Carbamate crystallization temperature calculator

Carbamate crystallization temperature calculator

This Carbamate Crystallization Temperature Calculator has been the result of the co-operation between UreaKnowHow.com and Virtual Materials Group.

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Statistical Process Control for improving your urea product quality

Statistical Process Control for improving your urea product quality

Statistical Process Control is a good way to check, but more-over control your product quality, and reduce the amount of complaints and overdosing of formaldehyde, and avoid caking and dust in the warehouse. Typically one wants to do quality control on the Size Guide Number (SGN) and Uniformity Index (UI), because these parameters determine how ones fluid bed granulation or prilling plant is running. One can also opt to apply Statistical Process Control on the load-out product, to enable a product certification and happy customers...More information

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How to avoid Baffle Hammering Problems ?

How to avoid Baffle Hammering Problems ?

Baffle hammering is a widely occurring failure mechanism in heat exchangers. In urea plants baffle hammering has been experienced in various heat exchangers such as HP scrubbers, Low Pressure Carbamate Condensers and Kettle type carbamate condensers. By means of HTRI a specific vibration study can be performed to prove that indeed critical vibration  do occur under the current conditions and which measures are necessary to realize a vibration free design. UreaKnowHow.com has experience to perform these HTRI studies in co-operation with HTRI specialists. For more information: Download the PDF

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Reliable Pressure Measurement in HP Urea Synthesis

Reliable Pressure Measurement in HP Urea Synthesis

SKW Pieteritz in Germany has successfully developed a reliable pressure transmitter for the high pressure synthesis section in any urea plant. This pressure transmitter is part of the Innovative Overpressure Protection System for high pressure urea synthesis sections, which was presented during the AICHE Ammonia Safety Conference 2012 and is offered by the Safety Valve producer LESER in Germany (www.leser.com). It has been agreed between the parties involved that UreaKnowHow.com will offer the pressure transmitter itself to urea producers. To measure the pressure in a high pressure gaseous or liquid carbamate lines, several challenges are to be encountered: crystallization, erosion and corrosion risks. Solutions have been found to avoid these risks and these pressure transmitters are successfully in operation since September 2011. For more information, download the PDF.

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Need support for your new Grass Root Urea Plant or Revamp Project ?

Need support for your new Grass Root Urea Plant or Revamp Project ?

UreaKnowHow.com has the know how and experience to support you with your new Grass Root Urea Plant or Urea Revamp Project. UreaKnowHow.com can support you in a wide range of services and activities during the complete project lifetime.

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Orifice Plugs increase the performance of VOP Heat Exchangers

Orifice Plugs increase the performance of VOP Heat Exchangers

Vertical One Pass (VOP) heat exchangers are many times applied in urea plants. As the residence time in these heat exchangers is small, unwanted side reactions like biuret formation and hydrolysis of urea are limited. Some phenomena however limit or reduce the performance of these heat exchangers: Bad distribution of gas and liquid at the inlet and consequent fouling of the tubes.UreaKnowHow.com offers a very reliable and maintenance friendly solution to improve the performance of VOP Heat Exchangers. This solution have been proven for more than five years and increases the performance and reduces the fouling tendency in a medium and low pressure recirculation heater. The restriction orifices are very easy and quick to install and remove during a shut down. For more information, download the PDF.

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Energy Reduction Revamp Project: Step 1 - Quick Scan

Energy Reduction Revamp Project: Step 1 - Quick Scan

Energy costs have a significant impact on the production costs of the urea product. Older urea plants have to compete with large scale new plants however suffer typically from higher energy costs due to the applied older technologies and due to lower efficiencies of older machines. UreaKnowHow.com co-operates with a group of energy management specialists with totally more than 40 years experience in energy management and revamp projects to improve the energy performance figures of your urea plant and reduce the variable urea production costs. Step 1 of such a typical Energy Reduction Revamp project is a Quick Scan of the actual energy situation in your urea plant. 

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Van Bommel Dedusting Technology dedust your Prills or Granules

Van Bommel Dedusting Technology dedust your Prills or Granules

Dusty urea product leads to many problems with clients, employees, transporters and farmers. Dusty urea product is typically caused by operation parameters of the evaporation section in the urea melt plant, operation parameters of the granulation or prilling section, storage conditions and logistic procedures. In most of these cases an end-of pipe solution is the most efficient and cost-effective solution to improve the product quality and produce premium-grade urea. The “Van Bommel Dedusting Technology” (VBDT) offers such a solution. For more information, download the PDF.

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Benchmark Study Synthesis Pressure Safety Valves

Benchmark Study Synthesis Pressure Safety Valves

Synthesis Pressure Safety Valves tend to pop up unexpectedly leading to safety risks and a forced shut down of the plant. UreaKnowHow.com has initiated a Benchmark Study about the experiences with these critical equipment items. Five urea plants covering all major process technologies have participated and answered a set of fifteen questions related to the design, operation and maintenance of these valves. Contact information of the participants plus an industry expert is included for further exchange of information. To summarise: A perfect opportunity to solve finally all your problems related to the Synthesis Pressure safety Valves.

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Training Programs

Training Programs

Regularly UreaKnowHow.com organises various Training Programs: Complete Training Programs for any engineer, manager, supervisor and operator working in any kind of urea plant or more specific Maintenance Training Programs. These Training Programs can be Open at a central location, organised In-house at a certain urea plant or Half-open hosted by one urea plant while third parties are invited also to join.

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