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We have a Leak...Do we need to stop the plant?

High Pressure flange connections in urea plants

How to Manage Leaks in Urea Plants

In 2017, AmmoniaKnowHow.com and UreaKnowHow.com introduced FIORDA, the Fertilizer Industry Operational Risk Database, a global open source risk registers for ammonia and urea plants. On January 1, 2018, the Risk Register Safety Risks in Urea Plants contained its first 100 safety risks. A surprising conclusion from this Risk Register is that most safety risks may lead to a sudden leak releasing a cloud of toxic ammonia. Early detection of a leak is therefore important as a small leak can be more easily contained and clogging can be avoided.

But what to do when there is a leak ?

Can one retighten a flange connection, install a clamp or does one need to stop the plant immediately ?

This Revamp Guide discusses why in urea plants leaks easily occur, what happens when there is a leak, what are the consequences of this, what are critical leaks and what are the prevention and mitigation measures?