Presented By :

Imran Khan
Apprentice Engineer
P. No. 20320
Batch # 14
Objective

 Multi-layered vessel fabrication

 Welding and fabrication techniques

 Modifications in Reactor

 Stamicarbon Urea Synthesis Process

Outlines
 Urea Synthesis Process
 Specifications of Urea Reactor (UR-211)
 Mechanical Construction
- Shell
- Leak Detection System
- Hemispherical Heads
- Sieve Trays
- Top Cover & Nozzles
- Insulation
 Installation of Siphon Jet Pump
 Current Status
- Stamicarbon Inspection
- Lining Repair Job
Urea Synthesis Process

Urea is produced from carbon dioxide and ammonia and composed of

two chemical reversible reactions

1) 2NH3 + CO2 NH4COONH2 (-28.4 Kcal/ Mole)

2) NH4COONH2 NH2CONH2 + H2O (+5.97 Kcal/ Mole)

The first reaction is fast and takes place in very short period of time,
whereas second reaction is relatively slow and requires longer time
 Off Gases

Off Gases to Vent

thru UC-291 4kg/cm2
Absorber

Carbamate Solution
from UP-271

HV-221.09
HV-231.02 Gas

Liquid
HV-221.10

34% Urea
Solution

NH3 from HP-Pump (UP-

211)

CO2 In from CO2

Compressor Urea Solution 54%
HV-231.07 LV-231.04 to LP Section
Specifications of Urea Reactor (UR-211)

 Internally lined/overlayed multilayered vertical

vessel with sieve trays & overflow pipe as internals.
 Fabricated by M/s. Nooter Corporation USA in year
1997-98.
 Process Design

 Codes & Standards

 Construction Details R8
R8

R7
• Reactor Shell R7

• Hemispherical Heads
R 66
R
• Inlet Nozzles
• Reactor Overflow R 55
R

• Sieve Trays
• Top cover & Outlet Nozzles R 44
R

• Insulation
R 33
R
• Modifications
•Siphon jet pump Installation R2
R2

•Provision of Manholes in Trays

R1
R2
Shell Can

3 Plates per Wrap, Total 39 Wrap Plates (13 Nos.)

Plates per Shell Can
Width = 3042mm , Length= 3669 mm
Thickness = 7.94mm

Material = SA-724 Gr. B

Liner (01 Nos.)

Core Plate (01 Nos.)

Width = 3669 mm , Length = 9242 mm

Thickness = 19.1 mm

Material = SA-724 Gr. B

Reactor Shell
 Core Plate
 Machining of Leak detection grooves and barrier layer faces
 Weld seam barrier layer is overlayed on pre-machined faces by
using 310 MoL (25:22:2) through plasma arc welding (PAW) on
inside of core plate
 Longitudinal welding : SMAW with E- 9018-D1 as filler rod

Groove for Barrier

3669 mm layer faces

Leak Detection
Grooves(3×5
9242 mm mm)

19 mm
Welding of Wrap Plates
 Drilling of vent holes prior to welding for venting of
welding gases
 Qty : 04 (Both ends of each Shell Can )
 Dia. : 9.5 mm up to core plate in first 3 wrap plates
and 19.5 in the remaining 10 Nos. of plates
 At 90 degrees apart radially drilled in wrap plates
 Longitudinal seams : SMAW process
 Electrode : E-9018-D1
Liner Welding
 04 plates are rolled, welded and inserted in each shell
can

- 03 longitudinal butt welding of rolled plates

- Final Liner weld seam after insertion in shell can

- Welding technique : PAW (Plasma Arc Welding)

Shell Cans Welding
 Both ends of each Shell Can are build-up using
SMAW and E-9018-D1 as Electrode for integrating
core and all wrap plates

 Circumferential welding joint

 Root pass : SMAW & E-9018D1 as Electrode
(at core plate )
 02 barrier layers welded by using plasma arc welding
with 310 MoL prior to final circumferential weld joint
of the liner
 Leak Groves & Liner Welding

A A B

See Details
Hemispherical Heads
Material : A-516 Gr-70
Plate thickness : 135 mm
Process : Hot forging
Thickness after forging : 119mm
Heat treatment : Normalizing (To relieve work hardening
stresses)

•After dimensional checks bevels were made on circumferential ends as

per drawing (at 8˚).
Hemispherical Heads
 Manhole and nozzles are fabricated and installed by full
penetration welding
 Manhole is welded by SMAW using E- 9018 D1 as Electrode.
 After this welding the inside surface of heads is strip overlayed
by Plasma Arc Welding technique using 310 MoL as filler in 03
layers.
 Head to Shell Weld Seam
STD. 8⁰ U-Bevel

3 To 1 Taper Weld
Build up

Hemi. Head

Core Plate
25 Min.

Liner Plate
30 ̊ Head Overlay
 SIEVE TRAYS
Total No. of Sieve Trays : 10 EA Overflow Pipe

No. of segments per tray : 06 EA

Material : 316 L (BC01)
Thickness : 10 mm
Clamping Nut Bolts : M14 (25/22/2)

# Tray No. No. of Holes Hole Dia. Pitch

(mm) (mm2)

1 1, 2, 3 1270 8 52
2 4, 5, 6 920 8 62
3 7, 8, 9, 10 570 8 79
Top Cover & Bolting
Top cover
Outside Diameter : 1220 mm
Thickness of Cover : 331 mm
Material of Cover : A-266 class 2
Top Cover Weight : 2.5 Tons
Number of Nozzles : One 6” and other is 3”
Overlay : 9.5 mm (310 Mol , PAW)
Number of Holes : 16 (diameter: 96 mm)
Gasket : 804 mm I.D x 854 mm O.D (Serrated type
with PTFE envelope, BC-03)

Detail of bolting
Number of bolts : 16 each
Size of bolts : M-90 X 6
Length of Bolts : 632 mm
Material of Bolts : A-193 Grade B7
Top Cover
Siphon Jet Pump Skirts
 Reduction of HS steam consumption

(25-60 Kg/hr) in stripper

 Improvement in urea conversion

 Improvement in gas-liquid mixing

 Improvement in equal temperature

distribution throughout the reactor

 Reduction in stagnant zones in reactor

 Easy to install on conventional trays

with minor modifications

Sieve Trays after Modification

S.No Tray No. of Holes Hole Dia. Pitch (mm2) No. of Holes after
No. (mm) Modification
1 1, 2 730
1270 52
2 3 600

3 4 600
920 8 62
4 5, 6 480
5 7, 8, 400
570 79
6 9, 10 345
Siphon Jet Pump Skirts
SIPHON SKIRT

GUIDE RING
OVERFLOW
PIPE

EXISTING
SIEVE TRAY

MANHOLES
Installation Details

900 mm

Siphon Skirt
08 Segments
500 mm

Guide Ring
Siphon Jet Pump Skirts
Inspection History of UR-211
 TA-2000 &TA-2001 :
 Jointly executed by FFBL & Stamicarbon
 Revealed no major abnormality
 UT of Liner revealed a corrosion rate of about 0.05 mm/yr.

 TA-2004
 Siphon jet skirts were installed
 Minor repair of pinholes defects was carried out using pencil grinder

 TA-2006
 Minor repairs were carried out as previously
 But increase corrosion rate of liner observed as compared to previous years

 TA-2007
 To confirm the thickness monitoring results achieved during TA-2006
 Increase in corrosion rate i.e. 0.15mm/yr and 0.213 mm/yr
 Minimum thickness of 7.41mm at top compartment
Inspection History of UR-211
 TA-2009
 Inspection and Eddy Current thickness measurement by
Stamicarbon
 SIIC cracks found by Eddy Current testing just below the top
head to shell circumferential weld
 Surface was ground smooth using pencil grinder. DPT
revealed cracking and subsequent grinding indicated the
~4mm deep crack
 Liner Thickness Measurement:

Compartment 1997 2009 (mm) Corrosion

Average(mm) Min. Max. Avg. Rate
(mm/yr)
1 (Top) 8.61 7.1 7.6 7.35 0.15
5 (Middle) 8.67 7.5 8.2 7.78 0.11
10 (Bottom) 8.67 8.2 8.5 8.38 1.04
Inspection History of UR-211
 Stamicarbon TA-09 Inspection Recommendations:
 Partial Relining of the top compartment within 1-2 years

 Lower the liquid level in the reactor up to ½ meter below the top

circumferential weld seam

 Improve insulation gas phase area in top

 Next inspection after 4 years effective on-stream time

 But, relining to be checked after 1 year

Shell Liner
 Plates are hot rolled, solution annealed and
pickled.
 dimensions
 Length : 3680 mm
 Width : 2292 mm (radius)
 Thickness : 8.4 mm
 Quantity : 04 plates per shell can (total 32
plates in 08 shell cans)
 Material : SS-316 LN
(Stamicarbon BC. 01)

BACK
Liner long Weld seam
Section A-A

38mm Core Plate

Leak detection
Grooves
16mm

5mm

5 mm
30⁰

Liner PAW
Weld seam barrier layer
overlaid on pre-machined
60 ⁰ 8 Min. Gap
faces (PAW).
Liner long Weld seam

BACK
 Circumferential Weld seam
4 Nos. Vent Holes located 90
apart thru each end of each Shell
152 mm
Can
½’’-3000#
Half coupling
128.5 mm

Wrap Plates

3 mm
30 ̊
Core Plate 19.05 mm

Liner 8.4 mm
Liner Circumferential Weld Seam

BACK
Leak Groove and Hole
¾ ’’ SCH-160 Pipe
SS-316L
½’’-NPT with
SS Plug
Circ. Leak Groove

10mm
Leak Groove
Long. Leak Groove
BACK
Strain Induced Integranular Cracking (SIIC)
 SIIC is an electrochemical corrosion mechanism in
combination with deformation (strain).
The following conditions are a pre-requisite for occurrence of these
cracks :
 The presence of an electrolyte as a result of condensation of
ammonium carbamate in the gas phase or liquid phase. If the liquid
level is extremely high, such cracks are also observed in the liquid
phase because an electrolyte is always present.
 Plastic deformation (=strain) of the liner material. Plastic deformation
of the liner plates will always occur during start up of the plant
(heating the synthesis section with steam).
 Other conditions can enhance this failure mode, such as :
 inferior liner material and/or weld quality ;
 presence of chloride and/or sulphur in the porous oxide layer ;
 an increased gap between the liner plates and the shell ; and
 large number of pressure cycles (start/stops).
BACK
SIIC-(Grinding using Pencil grinder)

BACK
Chemical Compositions
Material C Cr Ni Mo Si Mn N
(max)

304L 0.03 18-20 8-12 --- 0.75 2 0.10

304L U.G (BB) 0.03 17-20 8-12 --- 1 2 0.22

316L 0.03 16-18 10-14 2-3 0.75 2 0.10

316L U.G
0.03 17-18.5 13-15 2.2-3 1 2 0.22
(BC.01)
X2CrNiMo 24.5-
0.02 21-23 1.9-2.3 0.40 2 0.1-0.16
25 22 2 (BC. 05) 25.5
Safurex (BE.
0.03 28-30 5.8-7.5 1.5-2.6 0.5 0.8-1.5 0.3-0.4
06)

BACK
Mechanical Properties
Material Yield Tensile Elongation Thermal Module of
strength strength (%) Expansion Elasticity
(Mpa) (Mpa) 20 ̊/225 ̊C * 10-6/ ̊C N/mm2 at
20 ̊/225 ̊C 20 ̊/225 ̊C 20 ̊/225 ̊C 20 ̊/225 ̊

C. Steel 248 / 202 482 / 482 >16 12.5 / 12.5 190

BC.01 190 / 135 490 / 412 > 40 16.5 / 16.5 184

BC.05 270 / 195 580 / 495 > 30 16.5 / 16.5 184

Safurex 650 / 465 800 / 717 > 25 11.5 / 11.5 184

BACK
Safurex

• Corrosion Resistance
• Low overall cost
• Low weight

BACK
Plasma Arc Welding (PAW)
Plasma•.arc welding (PAW) is a advanced version of the gas
tungsten arc welding (GTAW).

GTAW has a free-burning arc, which is unstable and tends

to wander in the low current range. With increase in
current, the arc power increases and the arc diameter also
increases.

This leads to a lack of concentrated power in the work-

piece, which results in a bigger seam and a larger heat-
affected zone.

Unlike GTAW-welding torches, PAW uses a constricting

nozzle and employs two separate gas flows, which give rise
to a concentrated plasma arc having a narrow columnar
shape.

The plasma column is now stabilized along the axis of the

electrode and is more intense than the GTAW-welding arc.

 The column temperature in PAW is 10,000-24,000 K as BACK

compared to 8,000-18,000 K in case of GTAW
Process Design

Type of Reactor : Plug Flow Reactor

Density of Inlet Liquid : 990-1130 Kg/m3
Density of Inlet Gas : 114.7-126 Kg/m3
Operating Temperature : 170.2º C at inlet & 183º C at outlet
Flow Rate of Inlet Gas : 198 m3/hr
Flow Rate of Inlet Liquid : 219 m3/hr
Reactor Hold up Volume : 192 m3
Residence Time : 60 minutes (at 100 % load)
Inside Diameter of Reactor : 2917 mm
Number of Sieve Trays : 10
Height of Reactor : 29100mm
Codes& Standards

Design Code : ASME Boiler & Pressure Vessel Code,

Section VIII, Division-2. 1995
Design Pressure : 162 Kg/cm2 (2304 psig)
Design Temp : 190º C (374º F)
Hydro test Pressure : 2880 psig
Corrosion allowance : 1mm Ext. on Head & Shell, 2mm Int. & Lining
Wind Loading : Per UBC 88, Wind Speed = 150 Km/hr, Exposure ‘C’
Radiography : 100 % all liner, Shell can and shell to head weld joints
PWHT : Heads only
Leak Detection System
• 8 Nos. of Inlet air lines
• Leak Detection Grooves
• Ammonia Analyzer
HP Urea Synthesis Loop
 M90
Studs
Construction Details (16 nos)
Top Hemispherical
Head

Multilayer
 Reactor Shell Shell Can, 3670 mm
(Typical)
R8
 Hemispherical Heads (Typical) R7
Sieve Trays (10
 Sieve Trays R6 Nos.)

 Reactor Overflow R5

 Inlet / Outlet Nozzles R4

Overflow Pipe

 Modifications
R3
 Siphon Jet Pump Installation
 Provision of Manholes in Trays R2

R1

Bottom Hemispherical
Head

34% Urea
Liquid Inlet Gas Inlet