Leak Detection System

Monitor leaks to ensure plant safety

Having a state-of-the-art leak detection system (LDS) in urea plants is not an option – it is a necessity. 

Severe conditions in the synthesis section of the plant constantly affect the protective liners that cover the carbon steel high-pressure equipment. Over time, these liners become thinner, potentially causing ammonium carbamate to leak and leading to corrosion.

In case of a leak, a hazardous situation can happen, placing in danger your staff, equipment, and the surrounding environment. But this can be prevented with a reliable leak detection system.

ADVANCE MONITOR Leak Detection SystemWhy Leak Detection Monitoring?

The loose liners protecting the carbon steel vessel with time become vulnerable to the following types of corrosion: 

  • Crevice corrosion
  • Corrosion in the Heat Affected Zones (HAZ)
  • Condensation corrosion 
  • Fatigue crevices

If there is a leak in the protective lining and ammonium carbamate reaches the carbon steel vessel, active corrosion takes place at a rapid speed and plant operations must be stopped immediately.  

Timely detection of a liner leakage can not only reduce damages to equipment but, most importantly, protect the health and safety of plant staff. 

Benefits of a Reliable LDS

A proven industrial LDS is critical for ensuring the safe operation of lined high-pressure equipment. The system monitors the lining continuously and triggers an alarm when detecting a leak, also indicating its location. 
By installing an LDS, you get the following benefits:

  • Use a single system for more than one piece of high-pressure equipment 
  • Monitor for leaks continuously
  • Achieve a quick response time (under 60 minutes) 
  • Increase the lifetime of your high-pressure equipment 
  • Significantly lower repair costs, if any
  • Reduce turndown period and production losses

A reliable system can update you continuously on the integrity of protective liners during everyday plant operations, although it does not replace a complete and careful inspection of liners during a normal turnaround. 

Types of Leak Detection Systems

Choose between the three types of LDS we offer:

Pressurized  Vacuum Combined
  • Ideal for newer high-pressure vessels with passageways (grooves) in the carbon steel wall
  • Highly reliable
  • Highly accurate
  • Good diagnostics – receive proof of segment communication via a flowmeter
  • Continuous distributed control systems (DCS) readings
  • Ideal for older high-pressure equipment with leak detection holes only (no grooves)
  • Highly reliable
  • Highly accurate 
  • Limited diagnostics – needs periodic tests to check segment communication 
  • Continuous DCS readings   
  • Ideal as an integrated system for several pieces of older and newer high-pressure equipment 

Stamicarbon recommends using a pressurized leak detection system for all high-pressure equipment with passageways (grooves).

Our pressurized LDS is easy to use and maintain, providing immediate flowmeter readings in case of a passageway blockage behind the liner, which is only possible to identify with periodic tests in vacuum or hybrid systems. 

A pressurized system also prevents the risk of false alarms caused by ambient air containing ammonia entering the tubing in case of a tube leakage.  



A leak detection system is crucial for safe plant operations, so it needs to be inspected regularly. And as the high-pressure equipment ages and its protective lining becomes thinner, a high-quality system becomes even more critical. 

Our systems are compatible with both new and existing (older) high-pressure equipment. We can also provide additional services, including: 

  • Inspection of your current leak detection system
  • Assistance with installation, commissioning, and start-up
  • Training of operators and technicians 
  • Troubleshooting support

In the event of a leak, Stamicarbon can also help repair damaged equipment and perform equipment relining to replace corroded liners. 

Contact us to receive more information about the most suitable LDS for your plant.


  • Stami Urea Advance Brochure