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.

Why 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:

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.