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.
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.