Fertilizer manufacturing facilities using ammonia and nitric acid to produce a solution of ammonium nitrate face unique Pollution Prevention and Control measures.
Prilled ammonium nitrate production typically requires generation of synthesized gas through a shift conversion reaction process involving natural gas, steam and hydrogen at very high pressures and temperatures.
The pressures, temperatures and gas compositions generated through the conversion of un-odorized natural gas into reformed gas, syngas and loop gas creates a production environment with high gas leak risk profiles.
There are many examples of facility leak risk management system failures that, at times, have resulted in catastrophic outcomes.
Background
Conventional leak detection technologies and methods deployed in this type of plant have many shortcomings, often rendering them ineffective.
Fixed (line of sight) process-area-wide gas leak detection systems act only as crude reactionary detectors. By the time these systems have triggered (typically initiating a plant ESD) the situation may already be critical. Conventional “snoop” testing or generic “pre-hot work checks” using slow response personal LEL monitors are not accurate and reliable enough to manage potential leak risks present at a component level.
ATMECO leak risk reduction and control
ATMECO provides detailed, methodical and customizable gas leak detection survey and reporting services to a range of upstream oil & gas production and downstream petro chemical refining facilities worldwide.
Focusing on ammonium nitrate production facilities ATMECO has developed and deployed a component integrity management system (CIMS) suitable to the industry.
With input from such facilities, ATMECO customized a suite of technologies and survey methodologies to meet the unique gas leak risk management challenges of ammonia nitrate production.
An ATMECO Component Integrity Management System (CIMS) delivers on 3 primary objectives: 1. In-field (component level) identification and cataloguing of all potential leak sources (PLS) across the entire production process (Gas conversion through solids production)
- Survey, leak quantification and remedial response prioritization based on process stream, component class, and contingent risk factors.
- Ongoing leak risk reduction through pre-shut (scoping) surveys, start-up integrity verification surveys and on-line leak detection surveys in accord with corporate process integrity leak risk management policies and objectives.
Predominant process gasses through the shift conversion process include VOC’S, carbon monoxide, carbon dioxide, nitrogen dioxide and hydrogen. Typical sources include: storage tanks, valves including PRVs, flanges, pumps/compressor seals, sewer’s vents/drains, waste water treatment units, solid urea transfer points, screens, etc.
ATMECO leak detection technology and survey methodologies detect, catalogue and report leak risks at a component level. Technologies include;
- Optical Gas Imaging: Detection of all hydrocarbon process gas leaks up to the shift conversion stage.
- Airborne ultrasonic: Detection of post shift conversion stage high-pressure process gas leaks to atmosphere.
- Quantification down to parts-per-million (ppm) of hydrocarbon and hydrogen rich process gas leaks using Flame Ionization Detection (FID) and Thermal Conductivity Detection (TCD)
- Passing valve (Internal leak) detection, verification and estimation using Acoustic Emission sensing
- Detailed and accurate identification of all potential leak sources on client P&IDs
- Potential leak source data, leak information and remedial response via a secure cloud based component integrity management system (CIMS)
Potential leak source condition information managed through the CIMS system is centrally accessible to all key personnel in management, operations, inspections, and maintenance departments.
Contact ATMECO to find out how we can assist you with the unique gas leak risk management challenges found in your ammonia urea production facility.
