Lessons learned from replacing a HP Stripper and HP Scrubber
Eng. Ahmed Ibrahim
Ahmed graduated from the Alexandria University – faculty of engineering in 2004 with a Bachelor’s Degree in chemical engineering, Ahmed is a urea operation general manager with a twenty years of successful experience in urea plant 3 of 1750 MTD, licensed by Stamicarbon and Hydro-Agri. Commencing as a production shift engineer in liquid fertilizer (UAN) plant, then as a shift engineer in urea plant and advancing to senior leadership, he is Certified Energy Manager (CEM),he participated as team leader in 6 Overhauls. He teaching 4 courses for engineers and technicians
Ahmed involved in urea revamp project, experience on identifying bottlenecksand reduce energy consumption. In addition, he had been involved in many HP equipment replacement
Abstract
In May 2022 Abu Qir fertilizers replaced the HP Stripper and HP Scrubber during their urea plant-3 turnaround. The plant had previously conducted an unplanned turnaround in 2018 due to the failure of the HP Scrubber. At the time, the estimated remaining life for the two vessels was almost three years, at which point a full replacement was advised by the licensor.
This paper will detail the fabrication of the two vessels; pre-turnaround activities consists of (foundation, steel structure, lifting and piping work package); shut-down, pre-commissioning, commissioning and start-up. Challenges and lessons learned with several recommendation and tips will be shared, as will the outcome of the turnaround, including improved steam consumption, national public grid and ammonia emissions.
