Inspection and Repair of S-50 Series Converter for Improving Reliability of Ammonia Plant at GNFC, Bharuch

摘要

Gujarat Narmada Valley Fertilizers & Chemicals Limited (GNFC) has single stream Ammonia Urea plant having name plate capacities of 1350 MTD and 1800MTD respectively. Ammonia plant is having Texaco gasification technology to produce Crude gas from Partial Oxidation of Fuel Oil. The plant capacities were enhanced by carrying out various modifications, debottlenecking and revamps over the last two decades. In the year 2009, S-50 series was added in the synthesis loop to improve productivity and reduce the energy level. S-50 series loop was commissioned in June'2010. After 4 months of operation, leakage was noticed from the weld joint of Waste Heat Boiler (E703M) of S-50 series loop. Plant was shut down and the loop was bypassed by necessary piping modification. The WHB was inspected at site and repair was planned at the shop of a pressure vessel manufacturer. The synthesis reactor R-702 was also inspected during this period and surprisingly major crack was observed in main weld joint C-4 of the R-702 reactor. This paper covers the inspection as well as subsequent repair of synthesis reactor R-702 of S-50 loop.