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Jinfeng Coal Chemical Urea Plant: Racing Against Time to Maintain Continuous Operation – Emergency Repair of Compressor No. 2 / Author/Source: Jinfeng Coal Chemical / Date: 2020-09-03 / Views: 19 On August 25, Li Lei, the operator incharge of the compressors at the urea plant, was carrying out oil and water removal tasks on various separators on site when he suddenly heard abnormal noises coming from Compressor No. 2. He immediately put down his work, brought the compressor to a stop urgently, contacted the control room and reported the situation to his supervisors. At the same time, he worked together with other crew members to take corrective action, performing pressure relief and shaft rotation on Compressor No. 2; it was later determined that a piston rod in one of the units had broken. It is reported that the workshop is equipped with a turbo compressor and three reciprocating compressors—one large and two small—to provide carbon dioxide at a certain pressure for urea production. At this time, due to turbine maintenance, three compressors are operating simultaneously to supply the two urea production units, AB. The shutdown of Unit 2 would result in a significant reduction in the amount of carbon dioxide available. To ensure that the urea production system can resume normal operation as soon as possible, it is urgent to carry out repairs on Unit 2. The workshop promptly organized its management staff, chemical engineers, and maintenance workers to arrive at the site immediately in order to carry out maintenance work on Compressor No. 2. The plant manager coordinated with maintenance workers from other workshops to provide support for the emergency repair work. Since the piston rod needed to be replaced, this added some difficulty to the maintenance work. Yet they hesitated not for a moment; working in the scorching heat and sweating profusely, they got started on the repairs. The work progressed at full pace, and finally, around 6 p.m., the maintenance of Unit 2 was completed. The operator quickly started compressor #2 and integrated it into the system, and everything returned to normal; a slight smile appeared on the faces of all those present. The maintenance of the compressor this time not only demonstrated the skill and coordination of the operators and maintenance workers, but also tested the control operator’s ability to adjust the process in abnormal situations.