Zhongyuan Dahua Urea Plant is hastily reinstalling the trays in Tower C101

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Zhongyuan Dahua Urea Plant accelerates the reinstallation of tower tray C101 / Author/Source: Zhongyuan Dahua / Date: 2022-03-26 / Clicks: 18 As of March 23, the spring maintenance work on the urea production unit at Zhongyuan Dahua’s fertilizer division was approaching its conclusion, and the reinstallation of tower tray C101, which is one of the key components of the medium-pressure system used in carbon dioxide absorption, was being carried out in an orderly manner at an accelerated pace. In normal operation, the carbon dioxide absorption tower C101 is primarily used to absorb carbon dioxide from the gas phase of the medium-pressure separator. The tower has a total of four trays; to facilitate disassembly and assembly as well as access to the manholes, each tray is divided into several sections. However, this increases the difficulty of installation, and maintenance personnel may accidentally install them in the wrong order or position if they are not careful. Tower trays with poor installation quality can affect the efficiency of carbon dioxide absorption; in severe cases, the upward movement of gases can cause overheating at the top, block the tubes of the ammonia cooler, and when ammonia enters the liquid ammonia storage tank, it can corrode the equipment and pipelines, leading to the shutdown of the ammonia pump and even causing plant shutdowns. To ensure the safe and stable operation of the system after it is put into use, Zhang Haoyu, the manager of the urea production plant, paid close attention to the quality and progress of tower tray installation, providing supervision throughout the process. Time is tight and the tasks are heavy. Over the past few days, Wang Yanwei, the process technician at the branch factory, has led team members such as Gu Shiyu and Qu Xinyan to work overtime, staying at the C101 maintenance site day and night to fully support the work of repairing and reinstalling the trays. They carefully inspected the components on each tray, and repaired or replaced any damaged parts promptly ； Carefully verify the installation sequence of each component to guide maintenance personnel in proper installation ； After each tray was installed by the maintenance crew, they carefully checked every nut, gasket, and seal one by one to ensure that all components were properly installed. Finally, and most importantly, a sealing test must be conducted on that tray. This involves filling each layer of the tray with water up to the level of the overflow weir, and then observing the amount of leakage. If the leakage meets the criteria of \"a time interval of no less than 15 minutes between stopping the water supply and the start of leakage from the gaps between the bubbles, and no less than 30 minutes before all the water on the tray has leaked away\", then the test is considered successful. Otherwise, the quality of the installation needs to be checked again; in some cases, the tray may need to be removed and reinstalled until the test is successful. In the confined space, everyone tried over and over again; sometimes they would squat there for hours. Thanks to his strong technical skills, extensive experience in testing tray leaks, and his determination to see things through to the end, Wang Yanwei worked with great care and precision, carefully monitoring the amount of leakage and verifying the timing of it, ensuring that each tray was tested in accordance with the requirements. For the trays that failed the tests, he immediately investigated the reasons until they passed the tests. The spring maintenance work for the fertilizer production facilities in 2022 is coming to an end. The employees of the urea plant remained committed to their duties, working diligently and without complaint, day and night, at their respective posts. They showed a sense of ownership, using their hard work and intelligence to ensure a successful conclusion to this major maintenance effort and to lay a solid foundation for a successful operation, thereby contributing to the company’s development.