Fertilizer Plant Compressor Issue

Fertilizer Plant Compressor Issue

The fertiliser plant operates under high-pressure conditions, utilizing natural gas as the raw material to produce urea fertiliser. The large size Compressor plays a crucial role in compressing the gas. If the gas pressure drops below a certain level, the Compressor kicks in to compress it and push it back into the header using a non-return valve (NRV) between the inlet and outlet. This raises the outlet pressure and improves the overall efficiency of the fertiliser plant. The Compressor is an essential component found in most energy-sensitive fertiliser plants. However, in one plant located in northern India, this Compressor installation remained non-functional due to tripping caused by low flow.

BiC, pramoter acting as the head instrumentation in the fertiliser plant, was assigned the challenging task of rectifying this issue. The prolonged low gas pressure resulted in decreased efficiency and financial losses for the plant.


A well-known group in setting up a fertilizer plant in northern India. criticality of the equipment ordered from a government-owned South Indian company, which had a monopoly in supply and quality production however it was historical data indicate that delays are very common during manufacturing process=due to their internal issue. 

Lack of communication facilities during the 90s, making it difficult to address project issues and delays as there was no status was possible to get. 


The team began by removing and recalibrating all the instruments. They conducted tests on the Compressor and motor to ensure they were functioning according to specifications and in the correct direction. The team also focused on the primary elements connected to the anti-surge system. During this investigation, they made an intriguing discovery.


The team found that the suction flow primary element had been improperly calibrated, with a significant difference between the measured and required differential pressure as stated in the design data. Essentially, the differential pressure was much higher than necessary, preventing the Compressor from coming online.

To verify their findings, the team contacted the Compressor supplier and compared the data sheet, confirming that there was indeed an error. They then recalibrated the transmitter based on the corrected data.


The successful recalibration of the transmitter led to the Compressor operating smoothly and being put into operation as required. The resolution of this issue highlights the expertise and experience of BiC, and their ability to handle and overcome complex challenges.

BiC promoter, with his extensive multi-disciplinary experience, demonstrated accountability in resolving this critical issue. His expertise positions him well to tackle any similar challenges that may arise in the future.


The promoter at BiC, who was heading the plant during this period, initiated changes with the belief that solutions exist for every problem. Over time, many such challenges were overcome, leading to the refinery utility's trouble-free and highly efficient performance. The refinery utility remains one of the largest and most efficient in operation

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