Client
Middle Eastern Ammonia & Urea Complex:
As part of a major analyzer upgrade project, the client replaced several process analyzers across their ammonia and urea production facilities. While the new instruments promised improved performance, the operations team needed reliable insight into actual measurement accuracy under real operating conditions. Without this knowledge, calibration and maintenance were being performed on fixed schedules — often leading to unnecessary interventions or unnoticed risks.
Key notes
- Industry: Fertilizer (Ammonia/Urea)
- Analyzers: Moisture, Hydrogen, TOC, TCL, Ammonium, Dissolved Oxygen
- Impact: Smarter maintenance intervals, reduced uncertainty, improved reliability dentified analyzers with high uncertainty at specific operating points
- Enabled the client to optimize calibration and maintenance frequencies
- Improved confidence in analyzer data for both process control and compliance reporting
- Reduced unnecessary interventions, cutting maintenance costs while ensuring reliability
Engineerim was engaged to perform a comprehensive measurement uncertainty analysis for the upgraded analyzers. Our scope included:
- Dissolved Oxygen
- Hydrogen
- Moisture
- Ammonium
- Residual Chlorine (TCL)
- Total Organic Carbon (TOC)
Using ISO-compliant methodologies, we evaluated the full uncertainty chain at operating points, factoring in process variability, sample flow dynamics, and calibration practices. This approach provided the client with a transparent and auditable framework for analyzer performance.
Our analysis highlighted areas where uncertainty was well within acceptable limits and flagged cases requiring further action. One critical finding was the moisture analyzer, which showed an uncertainty of 15.6% due to high sample flow variability. By quantifying these effects, we gave the client a clear picture of where analyzer data could be trusted — and where corrective measures were needed.
With Engineerim’s uncertainty analysis, the ammonia and urea complex achieved greater operational reliability and efficiency. Instead of following rigid maintenance schedules, they now base calibration and maintenance on proven uncertainty data — ensuring trustworthy analyzer performance and smarter use of resources.