Author: Dan Cojocaru

Dan Cojocaru

Ammonia Process Safety Consultant

Dan has over 20 years of operational, engineering and consultancy experience in ammonia plants and LNG projects. He started his career as a field operator at ammonia plant and worked his way up being uniquely exposed to Operator, Licensor and EPC worlds on his professional path. His experience in all project phases starting from Concept and Front End Engineering (FEED) through Detailed Design, Commissioning and Operation is extensively enhanced by his Process Safety expertise. All of that brings Dan to founding Fertilizer Industrial Services – the UK based company providing Owner Engineer support to fertilizer companies developing greenfield and revamp projects. The team experience is also shared with operators and engineers worldwide via online training courses of Fertilizer Academy platform, and ammoniaknowhow.com industry forum. Dan is a Chartered Chemical Engineer of The Institution of Chemical Engineers IChemE, a Registered Professional Engineer of Queensland (RPEQ) and senior member of American Institute of Chemical Engineers (AIChE).

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    Courses by Dan Cojocaru:

    €750
    5 modules with 26 lessons

    Pre-Start-up Safety Review in Fertilizer Plants

    Pre-start-up safety review (PSSR), means a final check prior to initiating the use of process equipment. It implies a management system within that program for ensuring that new or modified processes are ready for startup.

    This training course examine the application of the practice of PSSR to the fertilizer plants hardware, software, engineering, and management activities, and documentation associated with operating processes.

    Author(s):
    €120
    10 lessons

    Catastrophic Explosion in the CO2 Removal System Case Study

    Case Studies training courses will present various incidents in fertilizer industry detailing the incident causes, consequences, and lessons learned. This training series introduce a process safety analysis of each incident and the impact in Operational Excellence program.

    This incident is related to the corrosion in the semi lean amine (a-MDEA) line to CO2 absorber tower, in combination with other factors that lead to the explosion of synthesis gas due to back flow from the tower.

    Author(s):
    €120
    10 lessons

    Rupture of a Liquid Ammonia Storage Tank Case Study

    Case Studies training courses will present various incidents in fertilizer industry detailing the incident causes, consequences, and lessons learned. This training series introduce a process safety analysis of each incident and the impact in Operational Excellence program.

    This incident is related to the sudden increase in pressure of a 20,000 ton liquid ammonia storage tank caused the roof to shell connection to rupture and the spread of ammonia vapor in the concentration of approximately 30-100 ppm in the region’s atmosphere in a radius of approximately one kilometer.

    Author(s):
    €120
    10 lessons

    Methanator Feed Preheater Flange Leak and Explosion Case Study

    Case Studies training courses will present various incidents in fertilizer industry detailing the incident causes, consequences, and lessons learned. This training series introduce a process safety analysis of each incident and the impact in Operational Excellence program.

    This incident is related to fire caused by a gas leak at the outlet flange of the methanator feed heater leading to a jet fire impinging on a pipe followed by explosion. The instrument cables and other hardware were damaged forcing a plant shutdown.

    Similar leaks, in the same location was noticed by us in other ammonia plants leading to development of this training course.

    Author(s):
    €120
    10 lessons

    Primary Reformer Firebox Explosion Case Study

    Case Studies training courses will present various incidents in fertilizer industry detailing the incident causes, consequences, and lessons learned. This training series introduce a process safety analysis of each incident and the impact in Operational Excellence program.

    This incident is related to a top fired primary reformer exploded in an ammonia plant. Incident investigation concluded that the direct cause of the accident was the introduction, by error, of a large amount of fuel gas through unlighted arch burners.

    This case study is an excellent lessons learned for operators and engineers involved in both operation and design of new ammonia plants.

    Author(s):
    €240
    2 lessons with 20 topics

    Two Fire Case Studies in Ammonia Plant Compressor Room

    Case Studies training courses will present various incidents in fertilizer industry detailing the incident causes, consequences, and lessons learned. This training series introduce a process safety analysis of each incident and the impact in Operational Excellence program.

    The first incident is related to a hydrogen leak followed by a fire occurred on a 1 inch synthesis gas line on the discharge side of the synthesis gas compressor.

    The second incident is related to the disconnection of a 1/2 inch instrumental tube caused a fire in the compressor room.

    Author(s):
    €850
    23 lessons

    Ammonia Storage Tanks Decommissioning and Recommissioning Training

    Ammonia Storage Tanks are an integral part of any ammonia plant and the safety and integrity of these tanks are of utmost importance to the operating companies and to the communities at the location.

    This training covers the decommissioning & commissioning activities for tanks depletion, warming up, purging with nitrogen and air and creating the condition for internal inspection.

    Author(s):
    €2800
    11 modules with 14 lessons

    Ammonia Plant Operation – Advanced Training

    Ammonia Plant Operation – Advanced Training is developed for more experienced operators and can transition field operators to control room operators.

    Trainees will better understand potential operational upsets and troubleshooting during ammonia plant start-up, routine operation, and emergency shut-down.

    Author(s):
    €700
    15 topics

    Introduction to Ammonia Plant Process Units

    Ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. This training course describes the process units, operation parameters and theory of the reactions involved in ammonia production.

    The purpose of this training program is to provide operators and engineers with an introduction to ammonia process units and get them familiarized with the ammonia plants.

    Author(s):
    €1400
    11 modules with 14 lessons

    Ammonia Plant Operation – Beginner Training

    Ammonia Plant Operation – Beginner Training aims to introduce the ammonia plants operators and engineers in the  operational phases of a typical ammonia plant.

    Trainees will understand the preparation of each unit for start‐up, normal operation and checks, shut‐down and main process upsets and deviations for each unit.

    Author(s):