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Modernization of 3 turbocompressors in a fertilizer plant

02/20/20 – At the end of October 2019, our teams completed a major modernization project involving 3 turbocompressors in a fertilizer production plant in Africa.

This modernization project was decided by the customer for the following reasons:

  • Hydraulic governors (PG-PL from Woodward) equipping turbocompressors with mechanical technologies, were coupled to a complex set of linkages before ultimately controlling the valves of the turbines; which resulted in a much longer reaction time.
  • This old speed control technology made it difficult to communicate with the control room, even though turbocompressors are critical machines for the process in place.
  • The modernization increases the level of machine safety since it made it possible to associate with control systems, auxiliary safety equipment thus complying with the API 612 & 670 standards, and a SIL3 classification.

Modernize to meet the various needs

  • Slow reaction of mechanical technologies (hydraulic governors) on turbocompressors
  • Lack of direct communication in the control room for ultra-fast reaction in critical applications
  • Compliance with safety standards and SIL-3 classification
  • Turbocompressor on which the installation was mounted (speed 5,400 rpm - pressure 4.5 bar)

    Turbocompressor after modernization
  • Turbocompressor control room with the 505D control system and the ProTech TPS overspeed protection system

    505D et ProTechTPS en salle de contrôle
  • Installation of the QuickTrip for the safety of the turbocompressor (trip block assembly to release the hydraulic pressure from the turbine inlet)

    Installation QuickTrip pour la sécurité du turbocompresseur
  • Installation of the VariStroke actuator

    montage de l'actionneur VariStroke de Woodward
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Thus, the entire project, including the installation plans, the equipment supply and the commissioning and start-up, was carried out under the supervision of the AWF teams.

The onsite installation work was carried out by the customer teams under the supervision of AWF.

Today, the 3 turbocompressors are each fitted with a Woodward set (new generation 505 D + VariStroke-GI + ProTech TPS + QuickTrip).

To date, the customer is satisfied with the system which perfectly meets their expectations:

  • flexible and accurate control,
  • equipment with the latest standards for installations based on turbomachines,
  • real-time monitoring of its processes.

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