Modernization of Turbocompressors

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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 control room with the 505D control system and the ProTech TPS overspeed protection system
Installation of the QuickTrip for the safety of the turbocompressor (trip block assembly to release the hydraulic pressure from the turbine inlet)
Installation of the VariStroke actuator

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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.

Modernization of 3 turbocompressors in a fertilizer plant

Turbocompressor on which the installation was mounted (speed 5,400 rpm - pressure 4.5 bar)

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

Installation of the QuickTrip for the safety of the turbocompressor (trip block assembly to release the hydraulic pressure from the turbine inlet)

Installation of the VariStroke actuator

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