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16 - CHM - Chemical and Process Engineering

CHM 135 - Fertilizers Turbomachinery Design, Operation Control and Protection Systems

Code Start Date Duration Venue
CHM 135 18 December 2023 5 Days Istanbul Registration Form Link
CHM 135 08 January 2024 5 Days Istanbul Registration Form Link
CHM 135 12 February 2024 5 Days Istanbul Registration Form Link
CHM 135 18 March 2024 5 Days Istanbul Registration Form Link
CHM 135 22 April 2024 5 Days Istanbul Registration Form Link
CHM 135 27 May 2024 5 Days Istanbul Registration Form Link
CHM 135 01 July 2024 5 Days Istanbul Registration Form Link
CHM 135 05 August 2024 5 Days Istanbul Registration Form Link
CHM 135 09 September 2024 5 Days Istanbul Registration Form Link
CHM 135 14 October 2024 5 Days Istanbul Registration Form Link
CHM 135 18 November 2024 5 Days Istanbul Registration Form Link
CHM 135 23 December 2024 5 Days Istanbul Registration Form Link
Please contact us for fees


Course Description

This 5 day training course is designed to provide participants with the latest technology for Fertilizers Turbomachinery Design, Operation Control and Protection Systems. The program will give in-depth knowledge of the turbo machinery design, operation, troubleshooting, Hydraulic, Mechanical and Electronic Governors, Generator Control (ISO/Droop), Performance Control, Over-speed Protection and Anti-surge Systems. The course will also focus on Standards:  API 610 (EN ISO 13709) (last edition), EN ISO 10436 or API 611, API 612, EN ISO 21049 (API 682), API 684, API 685 , EN ISO 10438 or API 614 , API 671 , API 612 & 670 requirements for turbo machinery systems.  

Turbomachinery plays a very essential role in Fertilizers and many petrochemical and industrial plants. Centrifugal compressors in general run at very high speeds and are exposed to high temperature. The compressor operation is confined between the Surge and Stonewall limits. The compressor performance also is affected by the variation in operating conditions. Elevated temperature and large centrifugal stresses make the compressor operating under very critical conditions requires very complicated monitoring and protection systems. Accurate instrumentation, monitoring, troubleshooting and maintenance programs are essential for maintaining and increasing the available time of the machines. 

This course will address the design, performance, operation limits, control system and the troubleshooting techniques of centrifugal compressors and the parameters affecting the above.

Course Objectives

  • Recognising different compressors and turbomachinery’s designs and operations
  • Realizing how different design parameter affects the machines performance and operation
  • Reading and calculating the performance curves of centrifugal compressors
  • Realizing the control and protection systems of centrifugal compressor and Steam Turbine systems
  • Performing the start and shut down of the compressor and Steam Turbine properly
  • Recognizing the latest techniques to turbomachinery condition monitoring
  • Evaluating turbomachinery performance during start-ups and operations
  • Identifying turbomachinery system components
  • Defining and use appropriate monitoring techniques and tools
  • Employing effective operation and shutdown procedures
  • Analyzing common turbomachinery problems, such as vibration, temp/pressure operation and surge
  • Recognizing the inter-relationships of drivers, couplings, gearboxes, and driven equipment
  • Identifying the economic considerations

Who Should Attend?

  • 1st Line Operation and Maintenance personnel.
  • Process and Operation Engineers and Team Leaders.
  • Mechanical and Maintenance Engineers and Supervisors 
  • Reliability Engineers and Supervisors
  • Inspection Engineers and Supervisors
  • Instrumentation and Process Control Engineers and Supervisors
  • Process Safety Engineers and Supervisors  
  • Others involved in the design, operation,  modification or maintenance of Ammonia and Urea process plants

Course Details/Schedule

Day 1

  • Major components of Turbomachinery
  • Auxiliary systems: lube oil, seal oil, start-up, etc
  • Steam Turbines, Types and Applications
  • Operating principles of Steam turbines
  • Types of Turbine’s Governing Systems
  • Hydraulic & Mechanical Governors
  • Limitations of Hydraulic & Mechanical Governors
  • Electronic Governors – Architecture
  • Functions and Advantages of Electronic Governors
  • Woodward 505/ 505E Governor and main features
  • Woodward CPC-II Electro Hydraulic Converter
  • Woodward  ProTech-SX Safety System- IEC61508 SIL-2 Certified
  • API 684/API 611/API-612 /670, ISO 10436 & ISO 10437 Compliance

Day 2

  • Steam Turbine key performance variables and means to monitor
  • Evaluation of turbine performance parameters during start-up and normal operation
  • Troubleshooting control systems for Steam turbines: start-up, speed and temperature controls, vibration
  • Multi-stage Turbine Control
  • Steam Mapping (Induction / Extraction Turbine)
  • Over Speed Protection – Mechanical
  • Electronic Over Speed Protection (OSP)
  • Woodward ProTech-GII with Voted Inputs
  • Trip Block (TMR) – Solenoid (TMR-SOV) with a 2oo3 voting design, (ESD)
  • API-612 / 670 Compliance

Day 3

  • Centrifugal Compressor (Types and Configurations)
  • Compressor Governing System (Performance)
  • Centrifugal Compressor Performance & Control
  • The Performance Curves
  • Compressor map
  • Limits of Flow rates
  • Limits of operating speed
  • Compressor Surging Phenomena and Consequences
  • Anti-surge Controls (Recycle or Blow-off)
  • Surge Limit Line (SLL) on OEM Maps
  • Surge Mapping on Anti-Surge Controller
  • Proximity to Surge Calculations
  • Functioning of Anti-Surge Controller
  • Loop Decoupling of Multiple Controllers
  • Anti-Surge Valve Sizing

Day 4

  • Principles of operation and general components of compressors: rotors, seals, diaphragms, etc
  • Operating characteristics curves
  • Choking phenomenon
  • Compressor instrumentation: various control loops; anti-surge control loops
  • Compressor safety interlock and trip systems
  • The compressor permissive to start
  • Typical compressor valve arrangement
  • The anti-surge control valve position
  • Prestart valve positions
  • Purge cycle
  • Normal start up
  • Normal shut down
  • Emergency shut down
  • Steam turbine and compressor systems start-up and shutdown procedures

Day 5

  • Principles of troubleshooting
  • Lubrication systems
  • Seals System (Seal Gas and Seal Oil)
  • Condition monitoring systems
  • Pressure and temperature measurements
  • Effective Diagnoses systems
  • Vibration Analysis
  • Auxiliary System monitoring…… 
  • Normal operation - monitoring of parameters
  • Logging of monitoring checks
  • Vibration monitoring
  • Generator Governing System (ISO / Droop)