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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	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
CHM 135	27 January 2025	5 Days	Istanbul	Registration Form Link
CHM 135	24 March 2025	5 Days	Istanbul	Registration Form Link
CHM 135	19 May 2025	5 Days	Istanbul	Registration Form Link
CHM 135	14 July 2025	5 Days	Istanbul	Registration Form Link
CHM 135	08 September 2025	5 Days	Istanbul	Registration Form Link
CHM 135	03 November 2025	5 Days	Istanbul	Registration Form Link
CHM 135	29 December 2025	5 Days	Istanbul	Registration Form Link

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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)

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SAHARA Group Training and Consultancy INC (in Turkish: SAHARA Group Eğitim ve Danışmanlık AŞ)

Tax Office: Beyoğlu (Istanbul/Turkiye,Tax No: 7390525151 (Vergi Dairesi: Beyoğlu (İstanbul), Vergi No: 7390525151)

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16 - CHM - Chemical and Process Engineering

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

Course Description

Course Objectives

Who Should Attend?

Course Details/Schedule

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Day 5

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