Fertilizer plants create essential resources to supply plant nutrients, playing a critical role in supporting agricultural productivity. Given the strict delivery agreements in the agriculture industry, it is essential that fertilizer plants operate continuously, efficiently, and, above all, safely. Any disruption, such as equipment failure or safety incident, could halt production, leading to missed quotas and delays in supply. Such interruptions not only result in financial losses but also risk damaging the plant’s reputation and relationships with clients who rely on timely deliveries for their agricultural operations.
Like most industrial plants, rotating machinery is the backbone of their operation. Ammonia compressors and rotary granulators are critical machinery for fertilizers. Due to their critical function in this process of fertilizer production, monitoring these machines is essential. To ensure both operational safety and availability implementing speed monitoring, overspeed protection, and vibration monitoring systems is key to operational efficiency.
Overspeed detection and speed monitoring
Overspeed detection systems act as a safeguard, preventing machinery from exceeding safe operational rotational speed limits. In the fertilizer industry, an overspeed event could lead to catastrophic failures and halt production. Failure to detect overspeed could endanger both plant personnel and the surrounding environment of the plant. Overspeed detection systems are designed to detect when preset speed thresholds are surpassed and activate emergency shutdowns accordingly, preventing equipment damage and minimizing the risk of accidents.
Speed monitoring systems convert speed sensor inputs into highly accurate outputs for further processing. Multichannel monitoring devices can be used for monitoring functions, which include reverse rotation, creep, underspeed, and standstill. In environments like fertilizer plants, where the machinery must handle hazardous materials and maintain precise conditions, speed monitoring can be crucial for ensuring operational safety, maintaining product quality, and reducing the likelihood of accidents.
Learn more: The vital role of overspeed protection and speed monitoring systems in fertilizer plants »
The Istec SpeedSys line consists of both overspeed detection systems (ODS) and speed monitoring systems.
The SpeedSys ODS range for SIL-rated overspeed detection systems that ATEX certified to prevent overspeed events for any (critical) rotating asset. The SpeedSys Tachometers for single and multi-channel speed monitoring functions.
Vibration monitoring
Vibration monitoring is a widely implemented method of condition monitoring that is used to determine the condition of rotating machinery. By periodically or continuously measuring machine vibrations, changes in machine behavior can easily be detected. Vibration is one of the first parameters to show detectable changes when machine failures or damages are in the early stages of development. Abnormal vibration patterns can indicate various issues, including misalignment, imbalance, bearing wear, or rotor damage; problems that can lead to severe machine failures if left unchecked. For critical machines in fertilizer plants like compressors and steam turbines, vibration monitoring is essential in detecting these issues early. By detecting these anomalies early, maintenance teams can take corrective action to avoid machine damage.
With new developments, like cloud-enabled devices to support remote monitoring, vibration monitoring is becoming more accessible for less critical machinery. Modern cloud-enabled hardware like the VibSys from Istec offers an affordable device to collect and process high-quality vibration data, to be analyzed in any preferred software suite. The affordability and small technical impact of VibSys expands the range of rotating machines that can be monitored. With VibSys this is no longer limited to critical machinery only, but also for less critical machinery such as pumps, fans, and gearboxes.
Speed monitoring, overspeed detection, and vibration monitoring are essential to the operational availability and safety of rotating machinery. This is especially important in fertilizer plants, where equipment malfunctions can lead to catastrophic consequences, such as chemical leaks and explosions.
The proactive approach, explained in this article, not only extends the lifespan of critical machinery but also minimizes the risk of accidents that could compromise the safety of personnel, disrupt production, or lead to hazardous environmental incidents. Both SpeedSys and VibSys, highlighted in this article, contribute significantly to a safer and more sustainable work environment by protecting both personnel and rotating assets.
