Modernising acid cooler protection without disrupting production
September 2026Maintenance, Test & Measurement, Calibration
Remote monitoring specialist Omniflex has supplied an advanced anodic protection control system to South African phosphate producer Foskor, helping modernise the company’s acid cooler infrastructure while maintaining continuous operation during the upgrade.
The project involved replacing a long-serving legacy transformer rectifier system used to protect acid coolers in Foskor’s phosphoric acid production process. Rather than replicating the existing installation, Omniflex delivered a distributed PowerView CP solution that combines programmable transformer rectifiers with distributed control system integration and comprehensive remote monitoring capabilities.
Acid production environments place significant demands on plant equipment, making reliable anodic protection essential for extending asset life and maintaining efficient production. Upgrading these systems can be challenging, particularly where production cannot be interrupted, and new equipment must integrate seamlessly with existing infrastructure.
“Many industrial facilities rely on legacy protection systems that continue to perform an essential role, but modernising them without disrupting production can be a significant challenge,” says Ian Loudon, international sales manager at Omniflex. “This project demonstrates how distributed control and remote monitoring can provide a practical upgrade path, giving operators greater visibility of system performance while reducing maintenance requirements and extending the life of critical process assets.”
The distributed architecture positions transformer rectifier units close to the acid cooler tanks, reducing installation costs and cabling requirements while allowing engineers to monitor performance remotely. Engineers can securely access operational data from anywhere, enabling faster fault diagnosis, simplified troubleshooting and reduced maintenance costs.
“Omniflex delivered an excellent product, helping us to cost-effectively upgrade our acid cooler transformer rectifiers with programmable control,” says Lebo Vries, instrumentation engineering manager at Foskor.
Following careful planning, phased implementation and comprehensive testing, the upgraded system now provides reliable anodic protection while supporting uninterrupted plant operations. The installation incorporates dual transformer rectifiers per panel, PowerView CP control and both manual and distributed control system operation, creating a flexible platform that supports long-term operational reliability.
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