Turbo Expander Training

Section V: Turboexpander Start-up and Operations
TURBOEXPANDERS
1 Atlas Copco Group Presentation 2013
Atlas Copco Group Presentation 2013
Committed to Customer Value
Atlas Copco Mafi-Trench Company LLC
Turboexpander Training
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Knowledge
Section V:
Turboexpander Start-up And Operations
Gas Processing Is it safe?
Gas processing is not inherently dangerous, but more so than skydiving, it is unforgiving of mistakes!
To prevent accidents, we have to remember only one word; thats
Safety SAFETY safety Safety Safety SAFETY Safety
SAFETY
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So, what is a Turboexpander ?

12
Its a machine used to produce refrigeration and recover otherwise wasted energy...
An expander acting as a J.T.
100% of Flow 737 psig @ -24F

It functions as a differential pressure control valve
218 psig @ -110 F
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An expander acting as a J.T.
100% of Flow 737 psig @ -24 F 218 psig @ -110 F
And recovers 6,003 Hp @ 16,500 RPM

Single Turboexpander Process Train
LPG Absorber
Cold Separator
16
Starting your MTC Turboexpander System
17
A typical representation of a MTC Turboexpander System
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19
1. Purge housings and related piping following plant protocol 2. Pressurize machine housings out to the related block valves using seal gas
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5o psig/Per Min. 50 psi-Delta

3.5 Bar/Per Min. 3.5 Bar-Delta

Target housing pressures:
218 psig
218 psig
218 psig
Proceed to Start-up:
24
Process Train Stable on J.T. Valve
X X X X
Cold Separator
Low pressure separator
Blocked In
To Re-compressor
25
Expander ESDV and all manual block valves verified closed...

X X X X
Cold Separator
Blocked In
To Re-compressor
26
Block in Seal Gas PDCV
27
Use seal gas PDCV bypass to pressurize all housings and piping out to the block valves...
28
DO NOT EXCEED A RATE OF 50 psig per minute!
Do not exceed a differential of 50 psi (Delta-P) across the machine!

Monitor housing pressures:
218 psig
218 psig
218 psig
31
Monitor all housings as pressure builds...

When compressor housing pressure equals compressor suction pressure, open that block valve...
Open compressor suction block valve...

X X X
X O Blocked In
Cold Separator
To Re-compressor
34
When expander housing pressure equals expander discharge, open that block valve...
35
Open expander discharge manual block valve...

X X O X
Cold Separator
Blocked In
To Re-compressor
36
Close Seal Gas Regulator By-pass; confirm seal gas ALARM is cleared.
Start lube oil system:

1. Open regulator bypass 2. Pump A in MANUAL 3. Pump B (stand-by) in AUTO 4. Slowly close bypass: confirm ALARM clears 5. Reset pump B to OFF, then to AUTO
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Drain Housings...
Compressor Drains...
Expander Casing Drains...
41
Open expander suction block valve; Expander ESDV remains closed...

To Re-compressor O X O O
Cold Separator
LPG Absorber
42
In coordination with Control Room Personnel, start Turboexpander by pressing START at expander control screen...
Expander inlet ESDV opens; shaft begins to rotate...

To Re-compressor O O O O
Cold Separator
44
Turboexpander/Compressor Operation
TRIP
Expander Quick Closing Valve
Expander Inlet Guide Vanes
Independent DCS control of J-T valve
45
As IGVs open, J.T. Valve will close. As J.T. closes, switch DCS IGV controller to Remote
16,500 RPM
300 psig
-110 F
One-to-two hours to stabilize

What is Surge?
48
Surge is a disturbance in the flow into, through, or out of the compressor...

Surge controller should be set to Automatic.
50
Confirm Surge Controller is set to AUTOMATIC

Surge Control System
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Turboexpanders produce really cold gas...

Monitor: 1. Seal Gas Pressure Diff. 2. Lube oil Pressure Diff. 3. Vibration Levels 4. Bearing Temperatures
Reliability / Maintenance
Condition monitoring requires: Knowledge of parameters to be monitored Appropriate redundancy Trending of acquired data Adequate spare parts Pre-planning for corrective actions
54
Safety, Safety, Safety!
55
First in MindFirst in Choice
Atlas Copco has a clear vision
Turboexpander Training
We are committed to your superior productivity through interaction and innovation.
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Section V: Turboexpander Start-up and Operations

Atlas Copco Group Presentation 2013

Committed to Customer Value

Atlas Copco Mafi-Trench Company LLC

Atlas Copco Group Presentation 2013

Atlas Copco Group Presentation 2013

Gas Processing Is it safe?

Atlas Copco Group Presentation 2013

To prevent accidents, we have to remember only one word; thats

Atlas Copco Group Presentation 2013

Safety SAFETY safety Safety Safety SAFETY Safety

Atlas Copco Group Presentation 2013

So, what is a Turboexpander ?

An expander acting as a J.T.

100% of Flow 737 psig @ -24F

218 psig @ -110 F

Atlas Copco Group Presentation 2013

An expander acting as a J.T.

100% of Flow 737 psig @ -24 F 218 psig @ -110 F

And recovers 6,003 Hp @ 16,500 RPM

Single Turboexpander Process Train

Atlas Copco Group Presentation 2013

Starting your MTC Turboexpander System

Atlas Copco Group Presentation 2013

A typical representation of a MTC Turboexpander System

Atlas Copco Group Presentation 2013

Atlas Copco Group Presentation 2013

Atlas Copco Group Presentation 2013

5o psig/Per Min. 50 psi-Delta

3.5 Bar/Per Min. 3.5 Bar-Delta

Target housing pressures:

Atlas Copco Group Presentation 2013

Process Train Stable on J.T. Valve

Low pressure separator

Atlas Copco Group Presentation 2013

Expander ESDV and all manual block valves verified closed...

Atlas Copco Group Presentation 2013

Block in Seal Gas PDCV

Atlas Copco Group Presentation 2013

Atlas Copco Group Presentation 2013

DO NOT EXCEED A RATE OF 50 psig per minute!

Do not exceed a differential of 50 psi (Delta-P) across the machine!

Monitor housing pressures:

Atlas Copco Group Presentation 2013

Monitor all housings as pressure builds...

Open compressor suction block valve...

Atlas Copco Group Presentation 2013

Atlas Copco Group Presentation 2013

Open expander discharge manual block valve...

Atlas Copco Group Presentation 2013

Start lube oil system:

Atlas Copco Group Presentation 2013

Expander Casing Drains...

Atlas Copco Group Presentation 2013

Open expander suction block valve; Expander ESDV remains closed...

Atlas Copco Group Presentation 2013

Expander inlet ESDV opens; shaft begins to rotate...

Atlas Copco Group Presentation 2013

Expander Quick Closing Valve

Expander Inlet Guide Vanes

Independent DCS control of J-T valve

Atlas Copco Group Presentation 2013

One-to-two hours to stabilize