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8/6/2008
Capacity of hydrocarbon processing plants have increased since turbo expander-compressor technology was utilized in early 1960s
EXPANDER FLOW DEVELOPMENT
1200.00 1000.00 800.00 600.00 400.00 200.00 0.00 1961 1962 1967 1968 1969 1970 1978 1982 1992 1996 1997 1999 2000 2002
Ye a r
E x pander Fl ow
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Ye a r
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Due to large capacity many plants have parallel turbo expander-compressor trains
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Case Study Reference: For this case study a bp gas plant with two parallel turbo expander-compressor trains with the following gas dynamics performance was considered:
90
1.8
Su rg e lin e
EXPANDER EFFICIENCY, %
80 75 70 65
80% 110% 100% SP EED
1.6
1.5 1.4
Mw P1 (Psia) T1 (oF)
19.38
18.23
co n tro l lin e
Turbo Expander
Compressor
85
1.7
110%
90%
1.3 1.2
1,080
290
60
70%
55
1.1 1.0
0.0 500000.0 1000000.0 1500000.0
0. 0 200000. 0 400000. 0
-6
107
50
EXPANDER FLOW, lb/hr
600000. 0
800000. 0 1 000000. 0
P2 (Psia) T2 (oF)
350
430
14,000 12,000
14,000 12,000
110%
110%
SHAFT POWER, hp
- 96
172
10,000
90%
10,000
SHAFT POWER, hp
100% SP EED
8,000
80%
8,000
Surge line
100% SP EED
706,000
615,000
6,000 4,000
70%
90%
80%
7,876
7,725
2,000 0
0.0 500000.0 1000000.0 1500000.0
70%
200000. 0
400000. 0
600000. 0
800000. 0
1 000000. 0
14.70%
Case Study Reference: An efficiency curve for parallel EC could be developed to guide operation for one or two trains in service for the maximum efficiency
% Efficiency
1 unit 2 units
100
150
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Operational Challenge: Start-up of one unit when the parallel unit is in full load operation: Compressor cannot compress directly into discharge header and hence Requires recirculation.
% COMP-Recycle flow
120 % recycle flow 100 80 60 40 20 0 0 50 100 150 % Mass flow % COMP-Recycle
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Operational Challenge:
The following conditions are to be monitored during start up of an EC while recycle valve open: Compressor discharge process gas temperature Axial Loads Radial Loads
Development of the above conditions depends on pressure ratio of the compressor. Two scenarios will be examined: Low Pressure Ratio High Pressure Ratio <= 1.2 > 1.2
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90 85 EXPANDER EFFICIENCY, % 80 75 70 65
80% 100% 110% 90%SPEED
1.4
1.3
Mw
19.29
18.88
1.2
1 1 0%
1.2
90%
Surge line
Turbo Expander
1.3
Compressor
1 00% SPEED
P1 (Psia)
1,080
550
1.1
80%
60
70%
55
1.1
70%
T1 (oF)
-6
110
50
0. 0E+ 00 5. 0E+ 05 1 . 0E+06 1 . 5E+ 06
1.0
2. 0E+05 4. 0E+05 6. 0E+05 8. 0E+05 1 . 0E+06
1 1 0%
P2 (Psia)
600
670
5000
110%
5000 4500
100% SPEED 90%
4500
1 00% SPEED
T2
(oF)
- 80
144
SHAFT POWER, hp
4000
80%
90%
3500
70%
700,000
650,000
Surge line
80% 70%
4008
3978
1000 500
500 0
1 . 0E+ 06
7.5%
0 37th Turbomachinery Symposium 0. 0E+ 00 2. 0E+05 4. 0E+05 6. 0E+ 05 8. 0E+ 05 EXPANDER FLOW, lb/hr
2. 0E+04
2. 2E+05
4. 2E+05
6. 2E+05
8. 2E+05
10
Axial Thrust Lead Start up axial load 18000 16000 14000 Speed, RPM 12000 10000 8000 6000 4000 2000 0 -5000 -4000 -3000 -2000 -1000 0 1000 2000 3000 4000 5000
Thrust load Lead Thrust Thrust loadLead Thrust
P2/P1=1.2
Radial Load , Lb 300 250 Radial load 200 150 100 50 0 0 10000 RPM 20000 Radial Load , Lb
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Surge line
EXPANDER EFFICIENCY, %
Mw P1 (Psia) T1 (oF)
19.38
18.23
80 75 70
110%
1.6
1.5 1.4
control line
Turbo Expander
90
1.8
Compressor
85
1.7
110%
1,080
290
65
8 0%
90 %
100 % S P EE D
1.3 1.2
60
70 %
55
1.1 1.0
0.0 500000.0 1000000.0 1500000.0
0. 0 200000. 0 400000. 0
-6
107
50
EXPANDER FLOW, lb/hr
600000. 0
800000. 0
1 000000. 0
P2 (Psia) T2 (oF)
350
430
14,000 12,000
110%
8,000
80%
SHAFT POWER, hp
- 96
172
10,000 8,000
Surge line
100% SP EED
100 % S P E E D
706,000
615,000
7 0%
90%
80%
70%
7,876
7,725
1000000.0
1500000.0
200000. 0
400000. 0
600000. 0
800000. 0
1 000000. 0
14.70%
12
P2/P1=1.4
Valve close
Valve open
10
15
20
25
30
35
Tim e, Minute
Radial Load , Lb 400 350 300 250 200 150 100 50 0 0 10000 20000
Radial load
Radial Load , Lb
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Comparison of compressor discharge gas temperature for low and high pressure ratio cases.
P2/P1=1.4
Alarm
P2/P1=1.2
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Therefore the main operational problem associated with start up parallel turbo expander-compressor units is process gas temperature at the compressor discharge for high pressure ratio compressors The following remedies may be applied depending on circumstances. All these shall continue until the compressor discharge pressure approaches to compressor discharge header pressure:
Diluting closed loop warm recycle gas with cold gas Venting compressor discharge to a lower pressure sink Venting /flaring compressor discharge flow
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Adding cooling gas from expander inlet to the recycle gas to maintain the discharge temperature below the Alarm Level
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Because of loss of process gas and environmental consequences requires special attention
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Alternate -1 Maintain flow of the operating unit at 100% Alternate-2 Increase flow of the operating unit to 130% Alternate-3 Decrease flow of the operating unit 70%
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speed/design speed
120 100 80 60 40 20 0 0 50 100 150 % Mass Flow
1.6 1.5 1.4 1.3 1.2 1.1 1 0
% full speed
Pressure Ratio
Speed
Comp-P2/P1
50
100
150
% Mass Flow
Pow er- KW/ per unit EXP- w t% liquid 8000 Wt % Liquid 6000 KW 4000 2000 0 0 50 100 150 % Mass Flow Pow er- KW 20 15 10 5 0 0 50 100 150 % Mass flow EXP- w t% liq
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1400 1200
$ 1,000
10
15
20
25
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Conclusions: Capacity of cryogenic gas plants have increased over the last forty years There are many cryogenic natural gas processing plants with parallel turbo expander-compressor units Start up of one train EC while the other is in operation is an operational challenge Compressor gas recycling is mandatory during start up Several operational parameter of EC are to be monitored. Compressor discharge gas temperature is the critical parameter to be controlled Two scenarios were considered, low pressure ratio (<=1.2) and high pressure ratio (>1.2) compressor The former scenario does not impose any operational challenge during start up The latter scenario demands special attention and procedures 1. The most convenient method is to vent the recycle flow into the expander discharge stream 2. The compressor recycle gas may be cooled down by diluting it with cold gas from the expander discharge 3. If neither of the above is possible, the only remedy is to vent/flare gas - The most economical approach is to increase flow of the operating EC to 130% and then start up the parallel EC
8/6/2008 37th Turbomachinery Symposium 24