Start-up of Parallel Turbo Expander-Compressor Units Operating In Hydrocarbon Processing Plants

37th Turbo machinery Symposium Houston, Texas September 7-11, 2008

Doug Bird Reza Agahi Behrooz Ershaghi

bp Energy Canada Atlas Copco Gas and Process Mafi-Trench Co.

8/6/2008

37th Turbomachinery Symposium

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

Li near (E x pander Fl ow)

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37th Turbomachinery Symposium

Upper limit of installed experience for turbo expander-compressors power is at 15,000 KW

EXP ANDER P OWER

14 0 0 0 12 0 0 0 10 0 0 0 8000 6000 4000 2000 0

Ye a r

E X P A NDE R P OWE R DE V E LOP M E NT

Li near (E X P A NDE R P OWE R DE V E LOP M E NT )

8/6/2008

37th Turbomachinery Symposium

Due to large capacity many plants have parallel turbo expander-compressor trains

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37th Turbomachinery Symposium

Operational Challenge: Simultaneous Start-up Similar to a single train star-up

8/6/2008

37th Turbomachinery Symposium

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, %

PRESSURE RATIO, P2/P1

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

100% S P E E D 90% 80% 70%

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

COMPRESSOR FLOW, lb/hr

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

Flow (lb./hr) HP Liquid Fractio 8/6/2008 n

706,000

615,000

6,000 4,000

70%

6,000 4,000 2,000 0

0. 0

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%

EXPANDER FLOW, lb/hr

COMPRESSOR FLOW, lb/hr

37th Turbomachinery Symposium

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

Isentropic Efficiency of Expander 100 90 80 70 60 50 40 30 20 10 0 0 50

% Flow

% Efficiency

1 unit 2 units

100

150

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37th Turbomachinery Symposium

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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37th Turbomachinery Symposium

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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37th Turbomachinery Symposium

Operational Challenge: Low Pressure Ratio Compressor P2/P1 <1.20

90 85 EXPANDER EFFICIENCY, % 80 75 70 65
80% 100% 110% 90%SPEED

1.4

PRESSURE RATIO, P2/P1

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%

EXPANDER FLOW, lb/hr

COMPRESSOR FLOW, lb/hr

P2 (Psia)

600

670
5000
110%

5000 4500
100% SPEED 90%

4500

4000 SHAFT POWER, hp 3500

1 00% SPEED

T2

(oF)

- 80

144
SHAFT POWER, hp

4000
80%

90%

3500
70%

Flow (lb./hr) HP Liquid Fraction 8/6/2008

700,000

650,000

3000 2500 2000 1500

Surge line

3000 2500 2000 1500 1000

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

COMPRESSOR FLOW, lb/hr

Operational Challenge: Low Pressure Ratio Compressor P2/P1 <1.20

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

Estimated Recycle Gas Temperature rise

Bearing thrust capacity each side

Temperature , F

400 350 300 250 200 150 100 50 0 0 5 10 15 20 25 30 35 Tim e, Minute

P2/P1=1.2

closed Valve Valve Closed

open Valve Valve Open

Figure- 5 Turbo Expander Compressor Thrust Loads at Start Up

Radial Load , Lb 300 250 Radial load 200 150 100 50 0 0 10000 RPM 20000 Radial Load , Lb

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Operational Challenge: How Pressure Ratio Compressor P2/P1 >1.20

Surge line

EXPANDER EFFICIENCY, %

Mw P1 (Psia) T1 (oF)

19.38

18.23

PRESSURE RATIO, P2/P1

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

100% S P E E D 90% 80% 70%

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

COMPRESSOR FLOW, lb/hr

P2 (Psia) T2 (oF)

350

430

14,000 12,000 10,000

SHAFT POWER, hp
9 0% 110%

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

Flow (lb./hr) HP Liquid 8/6/2008 Fraction

706,000

615,000

6,000 4,000 2,000 0

0.0 500000.0

7 0%

6,000 4,000 2,000 0

0. 0

90%

80%

70%

7,876

7,725

1000000.0

1500000.0

200000. 0

400000. 0

600000. 0

800000. 0

1 000000. 0

EXPANDER FLOW, lb/hr

COMPRESSOR FLOW, lb/hr

14.70%

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Operational Challenge: High Pressure Ratio Compressor P2/P1 >1.20

Estimated Recycle Gas Temperature rise

18000 16000 14000 12000 Speed, RPM 10000 8000 6000 4000 2000 0 -5000 -4000 -3000 -2000 -1000

Start up axial load Bearing thrust capacity

600 500 Temperature , F 400 300 200 100 0 0
0 1000 2000 3000 4000 5000

P2/P1=1.4

Valve close

Valve open

10

15

20

25

30

35

Tim e, Minute

Thrust load, Lb.

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.

Estimated Recycle Gas Temperature rise

600 500 Temperature , F 400 300 200 100 0 0 5 10 15 20 25 30 35 Tim e, Minute

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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Diluting Closed Loop Warm Recycle Gas with Cold Gas

Adding cooling gas from expander inlet to the recycle gas to maintain the discharge temperature below the Alarm Level

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Venting Compressor Discharge to a Lower Pressure Sink

Venting the recycle gas to expander discharge piping

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Venting /Flaring Compressor Discharge Flow

More common in Older plants

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Pros and Cons of the remedies:

Diluting closed loop warm recycle gas with cold gas:

1. Loss of refrigeration 2. Loss of condensate recovery 3. Requires cold gas piping, valves, space, etc. 1. No loss of process gas 2. No environmental consequences

Venting compressor discharge to a lower pressure sink

1. Loss of refrigeration 2. Loss of condensate recovery

3. Requires gas piping, valves, space, etc.

1. No loss of process gas 2. No environmental consequences

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Pros and Cons of the remedies:

Venting /flaring compressor discharge flow

1. Loss of process gas 2. Environmental consequences 1. No piping loop 2. Suitable for older plant with no expansion provisions

Because of loss of process gas and environmental consequences requires special attention

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Three start up alternatives will be evaluated:

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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Turboexpander Performance parameters during start up

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

Compressor pressure ratio

% 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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Cumulative Economical Consequences

1400 1200
$ 1,000

1000 800 600 400 200 0 -200 0 -400 -600

Poly. (100% Flow) Poly. (70% Flow) Poly. (130% Flow)

10

15

20

25

Duration of start up, min

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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
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