Turbo expander training

Section V: Turboexpander Start-up and Operations

TURBOEXPANDERS 1

Atlas Copco Group Presentation 2013

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Turboexpander Training

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Section V: Turboexpander Start-up And Operations

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“Gas Processing” Is it safe?

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Gas processing is not inherently dangerous, but – more so than skydiving, it is unforgiving of mistakes! 7


To prevent accidents, we have to remember only one word; that’s…

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Safety SAFETY safety Safety Safety SAFETY Safety

SAFETY 9


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So, what is a Turboexpander ? 11


It’s a machine used to produce refrigeration and recover otherwise wasted energy...

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An expander acting as a J.T.

100% of Flow 737 psig @ -24°F It functions as a differential pressure control valve… 13


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 15


Single Turboexpander Process Train

LPG Absorber

Cold Separator

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Starting your MTC Turboexpander System

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A typical representation of a MTC Turboexpander System

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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 21


3.5 Bar/Per Min. 3.5 Bar-Delta 22


Target housing pressures:

218 psig

218 psig

218 psig 23


Proceed to Start-up:

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Process Train Stable on J.T. Valve

X X X

Low pressure separator

X X

Cold Separator

Blocked In

To Re-compressor

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


X X

Cold Separator

Blocked In

To Re-compressor

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Block in Seal Gas PDCV

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Use seal gas PDCV bypass to pressurize all housings and piping out to the block valves...

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DO NOT EXCEED A RATE OF 50 psig per minute!

Do not exceed a differential of 50 psi (Delta-P) across the machine! 29


Monitor housing pressures:

218 psig

218 psig

218 psig 30


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Monitor all housings as pressure builds... 32


When compressor housing pressure equals compressor suction pressure, open that block valve... 33


Open compressor suction block valve... X X X

Cold Separator


X O Blocked In

To Re-compressor

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When expander housing pressure equals expander discharge, open that block valve...

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Open expander discharge manual block valve... X X O


X X

Cold Separator

Blocked In

To Re-compressor

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Close Seal Gas Regulator By-pass; confirm seal gas ALARM is cleared. 37


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... 39


Compressor Drains... 40


Expander Casing Drains...

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Open expander suction block valve; Expander ESDV remains closed... To Re-compressor

O X O

LPG Absorber

O O

Cold Separator

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In coordination with Control Room Personnel, start Turboexpander by pressing “START” at expander control screen... 43


Expander inlet ESDV opens; shaft begins to rotate... To Re-compressor

O O O

O O

Cold Separator

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Turboexpander/Compressor Operation TRIP

Expander Quick Closing Valve

Expander Inlet Guide Vanes

 Independent DCS control of J-T valve

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As IGV’s open, J.T. Valve will close. As J.T. closes, switch DCS IGV controller to “Remote” 46


16,500 RPM

300 psig

-110° F

One-to-two hours to stabilize… 47


What is Surge?

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Surge is a “disturbance” in the flow into, through, or out of the compressor... 49


Surge controller should be set to “Automatic”.

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Confirm Surge Controller is set to AUTOMATIC… Surge Control System

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Turboexpanders produce really cold gas... 52


Monitor: 1. Seal Gas Pressure Diff. 2. Lube oil Pressure Diff. 3. Vibration Levels 4. Bearing Temperatures 53


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

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Safety, Safety, Safety!

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First in Mind—First 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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Turbo expander training

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