Turboexpansor. Manual Detallado LAT

INSTRUCTION MANUAL

TURBOEXPANDER WITH COMPRESSOR LOAD

DESIGNED AND MANUFACTURED FOR: VALERUS ENGINEERING

LAT PROJECT: LAT517EC May, 2012

LAT517EC INSTRUCTION MANUAL------SECTION 1

SECTION ONE DESCRIPTION AND TECHNICAL DATA 1.1

INTRODUCTION The system described in this instruction manual is designed for the expansion and compression of Natural Gas and consists of one frame size L2000 Turboexpander-Compressor unit. The unit is single-stage Turboexpander loaded by an integral, single-stage centrifugal compressor.

The Turboexpander-Compressor unit is mounted on own structural steel skid and is serviced by a commonly mounted lube oil and seal gas system. The package includes the complete control system with Hardware and Software, field instruments, valves, cables, junction boxes, etc., that are all fully cabled within the skid. There is also a Unit Control Panel mounted on the skid for the control and shut down of the Turboexpander-compressor.

The unit is designed exclusively for Valerus. Project: TERMOYOPAL 40 MMSCFD CRYO and is to be installed at Colombia.

UNIT IDENTIFICATION

Model No. & Serial No.

Main: 20-6E7C

S.N.: 1061

Spare: 20-6E7C

S.N.: 1063

1-1


1.2

DESIGN SPECIFICATIONS Unit Tag No. Molecular Weight Inlet P1 (psia) T1 (º F) Outlet P2 (psia) T2 (º F) Flow (lb/hr) Shaft Speed RPM Efficiency (%) Wheel Power (hp)

EXP EC-0510 19.72 894 6.64 215 -94.5 74936 41,000 85% 1089

COMP C-0510 18.58 189 103.5 298 178.4 73103 41,000 78% 1044

EXP EC-0510 19.95 894 5.44 215 -92 82393 41,500 85% 1174

COMP C-0510 18.61 189 101.3 301.1 177.5 77650 41,500 78% 1128

OFF DESIGN Unit Tag No. Molecular Weight Inlet P1 (psia) T1 (º F) Outlet P2 (psia) T2 (º F) Flow (lb/hr) Shaft Speed RPM Efficiency (%) Wheel Power (hp)

1.3

1.4

SEAL GAS REQUIREMENTS Molecular weight:

18.58/18.82 (Nor./Max.)

Supply pressure:

315/400 Psig (Nor. / Max.)

Supply temp:

70/100º F (Min. / Max)

INSTRUMENT AIR REQUIREMENTS Operating pressure:

60 Psig

Supply pressure:

90 Psig

Supply Temperature:

0/140 ºF

Design Pressure:

200 Psig

1-2


1.5

LUBRICATION SYSTEM DATA 1.5.1 LUBE OIL RESERVOIR CAPACITY Maximum Operating Level: 3” Measured from above centerline of reservoir Volume at the Maximum Operating Level:

139Gallon

Minimum Operating Level: 2.5” Measured from below centerline of reservoir Volume at the Minimum Operating Level:

90 Gallon

Total Volume:

200 Gallon

1.5.2 LUBE OIL SYSEM DATA OPERATING PARAMETERS ITEM NO.

DESCRIPTION

NORMAL OPERATION RANGE

1

Oil viscosity @ 100 °F

150 SSU/32 C.ST.

2

Oil Flow To Bearings

18 GPM

3

Oil Pressure to Bearings

315 Psig

4

Temperature, Oil Inlet to Bearing

120 °F

5

Temperature, Bearing Drain

140 – 160°F

6

Accumulator Pre-charge Pressure

235 psig

7

Unit Running Speed

41,000 rpm

8

Speed to Avoid

N/A

Oil Supply Temperature to Bearings Start-up: 80°F (minimum) Normal Operating:

120°F

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WARNING: START-UP AND CONTINUOUS RUNNING OF THE TURBOEXPANDER, WITH A BEARING OIL SUPPLY TEMPERATURE OF LESS THAN 80°F, MAY RESULT IN DAMAGE TO THE SOFT METAL OF THE BEARINGS.

1.5.3 AIR FAN COOLER Cooler Tag No.:

E-5060

Cooler Type:

Motor Drive Air Fan Cooler

Cooler Heat Load:

140,000 Btu/Hr

Design Pressure:

490 psig @ -20/200°F

Oil Flow:

21.4 gpm

Viscosity:

150 SSU @100º F

1.5.4 OIL SPECIFICATIONS For recommended lubricants and required quantities refer to the Lubricant List.

General Requirements for NON-FOAMING TURBINE OIL ISO Viscosity Grade

32

Pour Point ºC

~-27º to ~-40º C(-17° to -40ºF )

Flash Point ºC

157º to 170º C(315° to 350ºF )

Viscosity:

32 cSt @ 104 ºF

Gravity, API

~32.6

Specific

~0.86

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1.6

RECOMMENDED CONTROL SETTINGS For recommended Control Settings refer to System Schematic-P&ID (LAT517EC-20D3), System Bill of Materials (LAT517EC-20-A11), Electrical Bill of Materials (LAT517EC-20-A8) and Instrument Index List (LAT517EC-20-C16).

AUXILIARY SYSTEM SET POINTS TAG NO.

DESCRIPTION

ENG. UNITS

SET POINT

°F

110

TCV-5060

Temperature Control Valve

PSV-5020

Reservoir Safety Relief Valve

psig

350

PSV5030/5040

Pump Relief Valve

psid

140

psid

100

psid

15

psig

20/40

°F

100

psig

235

inch

1.098

PCV-5020 PCV-5085 PR-1/ PR-2 TSHL-5025 AC-5000 PCV-5000

Oil Diff. Back Pressure Regulator Seal Gas Diff. Press. Reducing Regulator Actuator Instrument Air Pressure Regulator Oil Reservoir Heater Thermostat Accumulator Pre-Charge Pressure Inlet Nozzle Vane Actuator Travel Distance

Other control settings refer to Instrument Index List (LAT517EC-20-C16).

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1.7

DETAILED DESCRIPTION Refer to the Service Assembly (LAT517EC-20-D1), Parts List (LAT517EC-20-A9) and System Schematic P & I Diagram (LAT517EC-20-D3) drawings.

1.7.1 TURBOEXPANDER VARIABLE NOZZLES The perimeter of the turbo expander wheel is surrounded by the variable nozzle assembly. The variable nozzles, or inlet guide vanes (IGVs), control the process gas flow and may act to regulate back pressure. This is done by applying an instrument air signal to the actuator. This adjusts the openings between nozzle segments.

Regardless of the degree of change

made to the nozzle openings, the resulting high velocity streams are directed into the wheel at the correct angle.

This design yields high

efficiency over a wide range of flow rates.

1.7.2 SEAL SYSTEM The process gas in the expander and compressor is sealed around the shaft by a labyrinth seal in the heat barrier wall. Process gas is leaked out through the labyrinth seal to keep lube oil from entering the expander

casing.

However, to prevent the loss of process gas, there is a provision to inject a stream of compatible, warm, dry, pressurized gas into the labyrinth at a rate slightly higher than that leaking out through the seal. This warm gas is referred to as “seal gas” and is supplied by the Customer. The outwardly flowing seal gas, with the excess gas flowing inwardly, retains process gas within the expander case and lube oil within the bearing housing. Outwardly flowing seal gas from the labyrinth seal enters the expander case and mixes with the process gas. Seal gas flowing inwardly across the labyrinth seal will enter the bearing housing where it mixes with the lube oil.

1-6


This seal gas/lube oil mixture is discharged from the bearing housing and flows to a pressurized reservoir. In the reservoir, the seal gas is separated from the lube oil and vented out through a mist eliminator partially to the compressor suction. If the unit is to be kept on standby, with the seal gas system on and the lube oil system pressurized, then the seal gas should be allowed to enter the compressor labyrinth seal.

If it’s necessary to compensate for entrapped oil, then adjust the flow of seal gas to the bearing housing. An excessive amount of oil accumulated in the bearing housing can result in a decrease of the expander speed and/or an increase in oil drain temperature.

CAUTION: IF HEAVY HYDROCARBONS ARE PRESENT IN THE SEAL GAS, THERE IS A TENDENCY FOR ACCELERATED DILUTION OF THE VISCOSITY OF THE LUBE OIL, ESPECIALLY AT START-UP AND IN THE HIGH PRESSURE EXPANDERS. FREQUENT CHECKS OF THE LUBE OIL VISCOSITY ARE ADVISED. 1.7.3 LUBRICATION SYSTEM The lubrication system circulates cooled, filtered and pressurized lube oil, as shown on the System Schematic P & ID (LAT517EC-20-D3) Diagram. Operating temperature and pressure values are given in Sub-Section 1.5 and documents containing the recommended control settings are referenced in Sub-Section 1.6. The component Manufacturer's Data is given on the Bill of Materials for System Schematic (LAT517EC-20-A11) drawing and in Section Six of this manual. The Service Assembly (LAT517EC-20-D1) shows in crosssection the lubricant supply and discharge passages within the unit. A bladder-type accumulator is included in the lubrication system to supply oil

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during a shutdown due to low oil pressure. In the case of a low oil pressure shutdown, the accumulator supplies oil to the bearings during the coast down of the Turboexpander. The accumulator also helps to sustain oil pressure during the time it takes the auxiliary pump to reach operating pressure after a low oil pressure alarm. A detailed description of servicing the accumulator bladder is given in Section Three.

1.7.4 ALARM & SHUTDOWN CONTROL SYSTEM The Turboexpander control consists of Allen Bradly Programmable Logic Controller, which is used for the annunciation and system control of the unit. The PLC, which is pre-programmed with all the control logic and alarm & shutdown conditions as well as start-up permissive, continuously monitors the unit's operating condition and signals an alarm when any of the preset process parameters are exceeded. It wills also shutdown the unit if any of its preset safety parameters are exceeded. A Panel View 1000 Plus standard terminal is used for operator graphic interface and annunciation.

There are two types of alarms: warning alarms and trip alarms.

Warning

alarms are initiated when an operating parameter is exceeded. This alarm signifies an abnormal condition which requires operator attention or intervention. Trip alarms are initiated when either an operating parameter is exceeded beyond the possibility of any corrective action, or a safety parameter is surpassed. When a trip alarm is triggered, the PLC wills automatically

shutdown

the

Turboexpander.

For

a

list

of

Warning

Alarms/Shutdowns and their corresponding settings, refer to Sub-Section 1.6. Also refer to the Instrument Index (LAT517EC-20-C16) and the HMI instruction manual for detailed information of the settings and HMI instruction. Some of the features provided in the PLC system are as follows:

•

A "first-out" capability is programmed into the PLC for trip alarms, (i.e. upon receipt of concurrent trip alarms), the PLC will select the alarm which occurred

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first and annunciate it on the HMI with a fast flashing red display. First out alarm will lock in. •

The trip/shutdown alarms, which lock in, identify any complications subsequent to the "first out," and are displayed as slow flashing red display points on the HMI.

•

A "first-out" alarm feature for warning alarms is also programmed into the PLC so that upon receipt of concurrent warning alarms, the PLC will select the alarm which occurred first and annunciate it on the HMI with a fast flashing amber (yellow) display. First out alarm will lock in.

•

Warning alarms, which lock in, identifying any complications subsequent to the "first out" are displayed as slow flashing amber display points on the HMI.

•

To acknowledge and reset alarms and shutdown signals there are "Acknowledge/Reset" buttons. One is located on the local gauge board (LGB) and is an input to the PLC and another is on the HMI. These buttons serve to clear alarms and shutdown signals subsequent to the "first out" and bring the unit into ready condition. If the fault still remains after an “Acknowledge/Reset” button is activated, flashing display points will become steady and the unit will not go into a ready condition. Human–Machine Interface (HMI) Function The Panel View 1000 Plus terminal features a suite of advanced alarm handling capabilities. The terminal can record and display important data on triggered alarms, while alarm banners alert operators and maintenance personnel to slow or faulty conditions. In addition, it offers the ability to secure applications to qualified users upon request. Some of the features provided in the PLC/HMI system are as follows:



The first screen of HMI is the “Main Menu” with 16 active keys called F-1 to F16 each assigned to one of the different viewing/control functions. By touching various keys, the operator can navigate between the different screens to observe dynamic values of the process at each instant they happened. They 1-9


can also view the alarm set point screen or alarm/shutdown/ analog display summaries. The System has a “first-out” alarm feature. When a number of alarms are triggered, the Panel View unit displays the first alarm. To see other alarms on the screen, two push buttons are used which allow the operator to scroll up/down through the alarms. The first-out alarm is locked-in, and can only be cleared if the cause of the alarm is removed and the operator pushes the “Alarm Acknowledge” button. 

During normal operation of the machine where there are no alarms, all windows on the “ALARM SUMMARY“screen are lit in green and on the “SHUTDOWN SUMMARY” screen in red with a continuous light. However, if there is a window with an alarm, that window will turn flashing yellow.



To clear subsequent alarms, the operator has to acknowledge them individually on their corresponding screens



When it becomes necessary to change alarm or shutdown setpoints in the HMI, it can only be done by entering the passcode within 25 seconds on the “Setpoint Security Screen” and then going to the “Alarm Set points Screen” or the “Shutdown Set points Screen” and entering the desired values using the key pad. After saving the value, the operator can then return to the “Main Menu.”



A DETAILED HMI INSTRUCTION MANUAL IS SHOWN ON LAT517EC-20A42

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1.7.5 AUTOMATIC THRUST BALANCE SYSTEM To protect the thrust bearings from overload and damage, the unit is provided with an Automatic Thrust balancing System. The thrust balancing system senses hydrodynamic oil pressure on the front and back thrust bearings, compares them, and adjusts the pressure of the cavity behind the compressor wheel so that the rotor system remains in balanced in the center position. The system provides continuous thrust adjustments by varying the pressure of the cavity behind the compressor wheel.

Any increase in the thrust bearing

pressure towards the expander will cause the automatic thrust balancing valve to close, which builds up the cavity pressure behind the compressor wheel. An increase in the thrust bearing pressure towards the compressor will cause the automatic thrust-balancing valve to open and to relieve the pressure in the cavity. This adjustment is made automatically at all shaft speeds.

Factors that can cause adjustments include: 

A change in operating conditions



Major deterioration of some of the internal components, which could be caused by particles suspended in the process gas



Deposits such as ice in the expander wheel vent passages

An alarm is activated if the differential pressures between the front and back thrust bearings reach a pre-selected limit. This limit is listed in Sub-Section 1.6. The thrust balancing system is set at the factory and does not need to be readjusted.

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1.7.6 ANTI-SURGE CONTROL SYSTEM The unit is equipped with an Anti-Surge Control System, designed to eliminate compressor surge. Surging is an unstable operational state realized when the flow through a compressor is reduced well below the design condition. When the incoming flow to the compressor is decreased below normal operating conditions, the pressure difference between the compressor inlet and discharge is increased. This increased pressure difference can cause a reversal of flow direction and an axial thrust on the shaft. The Anti-Surge Control System protects the compressor from this harmful condition by monitoring the compressor process condition and, when needed, controls the flow of recycled compressor process gas.

To monitor the

compressor process condition, the system uses a flow and differential pressure transmitters. The pressure transmitters (PT-5001 and 5003, customer provided) are used to measure the pressure difference between the compressor inlet and discharge pressures. The flow meter (FIT-5000, customer provided) is used to measure the pressure of the compressor suction flow.

The function of the anti-surge microprocessor is to keep the ratio between these two signals within a preset limit. The anti-surge microprocessor accomplishes this task by sending a signal, which in turn, controls the anti-surge recycle valve (FV-5000, customer provided). The anti-surge recycle valve allows process gas to be recycled into the compressor inlet so that it can operate below the surge line. For the details of anti-surge recycle valve assembly refer to the System Schematic P & ID (LAT517EC-20-D3) diagram and the System Bill of Materials (LAT517EC-20-A11).

1-12


SECTION TWO INSTALLATION 2.1

DELIVERY, CHECK OF CONSIGNMENT AND STORAGE Please make sure that on receipt of the consignment packing is undamaged, as it is designed to protect the consignment during transportation from damage, e.g. by water, etc.

To increase the degree of protection against entering impurities, all nozzles and openings of the plant were closed prior to shipment. They can be only opened, if there is no danger of dirt and foreign matter entering the machine.

NOTE: During transportation of the unit, the transportation vehicle should have a flat deck, if not; the skid will be uniformly supported at the intervals no more than 2 feet. For the lifting purposes, 0.35 acceleration factor has been taken into consideration.

After arrival on site, the consignment completeness must be checked against shipping note.

If any damage to packing or any missing parts are discovered, make a note of it in shipping documents when confirming receipt, have this countersigned by recipient and carrier and inform the insurance company accordingly.

2-1


If packing is removed for inspection of material on receipt, make sure that no parts of equipment or other material is discarded with the packing.

Have any complaints registered by a claims engineer and report them directly to the LAT home office in Valencia, California – See Sub-section 4.5 “Field Service.” In case, if Turboexpander-Compressor plant should be stored at Customer’s premises for extended period of time (up to one year or longer), please contact our Service Department for detailed instructions.

2.2

EQUIPMENT FOUNDATIONS The skid dimensions for mounting the machinery and the lube oil system on their foundations are given on the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2).

The Customer should provide a level foundation that will

support the entire weight of the package.

2.3

LIFTING AND HANDLING A suitable hoist or crane should be provided for lifting the skid onto the foundation. There are lifting lugs on the side of skid for attaching the hoist or crane. NOTE: Spreader bars may be required to avoid damage to the unit by the slings.

2-2


2.4

PLANT PROCESS CONNECTIONS Connection sizes, ratings, and locations for plant process inlet and discharge piping are shown on the Expander-Compressor Machinery Arrangement (LAT517EC-20D2). Allowable pipe nozzle loads for the expander and compressor flanges are listed on the Maximum Pipe Nozzle Loads Drawing (LAT517EC-20-A10).

2.5

INLET SCREENS(SUPPLIED BY CUSTOMER) An 80-mesh expander screen and a 30-mesh compressor screen are provided and to be installed in the process inlet pipes to the unit. The screens should be installed in the Customer's inlet piping as shown on the System Schematic P & I Diagram (LAT517EC-20-D3) and Expander-Compressor Machinery Arrangement (LAT517EC-20-D2).

The expander inlet screen is designed to withstand a maximum differential pressure of 75 psid and the compressor screen is designed to withstand about 75 psid collapse pressure differential. It is therefore recommended that screens should be instrumented and protected as necessary.

2.6

PROCESS GAS CLEANLINESS The process gas entering the expander should be clean, since dust or other foreign matter in the gas could damage the expander. Inlet screens are not intended to filter out dust so the Customer should ensure that the process gas has been cleaned and filtered before entering the expander. The Customer must also control gas composition to avoid frost build-up on the nozzles and expander wheel.

2-3


2.7

SEAL GAS SYSTEM Connect Customer's seal gas supply to the connection located at the edge of the skid. For seal gas requirements see section 1 of the IOM and to the ExpanderCompressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic P & I Diagram (LAT517EC-20-D3) for the connection’s size, rating, and location.

2.8

INSTRUMENT AIR Connect the instrument air supply to the connection. Refer to section one for instrument air requirements and to the System Schematic P & I Diagram (LAT517EC-20-D3) and Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) drawings for the connection’s size, rating, and location.

2.9

VARIABLE NOZZLE ACTUATOR Install the variable nozzle actuator on the bonnet assembly, and connect the actuator rod. Be sure to align the rod and the adjusting nut. Connect the instrument air supply and air signal lines. Check the calibration of the nozzle actuator. This is set at the factory, but it may require readjustment after shipment. There should be a full range of motion of the nozzles within the range of signal pressure applied. Refer to the Nozzle Actuator Assembly (LAT517-10-D110) and System Schematic P & ID (LAT517EC-20-D3).

2.10 EXPANDER INLET SHUTDOWN VALVE An expander inlet shutdown trip valve assembly with solenoid should be installed in the process piping at the expander inlet. An adequate air supply must be connected to the valve. The valve designed to close within 1/2 second or less. Install instrument air to the positioner on the shutdown valve. NOTE: If for any reason the shutdown valve is to be installed further then what is specified in the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2), LA TURBINE must be consulted. 2-4


2.11 ELECTRICAL CONNECTIONS Refer to the following drawings for wiring: Drawing Title

LAT Dwg. No.

System Schematic P & I Diagram

LAT517EC-20-D3

Expander- Comp. Machinery Arrangement.

LAT517EC-20-D2

Wiring Diagram Electrical Bill of Material

LAT517EC-20-D4 LAT517EC-20-A8

Unit Control Panel Layout

LAT517EC-20-D5

System Bill of Materials

LAT517EC-20-A11

Refer also to Section 6 for Component Manufacturer's Data.

On all

components, care must be taken to ensure the correct terminal connections. Make certain that sensor lines to the various transmitters are NOT shorted to ground and are properly connected to the terminals in the junction boxes. CAUTION: VERIFY THAT ALL SWITCHING POWER FEEDERS AND CIRCUIT BREAKERS ARE IN THE OFF POSITION WHEN CONNECTING THE POWER SUPPLY.

2.12 JUNCTION BOXES Junction boxes should always be closed except during actual wiring and connecting. In no case should the junction boxes be allowed to stand open overnight or for extended periods. This precaution will protect the electric circuitry from dirt, rain, moisture and other potential sources of electrical abuse.

2-5


2.13 COMPRESSOR DISCHARGE CHECK VALVE (CUSTOMER SUPPLIED) A check valve or other method of preventing reverse flow is recommended to be installed in the Customer's process piping at the compressor discharge to prevent process back flow through the compressor, on shutdown or other interruptions. Make certain it is installed in the proper direction.

2.14 LUBE OIL COOLER An air-fan lube oil cooler is furnished. The cooler is equipped with vent and drain connections, which are to be connected to the appropriate Purchaser's removal system.

Refer to Sub-section 1.5.3 for flow and temperature

information and to the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic P & I Diagram (LAT517EC-20-D3) drawings for connections sizes, ratings, and locations.

2.15 DISPOSAL SYSTEM Connect the reservoir safety relief valve to the appropriate Customer's Disposal System. The connection size, rating, and location is shown on the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic P & I Diagram (LAT517EC-20-D3) drawings.

2.16 EXPANDER/COMPRESSOR DRAIN CONNECTION An expander and compressor drain connections are provided on the expander and compressor casings. The drain connections are provided to drain the liquid from the expander and compressor casings and into the appropriate Customer's removal system. Refer to the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic P & I Diagram (LAT517EC-20-D3) drawings for the connections sizes, ratings, and locations. 2-6


2.17 RESERVOIR DRAIN CONNECTION A drain connection is provided on the lube oil reservoir. The drain connection is provided to drain the lube oil from the reservoir and into the appropriate Customer's removal system. Refer to the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic P & I Diagram (LAT517EC-20-D3).

2.18 RESERVOIR FILLER PUMP CONNECTION When the lube oil reservoir is pressurized, a connection is provided on the lube oil reservoir to fill the reservoir with a manual filler pump (HP-1). Refer to the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic P & I Diagram (LAT517EC-20-D3) for connecting the Customer's oil supply and for the connection’s sizes, ratings, and locations. When the system is not in service, the reservoir may be filled using the inspection hole on either end of the reservoir.

2-7


SECTION THREE OPERATING INSTRUCTIONS

3.1

PRECAUTIONS If, after installation, it is believed that injurious foreign matter has entered the unit, it must be disassembled, cleaned, and reassembled before the initial start-up. Verify that the cold section of the expander, i.e., nozzles, wheel, etc., is free of oil or grease. Assembly and disassembly instructions are given in Section Four. NOTE: This may be a good time to have LAT Field Technical Advisor instruct the Customer's personnel in the assembly and disassembly of the unit. Compressor Surge: To avoid compressor surge, the unit has been equipped with anti-surge control system in PLC. For the system description refer to Sub-section 1.7.6 “Anti-Surge Control System”,

P & I Diagram LAT517EC-20-D3; for the components supplied

by LAT refer to the System Bill of Materials LAT517EC-20-A11. Inlet Screens (Customer Supplied): Expander and compressor inlet screens should be checked at the earliest opportunity and repeatedly until no foreign matter is found. A BLOCKED SCREEN REDUCES PRESSURE, FLOW, AND EFFICIENCY.

3-1


3.2

EXPANDER OVERSPEED - CAUTION THERE IS A DANGER OF OVERSPEED UNTIL THE COMPRESSOR SUCTION REACHES DESIGN PRESSURE. THE EXPANDER COULD REACH FULL SPEED WITH LESS THAN FULL EXPANDER POWER UNTIL THE COMPRESSOR SUCTION DESIGN PRESSURE HAS STABILIZED.

3.3

PRE-START INSTRUCTIONS The following steps must be taken before placing the system into operation:

3.3.1 Oil Reservoir PROCEDURE FOR FILLING RESERVOIR Refer to the System Schematic Diagram (LAT517EC-20-D3). Fill the lube oil reservoir with lubricant in accordance with specifications given in Section 1. When the system is not in service, the reservoir may be filled using the inspection hole on either end of the reservoir. When the reservoir is pressurized, oil may be added by using the manual fill pump (HP-001). After all components, such as the coolers or filters, are filled with oil and free from entrapped air, ascertain that the lube oil reservoir is filled to a point between maximum and minimum levels, as specified in Section 1.5.1. CAUTION: LA

TURBINE

ALREADY

FLUSHED

THE

OIL

SYSTEM

(RESERVOIR,

ACCUMULATOR, COOLER, AND/OR OIL PIPING SYSTEM) BEFORE SHIPPING. THE CUSTOMER MUST PREVENT FOREIGNER MATTER FROM GETTING INTO THE LUBE OIL SYSTEM.

3-2


3.3.2 Electrical Verify that all electrical circuits are properly connected and that motors rotate in the proper direction. Refer to wiring diagram (LAT517EC-20-D4).

3.3.3 Accumulator Bladder (AC-5000) Verify that the accumulator bladder is charged to the correct pressure level specified in Section 1.6.

To charge the accumulator bladder before placing the unit into

service, perform as follows: 

Close the accumulator block valve (V1-104) to isolate the accumulator from the oil system.



Cautiously open accumulator drain valve (V1-103)



Connect the charge kit ACHK-101 (ship loose) to the filling valve located on top of the accumulator.



Fill the accumulator with nitrogen gas to the pressure level recommended in Section 1.6 (Accumulator Charge Pressure).



Remove the charge kit.



Close accumulator drain valve (V1-103).



Cautiously and slowly open accumulator block valve (V1-104).

3.3.4 Valves Verify that all valves are in the correct open or closed position. Refer to the System Schematic Diagram (LAT517EC-20-D3).

3.3.5 Control Settings Verify that all gauges, controls, and safety devices are properly connected, set, and operative. Refer to Section 1.6 for correct lube oil operating temperature, pressure, and viscosity readings, and for recommended control settings. Settings were made at the factory, but they may have drifted during transit.

3-3


3.3.6 Seal Gas Verify that a suitable seal gas supply is properly connected. The seal gas supply requirements are listed on Section 1 of the manual and System Schematic Diagram (LAT517EC-20-D3) drawing.

3.3.7 Instrument Air Verify that a suitable instrument air supply is properly connected to the air header. The instrument air supply requirements are listed in Section 1.4 and on the System Schematic Diagram (LAT517EC-20-D3) drawing.

3.3.8 Nozzle Actuator Verify that the range of the nozzle actuator rod responds proportionally to the specified air pressure signal supplied by Customer. The range capability of the actuator is usually greater than the nozzle actuator travel, which is set near the middle of the actuator range. The positioner on the actuator is adjusted to make the nozzle position respond proportionally to the air pressure signal. Refer to Section 6, Component Manufacture’s Data and Nozzle Actuator ASS’Y. DWG. (LAT517EC-20-D110)

3.3.9 Inlet Shutdown System (XV-5000, CUSTOMER SUPPLIED) Verify that the expander inlet shutdown valve (Customer supply) is installed in the process piping at the expander inlet and is functional. The solenoid valve must close the expander shutdown valve within one-half (1/2) second . The shutdown valve should be installed as specified on the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) drawing.

3-4


3.3.10 Expander/Compressor Inlet Screens Verify correct installation of the expander and compressor inlet screens (Supplied By Customer). They are to be installed in the expander and compressor process inlet pipes to the unit as specified on the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic Diagram (LAT517EC-20-D3) drawings.

3.4 3.4.1

INITIAL STARTING PROCEDURE General Instructions Briefly, the starting procedure consists of: 

Admitting and regulating Customer's seal gas supply.



Starting the lube oil supply system.



Pressurizing the expander from discharge and compressor suction.



Admitting the process gas stream flow slowly.



Monitoring all control instruments and adjusting the oil pressure after the speed and flow rate are set and stabilized.

3.4.2 Detailed Instructions For correct seal gas and instrument air supply requirements and for correct lube oil operating temperatures, pressures, and viscosity requirements refer to sections 1.3, 1.4, and 1.5. NOTE: ENSURE THAT THE PLANT PROCESS GAS IS COMPLETELY SHUT OFF FROM THE EXPANDER BEFORE PROCEEDING WITH THE FOLLOWING STEPS:

3-5




The customer should connection the seal gas supply, and ensure the setting PCV-5085 is right. Refer to the System Schematic Diagram (LAT517EC-20-D3) drawings.



Admit the seal gas to expander



Let seal gas reach the desired temperature and pressure.



Turn on the power supply to the lube oil pump motors, oil reservoir heater, and control instrumentation.

Note, before turning on power to the oil reservoir

heaters, it should be verified the heater thermostat is properly set. For power supply ratings, refer to the Electrical Bill of Material (LAT517EC-20-A8). 

Ensure that the oil heater is activated. Observe that the lube oil reservoir is heated to approximately 100 o F and is filled between the maximum and minimum levels.



Check to ensure that the expander inlet shutdown valve is closed.



Verify that the inlet guide vanes "IGV" (turbine nozzles) are in the closed position.



Slowly admit seal gas to the expander and compressor labyrinth seals. It may take the seal gas system a few minutes to reach equilibrium.



Confirm that the seal gas has reached the correct pressure and flow requirements.



Open the lube oil pump bypass valves (V1-101, 102) and lube oil filter bleed valves.



Set filter-switching valve so that oil will flow through both filters.



Turn on main lube oil pump and allow oil to circulate to purge the lines of air. If the lube oil pump does not start, troubleshoot/repair as required and verify the oil pump control logic.



Slowly close the pump bypass valves (V1-101, 102).



Verify that minimum lube oil supply pressure to the filter has been established. If not, start the auxiliary pump.



When the duplex oil filter (F-5075, 5080) has been purged of air, which is indicated by the stable pressure readings, and then slowly close the filter bleed valves (NV-.25). Select the desired filter with the filter block valve. If preferred, the unit may be operated with both filters on line. 3-6




When the minimum oil differential pressure has been established, the auxiliary oil pump can be stopped for the unit control panel by push-button.



Check the differential oil pressure across the duplex oil filter. A higher than normal reading may suggest that filter element should be inspected and/or replaced if necessary.



Clear annunciator system of all alarm and shutdowns.

NOTE: 

The above start-up steps for the lube oil system need not be performed during a re-start if the lube oil and seal gas systems have not been shutdown and are actively flowing to the unit.



Inspect all seal gas and lube oil system temperature, pressure, and flow gauges and verify that they are showing normal operating values.



Verify that the minimum bearing oil supply temperature (80 F- start-up, 80 oFcontinuous operation) down stream of the coolers has been reached.

CAUTION: Starting the units with low oil supply temperature may result in damaging the bearings. 

Carefully open the expander and compressor case drain valves to drain any liquid that may be present in the casings. Use extreme caution when opening the drain valves, since the casings have been pressurized. After all the liquid has been drained, close the drain valves.



Verify that the compressor discharge process block valve is closed, and then pressurize the compressor case by opening the compressor inlet process block valve.

 Verify that the expander inlet process block valve is closed, then pressurize the expander casing by slowly opening the expander discharge process block valve.

3-7


WARNING: 

When the casings are pressurized, slowly open the compressor discharge process block valve and the expander inlet process block valve.



Verify that the start up interlocks has been established. "Expander Ready" light on the unit control panel should be on.



Observe the alarm and shutdown displays. There should be no indications of an alarm or shutdown condition.



To start the expander, open the inlet shutdown valve by pressing the "Expander Start" button on the unit control panel. The shutdown valve will open and the "Expander Running" light will come on. If the inlet shutdown valve does not open, verify the start-up interlocks at DCS are established and troubleshoot as required.



Gradually open the expander inlet guide vanes (IGV's) by operating control unit (HIC-5000) from local control panel HMI. Opening IGV's will allow process gas to enter the expander. Admit process gas to the expander so that the rotor starts to rotate. Monitor all gauges and ensure that speed stabilizes, which may require five minutes or more. This should provide time to break in new seals. Verify that the lube oil flow to the bearings is supplied at the correct temperature and pressure.



Gradually increase the expander speed in steps of about 12% of design speed per minute by further opening the inlet guide vanes IGV's. A 5-minute hold at 50% speed and 80% speed is recommended to verify bearings temperature and vibration levels are stable and within limits. Continue opening the inlet guide vanes until the desired operating speed is reached.

3-8


NOTE: Avoid excessive nozzle movement such as "hunting", because the inlet guide vanes and linkage for the expanders are of a non-lubricated design.



Check seal gas system pressure gauges. Observe that the supply pressure, temperature, and flow to the unit is as specified in Section 1 of manual and System Schematic P&ID.

Monitor the lube oil system pressures and

temperatures gauges and verify that the readings are within the normal operating range. The unit should be running at normal operating condition and speed. If necessary to compensate for entrapped oil, adjust the flow of seal gas to the bearing housing using the needle valve. An excessive amount of entrapped oil accumulated in the bearing housing, is indicated by a decrease in expander speed and an increase in the oil drain temperature. 

Meantime, monitoring thrust meters and verify all operating pressures and temperatures.

3.5

NORMAL OPERATION & PERIODIC SERVICE Normal operation requires only routine monitoring of the control system, temperature gauges, and pressure gauges.

List for seal gas system and

instrument air requirements refer to Section 1.5 for correct lube oil operating temperature, pressure, and viscosity, and recommended control settings.

Inspection and maintenance routines will vary with operating conditions and operator preference. However, the following guidelines are recommended.

3-9


The following items should be checked, daily or more frequently to establish normal operating conditions. Any variations from normal operation should be investigated immediately. 

Reservoir oil level.



Seal gas temperature, flow and pressure.



Lube oil pressures.



Lube oil temperature.



Lube oil viscosity.



Lube oil filter differential pressure.



Thrust meters.

NOTE: For detailed schedule on preventive/periodic service refer to Preventive Maintenance for Expander - Compressor” in Section 4. The lube oil should be changed as often as found necessary by indication of lube oil contamination such as dirty oil filters, low oil viscosity, and high differential pressures across the filter. However, frequent checks especially of oil viscosity should be made immediately after start-up to determine the rate of lube oil contamination/dilution and to establish a normal checking frequency. The filter elements should be changed with each lube oil change.

3.5.1 Servicing Oil Filter (F-5075/5080) If a filter is taken out of service and drained, it must be refilled with oil before being placed back in service. Otherwise, any air/gas left inside the filter may be forced through the bearings and cause damage. Be careful not to disturb the oil pressure to the bearings when filling the filter housing of the one being serviced.

3-10


To replace a duplex oil filter element while in operation: 

Turn off the block valve to the filter to be serviced.



Close the filter equalizing valve.



Open the appropriate filter bleed valve of the filter to be serviced. This will relieve some of the filter pressure to the filter.



Close the filter bleed valve.



Since the filter housing is still under pressure, carefully drain the filter housing by opening its drain valve.



Open the filter housing to the one being serviced and remove the used element.



Install the new filter element.



Once the new filter element has been installed, close the filter drain valve and manually refill the filter housing with oil.



Reassemble the filter housing. Make sure it is closed securely and properly sealed.



Slowly open the filter equalizing valve to admit more oil into the filter.



Slowly open the filter bleed valve and wait until all air is removed from the housing. Allow approximately five minutes for the filter to be completely filled with oil.



Slowly turn on the block valve. This will allow more oil into the filter and purge it of gas. After approximately five minutes, once the filter has been purged of gas, close the filter bleed valve.



Be careful not to significantly reduce the oil pressure to the bearing during the switching process. Be sure to open only the vent and drain valve at the non operating housing.



Select desired filter with the switching valve. If desired, the unit may be operated with both filters on line.

3-11


3.5.2 Auxiliary Lube Oil Pump Test The auxiliary oil pump may be checked periodically by carefully cracking open the test valve (NV-.5). This lowers the differential pressure at (PDI-5040) which will automatically activate the auxiliary pump, and will signal an alarm. CAUTION: LOWERING THE DIFFERENTIAL PRESSURE BELOW THE LIMIT SET FOR PDI5040 (REFER TO "ALARM AND SHUTDOWN TRIP SCHEDULE") WILL TRIGGER AN EXPANDER SHUTDOWN. THEREFORE, AVOID ABRUPT CHANGES IN OIL PRESSURE.

3.5.3 Expander-Compressor Annual inspections of the Turboexpander-Compressor are not essential, unless damage is suspected.

3.5.4 Bearings Expander-compressor bearings are designed to last indefinitely under normal conditions.LAT has chosen these bearings to have high strength and therefore less sensitivity to unbalance. However, operation under abnormal conditions may result in bearing damage.

3.6

NORMAL SHUTDOWN To shutdown the Turboexpander-Compressor, follow the procedure below. 

Close inlet guide vanes by ramping down the actuator PCV-5000 by using local nozzle control (HIC-5000) from HMI or from customer DCS (PY-5000).

3-12


NOTE: Use the same rate during shut down as on start up (See section 3.4.2 "Detailed Instructions"). Machine flow is generally very small at 70% of speed and the unit can be tripped via shut down signal. 

Press the "Expander Stop" button on the unit control panel to close the expander inlet shutdown valve.



Verify that the expander inlet shutdown valve is closed and observe the expander speed (RPM) to determine that rotation has come to a complete stop.

NOTE: If the shutdown is to be short term, it is recommended to keep the auxiliary systems active and running. While the unit is to be kept on standby, the seal gas system and the lube oil system should remain operating and pressurized. The seal gas system will prevent lube oil from leaking into the casings when the casing pressure is less than the operating pressure. If the shutdown is to be long term, continue as follows: 

Close the expander and compressor inlet and discharge process block valves and allow the seal gas and lube oil systems to run for approximately five minutes.



Shut down the lube oil system and allow the seal gas system to run for another five minutes.



The seal gas supply may be shut off, only if the lube oil system has been shutdown.



If it is to be an extended shutdown, de-pressurize the expander and compressor casings.

3-13


3.7

EMERGENCY SHUTDOWN In the event of an emergency condition, the safety devices will automatically cause the expander inlet shutdown valve to close and shut off the process flow to the expander. If the shutdown is of fire, explosion, etc., the Customer should include the auxiliary systems shut off (oil and seal gas system) and expander & compressor casings blow down in conjunction with normal plant emergency shutdown procedures.

3.8

TOO COLD TO START The bearings are well bonded thermally to the bearing housing, and if the bearing housing is not cold, then the bearings should not be too cold - below approximately 80oF.

The potential danger here is that the portion of the journal bearing nearest to the expander may be so cold that oil will not circulate through it. This can occur when the unit and its auxiliaries are shutdown and cryogenic process gas leaks into the bearing housing and/or if the ambient temperature falls below -25oF.

Under these conditions, starting the unit, and counting on friction to warm the bearings is not safe. Nor is it safe to assume that deriming with warm gas will warm the bearing because there is excellent insulation between the expander and the bearing, and heat transfers slowly. Instead, the bearings should be warmed by circulating seal gas and lube oil. In extreme cold weather, warming the bearing housing with steam or hot water may be necessary.

3-14


SECTION FOUR MAINTENANCE

In these procedures, not every question can be answered or every problem anticipated. Maintenance personnel must use judgment in handling the parts, being careful also, in following the drawing.

IN CASE OF INCONSISTENCY IN ANY NUMBER, THE

DRAWING IS TO PREVAIL.

4-1


4.1

DISASSEMBLY OF THE EXPANDER-COMPRESSOR Disconnect all lube oil and seal gas piping and the pickup probes. Plug all lines to prevent the entry of any foreign matter.

The referenced drawings clearly indicate the attachment of all assembled parts; therefore, detailed hardware descriptions are omitted from the following procedures:

4.1.1 Field Removal Some of the components are heavy and a hoist should be made available for support during field removal. When the mechanical center section (M.C.S.) is removed in the field, extreme caution should be exercised in the handling of internal parts.

These parts have been precision machined and dynamically

balanced and careless handling of parts may result in irreparable damage. Avoid marring any flange face or gasket face.

4.1.2 Disassembly Into Major Components L.A. Turbine modular design enables disassembly into three major components: expander case, mechanical center section (M.C.S.) and compressor case. This eliminates the necessity of total disassembly when the main concern is isolated in one of the three primary areas. To separate the system into major components proceed as follows, referring to the Service Assembly (LAT517EC-20-D1) and the Parts List (LAT517EC-20-A9) drawing.

4-2




Disconnect process piping, instrument air and seal gas piping, and all instrumentation lines to the unit.



Support the compressor inlet spacer (330) with a hoist or forklift. Remove bolt (901) to disassemble the compressor inlet spacer (330) and O-ring (902)



Steady the bearing housing (200) with a hoist. Remove hex nuts (943a), which secures the compressor case (300) to the bearing housing (200). Then slide compressor case (300) away from the bearing housing, TAKING CARE NOT TO STRIKE COMPRESSOR CASE AG AINST THE COMPRESSOR WHEEL (280).

Two threaded holes in the bearing housing are provided for the

temporary use of two screws (501) which will aid in this step.

Move the

compressor case to the end of the track so that the weight is distributed between the two supports and the compressor wheel (280) is clear of the casing. Remove O-ring (910). If necessary, the compressor case may now be removed from the skid, being sure that the compressor wheel (280) is completely clear of the compressor case. 

While continuing to support the bearing housing (200), remove stud and hex nuts (944 and 944a), which secure bearing housing (200) to Expander Case (100). Two threaded holes in the bearing housing are provided for jack screws (501) to aid in moving the bearing housing away from the Expander Case. The complete mechanical center section may now be withdrawn. Care must be exercised not to strike the expander wheel (210) against all other internal components while withdrawing the assembly. Remove Labyrinth seal spacer (120) and Raco seals (955,955a). The entire mechanical center section should now be taken to a clean location for disassembly.

The machine is now separated into three major components. In this mode the variable nozzle assembly is still remaining attached to the expander casing. The expander wheel and compressor wheel remain attached to the mechanical center section (M.C.S.). For further disassembly of the major components see the 4-3


appropriate section in the following procedures.

4.1.3 Mechanical Center Section (MCS) Disassembly Most parts in the mechanical center section (M.C.S.) fit tightly together, and are provided with threaded holes for the use of jack screws during removal. The jack screws to use for a part (except for expander, compressor wheels, expander case and compressor case) are the retaining screws for that part. To ensure even removal and to avoid damage to parts, turn both jack screws uniformly. 

Position the unit horizontally on a workbench to facilitate component removal. CARE MUST BE TAKEN NOT TO

BUMP OR MAR EXPANDER WHEEL

(210), COMPRESSOR WHEEL (280)

, HEAT BARRIER WALL (221),

COMPRESSOR SEAL (270), COMPRESSOR WHEEL BACK SEAL (290) OR EXPANDER WHEEL BACK SEAL (220). 

Expander Wheel: Carefully remove expander wheel (210) from shaft (230) by removing retaining screw (211) and retaining washer (212). Remove expander wheel (210) utilizing the threaded hole provided for a 1/2-13 UNC-2B jack screw. DO NOT PRY OR USE ANY TOOL EXCEPT A JACK SCREW TO REMOVE THE EXPANDER WHEEL. Remove keys (213) from the shaft.



Compressor Wheel: Carefully remove compressor wheel (280) from shaft (230) by removing retaining screw (281), retaining washer (282).

Remove

compressor wheel (280) utilizing the threaded hole provided for a 1/2-13 UNC2B jack screw. DO NOT PRY OR USE ANY TOOL EXCEPT A JACKSCREW TO REMOVE THE COMPRESSOR WHEEL . Remove keys (283) from the shaft. 

Disassemble the expander wheel back seal (220), by removing screws (942).



To separate the heat barrier wall (221) from the bearing housing (200), remove screws (937) and washers (938). Remove the heat barrier wall (221) and Raco-seal (956) and O-rings (936, 932, 933 and 934) 4-4




Remove screws (911) to disassemble the compressor wheel back seal (290).



Disassemble compressor seal (270). Remove O-ring (914, 922, 923 and 924)



Break lockwires and remove screws (918) and washers (919). Using the two threaded holes provided for jackscrews; remove load (compressor end) bearing (251). Remove O-rings (920 & 921).



Withdraw the shaft (230). EXERCISE CARE TO KEEP SHAFT CENTERED IN ORDER TO AVOID DAMAGING DRIVE (EXPANDER END) BEARING.



Break lockwires and remove screws (927) and washers (928) to remove drive bearing (250). Two threaded holes are provided for jack screws. Remove Orings (925 & 926).

4.1.4 Nozzle Actuator Assembly Removal Refer to Nozzle Actuator Assembly (LAT517A-20-D110) drawing and to Section 6 “COMPONENT MANUFACTURERS’ DATA” under Fisher’s documents. 

To remove the nozzle actuator, follow Fisher’s instructions. After its removal, disconnect all instrument air lines. Remove Sel-lok pin (946) in the actuator rod, make certain there is no burr in the pinhole and lift the nozzle actuator off the bonnet assembly (111).



To remove the bonnet assembly (111), loose actuator lock nut and remove screws at the base of assembly. To remove upper section of actuator rod, lift assembly and remove jam nut. Remove Raco seal (957).

Make sure that the lower actuator rod (112) does not get hung up on the nozzle adjusting ring and pin (132) during removal. The actuator rod (112) should be positioned to relieve the force on the pin in the nozzle adjusting ring (132) in order to ease removal of the nozzle assembly. 4-5

Care must be exercised during the


removal procedure to ensure that the actuator rod or pin does not get bent. Support the nozzle assembly with a hoist.

4.1.5 Variable Nozzle Assembly Removal 

NOTE: It will be found that this is easier to the degree that the nozzle assembly is kept square to the expander case. Refer to the Service Assembly Drawing (LAT517A-20-D1) and Parts List (LAT517A-20-A9).



Remove screws (950), which secure the variable nozzle assembly to the expander case (100). Take care that the assembly does not fall. The nozzle cover & pins (130), nozzle segments & pins (131) and nozzle adjusting ring & pin (132) secured together with shoulder screws (951) will slide out as one unit. Take the assembly to a clean work area for further disassembly. Be aware of seal ring (137); if it does not slide off with the unit, Remove it from the nozzle fixed ring (133) that is still secured to the expander case (100).



Place the assembly on a workbench with the nozzle adjusting ring (132) face up. Remove shoulder screws (951) to separate the nozzle adjusting ring and pin (132) from the assembly. Take care not to bend the pin or drop the nozzle segment (131) from nozzle cover (130) while removing the nozzle adjusting ring and pin (132). If you encounter difficulty in separating these components, use jackscrews.

4.1.6 Expander Case Disassembly 

Remove screws (952) to separate the nozzle fixed ring (133) from the expander case (100). Remove shim (134).



If necessary, the expander case diffuser (104) may be removed from the expander from the expander case (100) by pulling it through the expander exhaust. Remove gasket (106).

4-6


4.1.7 Compressor Case Disassembly 

To separate the compressor follower (310) from the compressor case (300),remove screws (904). Remove shims (311).

4.2

CLEANING & REASSEMBLY

4.2.1 Cleaning After disassembly, the parts should be cleaned thoroughly. Parts other than those in the cold expander housing should be coated with a thin film of lubricating oil to protect against rusting.

4.2.2 Re-assembly Re-assembly of the unit is the reverse order of disassembly. Ensure that the expander end of the unit is not tilted below a horizontal position, which could allow coating oil to leak into labyrinth seal housing. The following list specifies applications of different sealants and lubricants that are recommended

for

use

in

re-assembly.

Unless

noted

Documents/Drawings, the following practices should be followed:

4-7

in

Related


RECOMMENDED SEALANTS AND LUBRICANTS Product Name

Application

1. Dow Corning 321 Dry Film Lubricant

Nozzle/Inlet Guide Vane Assembly

2. Gn Metal Assembly Paste Dow-Corning Item #01-275-5050

Casing Bolts, Studs, Nut Faces

3. Jet Lube SS-30 Anti-Seize Compound

Retaining Screws, Retaining Washers, All Fasteners, Threads & Nut Faces for Internal Parts of the Machines (Core Units)

4. Leak Lock Joint Sealer by Highside Chemicals

Tach Pick-up Threads, Gaskets on Nozzle Cover & Actuator Bonnet Assembly

5. O-Ring Adhesive #404 by LOCTITE

All O-Rings Joint Adhesives

6. Slic-Tite Teflon Paste by LA-CO Industries, Inc.

Sealants for all Threaded Pipes & Fitting

7. Lanolin AAA Quality, Lano-Lube by Flexbar

Lubricants for O-Rings

8. Silite Silicone Sealant (RTV) by Devcon

Sealant for Sealing Machined Surfaces or Special Applications e.g. Take-off Hole Plugs

9. LOCTITE Superbond Adhesives Item #495

Bonding Between Rubber, Metal, and Plastic Parts With Gaps to .004" in Electrical Shop Practices

4-8


10. LOCTITE Threadlocker # 242

Threads between Expander Wheel Back Seal & Heat Barrier Wall, Heat Barrier Wall Insert & Heat Barrier Wall, Compressor Seal & Compressor Wheel Back seal, Expander Case & Nozzle Fixed Ring

4.2.3 Re-assembly of Variable Nozzle Assembly 

To re-assemble this unit, place the nozzle segments (131) on the pins of the nozzle cover (130) in a closed position. Place the nozzle adjusting ring and pin (132) over the nozzle segments and engage the segment pins into the slots of the adjusting ring. Replace screw (951) to secure the assembly together.



To reinstall the variable nozzle assembly into the expander case (100), make sure seal ring (137) is secured on nozzle fixed ring (133). The pin of the nozzle adjusting ring (132) must engage with the hole in the bottom of the actuator rod (112). This may require some manipulation of the adjusting rod. DO NOT FORCE. To avoid bending the lower actuator rod you can move it up and down slightly to make sure the pin has engaged properly. Observe that slight manipulation of the actuator rod is opening and closing nozzle segments. Insert screws (950) to secure the nozzle assembly in the expander case.

4.2.4 Tachometer Pickup/Vibration Probes Refer to Service Assembly (LAT517A-20-D1), System Schematic P & I D (LAT517EC-20- D3)

and to

the Electrical Bill of Materials (LAT517EC-20-A8).

Tachometer probes can only be installed when the machine has stopped. Make sure that there is NO ROTATION of the shaft. Screw in the threaded probe.

After the probe is set, apply lock-tite to the threads and secure the probe with the locknut.

4-9


CAUTION: The vibration probes should be connected to the vibration monitoring system before installing them into the unit. Be sure not to scratch the polished surface of the shaft when installing the vibration probes. When the shaft is being handled, protect the polished surface of the shaft to avoid any damage or scratches.

4.2.5 Torque See service assembly drawing for detailed information, others see the following table.

TABLE (1): TORQUE FOR CASING BOLTS Bolt Size (in)

Thread Type

1/4

Torque

Thread Type

(ft-lb) (Kg-m)

Bolt Size (in)

10 UNC

4.75

0.66

1

8 UNC

284

39.27

5/16

48 UNC

8.5

1.18

1 1/8

7 UNC

404

55.86

3/8

16 UNC

15

2.07

1 1/4

7 UNC

569

78.67

7/16

14 UNC

24

3.32

1 3/8

6 UNC

753

104.11

1/2

13 UNC

37.5

5.18

1 1/2

6 UNC

989

136.74

9/16

12 UNC

46

6.36

1 3/4

5 UNC

1609

222.46

5/8

11 UNC

63.5

8.78

2

4 1/2 UNC

2436

336.79

3/4

10 UNC

113

15.62

2 1/4

4 1/2 UNC

3549

490.67

7/8

9 UNC

189.5

26.10

2 1/2

4 1/2 UNC

4466

617.46

4-10

Torque (ft-lb) (Kg-m)


4.3

INSPECTION

4.3.1 Recommended Clearance Check the journal and thrust bearings, and shaft for wear. Carefully examine the bearings and thrust washer faces for any signs of wear, such as scoring or babbitt depletion. If the wear is excessive, replace them with new parts. If there is difficulty determining whether the bearing is still satisfactory for use, consult the manufacturer before putting them back in operation. The recommended allowable clearances for the unit are given on the Clearance Modular System (7770001062).

4.3.2 Balance The shaft (230), expander wheel (210), and compressor wheel (280) have been accurately machined and dynamically balanced.

It is not necessary to check the

balance of the assembly or to follow alignment marks between its components unless suspicion of imbalance exists. If inspection reveals that the clearance or imbalance figures exceed those specified, the part should be corrected or replaced.

4.3.3 Labyrinth Seal Clearance SEE 7770001062

4-11


4.3.4 Compressor Wheel Clearance To set the clearance between the compressor wheel (280) and the compressor follower (310), first measure the shaft axial endplay. Next, push the shaft towards the expander end as far as the thrust bearings permit, and place soft solder wire at several points on the face of the blades. Engage MCS and compressor case in normal operating relationship, including tighten the retaining screws. This crushes the solder to the maximum clearance.

Withdraw the compressor follower through the

compressor inlet and measure the crushed thickness of the solder wire. Subtract the axial endplay from the crushed thickness of the solder. This yields the maximum clearance between the compressor wheel (280) and the compressor follower (310). This clearance should be set per drawing "Clearance Modular System" (7770001062) as measured between contour surfaces. Adjustment is made by adding or removing shims (311).

4-12


4.4 RECOMMENDED SPARE PARTS LIST "USE OF UNAUTHORIZED PARTS NOT ONLY INCREASES YOUR RISK EXPOSURE IN TERMS OF A REDUCTION OF LAT WARRANTY OBLIGATIONS AND AN INCREASED PRODUCT LIABILITY RISK, BUT ALSO SUCH A USAGE NEGATIVELY AFFECTS THE PRODUCTIVITY AND PERFORMANCE OF THE TURBOEXPANDERS." 4.5 FIELD SERVICE For 24-hour emergency service, please contact our Service Department at LA Turbine headquarter: Valencia, California, USA, Phone: (661) 294-8290, Fax: (661) 294-8249.

LAT Europe Office: Christian Maskaluk Managing Director Europe, Middle East, Africa Phone: +32 (0) 4 247 30 11 Mobile: +32 (0) 491 08 48 99

4-13


4.6 LATURBINE SERVICE /EMERGENCY CONTACT LIST DIRECT SERVICE RESPONSE PARTNER Office Phone:

(661) 294-8290

Mr. Troy O’Steen– Sales Manager Office Phone: (661) 294-8290 e-mail: [email protected]

Mobil Phone: (661) 755-0949

Mr. David Bloss– Field Service Business Manager Office Phone: (661) 294-8290 Mobil Phone: (661) 755-1942 e-mail: [email protected] Mr. Michael walhof– Sales Director Office Phone: (661) 294-8290 e-mail: [email protected]

Mobil Phone: (832) 289-4654

Mr. Houman Shokraneh – Engineering Director Office Phone: (661) 294-8290 Mobil Phone: (661) 231-5295 e-mail: [email protected]

4-14


SECTION FIVE DRAWINGS Drawing Title

Rev

L.A. TURBINE Dwg. No.

Service Assy Exp-Comp

1

LAT517-20-D1

Expander- Comp. Machinery Arrangement

5

LAT517EC-20-D2

System Schematic P & I Diagram

5

LAT517EC-20-D3

Wiring Diagram

3

Control Panel Layout and details Electrical Bill of Material

3 2

LAT517EC-20-D4 LAT517EC-20-D5

Machine Parts List Maximum Pipe Nozzle Load

0

System Bill of Material Instrument Index

5 1

LAT517EC-20-C16

HMI Instruction Manual

0

LAT517EC-20-A42

Campbell Diagram

0

LAT517EC-20-A82

Anti-Surge Algorithm

1

LAT517EC-20-A86

Performance Data Sheet

2

LAT517EC-20-A96

Nozzle Actuator Ass’y

0

LAT517EC-20-D110

Assembly Clearances Exp-Comp (2000 Frame)

0

7770001062

1

5-1

LAT517EC-20-A8 LAT517-20-A9 LAT517EC-20-A10 LAT517EC-20-A11


SECTION SIX

COMPONENT MANUFACTURER'S DATA

This section contains the names of the vendors who supply the subcomponents not manufactured by LA TURBINE. The names have been listed on the following page. For easy reference, the vendor’s names and their instruction manuals have been arranged in alphabetical order

6-1


COMPONENT MANUFACTURER'S DATA (ALPHABETICALLY BY COMPANY NAME) For the components tag numbers refer to the following documents: System Bill of Materials (LAT517EC-20-A11) and Electrical Bill of Materials (LAT517EC-20-A8). 

AGCO



AIR-X-CHANGER



AMOT



ASHCROFT



AL-TEK



ABBOTT-INTERFAST



APPLETON



BENTLY NEVADA



BONNEY FORGE



CASHCO



CALORITECH



CROSBY



FISHER



FULFLO



GEM



HILCO



HOFFMAN



INLINE



JACABY-TARBOX



JORDAN



KECKLEY



LEISTRITZ



MARSCH



MARVEL

6-2




MISTER MESH



PARKER



PENBERTHY



ROSEMOUNT/EMERSON



SOUTH GATE ENGINEERING



TYCO



T.R. ENGINEERING



THERMOELECTRIC



ZEMARC (GREER)

6-3

Turboexpansor. Manual Detallado LAT

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