Post on 02-Apr-2018
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Atlas Copco Group Presentation 20131
TURBOEXPANDERS
Section V: Turboexpander Start-up and Operations
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Atlas Copco Group Presentation 20132
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Turboexpander Training
Committed to Customer Value
Atlas Copco Mafi-Trench Company LLC
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Atlas Copco Group Presentation 20134
Innovative Solutions
Products Services
Knowledge
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Atlas Copco Group Presentation 20135
Section V:
Turboexpander Start-up And Operations
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Atlas Copco Group Presentation 20136
Gas Processing
Is it safe?
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Gas processing is notinherently dangerous,
but more so than sky-diving, it is unforgiving
of mistakes!
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To prevent accidents, we
have to remember only
one word; thats
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Safety SAFETY safety
Safety
Safety SAFETY Safety
SAFETY
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So, what is a Turboexpander ?
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Its a machine used to produce refrigeration
and recover otherwise wasted energy...
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An expander acting as a J.T.
It functions as a differential
pressure control valve
100% of
Flow
@ -24F @ -110 F
737 psig 218 psig
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An expander acting as a J.T.
100% of
Flow
@ -24 F @ -110 F
737 psig 218 psig
And recovers 6,003 Hp @ 16,500 RPM
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Single Turboexpander Process Train
LPG Absorber
Cold Separator
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Starting your MTC
Turboexpander System
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A typical representationof a MTC
Turboexpander System
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1. Purge housings and related pipingfollowing 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
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3.5 Bar/Per Min.
3.5 Bar-Delta
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218 psig
218 psig
218 psig
Target housing pressures:
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Proceed to Start-up:
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Atlas Copco Group Presentation 201325
Process Train Stable on J.T. Valve
Blocked In
To Re-compressor
X X X
X
X Low pressureseparator
Cold Separator
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Atlas Copco Group Presentation 201326
Blocked In
To Re-compressor
X X X
X
X
Expander ESDV and all manual
block valves verified closed...
Cold Separator
Low pressure
separator
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Atlas Copco Group Presentation 201327
Block in
Seal Gas PDCV
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Atlas Copco Group Presentation 201328
Use seal gas PDCV by-pass to pressurize all
housings and piping outto the block valves...
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Atlas Copco Group Presentation 201329
DO NOT EXCEED A RATE OF
50 psig per minute!
Do not exceed adifferentialof
50 psi (Delta-P)
across themachine!
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Atlas Copco Group Presentation 20133131
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Atlas Copco Group Presentation 201332
Monitor all housings as pressure builds...
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Atlas Copco Group Presentation 201333
When compressorhousing pressure equals
compressor suctionpressure, open that
block valve...
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Atlas Copco Group Presentation 201334
Blocked In
To Re-compressor
X X X
O
X
Open compressor suction
block valve...
Cold Separator
Low pressure
separator
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Atlas Copco Group Presentation 201335
When expanderhousing pressure equals
expander discharge,open that block valve...
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Atlas Copco Group Presentation 201336
Blocked In
To Re-compressor
X O X
X
X
Open expander discharge manual
block valve...
Cold Separator
Low pressure
separator
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Atlas Copco Group Presentation 201337
Close Seal GasRegulator By-pass;
confirm seal gas
ALARM is cleared.
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Atlas Copco Group Presentation 201338
Start lube oil system:1. Open regulator bypass
2. Pump A in MANUAL3. 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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Atlas Copco Group Presentation 201339 Drain Housings
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Atlas Copco Group Presentation 201340Compressor Drains
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Atlas Copco Group Presentation 201341
Expander Casing
Drains...
O d ti bl k l
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Atlas Copco Group Presentation 201342
To Re-compressor
OO O
O
X
Open expander suction block valve;
Expander ESDV remains closed...
LPG Absorber
Cold Separator
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Atlas Copco Group Presentation 201343
In coordination withControl Room Personnel,
start Turboexpander bypressing START at
expander control screen...
E d i l t ESDV h ft
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Atlas Copco Group Presentation 201344
To Re-compressor
O O O
O
O
Expander inlet ESDV opens; shaft
begins to rotate...
Cold Separator
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Atlas Copco Group Presentation 201345
Turboexpander/Compressor Operation
Independent DCS control of
J-T valve
Expander Inlet GuideVanes
TRIP
Expander Quick Closing Valve
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Atlas Copco Group Presentation 201346
As IGVs open, J.T. Valvewill close. As J.T. closes,
switch DCS IGV
controller to Remote
16 500 RP
M
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Atlas Copco Group Presentation 201347
16,500 RPM
-110 F
300 psig
One-to-two hours to stabilize
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Atlas Copco Group Presentation 201348
What is Surge?
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Atlas Copco Group Presentation 201349
Surge is a disturbance
in the flow into, through,or out of the
compressor...
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Atlas Copco Group Presentation 201350
Surge controller should be
set to Automatic.
C fi S C i
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Atlas Copco Group Presentation 201351
Surge ControlSystem
Confirm Surge Controller is set to
AUTOMATIC
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Atlas Copco Group Presentation 201352
Turboexpanders produce really cold gas...
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Atlas Copco Group Presentation 201353
Monitor:
1. Seal Gas Pressure Diff.
2. Lube oil Pressure Diff.3. Vibration Levels
4. Bearing Temperatures
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Atlas Copco Group Presentation 201354
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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Atlas Copco Group Presentation 201355
Safety, Safety, Safety!
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Turboexpander Training
First in MindFirst in Choice
Atlas Copco has a clear vision
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Atlas Copco Group Presentation 201357
We are committed to your
superior productivity through
interaction and innovation.
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