Turboexpansor. Manual Detallado LAT

7/27/2019 Turboexpansor. Manual Detallado LAT

1/52

INSTRUCTION MANUAL

TURBOEXPANDER WITH COMPRESSOR LOAD

DESIGNED AND MANUFACTURED FOR:

VALERUS ENGINEERING

LAT PROJECT: LAT517EC

May, 2012


2/52

LAT517EC INSTRUCTION MANUAL------SECTION 1

1-1

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


3/52


1-2

1.2 DESIGN SPECIFICATIONS

Unit EXP COMP

Tag No. EC-0510 C-0510

Molecular Weight 19.72 18.58Inlet P1 (psia) 894 189

T1 ( F) 6.64 103.5

Outlet P2 (psia) 215 298

T2 ( F) -94.5 178.4

Flow (lb/hr) 74936 73103

Shaft Speed RPM 41,000 41,000

Efficiency (%) 85% 78%

Wheel Power (hp) 1089 1044

OFF DESIGN

Unit EXP COMP

Tag No. EC-0510 C-0510

Molecular Weight 19.95 18.61

Inlet P1 (psia) 894 189

T1 ( F) 5.44 101.3

Outlet P2 (psia) 215 301.1

T2 ( F) -92 177.5

Flow (lb/hr) 82393 77650

Shaft Speed RPM 41,500 41,500

Efficiency (%) 85% 78%

Wheel Power (hp) 1174 1128

1.3 SEAL GAS REQUIREMENTS

Molecular weight: 18.58/18.82 (Nor./Max.)

Supply pressure: 315/400 Psig (Nor. / Max.)

Supply temp: 70/100 F (Min. / Max)

1.4 INSTRUMENT AIR REQUIREMENTS

Operating pressure: 60 Psig

Supply pressure: 90 Psig

Supply Temperature: 0/140 F

Design Pressure: 200 Psig


4/52


1-3

1.5 LUBRICATION SYSTEM DATA

1.5.1 LUBE OIL RESERVOIR CAPACITY

Maximum Operating Level: 3Measured from above centerline of reservoir

Volume at the MaximumOperating Level: 139Gallon

Minimum Operating Level: 2.5Measured from below centerline of reservoir

Volume at the MinimumOperating 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 160F

6 Accumulator Pre-charge Pressure 235 psig

7 Unit Running Speed 41,000 rpm

8 Speed to Avoid N/A

Oil Supply Temperature to BearingsStart-up: 80F (minimum)

Normal Operating: 120F


5/52


1-4

WARNING:

START-UP AND CONTINUOUS RUNNING OF THE TURBOEXPANDER,

WITH A BEARING OIL SUPPLY TEMPERATURE OF LESS THAN 80F, 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 @ -20/200F

Oil Flow: 21.4 gpm

Viscosity: 150 SSU @100 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 C ~-27 to ~-40 C(-17 to -40F )

Flash Point C 157 to 170 C(315 to 350F )

Viscosity: 32 cSt @ 104 F

Gravity, API ~32.6

Specific ~0.86


6/52


1-5

1.6 RECOMMENDED CONTROL SETTINGS

For recommended Control Settings refer to System Schematic-P&ID (LAT517EC-20-

D3), 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. DESCRIPTIONENG.UNITS

SET POINT

TCV-5060 Temperature Control Valve F 110

PSV-5020 Reservoir Safety Relief Valve psig 350

PSV-5030/5040

Pump Relief Valve psid 140

PCV-5020Oil Diff. Back PressureRegulator

psid 100

PCV-5085Seal Gas Diff. Press.Reducing Regulator

psid 15

PR-1/PR-2

Actuator Instrument AirPressure Regulator

psig 20/40

TSHL-5025Oil Reservoir HeaterThermostat

F 100

AC-5000 Accumulator Pre-ChargePressure

psig 235

PCV-5000Inlet Nozzle Vane Actuator

Travel Distanceinch 1.098

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


7/52


1-6

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 thebearing housing where it mixes with the lube oil.


8/52


1-7

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 its 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 cross-

section the lubricant supply and discharge passages within the unit.

A bladder-type accumulator is included in the lubrication system to supply oil


9/52


1-8

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 HMIinstruction 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


10/52


1-9

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.

HumanMachine 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 F-

16 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


11/52


1-10

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 onthe 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 SUMMARYscreen 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-20-

A42


12/52


1-11

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.


13/52


1-12

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).


14/52


2-1

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, i

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 agains

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.


15/52


2-2

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 Customers

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 wil

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.


16/52


2-3

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-20-

D2). 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.


17/52


2-4

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 Expander-

Compressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic P

& I Diagram (LAT517EC-20-D3) for the connections 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 connections 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.


18/52


2-5

2.11 ELECTRICAL CONNECTIONS

Refer to the following drawings for wiring:

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.

Drawing Title LAT Dwg. No.

System Schematic P & I Diagram LAT517EC-20-D3

Expander- Comp. Machinery Arrangement. LAT517EC-20-D2

Wiring Diagram LAT517EC-20-D4

Electrical Bill of Material LAT517EC-20-A8

Unit Control Panel Layout LAT517EC-20-D5

System Bill of Materials LAT517EC-20-A11


19/52


2-6

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.


20/52


2-7

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 connections 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.


21/52


3-1

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.


22/52


3-2

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 GETTINGINTO THE LUBE OIL SYSTEM.


23/52


3-3

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.


24/52


3-4

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 ActuatorVerify 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 Manufactures Data and Nozzle Actuator ASSY. 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.


25/52


3-5

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 inletpipes to the unit as specified on the Expander-Compressor Machinery Arrangement

(LAT517EC-20-D2) and System Schematic Diagram (LAT517EC-20-D3) drawings.

3.4 INITIAL STARTING PROCEDURE

3.4.1 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:


26/52


3-6

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 flowrequirements.

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.


27/52


3-7

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/orreplaced 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 oF-

continuous 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.


28/52


3-8

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.


29/52


3-9

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.


30/52


3-10

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.


31/52


3-11

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 nonoperating housing.

Select desired filter with the switching valve. If desired, the unit may be operated

with both filters on line.


32/52


3-12

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 PDI-

5040 (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).


33/52


3-13

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.


34/52


3-14

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.


35/52


4-1

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.


36/52


4-2

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.


37/52


4-3

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


38/52


4-4

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 UNC-

2B 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)


39/52


4-5

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 O-

rings (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 Fishers documents.

To remove the nozzle actuator, follow Fishers 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. Care must be exercised during the


40/52


4-6

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 nozzlesegment (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).


41/52


4-7

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 toprotect 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 in Related

Documents/Drawings, the following practices should be followed:


42/52


4-8

RECOMMENDED SEALANTS AND LUBRICANTSProduct Name Application

1. Dow Corning 321 Nozzle/Inlet Guide Vane

Dry Film Lubricant Assembly

2. Gn Metal Assembly Paste Casing Bolts, Studs,Dow-Corning Nut FacesItem #01-275-5050

3. Jet Lube SS-30 Retaining Screws, Retaining

Anti-Seize Compound Washers, All Fasteners,

Threads & Nut Faces for

Internal Parts of the

Machines (Core Units)

4. Leak Lock Joint Sealer Tach Pick-up

by Highside Chemicals Threads, Gaskets on Nozzle

Cover & Actuator Bonnet

Assembly

5. O-Ring Adhesive #404 All O-Rings Joint Adhesives

by LOCTITE

6. Slic-Tite Teflon Paste Sealants for all Threadedby LA-CO Industries, Inc. Pipes & Fitting

7. Lanolin AAA Quality, Lubricants for O-Rings

Lano-Lube by Flexbar

8. Silite Silicone Sealant Sealant for Sealing

(RTV) by Devcon Machined Surfaces or

Special Applications

e.g. Take-off Hole Plugs

9. LOCTITE Superbond Bonding Between Rubber,

Adhesives Item #495 Metal, and Plastic Parts

With Gaps to .004" in

Electrical Shop Practices


43/52


4-9

10. LOCTITE Threadlocker # 242 Threads between Expander Wheel

Back Seal & Heat Barrier Wall, HeatBarrier Wall Insert & Heat Barrier Wall,Compressor Seal & Compressor WheelBack seal, Expander Case & NozzleFixed 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.


44/52


4-10

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 Thread Torque Bolt Thread Torque

Size Type Size Type

(in) (ft-lb) (Kg-m) (in) (ft-lb) (Kg-m)

1/4 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


45/52


4-11

4.3 INSPECTION

4.3.1 Recommended ClearanceCheck 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


46/52


4-12

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 severa

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).


47/52


4-13

4.4 RECOMMENDED SPARE PARTS LIST

"USE OF UNAUTHORIZED PARTS NOT ONLY INCREASES YOUR RISK

EXPOSURE IN TERMS OF A REDUCTION OF LAT WARRANTYOBLIGATIONS 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


48/52


4-14

4.6 LATURBINE SERVICE /EMERGENCY CONTACT LIST

DIRECT SERVICE RESPONSE PARTNER

Office Phone: (661) 294-8290

Mr. Troy OSteen Sales ManagerOffice Phone: (661) 294-8290 Mobil Phone: (661) 755-0949e-mail: [email protected]

Mr. David Bloss Field Service Business Manager

Office Phone: (661) 294-8290 Mobil Phone: (661) 755-1942e-mail: [email protected]

Mr. Michael walhof Sales DirectorOffice Phone: (661) 294-8290 Mobil Phone: (832) 289-4654e-mail: [email protected]

Mr. Houman Shokraneh Engineering DirectorOffice Phone: (661) 294-8290 Mobil Phone: (661) 231-5295

e-mail: [email protected]


49/52


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 LAT517EC-20-D4

Control Panel Layout and details 3 LAT517EC-20-D5

Electrical Bill of Material 2 LAT517EC-20-A8

Machine Parts List 0 LAT517-20-A9

Maximum Pipe Nozzle Load 1 LAT517EC-20-A10System Bill of Material 5 LAT517EC-20-A11

Instrument Index 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 Assy 0 LAT517EC-20-D110

Assembly Clearances Exp-Comp (2000 Frame) 0 7770001062

5-1


50/52


6-1

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 vendors names and their instruction manuals have been

arranged in alphabetical order


51/52


6-2

COMPONENT MANUFACTURER'S DATA

(ALPHABETICALLY BY COMPANY NAME)

For the components tag numbers refer to the following documents: System Bill ofMaterials (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


52/52


MISTER MESH

PARKER

PENBERTHY

ROSEMOUNT/EMERSON

SOUTH GATE ENGINEERING

TYCO

T.R. ENGINEERING

THERMOELECTRIC

ZEMARC (GREER)

Turboexpansor. Manual Detallado LAT

Documents

Transcript of Turboexpansor. Manual Detallado LAT