Beruflich Dokumente
Kultur Dokumente
OF THE
TURBOEXPANDER
Edited: 3/23/09
Presentation.RPT.DOC
TABLE OF CONTENTS
INTRODUCTION/DESCRIPTION .................................... A
APPLICATION ................................................. B
MAINTENANCE ................................................. O
i
FUNDAMENTALS OF THE TURBOEXPANDER
INTRODUCTION/DESCRIPTION:
Turbine is the power unit and the Compressor is the driven unit.
1
In a Gas Processing Plant, the purpose of the Turboexpander is
APPLICATION:
2
It should be noted that the Expander Nozzles are used to control
through the Feed Gas Heat Exchanger and then to the Booster
3
tools, the basic initial sizing process can be simplified by
Gas Composition
Flow Rate
Inlet Pressure
Inlet Temperature
Pressure.
4
ENERGY EXTRACTION:
ηe = 34 / 40 = .85 or 85%
5
With the Δh's and ηe values known, we then only need the gas mass
HORSEPOWER BALANCE:
is:
6
Example:
= 961.9 - 30
= 931.9 Horsepower
PRESSURE?:
formula is:
ηc
7
The value of 1.4145 is, again, the constant to convert the units
units are btu/lb of gas flow. w is the symbol for mass flow
Δh'Adiabatic = HPCompressor x ηc
______________________
1.4145 x w
lower than the actual Head Rise, Δho, required to achieve the
Compressor, or ηc.
8
We will assume a mass flow rate, w, through the Compressor, of
= 18.30 btu/lb
9
DISCHARGE PRESSURE CALCULATION:
DEFINITION OF TERMS:
Z = Compressibility Factor
10
So, to repeat the formula for the Compressor, if the Inlet
calculated:
= 145 x 1.322
= 191.7 PSIA
Expander Wheel:
______
Ns = N x √ACFS2
________________________
11
Assume, ACFS2 = 25.0 (ACFS2 is the Actual Cubic Feet per Second
= 75 x 2343
5
= 35,146 RPM
First, for good efficiency, the term U/Co should equal about
12
The formula is:
_____________ ___
Co = √2 x g x J x √Δh's
_________________ __
= √ 2 x 32.2 x 778 x √40
__________________ __
= √ 50103.2 x √40
__
= 223.8 x √40
= 1415 ft/sec
Since the term U, Wheel Tip Speed, needs to be 0.7 of Co, then:
U = .7 x Co
= .7 x 1415
= 990 ft/sec
DEFINITION OF TERMS:
g = 32.2 ft/sec2
J = 778 ft-lb/btu
13
The term, U, is the peripheral velocity of the Expander Wheel
Diameter = U x 229.2
RPM
= 990 x 229.2
35,146
= 6.46 inches
14
HOW TO APPROXIMATE THE COMPRESSOR WHEEL DIAMETER:
Wheel Diameter:
Δh'Adiabatic = U2 x Ψ
____________
g x J
U2 = Δh' x g x J
.4
______________________
U = √(Δh' x g x J) / .4
_____________________________
____________
U = √1,146,110.7
U = 1070.6 ft/sec
15
Now calculate the Compressor Wheel Diameter from the equation:
= 1070.6 x 229.2
35,146
= 6.98 inches
** CAUTION NOTE:
While the above method does give the steps necessary to do the
16
TURBOEXPANDER CONTROLS, WITH REFERENCE TO THE TURBOEXPANDER
Compressor Suction.
17
Dual, Electric Motor Driven, Lube Oil Pumps (one Main and one
The oil then travels to the Bearings. Some systems have an oil
Bearings.
The Shaft Seals are Labyrinth type using Seal (Buffer) Gas to
The Seal Gas system typically uses warm process gas that has
18
The small amount of Seal Gas going across the Seal towards the
Bearing Housing mixes with the oil and drains to the Reservoir.
In the Reservoir, this separates from the oil and then is vented
Compressor Suction.
during start-up.
19
DESCRIPTION OF THRUST BALANCE SYSTEM:
20
The GTS improved version (Figure 7) operates in a similar manner
between the pressure vent port behind the Compressor Wheel and
21
The Thrust balancing is accomplished by maintaining or
the area behind the Compressor Wheel causing the load on the
turn, the Spool Valve will tend to close. With the GTS version,
22
DESCRIPTION OF SURGE CONTROL SYSTEM:
The line connecting these points describes the surge limit line,
area.
23
As flow is reduced, the pressure in the Compressor tends to be
repeats itself.
- FIGURE 8 -
SURGE CONTROL:
24
of the Surge Control system is to keep the ratio of ∆P/h from
in Figure 9 below.
- FIGURE 9 -
the sketch on the next page, Figure 10. In operation, the Inlet
25
Compressor are also measured using a DP Transmitter and
general, when the two (2) signals become equal within the bounds
rate is too low (i.e., near surge) then the Bypass Valve should
26
Compressor as necessary. In normal operation, the Bypass Valve
prevent surge.
MAINTENANCE:
surveillance. For example, wet Inlet Process Gas that may cause
isolated from the oil line by shutting off the Block Valve.
27
To accurately check the pre-charge pressure, the oil in the
creating a problem.
check is needed.
28
There have been several installations that have process streams
perhaps monthly.
sheets.
29
EXAMPLE OF DATA LOG SHEET
*DATE/TIME
*FLOW RATE
*SIGNAL TO EXPANDER ACTUATOR
*EXPANDER INLET PRESSURE
*EXPANDER INLET TEMPERATURE
*EXPANDER OUTLET PRESSURE
*EXPANDER OUTLET TEMPERATURE
*COMPRESSOR INLET PRESSURE
*COMPRESSOR INLET TEMPERATURE
*COMPRESSOR OUTLET PRESSURE
*COMPRESSOR OUTLET TEMPERATURE
*SHAFT SPEED
*VIBRATION
*EXPANDER BEARING RTD
*COMPRESSOR BEARING RTD
*EXPANDER THRUST PRESSURE
*COMPRESSOR THRUST PRESSURE
*SEAL GAS SUPPLY PRESSURE
*EXPANDER BACK WHEEL PRESSURE
*SEAL GAS FILTER DP
*LUBE OIL PRESSURE AT PUMP DISCHARGE
*LUBE OIL SUPPLY PRESSURE TO BEARINGS
*LUBE OIL RESERVOIR PRESSURE TO BEARINGS
*LUBE OIL FLOW INDICATOR
*LUBE OIL TEMPERATURE (UPSTREAM OF COOLER)
*LUBE OIL TEMPERATURE (DOWNSTREAM OF COOLER)
*LUBE OIL FILTER AP
*MISCELLANEOUS
OPERATOR COMMENTS:
________________________________________________________________
________________________________________________________________
________________________________________________________________
30
TROUBLE SHOOTING
31
COMPRESSOR IMPELLER HIGH COMPRESSOR CHECK PLAUSIBLE
BACK SEAL WASHED OUT DISCHARGE CAUSE OF COMPRESSOR
TEMPERATURE HIGH TEMPERATURE,
SAME AS ABOVE.
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ABOUT THE AUTHOR:
34