TURBOEXPANDER

Compressor Load
Training Program

1 - Introduction • Overview – GE Rotoflow

2 - Description Componentes • Core Unit

• Auxliary System
• Control System

3 – Operational Activities • Safe Start-up

• Normal Shutdown
• Emergency Shutdown

4 – Maintenance Activities • Level A Service Plan

• Level B Service Plan

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Product & Services
Nuovo Pignone PII Conmec
• Compressors • Pipeline Solutions • Multi-Vendor
• Turbines Compressor Services
• Reactors
• Air-Coolers
• Pumps - Valves
Odessa
• Metering Systems • Multi-Vendor Gas
GE Energy Turbine Services
• Fuel Dispensers Oil & Gas

Thermodyn A-C Compressor

• Low to Medium • Screw & Rotary Vane
Pressure Compressors Compressors
• Low to Medium Power • Custom Centrifugal
Steam Turbines • Single Stage Centrifugal
Gemini Rotoflow
• High Speed Recips. • TurboExpanders
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History of Rotoflow with Turboexpanders

 Linde of Germany developed the first radial inflow expander in 1936.

 Dr. Judson Swearingen, founder of Rotoflow Corporation, Inc., in Texas in 1958.

 First Rotoflow Expander built for cryogenic application Hydrocarbon process in early 1960’s.

 1st RF-Waste Heat Energy Recovery Expander in 1971.

 1st RF-Geothermal Power Recovery Expander in 1983.

 Atlas Copco acquired Rotoflow in June 1990.

 Rotoflow Expanders reached 120,000 rpm speed level in 1991.

 1stHigh Power-Speed Exp./Compr. With Active Magnetic Bearings in 1992.

 Expander-Compressor Power level of 19,000 hp in 1998.

 Rotoflow acquired by GE Oil&Gas in May 2000.

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What is a Turbo-expander ?

A Turboexpander is a
Rotating Machine which
recovers and uses energy,
that would be otherwise
wasted

As process fluid passes

through the Machine,
energy is removed by
reduction in pressure and
temperature

The potential energy of the

process medium is
transformed:
 In Kinetic Energy
in the
Nozzles
 In Mechanical
Energy in the
Impeller
 In usable Energy

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Turbo-Expander Design Principle

•Expansion with tradition valve (J/T)

•Expansion at 100% isentropic
efficiency p1 > p 2 p1

Enthalpy
•Expansion with turbo-expander
T1

JT
T2
Power
proportional Expander
to the differential enthalpy T2
T2 Ideal

p2 T1 > T2JT > T2exp > T2ideal

•Primary result of efficient expansion Entropy

is temperature reduction (drop)
•Secondary result is energy recovery
from change in enthalpy

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Complete range of process

EXTERNAL
REFRIGERATION

Saturated Gas Gas Exp

Flash. Liquid Exp Dense Phase. Exp Exp P1; T1
JOUL
THOMPSON
EXPANSION
Δ H =0
Pressure

LIQUID GAS

Two Phases P2; T2

Enthalpy
Turbo-Expander Definition

Types of “turbines”

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Turbo-Expander Design Principle

Expansion Process Achieved in Two Steps:

Step 1: Primary Expansion

• Through Inlet Guide Vanes (Isenthalpic)
• Designed for:
• optimal profile to convert pressure head
into velocity head
• optimal clamping
IGV’
• no blow-by s
• Simple adjusting mechanism in
cryogenic environment

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Turbo-Expander Design Principle

Step 2: Secondary Expansion

• Secondary Expansion is through
radial wheel (isentropic)
• Designed for:
• De-accelerating flow
• Condensing streams
• High efficiency
• High power
• High speed
• Stable rotor dynamics by using light
weight metal

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Radial Reaction Expander Wheel
The purpose of the expander wheel is to
convert energy of the incoming gas steam
into mechanical energy

- the gas is jetted tangentially into the wheel

- then it flows radially inward and exits at a
lesser diameter.

This arrangement reduces the velocity with

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Turbo-Expander Applications

Gas Processing Ocean Thermal Energy Conservation

Dew Point Control (OTEC)

Liquid Petroleum Gas Recovery Petrochemical

MTBE Hydrogen Purification

Ethane Recovery Hydrogen Liquefaction

LNG for Peak Shaving CO2 Recovery

Ethylene Recovery CO Recovery

Air Separation Geothermal Power

Production of N2, O2, and Ar Gas Pressure Letdown

Liquefaction of N2, O2, and Ar Helium Purification

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Turbo-Expander “Braking”
•Turbo-expander/ compressor
•Natural gas liquid re-injection
•Natural gas dew point control
•Ethylene plants
•Pipeline Junctions
•Air separation

•Turbo-expander/ generator
•Ethylene plants
•Geothermal energy recovery
•Pressure let down energy recovery
•Waste heat energy recovery
•IGCC

•Turbo-expander/ dyno
•Ethylene plants
•Air separation
•Helium liquefaction
•Hydrogen purification
•Jet engine testing

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Product Distribution

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Rotoflow Expander Technology

Turboexpander Performance &

Technical Features

Power 3 - 15,000 kW
Speed 3,000 - 120,000 rpm
Pressure Ratio Up to 14:1
Inlet Pressure Up to 200 bar (2940psi)
Temperature5 to 750 K
Fleet > 3200
Center of Excellence in Expander-Compressors with Active
Magnetic Bearings (AMB)
Over 120 Patents
> Variable Inlet Guide Vanes
> Automatic Thrust Balancing System
Modular Design

Single-Shaft Design
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Overview

GE Rotoflow Expanders Design Features

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Rotoflow Expander Technology

MCS

EXPANDER
CASE

COMPRESSOR
CASE
NOZZLE
ASSEMBLY

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Turboexpander-Compr. Major Component List
I. Expander inlet trip valve
II. Expander IGV actuator
III. Expander inlet strainer (80 Mesh)
IV. Compressor Anti-surge control
system – includes flow element,
control valve, and control logics
V. Compressor inlet strainer (40 mesh)
VI. Automatic Thrust Balance system –
includes control valve and control
logic
VII. Expander-compressor drain
manifold with check valve
VIII. Duplex gas filter
IX. Local control panel
X. AMB system – includes control
cabinet(s), junction boxes, and
Expander Rotor/AMB system
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Mechanical Center Section Components
Bearing Housing
Compressor
Heat Barrier
Seal
Wall
Compressor Expander
Wheel Wheel

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Expander Wheel Design Features

Advanced wheel technology

ensures maximum reliability.
Computer-generated profiles guide
casting or milling of aluminum,
titanium or stainless steel wheels.

Mechanical integrity is verified by

dynamic balancing and dye-
penetrant testing before and after
overspeed testing.

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Rotoflow Turbo-expanders Design Features

State of the art technology

Holography is used to tune Rotoflow expander wheels and
determine levels of resonance. COMIG and MAX-5 software is used
to further ensure reliable operation.
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Compressor Wheel Design Features

Open and closed wheel designs are offered to meet every

application requirement.

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Stiff Shaft Design

In Rotoflow turbo-expanders, the

high-speed expander/compressor
shaft is supported by two single-
piece journal type radial bearings.

All critical speeds above operating

speed (No speed limit)

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Conventional Oil Bearings

The patented bearing design

increases wear allowance and has
up to nine times the oil-film
strength of conventional bearings.
Oil whirl and oil film resonance are
eliminated and sensitivity to
imbalance due to deposits on
wheels is reduced.

Tilting pad bearings are also offered

for other applications.
Automatic Thrust Balancing System

Automatic Hydraulic
Thrust Control System

The patented GE Rotoflow hydraulic thrust load control system automatically

compensates for process-induced variations in axial thrust. Pressure signals from
two opposing thrust bearings are applied to opposite sides of a piston to actuate a
control valve that automatically adjusts pressure behind the compressor expander
or dyno wheel.

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ATB System for Magnetic Bearing

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Automatic Thrust Balancing System

Factors that can cause adjustmenet include:

• 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

pressure between the front and back thrust
bearings reaches a pre-selected limit.

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Tapered Shaft and Labyrinth Seal

The outwardly flowing seal gas retains process gas within the
expander and compressor casing and the inwardly flowing seal
gas retains lube oil within the bearing housing.
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Dust Free Seal
A patened GE Rotoflow design feature is a dust-free seal, whic virtually
eliminates erosion of the expander wheel back seal and shaft seal

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Dust Free Seal

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Inlet Guide Vanes

> Aero Designed for performance.

> Blow-by leakages avoided
& CLAMPING force optimized

• Controlled by an electric or
pneumatic actuator with positioner
• Provides precise, continuous control
from 0% to 130% of design flow
• GE Rotoflow patented design

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Radial Reaction Expander Wheel

NOZZLE ASSEMBLY
Nozzle Assembly with a new Adjusted Mechanism IGV(Nozzle Assembly) for Ultra precise
control , Minimal Friction Continuous Computer controlled adjusting capability less
sensitivity to dust, liquid and solid particles

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Magnetic Bearing (AMB) EC

•Oil bearings removed, no oil used.

•Shaft supported with a magnetic field.
•Package skid smaller since no lube oil system.
•Control panel for bearings required for control

•Introduced in process Industries in the early 1990’s.

•Advantages are
•Reliability,
•Oil free design, particularly in cryogenic applications
•Small foot print

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Expander Compressor (AMB)

Compressor
Expander

Rotor

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50 Frame Expander/Compressor

AMB
Turboexpander
Compressor
Requires less Floor
Space

Conventional Lube Oil Bearing Active Magnetic Bearing

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Natural Gas Processing

Application DPC
P in (BarA) 76
T in (C) - 12
P out (BarA) 38
T out (C) - 44
Flow (Nm3/hr) 39,900
Power (kW) 4,200
Speed (rpm) 13,500
Ship Date 1998
Location UK
Frame 50
Natural Gas Processing
Application DPC
P in (BarA) 89
T in (C) -6
P out (BarA) 67
T out (C) - 64
Flow (Nm3/hr) 1,112, 000
Power (kW) 5,200
Speed (rpm) 9,000
Ship Date 1994
Location Norway
Frame 60
Typical Expander skid packages

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Typical Expander skid packages

A Field Service Advisor can be scheduled for on-site inspection to review existing core unit,
auxiliary system-control system and instrumentation retrofit requirement.

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Turbo-Expander Compressor

See Service
Assembly

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