Professional Documents
Culture Documents
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
Main: 20-6E7C Spare: 20-6E7C
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DESIGN SPECIFICATIONS
Unit Tag No. Molecular Weight Inlet P1 (psia) T1 ( F) Outlet P2 (psia) T2 ( 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
OFF DESIGN
Unit Tag No. Molecular Weight Inlet P1 (psia) T1 ( F) Outlet P2 (psia) T2 ( F) Flow (lb/hr) Shaft Speed RPM Efficiency (%) Wheel Power (hp) 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
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Minimum Operating Level: 2.5 Measured from below centerline of reservoir Volume at the Minimum Operating Level: Total Volume: 90 Gallon 200 Gallon
Oil Supply Temperature to Bearings Start-up: 80F (minimum) Normal Operating: 120F
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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.
General Requirements for NON-FOAMING TURBINE OIL ISO Viscosity Grade Pour Point C Flash Point C Viscosity: Gravity, API Specific 32 ~-27 to ~-40 C(-17 to -40F ) 157 to 170 C(315 to 350F ) 32 cSt @ 104 F ~32.6 ~0.86
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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.
made to the nozzle openings, the resulting high velocity streams are directed into the wheel at the correct angle. efficiency over a wide range of flow rates. This design yields high
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.
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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 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.
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. 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 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 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.
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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.
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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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).
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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3.3
PRE-START INSTRUCTIONS
The following steps must be taken before placing the system into operation:
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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).
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).
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3.4 3.4.1
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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.
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.
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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.
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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.
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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.
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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.
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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.
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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.
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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).
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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.
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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.
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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.
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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.
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4.1
The referenced drawings clearly indicate the attachment of all assembled parts; therefore, detailed hardware descriptions are omitted from the following procedures:
balanced and careless handling of parts may result in irreparable damage. Avoid marring any flange face or gasket face.
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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 Move the temporary use of two screws (501) which will aid in this step.
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
Position the unit horizontally on a workbench to facilitate component removal. CARE MUST BE TAKEN NOT TO BUMP OR MAR EXPANDER WHEEL , HEAT BARRIER WALL (221), (210), COMPRESSOR WHEEL (280) 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).
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. 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.
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.
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4.2
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 in Related
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Application
Retaining Screws, Retaining Washers, All Fasteners, Threads & Nut Faces for Internal Parts of the Machines (Core Units) Tach Pick-up Threads, Gaskets on Nozzle Cover & Actuator Bonnet Assembly All O-Rings Joint Adhesives
5. O-Ring Adhesive #404 by LOCTITE 6. Slic-Tite Teflon Paste by LA-CO Industries, Inc.
7. Lanolin AAA Quality, Lano-Lube by Flexbar 8. Silite Silicone Sealant (RTV) by Devcon
Sealant for Sealing Machined Surfaces or Special Applications e.g. Take-off Hole Plugs Bonding Between Rubber, Metal, and Plastic Parts With Gaps to .004" in Electrical Shop Practices
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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
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.
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.
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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.
8 UNC 7 UNC 7 UNC 6 UNC 6 UNC 5 UNC 4 1/2 UNC 4 1/2 UNC 4 1/2 UNC
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4.3
INSPECTION
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.
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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).
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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
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Mr. Troy OSteen Sales Manager Office Phone: (661) 294-8290 e-mail: Tosteen@laturbine.com
Mr. David Bloss Field Service Business Manager Office Phone: (661) 294-8290 Mobil Phone: (661) 755-1942 e-mail: Dbloss@laturbine.com Mr. Michael walhof Sales Director Office Phone: (661) 294-8290 e-mail: Mwalhof@laturbine.com
Mr. Houman Shokraneh Engineering Director Office Phone: (661) 294-8290 Mobil Phone: (661) 231-5295 e-mail: Hshokraneh@laturbine.com
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Rev
1 5 5 3 3 2 0 1 5 1 0 0 1 2 0 0
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SECTION SIX
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
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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
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MISTER MESH PARKER PENBERTHY ROSEMOUNT/EMERSON SOUTH GATE ENGINEERING TYCO T.R. ENGINEERING THERMOELECTRIC ZEMARC (GREER)
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