COMPRESSORS

TURBOEXPANDERS
Turboexpander Reliability Has Increased Steadily Over The Years
BY BEHROOZ ERSHAGHI, LOUIS MANN, AND GABE GLYNN

Pipeline Residue gas Mixed overhead gas

gas compressor
Sales gas
Gas treatment Dehydration Warm overhead gas
Feed
gas Sweet gas Expander
Chiller compressor
Liquids

Wet gas
CO2/H2S

Demethanizer/
H2O Hg Dry gas Cold Cold gas

deethanizer
box compressor
Liquid
separator
Regenerator

Condenser
Absorber

& separator
Refrigeration
compressor

Regeneration Heater Condenser Liquid

compressor (NGL/LPG)

Typical turboexpander plant schematic

T
he use of cryogenic turboexpander manufacturing, design features, control components that are normally custom
technolog y in hyd rocarbon systems, and process environments. The designed for specif ic applications are:
processing started in the early g u id i ng requ irement s for t urboex- wheels, inlet guide vanes (IGV), rotor-
1960s with the utilization of effi- panders and centrifugal compressors in bearing systems, and seals.
cient near isentropic expansion (the the petroleum, chemical, and hydro-
method at the time was free expansion carbon gas processing industries are set
from a Joule-Thompson valve). For many out in American Petroleum Industry The majority of larger
decades now, radial inf low turboex- (API) Standard 617. API 617 specif ies turboexpanders in gas
panders with booster compressor loads that expanders should have a service life
have been a favored equipment choice in of 20 years, which includes at least five processing, petrochemical,
nat ura l gas processing. E x pa nder- years of uninterrupted service. In addi-
compressor (EC) units provide refrigera- tion, hazard and operability studies and energy recovery units
tion for extracting heavier hydrocarbon (HAZOP) and safety integrity level (SIL) are built to order,
components at the same time as having reviews specify required instrumentation
low energy costs. The main applications to minimize loss of production. including auxiliary and
are natural gas liquid (NGL) recovery, As a component reliability example,
dewpoint control, liquified natural gas magnetic rotor/bearing system reli-
control systems.
(LNG) pretreatments, and ethylene and ability is now in the range of 99.5-100%
petrochemical processes. Refrigeration is over 100,000 hours of operation with The mechanical development and
provided by expansion through a turbo- approx imately 10 hours prevent ive the performance of turboexpanders have
expander, and the free shaft power is maintenance every year. The majority of been improved over decades in a number
utilized to drive a booster compressor. larger turboexpanders in gas processing, of ways, such as w it h desig n tools,
As is the case with other turboma- petrochemical, and energ y recovery analytical methods, and lessons learned
chines, turboexpander reliability is a units are built to order, including auxil- from implementations. Robust rotor-
product of component desig n, iar y and control systems. The bearing systems, both oil-lubricated and

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 COMPRESSORS

magnetic bearings, can handle a wide range of released energy is then used to recompress the gas
radial and axial thrust loads during normal and feed i ng t he dow nst rea m process. I n most
of f-design operation, as well as unavoidable processes, the turboexpander outlet is in two
process upsets. A process of continual impeller phases, with liquid mass fraction ranging from
and inlet guide vane f low channel optimization 5-20%, and up to 40% in dense phase cases. In
ensures a wide operating range with minimal this system, the expander wheel f low passage
performance penalties. Additionally, recent geometry is designed to handle any amount of Oil bearing
improvements in IGV actuation systems have discharge liquid fraction with no signif icant turboexpander
a l lowed smoot her process cont rol a nd performance penalty. compressor cross section
better stability. The turboexpander feed is from the top of a
separator, which normally contains a small
amount of mist carryover. Mist particles are typ-
TURBOEXPANDERS IN INDUSTRIAL ically carried out with high gas stream velocities,
OPERATION although a high concentration of carryover (>1%)
The cryogenic process is the preferred method of and a formation of large radius droplets at the
separating a heavier hydrocarbon from natural turboexpander inlet may result in a high impact
gas. The treated gas is isentropically expanded to on the blade tips, which causes erosion in the flow
lower the pressure, which results in maximum path. Erosion will be more severe if there is a
cooling and condensate. The typical single-stage combination of fine dust in the nucleus of drop-
t u r b o e x pa nder pr e s s u r e r at io i s 4:1, but lets. In order to minimize this risk, process indus-
depending on the applied process it could be as tries have established guidelines for turboex-
high as 14:1. The static temperature is reduced to pander inlet separator designs and avoiding liq-
a cryogenic range as energy is removed. This uid slug.

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Turbomachinery International • May/June 2021 www.turbomachinerymag.com 19

COMPRESSORS

A turboexpander bypass or and by applying suitable coatings compat-

Joule-Thomson (J-T) valve is used for plant ible with the process media. Some of the
operation during the start-up, shutdown, process-related issues include stress corro-
and service period. On the one hand, as a sion cracking in case of sour gas, a high
free expansion (isenthalpic) J-T valve, the concentration of particulates, and hydrate
outlet stream is not sufficiently cooled for formation when the hydrocarbon mixture
liquefaction at reduced pressures. On the contains water vapor. Operation-wise,
other, because the turboexpander process IGVs are designed for continuous process
is isentropic, it provides maximum cooling. control with desired control band bias.
However, in some instances an unnec-
essary very fine process control band setting
DESIGN DEVELOPMENTS results in a hunting of the actuator position.
Manufacturers have encountered various This shortens the life of some IGV compo-
issues that necessitated design and opera- nents, particularly if some process contam-
tional guideline improvements. inants are present. Currently, in addition to
Examples: Inlet guide vane mechanism IGV assembly optimum linkage design,
and control; resonance-free impellers computational fluid dynamics (CFD), finite
Turboexpander variable inlet guide vane
avoiding critical excitations; axial load element analysis (FEA) and metallurgical
increased capacity and control; and analyses are carried out during the design
rotor-bearing system stability. phase. In addition, design and component depends on the prevention of high-cycle
A turboexpander variable IGV works integrity are validated using a stroke test fatigue and avoiding resonance frequen-
by converting a portion of process fluid apparatus developed for simulating the gall- cies in its operating range. The basic
head (i.e. 50%) to kinetic energy (gas veloc- ing resistance under applied process pres- guidelines for wheel performance design is
ity). Similar to an efficient control valve, the sure forces. to ensure a uniform flow and pressure dis-
IGV maintains a desired process setpoint tribution, a good leading-edge flow pat-
by regulating the volume flow through the tern, acceptable blade loading, and no
expander. In general, IGVs allow efficient WHEEL OPTIMIZATION flow separation.
operation across wide operating ranges, The converted static pressure to high Hydrocarbon turboexpanders require
while they must also be capable of high reli- velocity in the IGV assembly is further a wide operating range. Both the mechan-
ability in harsh process environments. expanded into the wheel, which extracts ical integrity of the turboexpander wheel
Basic aerodynamic design guidelines energy and results in high-volume refrig- and the stress loading must avoid creating
for IGV segments are uniform flow and eration with additional velocity head destructive resonance frequencies. For
pressure profile, balanced forces, no flow recovery in the discharge diffuser. Radial example, when the IGV discharge exci-
separation downstream of the throat, and inflow turboexpanders are 50% reaction, tation matches a wheel natural frequency
minimizing the passing frequency wake which means impeller enthalpy drop is mode, it will resonate and potentially ini-
region. Mechanical-related problems were about half of the stage enthalpy drop. This tiate a crack. Excitation force will increase
formerly related to excessive force or con- provides optimized velocity in the stator with a higher fluid density, power and
tact stress applied to pins and linkage, and and rotor, and it also minimizes the inci- Mach number, and flow instabilities, so
a clamping of the plates. These are nowa- dence into the radial blades. For a radial higher harmonic interferences need to be
days evaluated during the design process stage design with an optimum velocity considered during the design and final
phase, which takes into consideration the ratio of 0.7, total efficiency is up to, 90%. tuning stages.
range of process pressures and the selec- In some applications with high
tion of the actuator size. enthalpy drop (above 180 KJ/Kg), design
Most IGV problems are either: velocity ratio is a lower value due to the ROTOR-BEARING SYSTEM
mechanical, such as galling; process-re- mechanical limitation on the turboex- The selection of oil or magnetic bearings
lated, such as dust particles and process pander wheel peripheral speed. For a often comes down to the preference of
pulsation; or operation issues, such as given throughput, operating the turboex- the end-user. The decision is based on
actuator position hunting due to a fine pander at a lower speed or much higher footprint, oil-free operation require-
control band. Galling wear results in dam- head than design will result in lower pro- ments, oil dilution in case of heavy
age to the sliding surface, which in turn duction rates. This could be due to off-de- components in the seal gas, and
causes adhesion and high friction. Never- sign process conditions or rotor/bearing plant location.
theless, IGV galling resistance has been mechanical issues, and high vibration. The required load capacity for the shaft
improved by using materials with dissimi- Therefore, rotor/bearing design stability support, peripheral speed, process-induced
lar properties, material treatments, mini- is the key to high reliability. cross-coupling effects, and stability is deter-
mizing contact stress between moving In addition to stress analysis, the mined and set by analytical methods. The
parts, avoiding deflection of the plates, mechanical integrity of the expander magnetic-bearing stiffness is about seven

20 www.turbomachinerymag.com May/June 2021 • Turbomachinery International

 COMPRESSORS
Cable Pass-Thru

Thrust Disk Wiring Route

times lower than the equal-sized oil bear-
ing, and for this reason larger relative mag- Aux, Bail Bearings
Rotor Laminations
netic-bearing sizes are used to compensate
for the rotodynamic need. Turboexpanders
with magnetic bearings have proven their
rotodynamic robustness over several mil-
lion hours of operation.
There have been several lessons
learned from decades of design and oper-
ation of magnetic bearings. Two particu-
larly worth highlighting are the impor-
tance of protecting the rotor-bearing sys-
tem from external factors, such as corro- Magnetic bearing and rotor components
sive components in the process gas; and
choosing the right bearing size while tak-
ing into consideration the process param- control, and automatic booster a loss of control, or they could block or
eter influence on the load capacity. compressor anti-surge control. For collapse the inlet screen mesh, subse-
On oil-bearings machines, lubricant magnetic bearings, more advanced quently damaging the components.
type, cleanness, and diluted oil viscosity control cabinet features are available, In summary, cryogenic turboex-
after dissolve gas equilibrium are the including remote tuning, a toolbox for pander design and operation has signifi-
important factors for reliability. Journal oil bearing health check, hot swap back-up cantly evolved since the first applications
bearings could be either fixed geometry or battery change during operation, and of turboexpanders in hydrocarbon
tilted pad, depending on the peripheral two-out-of-three voting on speed. processing plants in the early 1960s. Yet
speed. Turboexpander oil bearings are a there remain opportunities for improve-
combination of journal and thrust bearings ment in performance, operability,
with a positive automatic axial load control. EXTERNAL PROCESS FACTORS and reliability. ■
Turboexpander compressor shaft seals The integration of turboexpander
are a labyrinth type. The purpose of the systems into the process environment is
shaft seal is to prevent process gas ingress as important as using a perfectly designed
to the bearing housing and to act as a machine. High reliability is only achieved Behrooz Ershaghi is
shield against the cold process side. Warm by careful consideration of all external Marketing and Technology
and dry seal gas with positive differential factors, including the gas conditioning, Manager at Atlas Copco Gas
pressure to the process side is injected into seal gas selection and the required and Process. He received his
the seal and vented through the bearing protective materials. For turboexpanders, MS degree in petroleum engineering
housing to the lowest process gas pressure, ignoring such factors can result in inlet and PhD in chemical engineering from
which is normally the booster compressor liquid carryover, corrosive components, the university of Southern California.
suction. The bearing housing and the oil process pressure fluctuations, incorrect
reservoir are pressurized, and the system depressurizations, and incorrect start-ups Louis Mann is a Research and
is enclosed with no hazardous gas leaking and shutdowns. Development Manager for
to the atmosphere. For magnetic-bearing As far as the inlet liquid is concerned, Atlas Copco Gas and Process,
turboexpanders, shaft-seal clearances are and depending on the fluid density and and he is responsible for new
two-to-three times larger than equivalent drag forces, it is normal for 1-2% liquid by turboexpander product and feature
oil-lubricated machines due to higher weight of mist form when entering the development. Mr. Mann received a BS in
bearing clearances. Therefore, in some casing inlet. It is carried by the expanding mechanical engineering from California
applications, floating ring seals are used to gas without erosion impact on the blades. Polytechnic State University, San Luis
minimize the seal gas flow rate. Fluid velocity in the IGV throat is near or Obispo and is a registered Professional
In addition to standard machinery over sonic velocity, so large dust-particles Engineer in the State of California.
protection, additional features are built impact will erode the IGV flow channel
into the system that helps categorize this and affect the wheel blade pressure surface. Gabe Glynn is the
piece of equipment as smart and rela- Some of the external factors affecting Applications Engineering
tively self-controlled (if desired). These IGV operation are particulates, hydrate Manager at Atlas Copco Gas
features include automatic thrust load formation, and a corrosive environment. and Process and is located in
equalizer (ATE) for both oil-lubricated Additionally, hydrates could form in a Santa Maria, California, USA. He holds a
and magnetic-bearing set-ups, automatic turboexpander when there is free water BS in mechanical engineering from
IGV control based on process signals, in the process gas. Such hydrates can California Polytechnic State University,
automatic seal gas differential pressure freeze the IGV mechanism and result in San Luis Obispo.

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