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16 - CHM - Chemical and Process Engineering

CHM 105 - Advanced Cryogenic Turbo-Expanders Technology

Code Start Date Duration Venue
CHM 105 30 October 2023 5 Days Istanbul Registration Form Link
CHM 105 25 December 2023 5 Days Istanbul Registration Form Link
Please contact us for fees


Course Description

Cryogenic   turbo-expanders   are   used   in   many   applications, including ethylene plants, refineries, gas processing plants, and air separation facilities. They frequently produce the coldest level of refrigeration available in the plant, and often operate with turbine outlet conditions where large quantities of liquid are condensed during the expansion process.

Turboexpanders  have  come  a  long  way  in  the  last  20  years. Their  high  efficiency  and  reliability  have  led  to  widespread  use around the world. The use of magnetic bearings in many critical turboexpander applications such as ethylene  plants  has  become common, and in the natural gas processing market, they are making inroads  as  well.

This course explains how turbo expander design features and how it works and the critical conditions in expander operations and troubleshooting. The course then discusses hydrate formation in turbo expanders and the operation of a turbo expander, including bearings and seals, lube oil system and the seal gas system.

API  617  (2002)  now  addresses  cryogenic  turboexpanders  in Chapter 4 of the Seventh Edition. Annex 4F of the same document provides guidelines for purchasing equipment using magnetic bearings, and this section is particularly applicable to turboexpanders. 

Course Objectives

  • Recognize the basic principles of the turbo expansion process
  • Identify and Analyse the turboexpander-compressor design principles
  • Identify the basic operation of a turbo expander,
  • Carryout efficiency operation of the turbo expander
  • Identify critical conditions in expander operations such as expander speed and hydrate formation in turbo expanders
  • Explain the overview of sub-vendor instrumentation information
  • Identify bearings and seals, lube oil system, the seal gas system
  • Apply turbo expander disassembly and assembly procedures as well as expander testing  
  • Describe turbo expander/compressor, noise control

Who Should Attend?

  • Operations and maintenance Engineers
  • Process Supervisors, Technicians and Operators
  • Process Engineers
  • Project Engineers
  • Process Improvement Engineers
  • Instrumentation Engineers and Supervisors 

Course Details/Schedule

Day 1

  • Overview of the Turboexpanders and Process Applications
  • What is a Turbo Expander?
  • When Turbo Expanders Used?
  • Typical Turbo Expander Processes
  • Applicable Codes & Standards
  • Design Considerations, Materials of Construction, and Design pressure 

Day 2

  • Hydrocarbon Turbo Expanders
  • Turbomachinery classification
  • Turboexpanders classification
  • Turbo Expanders constructions and their functions , Inlet Guide Vanes , Expander wheels , Shaft , Magnetic bearings , Labyrinth seals , Dry gas seal
  • Principles and geometry of a turboexpander-compressor
  • Turboexpanders loading devices

Day 3

  • Turbo Expander Auxiliaries ,Lube Oil System, Seal Gas System
  • Turbo Expander installation and commissioning
  • Turbo Expander startup and operations
  • Typical Turbo Expander Process
  • Turbo Expander/Compressor Operation
  • Oil bearings in turboexpanders 
  • Magnetic bearings in turboexpanders 
  • Automatic clamping systems 
  • High efficiency boosters

Day 4

  •  Typical Compressor Performance Map
  • Turbo Expander servicing and problem resolution
  • Turbo Expander Factory Testing 
  • Turbo Expander/Generator
  • Integral Gear Expander 
  • Dust-free design 
  • Automatic thrust balance system 
  • Seal gas systems 
  • Design considerations

Day 5

  • Turbo Expander disassembly and assembly procedures
  • Turbo Expander Condition Monitoring
  • Noise Control
  • Reliability
  • Nozzle efficiency 
  • Enthalpy-Entropy diagram of typical nozzle 
  • Expander performance curves 
  • Compressor performance curves
  • Overview of sub-vendor instrumentation information