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Fundamentals of Turboexpanders
Fundamentals of Turboexpanders
INTRODUCTION/DESCRIPTION:
The term "Turboexpander", Figure 1, is normally
used to define an Expander/Compressor machine as
a single unit. It consists of two (2) primary
components; the Radial Inflow Expansion Turbine
and a Centrifugal (Booster) Compressor combined as
an assembly. Its Wheels are connected on a single
Shaft. The Expansion Turbine is the power unit and
the Compressor is the driven unit.
APPLICATION:
The typical Turboexpander process installation is
shown in Figure 2, Simplified Process Schematic.
High pressure, moderately cold gas flows into the
Expander section of the Turboexpander. The gas
flows through the Expander Variable Inlet Nozzles
(Guide Vanes) and then through the Wheel,
exhausting at a lower pressure and at a substantially
colder temperature. Gas flows from the Expander to
the Demethanizer, where condensate is removed.
FIGURE 1 TURBOEXPANDER
EXPANDER/COMPRESSOR ASSEMBLY
CROSS-SECTION DWG.
FIGURE 2
FIGURE 3
TYPICAL TURBOEXPANDER
PROCESS SCHEMATIC
(SIMPLIFIED)
EXPANSION PROCESS
Gas Composition
Flow Rate
Inlet Pressure
Inlet Temperature
ENERGY EXTRACTION:
Where does the energy come from? With reference
to Figure 3, which shows the typical Expansion
HORSEPOWER BALANCE:
FIGURE 4
COMPRESSION PROCESS
= HPExpander - HPBearings
= 961.9
30
= 931.9 Horsepower
HPCompressor =
. .
.
= 18.30 btu/lb
The value of 1.4145 is, again, the constant to convert
the units into Horsepower, just the same as the
Expander formula. h'Adiabatic is the ideal Head Rise,
or energy change, from the Inlet Pressure to the
Discharge Pressure of the Compressor. The units are
btu/lb of gas flow. W is the symbol for mass flow
through the Compressor, and the units are
lbs/second.
DEFINITION OF TERMS:
Pout = Discharge Pressure, PSIA
Pin = Inlet Pressure, PSIA
Cp = Specific heat at constant pressure
T1 = Inlet temperature, R (R = F + 459.69)
Z = Compressibility Factor
= Greek Symbol "Gamma", stands for the Ratio
of specific heats
+ .
= 1415 ft/sec
Since the term U, Wheel Tip Speed, needs to be 0.7
of Co, then:
. /.
.
(
= 145 x [ 1.0665 ]
) .
U = .7 x Co
4.333
= .7 x 1415
= 145 x 1.322
= 990 ft/sec
= 191.7 PSIA
DEFINITION OF TERMS:
U = Tip Speed of Wheel, ft/sec
Co = Spouting Velocity, ft/sec
g = 32.2 ft/sec2
J = 778 ft-lb/btu
).
N=
=
=
Diameter
= 6.46 inches
).
= 35,146 RPM
HOW TO APPROXIMATE THE EXPANDER WHEEL
DIAMETER:
h'Adiabatic =
)
.
).
U =
FIGURE 5
U =
U =
P & ID 1
)
.
.
.
U = ,
U = 1070.6 ft/sec
Now calculate the Compressor Wheel
Diameter from the equation:
U =
FIGURE 6
P & ID 2
= 6.98 inches
** CAUTION NOTE:
While the above method does give
the steps necessary to do the initial
rough sizing of the Expander and
Compressor Wheels, it is vastly over
simplified. In the above, certain
values were assumed for specific
speed, efficiency, head coefficient,
etc. These assumptions were used
for ease of demonstrating the
formulas only. These assumptions
MUST NOT be used as "rule of
thumb" values, as they may give false
results in an actual case. Any actual
design analysis should be performed
by an experienced Turboexpander
Design Engineer.
TURBOEXPANDER CONTROLS, WITH REFERENCE TO
THE TURBOEXPANDER SYSTEM SCHEMATIC DWG
(FIGURE 5 & 6):
FIGURE 7
FIGURE 8
IMPROVED AUTOMATIC THRUST
EQUILIZATION DESIGN
FIGURE 9
PERFORMANCE MAP OF
THE COMPRESSOR
SURGE CONTROL:
The most common method of Surge Control uses the
Compressor P to represent head and the
differential pressure across an Inlet orifice (called
h) to represent capacity. The function of the Surge
Control system is to keep the ratio of P/h from
exceeding the slope of the surge line.
To provide some factor of safety, a control line (Set
Point) should be established to the right of the surge
line, as shown in Figure 10 on the next page.
FIGURE 10
SURGE CONTROL
FIGURE 11
ANTI-SURGE CONTROL SYSTEM