turboexpansor. manual detallado lat
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INSTRUCTION MANUAL
TURBOEXPANDER WITH COMPRESSOR LOAD
DESIGNED AND MANUFACTURED FOR:
VALERUS ENGINEERING
LAT PROJECT: LAT517EC
May, 2012
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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-1
SECTION ONE
DESCRIPTION AND TECHNICAL DATA
1.1 INTRODUCTION
The system described in this instruction manual is designed for the expansion
and compression of Natural Gas and consists of one frame size L2000
Turboexpander-Compressor unit. The unit is single-stage Turboexpander loaded
by an integral, single-stage centrifugal compressor.
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 Model No. & Serial No.
Main: 20-6E7C S.N.: 1061
Spare: 20-6E7C S.N.: 1063
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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-2
1.2 DESIGN SPECIFICATIONS
Unit EXP COMP
Tag No. EC-0510 C-0510
Molecular Weight 19.72 18.58Inlet P1 (psia) 894 189
T1 ( F) 6.64 103.5
Outlet P2 (psia) 215 298
T2 ( F) -94.5 178.4
Flow (lb/hr) 74936 73103
Shaft Speed RPM 41,000 41,000
Efficiency (%) 85% 78%
Wheel Power (hp) 1089 1044
OFF DESIGN
Unit EXP COMP
Tag No. EC-0510 C-0510
Molecular Weight 19.95 18.61
Inlet P1 (psia) 894 189
T1 ( F) 5.44 101.3
Outlet P2 (psia) 215 301.1
T2 ( F) -92 177.5
Flow (lb/hr) 82393 77650
Shaft Speed RPM 41,500 41,500
Efficiency (%) 85% 78%
Wheel Power (hp) 1174 1128
1.3 SEAL GAS REQUIREMENTS
Molecular weight: 18.58/18.82 (Nor./Max.)
Supply pressure: 315/400 Psig (Nor. / Max.)
Supply temp: 70/100 F (Min. / Max)
1.4 INSTRUMENT AIR REQUIREMENTS
Operating pressure: 60 Psig
Supply pressure: 90 Psig
Supply Temperature: 0/140 F
Design Pressure: 200 Psig
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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-3
1.5 LUBRICATION SYSTEM DATA
1.5.1 LUBE OIL RESERVOIR CAPACITY
Maximum Operating Level: 3Measured from above centerline of reservoir
Volume at the MaximumOperating Level: 139Gallon
Minimum Operating Level: 2.5Measured from below centerline of reservoir
Volume at the MinimumOperating Level: 90 Gallon
Total Volume: 200 Gallon
1.5.2 LUBE OIL SYSEM DATA
OPERATING PARAMETERS
ITEM NO. DESCRIPTION NORMAL OPERATION
RANGE
1 Oil viscosity @ 100 F 150 SSU/32 C.ST.
2 Oil Flow To Bearings 18 GPM
3 Oil Pressure to Bearings 315 Psig
4 Temperature, Oil Inlet to Bearing 120 F
5 Temperature, Bearing Drain 140 160F
6 Accumulator Pre-charge Pressure 235 psig
7 Unit Running Speed 41,000 rpm
8 Speed to Avoid N/A
Oil Supply Temperature to BearingsStart-up: 80F (minimum)
Normal Operating: 120F
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LAT517EC INSTRUCTION MANUAL------SECTION 1
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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.
1.5.3 AIR FAN COOLER
Cooler Tag No.: E-5060
Cooler Type: Motor Drive Air Fan Cooler
Cooler Heat Load: 140,000 Btu/Hr
Design Pressure: 490 psig @ -20/200F
Oil Flow: 21.4 gpm
Viscosity: 150 SSU @100 F
1.5.4 OIL SPECIFICATIONS
For recommended lubricants and required quantities refer to the Lubricant List.
General Requirements for NON-FOAMING TURBINE OIL
ISO Viscosity Grade 32
Pour Point C ~-27 to ~-40 C(-17 to -40F )
Flash Point C 157 to 170 C(315 to 350F )
Viscosity: 32 cSt @ 104 F
Gravity, API ~32.6
Specific ~0.86
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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-5
1.6 RECOMMENDED CONTROL SETTINGS
For recommended Control Settings refer to System Schematic-P&ID (LAT517EC-20-
D3), System Bill of Materials (LAT517EC-20-A11), Electrical Bill of Materials
(LAT517EC-20-A8) and Instrument Index List (LAT517EC-20-C16).
AUXILIARY SYSTEM SET POINTS
TAG NO. DESCRIPTIONENG.UNITS
SET POINT
TCV-5060 Temperature Control Valve F 110
PSV-5020 Reservoir Safety Relief Valve psig 350
PSV-5030/5040
Pump Relief Valve psid 140
PCV-5020Oil Diff. Back PressureRegulator
psid 100
PCV-5085Seal Gas Diff. Press.Reducing Regulator
psid 15
PR-1/PR-2
Actuator Instrument AirPressure Regulator
psig 20/40
TSHL-5025Oil Reservoir HeaterThermostat
F 100
AC-5000 Accumulator Pre-ChargePressure
psig 235
PCV-5000Inlet Nozzle Vane Actuator
Travel Distanceinch 1.098
Other control settings refer to Instrument Index List (LAT517EC-20-C16).
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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-6
1.7 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.
1.7.1 TURBOEXPANDER VARIABLE NOZZLES
The perimeter of the turbo expander wheel is surrounded by the variable
nozzle assembly. The variable nozzles, or inlet guide vanes (IGVs),
control the process gas flow and may act to regulate back pressure. This is
done by applying an instrument air signal to the actuator. This adjusts the
openings between nozzle segments. Regardless of the degree of change
made to the nozzle openings, the resulting high velocity streams are
directed into the wheel at the correct angle. This design yields high
efficiency over a wide range of flow rates.
1.7.2 SEAL SYSTEM
The process gas in the expander and compressor is sealed around the
shaft by a labyrinth seal in the heat barrier wall. Process gas is leaked out
through the labyrinth seal to keep lube oil from entering the expander casing.
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 thebearing housing where it mixes with the lube oil.
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LAT517EC INSTRUCTION MANUAL------SECTION 1
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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 cross-
section 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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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-8
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.
1.7.4 ALARM & SHUTDOWN CONTROL SYSTEM
The Turboexpander control consists of Allen Bradly Programmable Logic
Controller, which is used for the annunciation and system control of the
unit. The PLC, which is pre-programmed with all the control logic and alarm &
shutdown conditions as well as start-up permissive, continuously monitors
the unit's operating condition and signals an alarm when any of the preset
process parameters are exceeded. It wills also shutdown the unit if any of
its preset safety parameters are exceeded. A Panel View 1000 Plus
standard terminal is used for operator graphic interface and annunciation.
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 HMIinstruction 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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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-9
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 F-
16 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
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LAT517EC INSTRUCTION MANUAL------SECTION 1
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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 onthe 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.
A DETAILED HMI INSTRUCTION MANUAL IS SHOWN ON LAT517EC-20-
A42
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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-11
1.7.5 AUTOMATIC THRUST BALANCE SYSTEM
To protect the thrust bearings from overload and damage, the unit is provided
with an Automatic Thrust balancing System. The thrust balancing system
senses hydrodynamic oil pressure on the front and back thrust bearings,
compares them, and adjusts the pressure of the cavity behind the compressor
wheel so that the rotor system remains in balanced in the center position. The
system provides continuous thrust adjustments by varying the pressure of the
cavity behind the compressor wheel. Any increase in the thrust bearing
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.
Factors that can cause adjustments include:
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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LAT517EC INSTRUCTION MANUAL------SECTION 1
1-12
1.7.6 ANTI-SURGE CONTROL SYSTEM
The unit is equipped with an Anti-Surge Control System, designed to eliminate
compressor surge. Surging is an unstable operational state realized when the
flow through a compressor is reduced well below the design condition. When
the incoming flow to the compressor is decreased below normal operating
conditions, the pressure difference between the compressor inlet and discharge
is increased. This increased pressure difference can cause a reversal of flow
direction and an axial thrust on the shaft.
The Anti-Surge Control System protects the compressor from this harmful
condition by monitoring the compressor process condition and, when needed,controls the flow of recycled compressor process gas. To monitor the
compressor process condition, the system uses a flow and differential pressure
transmitters. The pressure transmitters (PT-5001 and 5003, customer provided)
are used to measure the pressure difference between the compressor inlet and
discharge pressures. The flow meter (FIT-5000, customer provided) is used to
measure the pressure of the compressor suction flow.
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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LAT517EC INSTRUCTION MANUAL------SECTION 2
2-1
SECTION TWO
INSTALLATION
2.1 DELIVERY, CHECK OF CONSIGNMENT AND STORAGE
Please make sure that on receipt of the consignment packing is undamaged, as it is
designed to protect the consignment during transportation from damage, e.g. by
water, etc.
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, i
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 agains
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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LAT517EC INSTRUCTION MANUAL------SECTION 2
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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.
2.2 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 wil
support the entire weight of the package.
2.3 LIFTING AND HANDLING
A suitable hoist or crane should be provided for lifting the skid onto the foundation
There are lifting lugs on the side of skid for attaching the hoist or crane.
NOTE:
Spreader bars may be required to avoid damage to the unit by the slings.
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LAT517EC INSTRUCTION MANUAL------SECTION 2
2-3
2.4 PLANT PROCESS CONNECTIONS
Connection sizes, ratings, and locations for plant process inlet and discharge piping
are shown on the Expander-Compressor Machinery Arrangement (LAT517EC-20-
D2). Allowable pipe nozzle loads for the expander and compressor flanges are
listed on the Maximum Pipe Nozzle Loads Drawing (LAT517EC-20-A10).
2.5 INLET SCREENS(SUPPLIED BY CUSTOMER)
An 80-mesh expander screen and a 30-mesh compressor screen are provided and
to be installed in the process inlet pipes to the unit. The screens should be installed
in the Customer's inlet piping as shown on the System Schematic P & I Diagram
(LAT517EC-20-D3) and Expander-Compressor Machinery Arrangement
(LAT517EC-20-D2).
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.
2.6 PROCESS GAS CLEANLINESS
The process gas entering the expander should be clean, since dust or other foreign
matter in the gas could damage the expander. Inlet screens are not intended to
filter out dust so the Customer should ensure that the process gas has been
cleaned and filtered before entering the expander. The Customer must also control
gas composition to avoid frost build-up on the nozzles and expander wheel.
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LAT517EC INSTRUCTION MANUAL------SECTION 2
2-4
2.7 SEAL GAS SYSTEM
Connect Customer's seal gas supply to the connection located at the edge of the
skid. For seal gas requirements see section 1 of the IOM and to the Expander-
Compressor Machinery Arrangement (LAT517EC-20-D2) and System Schematic P
& I Diagram (LAT517EC-20-D3) for the connections size, rating, and location.
2.8 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.
2.9 VARIABLE NOZZLE ACTUATOR
Install the variable nozzle actuator on the bonnet assembly, and connect the
actuator rod. Be sure to align the rod and the adjusting nut. Connect the instrument
air supply and air signal lines. Check the calibration of the nozzle actuator. This is
set at the factory, but it may require readjustment after shipment. There should be
a full range of motion of the nozzles within the range of signal pressure applied.
Refer to the Nozzle Actuator Assembly (LAT517-10-D110) and System Schematic
P & ID (LAT517EC-20-D3).
2.10 EXPANDER INLET SHUTDOWN VALVE
An expander inlet shutdown trip valve assembly with solenoid should be installed in
the process piping at the expander inlet. An adequate air supply must be
connected to the valve. The valve designed to close within 1/2 second or less.
Install instrument air to the positioner on the shutdown valve.
NOTE:
If for any reason the shutdown valve is to be installed further then what is specified
in the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2), LA
TURBINE must be consulted.
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LAT517EC INSTRUCTION MANUAL------SECTION 2
2-5
2.11 ELECTRICAL CONNECTIONS
Refer to the following drawings for wiring:
Refer also to Section 6 for Component Manufacturer's Data. 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.
2.12 JUNCTION BOXES
Junction boxes should always be closed except during actual wiring and
connecting. In no case should the junction boxes be allowed to stand open
overnight or for extended periods. This precaution will protect the electric
circuitry from dirt, rain, moisture and other potential sources of electrical
abuse.
Drawing Title LAT Dwg. No.
System Schematic P & I Diagram LAT517EC-20-D3
Expander- Comp. Machinery Arrangement. LAT517EC-20-D2
Wiring Diagram LAT517EC-20-D4
Electrical Bill of Material LAT517EC-20-A8
Unit Control Panel Layout LAT517EC-20-D5
System Bill of Materials LAT517EC-20-A11
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LAT517EC INSTRUCTION MANUAL------SECTION 2
2-6
2.13 COMPRESSOR DISCHARGE CHECK VALVE (CUSTOMER
SUPPLIED)
A check valve or other method of preventing reverse flow is recommended to
be installed in the Customer's process piping at the compressor discharge to
prevent process back flow through the compressor, on shutdown or other
interruptions. Make certain it is installed in the proper direction.
2.14 LUBE OIL COOLER
An air-fan lube oil cooler is furnished. The cooler is equipped with vent and
drain connections, which are to be connected to the appropriate Purchaser's
removal system. Refer to Sub-section 1.5.3 for flow and temperature
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.
2.15 DISPOSAL SYSTEM
Connect the reservoir safety relief valve to the appropriate Customer's
Disposal System. The connection size, rating, and location is shown on the
Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) and
System Schematic P & I Diagram (LAT517EC-20-D3) drawings.
2.16 EXPANDER/COMPRESSOR DRAIN CONNECTION
An expander and compressor drain connections are provided on the
expander and compressor casings. The drain connections are provided to
drain the liquid from the expander and compressor casings and into the
appropriate Customer's removal system. Refer to the Expander-Compressor
Machinery Arrangement (LAT517EC-20-D2) and System Schematic P & I
Diagram (LAT517EC-20-D3) drawings for the connections sizes, ratings, and
locations.
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LAT517EC INSTRUCTION MANUAL------SECTION 2
2-7
2.17 RESERVOIR DRAIN CONNECTION
A drain connection is provided on the lube oil reservoir. The drain connection
is provided to drain the lube oil from the reservoir and into the appropriate
Customer's removal system. Refer to the Expander-Compressor Machinery
Arrangement (LAT517EC-20-D2) and System Schematic P & I Diagram
(LAT517EC-20-D3).
2.18 RESERVOIR FILLER PUMP CONNECTION
When the lube oil reservoir is pressurized, a connection is provided on the
lube oil reservoir to fill the reservoir with a manual filler pump (HP-1). Refer to
the Expander-Compressor Machinery Arrangement (LAT517EC-20-D2) and
System Schematic P & I Diagram (LAT517EC-20-D3) for connecting the
Customer's oil supply and for the connections sizes, ratings, and locations.
When the system is not in service, the reservoir may be filled using the
inspection hole on either end of the reservoir.
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LAT517EC INSTRUCTION MANUAL------SECTION 3
3-1
SECTION THREE
OPERATING INSTRUCTIONS
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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LAT517EC INSTRUCTION MANUAL------SECTION 3
3-2
3.2 EXPANDER OVERSPEED - CAUTION
THERE IS A DANGER OF OVERSPEED UNTIL THE COMPRESSOR SUCTION
REACHES DESIGN PRESSURE. THE EXPANDER COULD REACH FULL SPEED
WITH LESS THAN FULL EXPANDER POWER UNTIL THE COMPRESSOR
SUCTION DESIGN PRESSURE HAS STABILIZED.
3.3 PRE-START INSTRUCTIONS
The following steps must be taken before placing the system into operation:
3.3.1 Oil Reservoir
PROCEDURE FOR FILLING RESERVOIR
Refer to the System Schematic Diagram (LAT517EC-20-D3). Fill the lube oil
reservoir with lubricant in accordance with specifications given in Section 1. When
the system is not in service, the reservoir may be filled using the inspection hole on
either end of the reservoir. When the reservoir is pressurized, oil may be added by
using the manual fill pump (HP-001).
After all components, such as the coolers or filters, are filled with oil and free from
entrapped air, ascertain that the lube oil reservoir is filled to a point between
maximum and minimum levels, as specified in Section 1.5.1.
CAUTION:
LA TURBINE ALREADY FLUSHED THE OIL SYSTEM (RESERVOIR,
ACCUMULATOR, COOLER, AND/OR OIL PIPING SYSTEM) BEFORE SHIPPING.
THE CUSTOMER MUST PREVENT FOREIGNER MATTER FROM GETTINGINTO THE LUBE OIL SYSTEM.
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3-3
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).
3.3.3 Accumulator Bladder (AC-5000)
Verify that the accumulator bladder is charged to the correct pressure level specified
in Section 1.6. To charge the accumulator bladder before placing the unit into
service, perform as follows:
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).
3.3.5 Control Settings
Verify that all gauges, controls, and safety devices are properly connected, set, and
operative. Refer to Section 1.6 for correct lube oil operating temperature, pressure,
and viscosity readings, and for recommended control settings. Settings were made
at the factory, but they may have drifted during transit.
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LAT517EC INSTRUCTION MANUAL------SECTION 3
3-4
3.3.6 Seal Gas
Verify that a suitable seal gas supply is properly connected. The seal gas supply
requirements are listed on Section 1 of the manual and System Schematic Diagram
(LAT517EC-20-D3) drawing.
3.3.7 Instrument Air
Verify that a suitable instrument air supply is properly connected to the air header.
The instrument air supply requirements are listed in Section 1.4 and on the System
Schematic Diagram (LAT517EC-20-D3) drawing.
3.3.8 Nozzle ActuatorVerify that the range of the nozzle actuator rod responds proportionally to the
specified air pressure signal supplied by Customer. The range capability of the
actuator is usually greater than the nozzle actuator travel, which is set near the
middle of the actuator range. The positioner on the actuator is adjusted to make
the nozzle position respond proportionally to the air pressure signal. Refer to
Section 6, Component Manufactures Data and Nozzle Actuator ASSY. DWG.
(LAT517EC-20-D110)
3.3.9 Inlet Shutdown System (XV-5000, CUSTOMER SUPPLIED)
Verify that the expander inlet shutdown valve (Customer supply) is installed in the
process piping at the expander inlet and is functional. The solenoid valve must close
the expander shutdown valve within one-half (1/2) second . The shutdown valve
should be installed as specified on the Expander-Compressor Machinery
Arrangement (LAT517EC-20-D2) drawing.
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LAT517EC INSTRUCTION MANUAL------SECTION 3
3-5
3.3.10 Expander/Compressor Inlet Screens
Verify correct installation of the expander and compressor inlet screens (Supplied By
Customer). They are to be installed in the expander and compressor process inletpipes to the unit as specified on the Expander-Compressor Machinery Arrangement
(LAT517EC-20-D2) and System Schematic Diagram (LAT517EC-20-D3) drawings.
3.4 INITIAL STARTING PROCEDURE
3.4.1 General Instructions
Briefly, the starting procedure consists of: Admitting and regulating Customer's seal gas supply.
Starting the lube oil supply system.
Pressurizing the expander from discharge and compressor suction.
Admitting the process gas stream flow slowly.
Monitoring all control instruments and adjusting the oil pressure after the speed
and flow rate are set and stabilized.
3.4.2 Detailed Instructions
For correct seal gas and instrument air supply requirements and for correct lube oil
operating temperatures, pressures, and viscosity requirements refer to sections 1.3,
1.4, and 1.5.
NOTE:
ENSURE THAT THE PLANT PROCESS GAS IS COMPLETELY SHUT OFF FROM
THE EXPANDER BEFORE PROCEEDING WITH THE FOLLOWING STEPS:
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3-6
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 flowrequirements.
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.
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LAT517EC INSTRUCTION MANUAL------SECTION 3
3-7
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/orreplaced if necessary.
Clear annunciator system of all alarm and shutdowns.
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 oF-
continuous 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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3-8
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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LAT517EC INSTRUCTION MANUAL------SECTION 3
3-9
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.
3.5 NORMAL OPERATION & PERIODIC SERVICE
Normal operation requires only routine monitoring of the control system,
temperature gauges, and pressure gauges. List for seal gas system and
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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LAT517EC INSTRUCTION MANUAL------SECTION 3
3-10
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.
3.5.1 Servicing Oil Filter (F-5075/5080)
If a filter is taken out of service and drained, it must be refilled with oil before being
placed back in service. Otherwise, any air/gas left inside the filter may be forced
through the bearings and cause damage. Be careful not to disturb the oil pressure to
the bearings when filling the filter housing of the one being serviced.
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LAT517EC INSTRUCTION MANUAL------SECTION 3
3-11
To replace a duplex oil filter element while in operation:
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 nonoperating housing.
Select desired filter with the switching valve. If desired, the unit may be operated
with both filters on line.
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3-12
3.5.2 Auxiliary Lube Oil Pump Test
The auxiliary oil pump may be checked periodically by carefully cracking open the
test valve (NV-.5). This lowers the differential pressure at (PDI-5040) which will
automatically activate the auxiliary pump, and will signal an alarm.
CAUTION:
LOWERING THE DIFFERENTIAL PRESSURE BELOW THE LIMIT SET FOR PDI-
5040 (REFER TO "ALARM AND SHUTDOWN TRIP SCHEDULE") WILL TRIGGER
AN EXPANDER SHUTDOWN. THEREFORE, AVOID ABRUPT CHANGES IN OIL
PRESSURE.
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.
3.6 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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3-13
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.
If it is to be an extended shutdown, de-pressurize the expander and compressor
casings.
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3-14
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.
3.8 TOO COLD TO START
The bearings are well bonded thermally to the bearing housing, and if the bearing
housing is not cold, then the bearings should not be too cold - below approximately
80oF.
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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LAT517EC INSTRUCTION MANUAL------SECTION 4
4-1
SECTION FOUR
MAINTENANCE
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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4-2
4.1 DISASSEMBLY OF THE EXPANDER-COMPRESSOR
Disconnect all lube oil and seal gas piping and the pickup probes. Plug all lines to
prevent the entry of any foreign matter.
The referenced drawings clearly indicate the attachment of all assembled parts;
therefore, detailed hardware descriptions are omitted from the following
procedures:
4.1.1 Field Removal
Some of the components are heavy and a hoist should be made available for
support during field removal. When the mechanical center section (M.C.S.) is
removed in the field, extreme caution should be exercised in the handling of
internal parts. These parts have been precision machined and dynamically
balanced and careless handling of parts may result in irreparable damage. Avoid
marring any flange face or gasket face.
4.1.2 Disassembly Into Major Components
L.A. Turbine modular design enables disassembly into three major components:
expander case, mechanical center section (M.C.S.) and compressor case. This
eliminates the necessity of total disassembly when the main concern is isolated in
one of the three primary areas. To separate the system into major components
proceed as follows, referring to the Service Assembly (LAT517EC-20-D1) and the
Parts List (LAT517EC-20-A9) drawing.
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4-3
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
temporary use of two screws (501) which will aid in this step. Move the
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
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4-4
appropriate section in the following procedures.
4.1.3 Mechanical Center Section (MCS) Disassembly
Most parts in the mechanical center section (M.C.S.) fit tightly together, and are
provided with threaded holes for the use of jack screws during removal. The jack
screws to use for a part (except for expander, compressor wheels, expander case
and compressor case) are the retaining screws for that part. To ensure even
removal and to avoid damage to parts, turn both jack screws uniformly.
Position the unit horizontally on a workbench to facilitate component removal.
CARE MUST BE TAKEN NOT TO BUMP OR MAR EXPANDER WHEEL
(210), COMPRESSOR WHEEL (280) , HEAT BARRIER WALL (221),
COMPRESSOR SEAL (270), COMPRESSOR WHEEL BACK SEAL (290) OR
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 UNC-
2B 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)
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4-5
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 O-
rings (925 & 926).
4.1.4 Nozzle Actuator Assembly Removal
Refer to Nozzle Actuator Assembly (LAT517A-20-D110) drawing and to Section 6
COMPONENT MANUFACTURERS DATA under Fishers documents.
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. Care must be exercised during the
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4-6
removal procedure to ensure that the actuator rod or pin does not get bent.
Support the nozzle assembly with a hoist.
4.1.5 Variable Nozzle Assembly Removal
NOTE: It will be found that this is easier to the degree that the nozzle assembly
is kept square to the expander case. Refer to the Service Assembly Drawing
(LAT517A-20-D1) and Parts List (LAT517A-20-A9).
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 nozzlesegment (131) from nozzle cover (130) while removing the nozzle adjusting
ring and pin (132). If you encounter difficulty in separating these components,
use jackscrews.
4.1.6 Expander Case Disassembly
Remove screws (952) to separate the nozzle fixed ring (133) from the
expander case (100). Remove shim (134).
If necessary, the expander case diffuser (104) may be removed from the
expander from the expander case (100) by pulling it through the expander
exhaust. Remove gasket (106).
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4-7
4.1.7 Compressor Case Disassembly
To separate the compressor follower (310) from the compressor case
(300),remove screws (904). Remove shims (311).
4.2 CLEANING & REASSEMBLY
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 toprotect 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
Documents/Drawings, the following practices should be followed:
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4-8
RECOMMENDED SEALANTS AND LUBRICANTSProduct Name Application
1. Dow Corning 321 Nozzle/Inlet Guide Vane
Dry Film Lubricant Assembly
2. Gn Metal Assembly Paste Casing Bolts, Studs,Dow-Corning Nut FacesItem #01-275-5050
3. Jet Lube SS-30 Retaining Screws, Retaining
Anti-Seize Compound Washers, All Fasteners,
Threads & Nut Faces for
Internal Parts of the
Machines (Core Units)
4. Leak Lock Joint Sealer Tach Pick-up
by Highside Chemicals Threads, Gaskets on Nozzle
Cover & Actuator Bonnet
Assembly
5. O-Ring Adhesive #404 All O-Rings Joint Adhesives
by LOCTITE
6. Slic-Tite Teflon Paste Sealants for all Threadedby LA-CO Industries, Inc. Pipes & Fitting
7. Lanolin AAA Quality, Lubricants for O-Rings
Lano-Lube by Flexbar
8. Silite Silicone Sealant Sealant for Sealing
(RTV) by Devcon Machined Surfaces or
Special Applications
e.g. Take-off Hole Plugs
9. LOCTITE Superbond Bonding Between Rubber,
Adhesives Item #495 Metal, and Plastic Parts
With Gaps to .004" in
Electrical Shop Practices
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LAT517EC INSTRUCTION MANUAL------SECTION 4
4-9
10. LOCTITE Threadlocker # 242 Threads between Expander Wheel
Back Seal & Heat Barrier Wall, HeatBarrier Wall Insert & Heat Barrier Wall,Compressor Seal & Compressor WheelBack seal, Expander Case & NozzleFixed Ring
4.2.3 Re-assembly of Variable Nozzle Assembly
To re-assemble this unit, place the nozzle segments (131) on the pins of the
nozzle cover (130) in a closed position. Place the nozzle adjusting ring and pin
(132) over the nozzle segments and engage the segment pins into the slots of
the adjusting ring. Replace screw (951) to secure the assembly together.
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.
4.2.4 Tachometer Pickup/Vibration Probes
Refer to Service Assembly (LAT517A-20-D1), System Schematic P & I D
(LAT517EC-20- D3) and to the Electrical Bill of Materials (LAT517EC-20-A8).
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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LAT517EC INSTRUCTION MANUAL------SECTION 4
4-10
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.
TABLE (1): TORQUE FOR CASING BOLTS
Bolt Thread Torque Bolt Thread Torque
Size Type Size Type
(in) (ft-lb) (Kg-m) (in) (ft-lb) (Kg-m)
1/4 10 UNC 4.75 0.66 1 8 UNC 284 39.27
5/16 48 UNC 8.5 1.18 1 1/8 7 UNC 404 55.86
3/8 16 UNC 15 2.07 1 1/4 7 UNC 569 78.67
7/16 14 UNC 24 3.32 1 3/8 6 UNC 753 104.11
1/2 13 UNC 37.5 5.18 1 1/2 6 UNC 989 136.74
9/16 12 UNC 46 6.36 1 3/4 5 UNC 1609 222.46
5/8 11 UNC 63.5 8.78 2 4 1/2 UNC 2436 336.79
3/4 10 UNC 113 15.62 2 1/4 4 1/2 UNC 3549 490.67
7/8 9 UNC 189.5 26.10 2 1/2 4 1/2 UNC 4466 617.46
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LAT517EC INSTRUCTION MANUAL------SECTION 4
4-11
4.3 INSPECTION
4.3.1 Recommended ClearanceCheck the journal and thrust bearings, and shaft for wear. Carefully examine the
bearings and thrust washer faces for any signs of wear, such as scoring or babbitt
depletion. If the wear is excessive, replace them with new parts. If there is difficulty
determining whether the bearing is still satisfactory for use, consult the manufacturer
before putting them back in operation. The recommended allowable clearances for the
unit are given on the Clearance Modular System (7770001062).
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.
4.3.3 Labyrinth Seal Clearance
SEE 7770001062
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LAT517EC INSTRUCTION MANUAL------SECTION 4
4-12
4.3.4 Compressor Wheel Clearance
To set the clearance between the compressor wheel (280) and the compressor
follower (310), first measure the shaft axial endplay. Next, push the shaft towards the
expander end as far as the thrust bearings permit, and place soft solder wire at severa
points on the face of the blades. Engage MCS and compressor case in normal
operating relationship, including tighten the retaining screws. This crushes the solder
to the maximum clearance. Withdraw the compressor follower through the
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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LAT517EC INSTRUCTION MANUAL------SECTION 4
4-13
4.4 RECOMMENDED SPARE PARTS LIST
"USE OF UNAUTHORIZED PARTS NOT ONLY INCREASES YOUR RISK
EXPOSURE IN TERMS OF A REDUCTION OF LAT WARRANTYOBLIGATIONS 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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LAT517EC INSTRUCTION MANUAL------SECTION 4
4-14
4.6 LATURBINE SERVICE /EMERGENCY CONTACT LIST
DIRECT SERVICE RESPONSE PARTNER
Office Phone: (661) 294-8290
Mr. Troy OSteen Sales ManagerOffice Phone: (661) 294-8290 Mobil Phone: (661) 755-0949e-mail: [email protected]
Mr. David Bloss Field Service Business Manager
Office Phone: (661) 294-8290 Mobil Phone: (661) 755-1942e-mail: [email protected]
Mr. Michael walhof Sales DirectorOffice Phone: (661) 294-8290 Mobil Phone: (832) 289-4654e-mail: [email protected]
Mr. Houman Shokraneh Engineering DirectorOffice Phone: (661) 294-8290 Mobil Phone: (661) 231-5295
e-mail: [email protected]
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LAT517EC INSTRUCTION MANUAL------SECTION 5
SECTION FIVE
DRAWINGS
Drawing Title Rev L.A. TURBINE Dwg. No.Service Assy Exp-Comp 1 LAT517-20-D1
Expander- Comp. Machinery Arrangement 5 LAT517EC-20-D2
System Schematic P & I Diagram 5 LAT517EC-20-D3
Wiring Diagram 3 LAT517EC-20-D4
Control Panel Layout and details 3 LAT517EC-20-D5
Electrical Bill of Material 2 LAT517EC-20-A8
Machine Parts List 0 LAT517-20-A9
Maximum Pipe Nozzle Load 1 LAT517EC-20-A10System Bill of Material 5 LAT517EC-20-A11
Instrument Index 1 LAT517EC-20-C16
HMI Instruction Manual 0 LAT517EC-20-A42
Campbell Diagram 0 LAT517EC-20-A82
Anti-Surge Algorithm 1 LAT517EC-20-A86
Performance Data Sheet 2 LAT517EC-20-A96
Nozzle Actuator Assy 0 LAT517EC-20-D110
Assembly Clearances Exp-Comp (2000 Frame) 0 7770001062
5-1
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LAT517EC INSTRUCTION MANUAL------SECTION 6
6-1
SECTION SIX
COMPONENT MANUFACTURER'S DATA
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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LAT517EC INSTRUCTION MANUAL------SECTION 6
6-2
COMPONENT MANUFACTURER'S DATA
(ALPHABETICALLY BY COMPANY NAME)
For the components tag numbers refer to the following documents: System Bill ofMaterials (LAT517EC-20-A11) and Electrical Bill of Materials (LAT517EC-20-A8).
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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LAT517EC INSTRUCTION MANUAL------SECTION 6
MISTER MESH
PARKER
PENBERTHY
ROSEMOUNT/EMERSON
SOUTH GATE ENGINEERING
TYCO
T.R. ENGINEERING
THERMOELECTRIC
ZEMARC (GREER)