Module 6 START-UP & OPERATION INSTRUCTIONS

BRITISH GAS Tunisia

Site Training session March 2009 - HASDRUBAL Project
Turbo Expander / Re-compressor unit
CRYOSTAR MTC 300/150
INTRODUCTION

www.cryostar.com
For training purpose only contact@cryostar.com 1
 Module 6 START-UP & OPERATION INSTRUCTIONS

 ALARM

An alarm is activated in case of a potential problem for the machine.

A “Common alarm” information is sent to the CMS .

A root cause analysis shall then be carried out, and fault reset.

For training purpose only 2

 Module 6 START-UP & OPERATION INSTRUCTIONS

TRIPS

They can be generated :

- from AMB panel
- from Skid (Systems, machine)
- from CCC Controller
- from EMS button
There are different TRIP levels:

Emergency Shutdown Trip 1

Emergency Shutdown Trip 2

In both cases a Common Trip information is sent to the ESD system.

For training purpose only 3

 Module 6 START-UP & OPERATION INSTRUCTIONS

COMMON TRIP

For training purpose only 4

 Module 6 START-UP & OPERATION INSTRUCTIONS

TRIP 1

A “Trip 1” signal is triggered to prevent damage to the

Turboexpander-Recompressor. In this case, the machine is
tripped, a “Trip 1” information is sent to the ESD.

In case of a “Trip 1”, the rotor is maintained in levitation as

active magnetic bearings remain energized.
This trip is initiated by:
 Seal gas differential pressure
 Over speed / under speed
 AMB radial & axial position
 AMB bearing temperature
 AMB over speed / under speed / max continuous speed
 AMB common trip & watchdog failure
 CCC system (hardware, surge)

For training purpose only 5

 Module 6 START-UP & OPERATION INSTRUCTIONS

TRIP 1
Normal Emergency Shut Down steps are:
P&ID
 Closing of Inlet main valves on process lines.

 The Anti-Surge system Valve (FV-07009) shall be opened with quick

exhaust within 1 or 2 seconds.
 Closing of the Quick Shut-off Valve (XV 07411).
 The turbine will coast down very fast due to the high load on the booster
side.
 The nozzles will close by the control signal set to zero (CCC).

In case of AMB bearing temperature HH, the AMB cannot withstand the
rotor levitate. In this case, the control cabinet will perform an automatic
de-levitation as soon as the LL speed limit is reached (typically 1200 rpm),
but bearing carrier remains pressurized.

For training purpose only 6

 Module 6 START-UP & OPERATION INSTRUCTIONS

TRIP 2

A “Trip 2” signal is triggered to prevent all risks of explosion of

the
machine.

In this case, the machine is tripped

A “Trip 2” information is sent to the ESD, and Common Trip
generated
This trip is initiated by:

 Cavity pressure pressure LL

 Plant ESD
 EMS on skid

For training purpose only 7

 Module 6 START-UP & OPERATION INSTRUCTIONS

TRIP 2
Critical emergency shut-down steps: P&ID

 Closing of the Quick Shut -off Valves.

 Closing of Inlet main valves on process lines

 Full opening of the ASV within 1 or 2 seconds.

 Closing of Seal Gas Valve (XV-07410)

 The nozzles will close by the control signal set to zero.

 AMB power is cut off (batteries ensure safe de-levitation of rotor)

 Rotor will be de-levitated (ESD action, speed < 1200 Rpm)

 Opening of all automatic drain valves

For training purpose only 8

 Module 6 START-UP & OPERATION INSTRUCTIONS

Trip1

Trip2

Cavity
Press.

For training purpose only 9

 Module 6 START-UP & OPERATION INSTRUCTIONS

Reminder: the AMB Turboexpander is equipped with 4 speed detectors.

Expander side Compressor side

Speed probe

Auxiliary Axial
Radial
Bearings bearing
bearings
(ball bearing) s

The temperature probes

(PT100) are embended in
Radial and axial
the windings of the axial position sensor
and radial bearings
For training purpose only 10
 Module 6 START-UP & OPERATION INSTRUCTIONS

The 2 speed probes for the Expander side: SIT 07410A & B
The 2 speed probes for the Compressor side: SIT 07410C & D

Machine C – 0751/0752

Impeller Turbine Compressor

Inlet/Outlet -18.95/-66.44 36.73/70.67

temp.(°C)
Nominal (Rated) 21200 rpm
speed
Min operating 9800 rpm
speed
Max continuous 22300 rpm
speed
Trip speed 23400 rpm
Wheel periph. 283.16 m/s 333.26 m/s
speed (at trip
speed)

For training purpose only 11

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION

 This chapter will describe how to

prepare, start, operate and shut down
a turbo expander with AMB
 The preparation for start-up

consists on the following steps which

must be conducted in this order:
 Inerting/Purging
 Powering AMB cabinet and levitating the rotor
 Pressurizing
 Operating seal gas
 Draining

For training purpose only 12

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION

PREPARATION PRIOR TO INITIAL START-UP

 The turbo expander must always be considered

pressurized, as long as not proven to be
depressurized and purged.
 Before starting any maintenance work make
sure that the machine is :
- depressurized,
- properly purged,
- vented
in order to avoid accidents by high gas pressure, as
well as the formation of explosive gas/air
mixtures.
For training purpose only 13
 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION

PREPARATION PRIOR TO INITIAL START-UP

 The different built-in indicators of

the transmitter board will display the
actual pressures in the various cavities
of the machine.

 Make also sure that all internal shut-off

valves were opened prior to
depressurization

For training purpose only 14

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP
Purging

 Before starting the Turbo-expander all internal parts of the package unit
(machine, seal gas line, drain lines, vent lines …) shall be purged with inert gas and
dried in strict adherence with the maintenance and operation procedures. The aim
is to keep the machine safe by removing the oxygen and avoid any air ingress
(electric components).
 Purging must occur prior to filling the machine with Process gas and prior to
pressurization in order to avoid hazardous gas pockets of an oxygen/hydrocarbon
mixture.
 For the purging procedure the entire system must be isolated by the Process
isolation valves (manual & Automatic). All MTC internal valves shall be open to
enable complete inertization.
 The inertization by pressurizing and depressurizing is the only recommended
method, as it inerts also all cavities and piping death ends.
For training purpose only 15
 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP
Purging

 The inertization shall be done by pressurizing the entire package unit with
inert gas via Inert gas supply CP9, and at a pressure of at least 8 barg.
 After each pressurizing the package unit shall be depressurized via a drain
point to the flare (CP8).
 An Oxygen analyser (scope Client) shall be placed at the gas vent point.
An Oxygen concentration of maximum 0.06% shall be measured after each
of pressurizing/depressurizing step.
 During this inertization process, internal drying of the machine will be
performed as well.

For training purpose only 16

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP
Purging

Pressure transmitters (2oo3) are measuring the

pressure of the Bearing Carrier. An alarm set point is
set on Low Pressure (PIT 07420) and a trip set point
on Low Low Pessure (PI 07417). The trip set point is
set to 2.0 barg.
 Once the cyclic pressurization (purging) is
completed the entire package unit shall be kept at a
pressure of above 2 barg .

 After installation and maintenance, purging of the

internal parts is compulsory and must be checked /
confirmed and signed by an authorized person.

For training purpose only 17

 PREPARATION PRIOR TO INITIAL START-UP
Module 6 START-UP & OPERATION INSTRUCTIONS

PREPARATION PRIOR TO INITIAL START-UP

- The pressurization is done by opening the isolating and the inertizing valves
- After each pressurization the package unit shall be depressurized via a purge point
to the flare.

For training purpose only 18

 Module 6 START-UP & OPERATION INSTRUCTIONS

PREPARATION PRIOR TO INITIAL START-UP

The depressurisation can be done by opening draining valves (CP8 line)

For training purpose only 19

 Module 6 START-UP & OPERATION INSTRUCTIONS

PREPARATION PRIOR TO INITIAL START-UP

Pressurize

Drain

For training purpose only 20

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Hazardous area protection

 The MTC needs electrical energy to feed the

magnetic field causing levitation of rotor.
This electrical energy is without danger, as long as
the turboexpander is operated in strict
accordance with the operating procedures.

For training purpose only 21

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Hazardous area protection

 The machine is operated in a hazardous

area. All necessary cautions have been taken
during the engineering phase.
 All instruments are selected according to
the required area classification.
 The AMB cable feedthrough (cable
connectors) and junction boxes are Ex
certified.

For training purpose only 22

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Hazardous area protection

 The machine itself is hermetically

encapsulated and the windings are situated
in an oxygen-free (i.e. inert) gas
atmosphere.

 Therefore, the safe machine operation is

not assured by certification requirements
but by strict fulfilling with the maintenance
and operation procedures.

 The Turboexpander-recompressor unit

is, in this respect, not different from the
process pipes or any other pressure vessel.

For training purpose only 23

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Levitation

 Once the correct purging has been done and checked, (PIT 07420)
the signal “Authorization to energize” can be sent
AMB panel from the CMS/ESD (software switch XS 07525)

 Operator can now proceed to suspension of the rotor.

For training purpose only 24

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Levitation

The signal “Authorization to energize” was sent (CMS).

If there are no interlock conditions (Low pressure in the cavity or Shut down
condition), the AMB cabinet can be energized.

Operator will manually close the main switch Q1 of the AMB Control Panel.

For training purpose only 25

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Levitation

Once AMB panel is energized (and alarms reset), “Levitation allowed”

information comes on local display and is sent to CMS.

CMS validation to the AMB Control, allows rotor suspension (XA-07503).

“Levitation” will be then displayed on AMB Cabinet

For training purpose only 26

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Pressurization while Levitation

Machine is safe as long as the pressure of the

Bearing Carrier is kept above the minimum set
point .

As the internal pressure drops below the set

point, the machine will shut down (Trip2) and the
power supply to the AMB panel switched off
(ESD).

For training purpose only 27

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Machine pressurization

The rotor shall be levitated before any pressurization,

- Bearing carrier shall be pressurized by the seal gas line

- Expander and Compressor casings by process gas lines via the
by-pass valves.

!
For training purpose only 28
 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Machine pressurization

Prior to start-up of the pressurization step

The globe valve between the bearing carrier

and the compressor inlet shall also be fully
opened.

(Active Magnetic Bearings energized)

(Rotor levitated)

For training purpose only 29

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP
Machine pressurization

Expander & Compressor casings pressurization is – typically -done by opening the

manual valves by-passing the main isolation valves of Expander outlet and
Compressor inlet lines (same as per Purging).

The Bearing casing pressurization is done by opening Seal Gas valve (XV07410)

As per the purging sequence, this pressure measurement is taken in the Bearing
Carrier.

After pressurization, the bypass Process valves shall be closed and the main
process isolation valves (customer scope) at Expander inlet/outlet and
Compressor inlet/outlet shall be open.

For training purpose only 30

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP
Start-up of Seal Gas system (machine pressurization)

Prior to start-up of the Seal Gas system:

Main process isolation valves at

Turboexpander - Recompressor inlet/outlet
shall be opened.

The Seal gas valves shall be closed.

The globe valves between the bearings and

the compressor casings shall be full opened.

The ball valves at connection points

on the TEX Seal Gas supply line, shall be full opened.

For training purpose only 31

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Start up of seal gas system

To start the Seal gas system the following steps must be followed:

 Open the Seal Gas valve to the Bearing Carrier (clean seal gas from
external source)

The Seal gas is “warm” (11°C), to avoid condensates.

 Adjust the Seal Gas differential pressure with PDCV 07410 valve (the related
bypass valves are closed, the isolation valves are opened).

 Set point is 0.5 bar

For training purpose only 32

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
PREPARATION PRIOR TO INITIAL START-UP

Draining

Drain any possible liquids from the expander, bearing and compressor casings,
by short opening of the respective valves.
After draining, close all valves.

For training purpose only 33

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
READINESS FOR EXPANDER START UP

All the alarm and trip set points shall be reset.

With the seal gas system, magnetic bearing

system, control system and all subsystems as
described above operational, the machine can
be declared ready for start-up.

While Commissioning:

Only an authorized Cryostar representative is

allowed to give the approval to enter the
commissioning phase.

For training purpose only 34

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
READINESS FOR EXPANDER START UP

Ready to start sequence

Before starting the machine, the following steps shall be followed:

1. The process plant is running in J.-T. valve operational mode, in steady-state

operation.

2. Following equipment position must be checked:

9 J.T. valve => OPEN

9 Compressor anti-surge valve => OPEN
9 Expander adjustable nozzles => CLOSED (mini 2%)
9 Quick closing valve => CLOSED

For training purpose only 35

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
READY TO START SEQUENCE

Ready to start sequence

3. The entire system has been purged.

4. Only after steps 1, 2 and 3, AMB cabinets shall be powered by authorized people.
5. Bearing carrier has been pressurized by seal gas line, Expander and Compressor
casings through Process gas lines.
6. Seal Gas system is operational
7. Casings have been drained
8. All trip conditions and alarms have been reset.
When all above conditions are fulfilled, the “Ready to Start” indicator on the CMS
will blinck.

Ready to Start
For training purpose only 36
 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
START-UP OF THE TURBO EXPANDER

All alarms, trip points and start interlocks must be satisfied (ref. Set Point list)

Quick Closing valve and nozzles must be closed

Compressor Anti-surge valve must be opened.

When pressing the START push button on the CMS, the QCV will open and the
machine will accelerate to a certain speed, as given by the closed nozzles leakage.

For training purpose only 37

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
START-UP OF THE TURBO EXPANDER

The nozzles shall be open slightly until the speed is above the minimum speed.

(1200 rpm/10s) to avoid trip (broken speed probe protection, inhibited 30s at start).

The J-T valve shall be closed while nozzles are opening so that the turbine
inlet pressure is maintained (CCC controller).

Step is 1% /s increase to reach warm-up speed for 5mn (8000 rpm, auto
mode by CMS).

When the turbine rotates, observe all system and turbine parameters to be within

normal range during this warm-up (Seal Gas ΔP, Bearings temperature).

For training purpose only 38

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
START-UP OF THE TURBO EXPANDER

Speed can be manually increased until reaching 11000 rpm (1rst No Dwell Zone
point), then the CCC system automatically ramps up to second NDZ point, 14300
rpm/1mn.
Manual control becomes possible again.

- All previous steps would be automatically managed

Operation Speed should be kept over Underspeed trip level (T1 by AMB control) –
5000 rpm.

Step increase is 1% /s to reach rated speed (21200 rpm).

For training purpose only 39

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
STEADY STATE OPERATION

In steady-state operation, the rotating speed shall be maintained below

the maximum continuous speed (22300 rpm).

As long as the expander/booster is operating in automatic mode it does

not need special attention, other than regular observation of the machine
behaviour by Operators and plant Supervisors.

The following are the typical checks to be performed regularly

during supervision walks :

 No surge allowed (inadequate flow rate at the given operating speed)

characterized by erratic compressor inlet and discharge pressure and
flow pulsations (usually audible) .

For training purpose only 40

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
STEADY STATE OPERATION

 Check the Seal Gas Pressure control Valve PDCV 07410 and readjust it
when necessary.

 Check bearing cavity parameters (pressure & temperature)

 Observe the axial thrust behaviour on the AMB cabinet.

 Check complete operating system for seal gas, control air and process gas
leakage regularly.

For training purpose only 41

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
STEADY STATE OPERATION
 Check seal gas filter pressure drop PDIT 07411 regularly.
Replace filter elements as described in the manual.

Regularly check the pressure drop of the inlet strainers .

 Adjust the nozzle opening and the machines loading to the

desired production by operating the Controller.

 Correct any alarm or interlock conditions immediately or as

soon as possible, considering that any alarm may lead to a trip.

For training purpose only 42

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION
EXPANDER NORMAL SHUT-DOWN

The normal Shut down can be initiated from the CMS control room

The following are the normal shut down steps :

 Keep the seal gas supply to the turbine operational.

 Unload the turbine by slowly closing the nozzles to fully closed position

 Slowly open the anti-surge valve to full opening.

 Quick-Shut-off valve to be closed from CMS.

For training purpose only 43

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION

EXPANDER NORMAL SHUT-DOWN

When desired, after the Stop sequence, the turbine can be

isolated by Process isolation valves .

Note :

Under normal conditions, Process isolation valves do not

need to be closed, but then, the rotor has to be kept levitated
in order to avoid uncontrolled machine rotation on auxiliary
ball bearings.

If Operator decides to delevitate the machine, Process

isolation valves must be closed.

Keep machine bearing barrier pressurized while lock-out is

performed.
For training purpose only 44
 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION

EMERGENCY SHUT-DOWN

The request for an Emergency shut down can be

issued from from different plant locations such as: Trip 1

 ESD (external) plant trip or other machines inter-trip

 AMB control cabinets, or Emergency Stop button

located on the skid.
!
Trip 2

For training purpose only 45

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION

EMERGENCY SHUT- DOWN

During an ESD where the AMB are de-energized, the Safety batteries will
ensure the rotor keeps suspended, until the minimum speed is reached
(typically 1500 rpm).

In case of QCV closing failure, the Process isolating valves shall be closed.

A typical QCV closing failure is detected when: (check CCC control

conditions)

• The QCV limit switch has not been activated within 5 seconds after
closing request (XZSC 07411)

• The turbo expander Low Low speed (1200 rpm) has not been reached
within 30 seconds after QCV closing request

For training purpose only 46

 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION

EMERGENCY SHUT-DOWN

Deviation from following parameters can initiate a trip

request resulting in an ESD:

 AMB Overspeed

 AMB Low speed

 AMB Watchdog Failure (Software/Hardware)

 AMB shaft displacement

!
 Seal gas supply diff. pressure Low Low (0.3/0.35 bar)

 CCC Controller failure,Others…

See TRIP 1
For training purpose only 47
 Module 6 START-UP & OPERATION INSTRUCTIONS

OPERATION

EMERGENCY SHUT-DOWN

Emergency Shut-down with AMB de-energized

Deviation from following parameters can initiate a trip

request resulting in an ESD with AMB de-energized:

 Bearing cavity pressure Low Low

 Emergency push button on skid

 Process trip from the ESD

!
This trip request isolates the power supply to the AMB
panel.

See TRIP 2
For training purpose only 48
 Module 6 START-UP & OPERATION INSTRUCTIONS

Questions ?

Thank you for your attention !

For training purpose only 49