Turbo Expanders For Cold Production and Energy Recovery Booklet PDF
Turbo Expanders For Cold Production and Energy Recovery Booklet PDF
Turbo Expanders For Cold Production and Energy Recovery Booklet PDF
Since Cryostar began in 1966 and followed with the production of their first turbine in 1974, their
focus and expertise has been to provide their customers with turbo-expander/compressor and
energy recovery systems for cold production and liquid recovery with the highest efficiency
ensuring economical and reliable operations.
Today, Cryostar’s installed base, including industrial gas machines, exceeds more than
1,200 turboexpanders located in more than 60 countries worldwide.
Cryostar’s innovative drive and continued commitment to invest in and develop their world class
engineering skills has moved them to the forefront of technological development in all their product
lines. Every turbines is designed using state-of-the-art technology to ensure each customer the very
best in product design. With a policy to the commitment to excellence, Cryostar has earned a position
as a world leader in their markets.
The results of Cryostar’s policies are clear: Companies have put their trust in Cryostar by selecting
Cryostar to supply turbo-expanders for many of the major projects in the Middle East, the North Sea
and Africa. Their success is explained by their commitment to the needs of their clients and partners
in:
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TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY
● Cryostar was the first company to supply 8 AMB expanders for natural gas processing (offshore
conditions in the North Sea environment)
● Cryostar has the largest base of expanders equipped with AMB in operation in the world
● Proven expertise of applications: dew point control, ethane recovery, NGL recovery, LNG production
and project with high amount of liquid at expander outlet.
● A complete range from 100 kW up to 12 000 kW with inlet pressure up to 150 bar and inlet temperature
down to -196°C as standard
● A company certified ISO 9001/2000. Cryostar was one the first companies to be ISO certified in its
field of activity.
● Use of the latest technologies to design their turbo-expander to obtain for each project the best
performance (each wheel is unique): Final Element Analysis, Computational Fluid Dynamic, 3D
modelisation, Laser Holographic test…
● Combination of their qualified service department with a design focus towards minimal downtime
and high availability results in maximum savings for your plant operations.
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Cryostar provides the
best configuration to match to the application
Cryostar designs all their turbo-expander packages to the strictest of industry and client requirements.
Compliance to API 617 is standard and in addition, each machine can be fully customized to meet even
the most stringent of client requirements.
To assure customers on-time delivery to the agreed specification level, an engineering team is selected
at the beginning of each project. The team includes of aero-designers, specialists in rotating machinery,
instrumentation and control systems, seal gas and lube oil systems all coordinated by a project manager
in conjunction with the quality department, fully involved at each step of the project.
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TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY
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8
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Inlet guide vanes adjusting mechanism – variable flow nozzles
For efficient flow control the expander is equipped with a variable inlet guide vanes assembly. Cryostar
expander variable inlet guide vanes are designed to provide zero by-pass losses (no loss of efficiency),
precision movement control and high efficiency over a wide operating range.
Similar to the wheel design, extensive use is made of superior computer programs for the optimization
of the nozzle shapes. It allows the optimal design of the vanes and limits the size of the actuator.
Preconditioned materials, matched clearances and special surface treatments assure smooth operation
at all conditions.
All Cryostar expander and compressor wheels are designed for the best efficiency. Modal analysis is
carried out for each wheel with the latest FEA methods, avoiding wheel blades resonances.
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TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY
Labyrinth seal
Seal gas
It is used when leakage of process gas can be recovered
inside the system or when it can be sent to a vent/.flare
system. The number of labyrinths depends on the process
conditions. The buffer gas is injected between the labyrinths.
This arrangement is not too sensitive to the quality of buffer
gas (particles content).
Intermediate Inner
Separation Labyrinth
seal labyrinth Primary
labyrinth
Secondary
Back-up seal
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BEARINGS: conventional type (oil lubricated bearings)
or active magnetic bearings?
Active Magnetic Bearings: not only the solution to decrease the dimensions and weight of the machine (no lube
oil system) but also a package with three key advantages:
● no risk of process contamination by oil.
● elimination of vibration: the active bearings cancel synchronous vibrations by letting the shaft free to rotate
around its inertia axis.
● no maintenance concept.
Cryostar has been the first company to develop and to implement AMB on expander/compressor used in natural
gas processing.
Electromagnets
Electromagnetic forces
ROTOR
laminations
F
Radial bearing
axial axial
The system includes also auxiliary ball bearings with damping mechanism to prevent destructive whirl during
coast down of the machine. Auxiliary ball bearings typically consist of ceramic balls with steel races.
A dedicated control panel containing amplifiers, control electronics and other equipment necessary for the
operation and safety of all magnetic bearings is part of the package. It provides alarm and shutdown protective
logic for the magnetic bearings, auxiliary bearings and control cabinet by itself.
Monitoring information in terms of speed, radial load, thrust load are available.
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TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY
The oil lubrication system is dedicated to ensure a proper and continuous lubrication of all bearings
and gears of the machine.
Cryostar is able to provide simple and low cost oil lubrication system but also some optimized systems
designed as per API 614 standard, latest edition. These systems meet the most stringent technical
requirements in term of selection of equipments, materials and test to be performed.
Under client request, Cryostar can build the oil system according to the latest edition of NACE MR0175
standard, in order avoid any risk due to sulfide stress and stress corrosion cracking.
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Control system of turbo-expanders
Cryostar turbo-expanders can be built with simple or very
sophisticated control systems, standard or fully customized.
The control system can be installed locally on the skid or can be
remote for installation in the control room for instance. In case
the client requires the possibility to achieve a local control (local
start/stop…) a combination is also possible.
In case of expander loaded with synchronous generator, Cryostar can provide a full package including
the generator control panel with protection devices, synchronizing function, voltage regulation…
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TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY
TECHNOLOGICAL EVOLUTION:
The latest technology to design your turbo-expander
During recent years, technological advances have provided modern high tech tools and they have
drastically changed the way Cryostar designs its equipment.
Cryostar has invested in the latest technology to support the expertise and shorten its response time.
Cryostar employees use state-of-the –art tools through the entire process.
● Computer Aided Design/Computer Aided Manufacturing [CAD/CAM] systems are used across the
entire design and production process.
● Finite Element Analysis [FEA] system is used to analyze static and dynamic impeller stresses for
robust wheel designs.
● Three-Dimensional Computer Fluid Dynamic [CFD] codes enables the analysis of the flow through
each stage. Combined with in-house blade design tool this results in the design of high-efficiency
impellers, inlet guide vanes and diffusers.
● Product Data Management [PDM] system enables to perform concurrent design activities by different
engineering disciplines which in turn significantly reduces the time of delivering a high quality turbo-
expander for your application.
● Fully computerized monitoring and data acquisition system performs accurate and precise testing.
Cryostar has invested in tools and facilities in order to reduce manufacturing costs, improve quality,
and shorten delivery schedules.
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Inspection and testing
For each machine built by Cryostar, an inspection and test plan (ITP) is prepared. Depending on the
project, the API 617 standard and ASME PTC10 code requirements are followed.
The ITP includes detailed information relating to the tests performed on the machine: hydrostatic
test, non destructive examination test, hardness test, welding test, positive material identification,
painting, wheels and rotor balancing, over speed testing, mechanical running test with vibration
measurements, performance test, noise test and other tests as per client requirements.
For example, all Cryostar rotating elements are dynamically balanced by precision microprocessor
controlled balancing equipment to ensure smooth operation over the entire operating speed range.
Cryostar uses state-of-the-art computer based data acquisition and vibration analysis equipment for
testing our turbo-expanders and all tests are conducted in accordance with ASME test codes. Cryostar
test facilities provide high-test accuracy, repeatability, and reliability.
A completely in-doors test facility is available since October 1999. Performance and mechanical run
testing are carried out with air using an open loop configuration.
Investing in excellence
To meet growing customer demands Cryostar committed to a rolling programme of investment in
workshop, test and office facilities. In 2006, the company completed a new workshop, and in 2007
opened an adjacent test stand. This third compressor/turbine facility offers:
● A total area, including compressors and frequency drive room, of 910 m² (650 for the test facility
itself and 260 m² for the air compressors and inverter rooms.
● A power supply of 6 MW / 6.6 kV / 50-60 Hz with the possibility to increase to 8 MW with additional
external generators
● Two air compressors of total 2 MW which can achieve 20000 Nm3/h – 10 barg in order to test the high
powered turbines
● A frequency drive of 6 MW
● A water tower of 6 MW with a circuit designed for 550 m3/h and
● An air compressor to supply dry and clean air for the whole facility
With the additional test facility, Cryostar will be able to test not only the ‘companders’ but also the
high powered TG and MTC turbines (3-12 MW).
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TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY
The diversity of the equipment allows Cryostar to cover a full operating envelope, maintaining a safe
and reliable operation whatever the propulsion system may be.
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CRYOSTAR & TRAINING - Centre of learning excellence
Forming partnerships with customers enables Cryostar to offer
efficient and bespoke services. The company’s Training Centre is
an extension of that partnership, adding value where the customer
needs it…
From its humble beginnings to support customers with knowledge
about Cryostar equipment, the Centre is now looking to offer bespoke
training packages across a wide range of topics.
To date, the Centre has attracted the support of many major companies,
including Daewoo, Samsung and Hyundai Korean Shipyards, Statoil of
Norway, Toyo Engineering of Japan, CLSICO of China, Petrofac UK, Air
Liquide and White Martins Gases of Brazil to name but a few.
Didier Walch, Customer Service Director, said: “The Training Centre
has become a strong relationship and technical link between the
company and more than 250 customers who attended our courses
last year”.
Lucien Gruppi, Training Co-ordinator added:
“In the future, the number of courses and sessions will increase.
Hands-on-sessions will also be improved, with the help of assembly
and maintenance workshops, and our test bed facilities.”
Cryostar’s global network of Business Centres will also be involved,
ensuring training sessions can be held locally, a huge advantage when
it comes to keeping travel costs down.
“It is Cryostar aim to expand this training offer, to give customers access
to a true centre training of excellence. As a result, Cryostar has selected
the best engineers and people to identify topics and design courses.
All courses will be available in a database managed with “Livelink
from Opentext”.
Structured learning
The training Centre is driven by three main processes:
● Analysis of the training needs (customers and internal).
● Production of the training material and updates.
● Training courses preparation and performances.
Our pre-sales and after sales service is second to none, which means customers receive expert
advice through the whole design and purchase cycle as well as possibilities of long term maintenance
contracts once the turbine is up and running to guarantee investment.
The Cryostar headquarter in Hesingue, France hosts one of the worlds biggest and most sophisticated
pump and turbine testing facilities. Here they pre-test all turbines leaving their site, ensuring that
only products that have passed their stringent test requirements are shipped to the customer.
CRYOSTAR France
CRYOSTAR Automation
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