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This manual is one of a series for your In order for you to learn the contents of
use in learning more about equipment that the manual, you must dig out the pertinent
you work with in the petroleum industry. Its facts and relate them to the subject. Simply
purpose is to assist in developing your knowl- reading the material and answering the ques-
edge and skills to the point that you can per- tions is not enough. The more effort you make
form your work in a more professional man- to learn the material, the more you will learn
ner. from the manual.
The manual was prepared so that you can Teaching yourself requires self-discipline
learn its contents on your own time, without and hard work. In order to prepare yourself
the assistance of an instructor or classroom for the sacrifice you will have to make, you
discussion. Educators refer to learning by self- should set goals for yourself. Your ultimate
study as Programmed Learning. It is a goal is to perform your work in a more profes-
method widely used in all industries as a sional manner. Training is one step in reach-
means of training employees to do their job ing that goal. Application of what you learn is
properly and teach them how to perform another. Seeking answers to questions is a
higher rated jobs. third.
You can demonstrate your desire to be a Once you have established your final goal,
professional by taking a positive attitude to- you must determine the means for reaching
ward learning the contents of this manual and that goal. You may decide, for example, that
others that are applicable to your job. you must complete a series of 10 to 15 manu-
als to get the basic knowledge and skills you
The author of this manual has years of need. After you decide which training mate-
experience in operating petroleum equipment. rial is required, you should set a time table for
He also has the technical knowledge of how completing each section of the material.
and why petroleum equipment functions. The
text was written for use by personnel with little Achieving your final goal may take more
or no previous experience with petroleum than a year, and will require hours of hard work
equipment. Consequently, some of the mate- on your part. You will know you have achieved
rial may be familiar to you if you have experi- your goal when you understand how and why
ence with oilfield equipment. From such ex- to operate oilfield equipment in order to ob-
perience, you have observed the effect of tain the maximum product at the lowest cost.
making operating changes. The manual will Your sacrifice will have been worth-while from
help explain why the changes occurred that the satisfaction of knowing that you can per-
you observed. It will also teach you how and form your job in a methodical professional
why equipment functions. manner, instead of a trial-and-error approach.
© 2003 Petroleum Learning Programs Ltd. No part of this manual may be reproduced in any form. Its use as a
reference in training courses is specifically reserved for Petroleum Learning Programs Ltd. All translation rights are
likewise reserved.
This your manual. You should write your 1. Turn to Page 1. Read the material until
name on the cover. Upon completion you will you come to the first problem or ques-
find it helpful to keep it in an accessible place tion.
for future reference. 2. Work the first problem or answer the
question and enter the answer in the
Problems are included throughout the text. proper space in ink. If the problem or
The solutions to the problems are given at the question is shown in both SI and En-
end of the book. glish Units of measurement, answer
only the part in units of measurement
The manual is used in training programs that you use.
all over the world. In some countries, English 3. Compare your answer with that shown
units of measurement such as feet, gallons, at the end of the book; be sure to use
pounds, etc, are used. In other countries, solutions to the problems in the units
Systems Internationale (SI) or Metric units, you are working in.
such as meters, liters, kilograms, etc., are If your answer is correct, continue read-
used. In order for the manual to be of maxi- ing until you come to the next problem
mum use, both SI and English units are shown. and work it. If not, restudy the manual
until you understand the reason for
The SI unit always appears first, and the your error. Rework the problem if
English unit follows in brackets [ ]. Example: necesary. Leave your wrong answer
the temperature is 25°C [77°F]. The English and note the correct one. This will keep
equivalent of the SI unit will be rounded off to you from making the same mistake
the nearest whole number to simplify the text later on.
and examples. A distance of 10 m may be 4. Proceed stepwise as shown above
shown as 33 ft whereas the exact equivalent until you have completed the text.
is 32.81 ft.
The above approach will require thought,
If you are working in English units, you making mistakes, and rethinking the situ-
may find it helpful to mark out the parts that ation. Concenrate on two things — the how
are in SI units and vice versa. and why. Do not cheat yourself by taking
short-cuts or looking up the answers in ad-
Some of the Figures have units of meas- vance. It saves time and errors but produces
urement. In such cases, two figures are in- no real understanding. Your future depends
cluded. The first one is in SI units, and the on how efficiently you perform your job and
second-figure will be on the next page and will not on how rapidly you proceed through this
have English units. Each figure is identified manual. Since this is your manual, any errors
with SI or English units. Be sure you use the you make are private.
figures in the units you are working in.
A validation or test covering the entire
The following procedure is recommended manual is included at the back of the book.
for using this manual: Answers will be sent to your supervisor or
training director at their request at no cost.
Cryogenic comes from the Greek word Ethane can be used as a feedstock to
Cryo which means very cold. Cryogenic petrochemical plants to make glycols and
gasoline plants are those which operate plastic; or it can be sold as fuel gas with
at temperatures below -75°C [-100°F]. methane. In the latter case, the ethane
When gas is chilled to this temperature, upgrades the gas value because ethane
most of the ethane and practically all of releases 75% more heat when it burns than
the propane and heavier hydrocarbons will methane. Ethane is usually worth more as
liquefy. The liquids formed can then be a petrochemical feedstock than as fuel gas,
separated by a series of fractionating tow- so it is economically desirable to remove it
ers into ethane, propane, butanes, and from methane.
natural gasoline. Cryogenic plants have less process
Prior to 1965, refrigerated absorption equipment — no absorber or still, but they
plants were used to recover ethane and have more mechanical equipment — Gas
heavier components from gas. The most Expander and Compressors — than a lean
efficient absorption plants recovered about oil absorption plant.
40% of the ethane, 95% of the propane, The cryogenic process is the most eco-
and all heavier hydrocarbons from the gas. nomical means for recovering a high per-
A comparison of hydrocarbon recovery centage of ethane and heavier hydrocar-
from gas in absorption and cryogenic bons from the inlet gas stream. Refriger-
plants is shown in the table below. ated absorption plants may be more eco-
You can see from the table that the main nomical for recovery of propane and
difference in the two types of plants is in heavier hydrocarbons from the gas stream
the ethane recovery. The cryogenic plant when no ethane recovery is desired.
recovery of ethane is 2 - 3 times that of an
absorption type plant.
-51°C
5500 kPa [-60°F]
[785 psi]
60°C SIDE
[075°F] REBOILER DEMETHANIZER
INLET
GAS LC
GAS/
GAS
HEX -32°C 7°C
[-25°F] BOTTOM [45°F]
FC REBOILER
EXPANDER
INLET
SEPARATOR
DEHYDRATOR 5600 kPa
[800 psi] TC
PRODUCT ANAL
RAW HEATER
38°C PRODUCT
[100°F]
PRODUCT PUMP
TC FC
changer, where it cools the inlet gas carbons is greater than 10%, the addition
stream. The gas then flows through the of refrigeration is necessary to chill the gas
Compressor which is driven by the Ex- to the desired temperature in order to re-
pander. Gas leaving the Expander-Com- cover 70 - 90% of the ethane and heavier
pressor enters the Residue Gas Compres- hydrocarbons from the gas.
sor, where its pressure is boosted to pipe- The flow is similar to that previously dis-
line pressure and it flows to gas sales. cussed; the main difference is that the in-
The bottom product from the let gas is chilled prior to entering the Ex-
Demethanizer is a mixture of ethane, pro- pander in two Gas-to-Gas Exchangers and
pane, butane, and natural gasoline. It is a gas Chiller which uses propane as a re-
pumped through a heater to a sales pipe- frigerant.
line, or to a fractionation system for sepa- Control valves shown on the flow sheets
rating each of the components. have the letters FO or FC beside them.
The process flow previously described They are abbreviations for fail open or fail
would apply to a plant in which the recov- closed which are the positions the valves
ery of ethane and heavier hydrocarbons is take on loss of air pressure.
less than 10% of the total inlet gas. When Another process flow was developed by
the recovery of ethane and heavier hydro- the Ortloff Corporation, Midland, Texas. The
SALES
GAS
RESIDUE GAS
COMPRESSOR
COMPR EXP
FC JT
VALVE
EXPANDER- FC
COMPRESSOR
3-9 psi
PC
PROPANE SIDE
REBOILER
INLET
GAS LC
DEMETHANIZER
WARM COLD
GAS/ CHILLER GAS/
GAS GAS
HEX HEX BOTTOM
FC REBOILER
EXPANDER
INLET
SEPARATOR
DEHYDRATOR
TC
PRODUCT ANAL
RAW HEATER
PRODUCT
PRODUCT PUMP
TC FC
TRIM
HEATER
HOT FLUID
principal difference in its design is that in- cooling to about -105°C [-160°F]. This cold
stead of all of the gas from the Expander liquid serves as reflux to the Demethanizer.
Separator flowing to the Expander, about It enters the top of the tower.
25% flows through a Reflux Condenser, The net effect of the Ortloff design is to
and the balance enters the Expander. The increase ethane recovery by 10 - 25% at a
portion that enters the Reflux condenser relatively low increase in plant cost. The dis-
is cooled to about -90°C [-130°F] with cold advantage is that additional recompression
gas from the top of the Demethanizer. The power (and fuel) is required to make up for
pressure of gas in the Reflux Condenser the loss of compressor power that occurred
is approximately inlet gas pressure. At this when 1/4th of the Expander Inlet Separa-
pressure, the entire gas stream condenses. tor gas by-passed the Expander.
When the pressure of this liquid stream is The Ortloff design can also be used in
lowered to Demethanizer pressure at the plants having refrigeration systems. Flow
Flow Control Valve, some of the liquid va- at the chiller is similar to that in the previ-
porizes, which results in the liquid portion ous flow diagram.
-90°C -105°C
[-130°F] [-160°F]
-100°C
[-150°F]
SALES
GAS REFLUX
RESIDUE GAS CONSENSER
COMPRESSOR FC
COMPR EXP
FC JT
VALVE
EXPANDER- FC
COMPRESSOR
PC
SIDE
REBOILER
INLET DEMETHANIZER
GAS LC
GAS/
GAS
HEX
BOTTOM
FC REBOILER
EXPANDER
INLET
SEPARATOR
FO
DEHYDRATOR
TC
PRODUCT ANAL
RAW HEATER
PRODUCT
PRODUCT PUMP
TC FC
TRIM
HEATER
HOT FLUID
C. Heat Exchangers
D. Demethanizer
The Demethanizer is a type of fraction-
ating tower used to remove methane from
the liquid hydrocarbons which condense
as the inlet gas stream is chilled. The top
portion of the tower is usually a larger di-
ameter than the lower part. It is a separa-
tor that separates the incoming gas/liquid
stream from the Expander. The liquid falls
to the bottom and flows into the fractionat-
ing portion of the vessel and the gas flows
out the top.
The fractionation portion of the tower
usually contains about 30 trays with bubble
caps or valves. Liquid flows across each
tray and spills over to the tray beneath it.
Gas vapors from the bottom of the tower
flow upward and bubble through the liquid
on each tray. The warm gas vapors boil the
methane from the liquid on each tray. The
products from the tower are methane gas
DEMETHANIZER
at the top, and a demethanized liquid prod-
uct out the bottom.
A reboiler and side stream heater pro-
vide the heat required to boil methane
from the liquid flowing across each tray
in the tower.
2-STAGE
COMPRESSOR
CONDENSER
Warm
SURGE
Inlet Gas
TANK
ECONOMIZER
GAS
CHILLER
Cold
Outlet Gas
REFRIGERATION SYSTEM
Problem 1
Match each item in the right column with the proper item in the left column.
____ 1. Gas Dehydration a. Remove C1 that liquefies when gas is chilled.
____ 2. Heat Exchangers b. Remove moisture from gas.
____ 3. Expander-Compressor c. Use nickel steel below -50°.
____ 4. Demethanizer d. Chill and compress gas.
____ 5. Refrigeration System e. Transfer refrigeration from outlet gas to inlet gas.
____ 6. Piping f. Chill inlet gas with high C2 + content.
Sales
Gas
COMPRESSION
Inlet
Gas
DEHYDRATION CHILLING
Liquid
Product
DEMETHANIZING
FUNCTIONAL PARTS OF CRYOGENIC PLANT
GAS TEMPERATURE, °F
GAS TEMPERATURE, °C
C1 at 5
520 kP 800 PSI
a C2 a
-70° -80 t 80
0 P
SI
Et C1 at
ha 800 P
ne SI
Th
at
-80 2760 kPa Co -100 Et
nd ha
en ne
se Th
sa at
Co
t2 400 psi nd
76 en
0 se
kP -120 sa
-90° a t4
00
C1 at ps
2760 i
kPa
C1 a
C
t 400
2
at
psi
13
-140
80
2
at
a
200 psi 20
0
ps
i
-110 -160
C1 at 1380 C1 at 200 ps
kPa i
-180
-120 0 20 40 60 80 100
0 20 40 60 80 100
Look at example 3 on the next page. 1380 kPa [800 to 200 psi]. As we said, op-
Suppose the capacity of the Demethanizer erating at a lower pressure requires more
is 20% of the methane in the inlet gas. In compression to boost the gas pressure to
order to increase the ethane recovery, and that of the sales pipeline. At some point,
not condense more than 20% of the meth- the value of incremental ethane which con-
ane, it will be necessary to operate the denses at a lower pressure is equal to the
chilling section at a lower pressure and incremental cost of compressing the gas
lower temperature. Ethane recovery can to pipeline pressure. This is the ideal oper-
vary from 42% to 92% by varying the pres- ating condition of temperature and pressure
sure in the chilling section from 5520 to in the chilling section.
Examples:
SI UNITS ENGLISH UNITS
1. When gas is chilled to a tempera- -100°C -88°C -66.5°C -148°F -126°F -88°F
ture of
At a pressure of 1380 kPa 2760 kPa 5520 kPa 200 psi 400 psi 800 psi
% C1 that condenses 12% 24% 50% 12% 24% 50%
% C2 that condenses 80% 80% 80% 80% 80% 80%
Volume of C1 that condenses from 10.6 21.1 44 10.6 21.1 44
100 volumes of gas
Volumes of C2 that condenses from 5.6 5.6 5.6 5.6 5.6 5.6
100 volumes of gas
2. When gas is chilled to a tempera- -90°C 99°C -107°C -130°F -146°F -161°F
ture of
At a pressure of 1380 kPa 1380 kPa 1380 kPa 200 psi 200 psi 200 psi
% C1 that condenses 5% 10% 20% 5% 10% 20%
% C2 that condenses 53% 78% 92% 54% 78% 92%
Volume of C1 that condenses from 4.5 8.9 17.8 4.5 8.9 17.8
100 volumes of gas
Volume of C2 that condenses from 3.7 5.5 6.4 3.8 5.5 6.4
100 volumes of gas
3. When gas is chilled to a tempera- -107°C -86°C -60°C -160°F -124°F -75°F
ture of
At a pressure of 1380 kPa 2760 kPa 5520 kPa 200 psi 400 psi 800 psi
% C1 that condenses 20% 20% 20% 20% 20% 20%
% C2 that condenses 92% 75% 42% 92% 75% 42%
Volume of C1 that condenses from 17.8 17.8 17.8 17.8 17.8 17.8
100 volumes of gas
Volume of C2 that condenses from 6.4 5.3 2.9 6.4 5.3 2.9
100 volumes of gas
The condensation curves on page 12 little effect on the volume of propane and
do not indicate the quantity of propane and heavier hydrocarbons that condense be-
heavier hydrocarbons which condense cause almost 100% of them will condense
from the gas as it is chilled. In a cryogenic regardless of C2 recovery.
plant, 90 - 98% of the propane liquefied, Methane which condenses with the
and 100% of the butane and gasoline liq- other hydrocarbons is removed from the
uefy when at least 60% of the ethane con- mixture in the Demethanizer. The quantity
denses. The point of this is that changing of methane which can be removed in the
operating pressures and temperatures to Demethanizer will depend upon the diam-
recover more or less ethane will have very eter of the tower and the number of trays
that it has. In any case, your Demethanizer Demethanizer, the only way of increasing
has a maximum quantity of methane which the ethane recovery without recovering
it will remove from the feed stream. Since more methane is to operate the chilling
the quantity of methane which can be re- section at a lower pressure and lower tem-
moved is fixed by the size of the perature.
Problem 2
Operating pressure in the Demethanizer of a cryogenic plant is 1380 kPa [200 psi]. If
C2 condensation in the Expander is 90%, C1 condensation will be ______%; Expander
outlet temperature will be ______°.
Up to this point, we have indicated that fore it will change into a liquid.
all that is necessary to liquefy hydrocar- In order to cool gas 1°, we must remove
bons is to simply lower the temperature. about 2.72 kJ/kg [0.65 Btu/lb] of heat. The
This is only partly true; in order for any gas heat removed from cooling gas is called
to change to a liquid, its latent heat of va- superheat. Once the gas is cooled to the
porization or simply latent heat, must be temperature at which it will condense, the
removed from the gas. The latent heat of latent heat must then be removed in order
hydrocarbons at cryogenic temperatures is to change the gas to a liquid. The magni-
about 465 kJ/kg [200 Btu/lb]. This heat must tude of latent heat is illustrated with the fol-
be removed from each kg [lb] of gas be- lowing example.
0.85 Wt Units
Gas
35°C -101°C
[95°F] [-150°F]
1 Wt Unit
Inlet
Gas
CHILLERS AND Liquid Product
EXPANDERS to Demethanizer
0.15 Wt Units
From the above, you can see that the move all of the heat they are capable of
percentage of latent heat (16%) is almost taking out. One of the shortcomings of the
the same as the percentage of gas that cryogenic plant is that there is no excess
condenses (15%). In cryogenic plants, the heat removal capability designed into the
inlet gas is cooled to its condensation tem- plant. In other words, if one heat exchanger
perature. The quantity of liquid that forms fails to perform as it should, other exchang-
depends upon the amount of latent heat ers or Expanders are unable to make-up
that is removed. If the total heat removal in the shortage in the inefficient exchanger.
the above example is 99% of that shown, The net result is a reduction of liquid prod-
the liquid that condenses would be 1% less uct. No spare heat removal capacity is built
or 14% instead of 15%, which is a 7% re- into the plant because it would require
duction in liquid production. refrigeration facilities capable of chilling
Heat is removed from the inlet gas in the gas to a temperature of about -100°C
heat exchangers, the Expander, and refrig- [-150°F]. The cost of such facilities would
eration chiller if it is installed. In order to make the entire cryogenic plant uneco-
make maximum liquid product, the heat nomical.
removal facilities must be operated to re-
In the previous section, we said the net One of the basic laws of science is that
effect of chilling in the plant was to remove energy contained in a fluid cannot be de-
latent heat to condense liquid product. The stroyed or created. Thus, if energy is added
Expander is capable of removing enough to or removed from a fluid such as gas,
latent heat to recover about 10% of the gas there must be a change in the heat content
stream. If the inlet gas contains more than (temperature) or pressure or velocity. The
10% ethane and heavier hydrocarbons, curve below and that on the next page in-
refrigeration systems are installed to re- dicate the internal energy in typical natural
cover hydrocarbons in excess of 10%. gas at various temperatures and pressures.
D. Theory of Gas Expansion The velocity energy is not shown on the
curves because the gas velocity entering
Gas at a temperature above absolute and leaving a compressor or Expander is
zero and a pressure about absolute zero about the same. Use of the curves is dem-
contains internal energy. We can’t see the onstrated with an example.
energy, but we know it exists because it Gas in a cryogenic plant has been
will produce work. Energy is contained in cooled to a temperature of -40°C [-40°F] in
gas in the forms of heat, pressure, or Gas-to Gas Exchangers. Its pressure is
velocity. 5500 kPa [800 psi]. These pressure and
SI UNITS
7000
-50 -40
G
AS -30
TE
6000 M
PE
-60
RA
TU
A
RE
PRESSURE, kPa GAUGE
, °C
5000
-70
NE
LI
ON
N SI
PA
4000 -80
EX
-40
OR
ON
-50
SI
-90
ES
PR
3000
M
CO
-100 -60
-110 -70
2000 -80
-90
-120 B -100 C
1000
0 200 400 600 800 1000 1200 1400 1600
3
INTERNAL GAS ENERGY, KW PER MILLION M /D
ENGLISH UNITS
1000
-20
-40
-6
0
-8
0
900
0°
A
800
GA
S
TE
MP
700
ER
-1
GAS PRESSURE, PSI GAUGE
00
AT
U
RE
,°
F
600
-20
-1
20
500
E
-40
LIN
-1
40
ON
SI
N
400
PA
EX
-60
OR
-1
N
6
IO
0
-80
S
ES
PR
300
M
CO
-10
0
-12
200
0
B C
-1
-14
80
-1
0
60
100
0 10 20 30 40 50 60 70
temperature conditions are Point A on the sor that the Expander turns. In this case,
curves. If the pressure of the gas is low- the energy given up by the gas is indicated
ered with a choke or pressure reducing by the dashed line A B. This line is a com-
valve to a pressure of 1400 kPa [200 psi], pression or expansion line. It represents
the gas temperature will drop to -72°C [- the maximum amount of energy that can
100°F]. This is represented by Point C on be removed from the gas when its pres-
the curves. sure is reduced from Point A to Point
You notice that the internal energy of B. The same amount of energy is re-
the gas does not change when its pres- quired to compress the gas from Point
sure is lowered. The reason for this is that B to Point A. The gas temperature at
no heat is entering or leaving the pressure Point B is -108°C [-163°F] which is
reduction valve, and no work is being done 36°C [63°F] lower than that at Point C.
to turn a turbine or other device, so the in- We said that the energy required to
ternal energy of the gas has to remain the compress gas from Point B to Point A was
same. The temperature drop which occurs the same as the energy which could be
when the pressure is reduced is called the removed from the gas in a Expander when
Joule-Thompson (J-T) effect. its pressure was reduced from Point A to
Suppose that the gas at Point A flows Point B. This is theoretically correct. In prac-
through an Expander, which is connected tice, Expanders and Compressors are each
to a Compressor so that energy can be about 80% efficient, so that when gas pres-
removed from gas flowing through the sure is dropped from Point A to Point B in
Expander and used to drive a Compres- an Expander , the Compressor attached to
that Expander will provide only a portion ture of gas leaving the Expander will be
of the power required to boost the gas pres- that shown at Point B. If the Compressor
sure from Point B to Point A. attached to the Expander is not fully loaded,
The table on page 18 summarizes the the temperature of gas leaving the Ex-
effects on gas temperature of pressure re- pander will fall between Points B and C.
duction and energy removal by an Expander. Thus, in order to get the lowest tempera-
Look at the internal energy contained ture of gas leaving the Expander, the Com-
in the gas at Points B and C. It is 800 kW pressor must be fully loaded.
per million m3/d [29.5 hp per MMcf/d] less The graphs on the previous pages indi-
at Point B than at Point C. When this cate the theoretical temperature of gas
amount of energy is removed from the gas leaving an Expander at a known pressure,
at the pressure and temperature at Point when the temperature and pressure of gas
C, the gas will cool to the temperature at entering the Expander are also known. In
Point B. The gas will cool from its tempera- practice, the temperature of gas leaving the
ture at Point A to the temperature at Point Expander will not be as cold as that shown
C by simply lowering its pressure. It will cool on the graphs because the stream leaving
to the temperature at Point B by lowering the Expander is a mixture of gas and liq-
the pressure and removing energy. The dif- uid, and the heat of vaporization given up
ference in the temperature between Points by the portion of gas which condenses in
B and C is the net cooling effect of remov- the Expander will result in raising the tem-
ing energy from the gas in the Expander. perature of the total stream. If no conden-
If gas flowed to an Expander that was sation occurs, the temperature leaving the
not connected to anything, its temperature Expander should be fairly close to that
would be that at Point C. However, if the shown on the graphs. However, each per-
Expander is connected to a Compressor, cent of gas that liquefies in the Ex-
and maximum energy is removed from the pander will raise the temperature of the
gas to drive the Compressor, the tempera- remaining gas about 1.7°C [3°F].
Example
10% of the gas condenses when its pressure is lowered from Point A to Point B on the
graphs on pages 16 and 17. Determine the temperature of gas leaving the Expander.
SI UNITS ENGLISH UNITS
Temp of gas out of Expander (Point B) -108°C -163°F
Percent of gas that condenses 10% 10%
Temp rise due to condensation 1.7 x 10 = 17°C 3 x 10 = 30°F
Actual temp of gas & liquid out of Expander -108 + 17 -163 + 30
= -91°C = -133°F
Problem 3
a. In order to condense hydrocarbons from a gas stream by chilling, two forms of heat
must be removed. They are __________________ and __________________.
b. Gas enters an Expander at -50°C and 6300 kPa [-60°F and 900 psi]. Outlet pressure is
2000 kPa [315 psi]. If the Compressor attached to the Expander is 100% loaded, the
theoretical temperature of gas leaving the Expander is _______°. If 8% of the gas
condenses, the temperature of gas leaving the Expander is _______°.
c. If no gas is flowing through the Compressor, the temperature of gas leaving the Ex-
pander is _________°.
e. The expander power is ________.
INLET
GAS
100%
Expander provides
enough cooling to
E C
condense 10% of
inlet gas.
LIQUID
PRODUCT
10%
MATERIAL BALANCE AT CRYOGENIC PLANT
-87°C
SALES [-125°F]
GAS
RESIDUE GAS 90°C
COMPRESSOR [-130°F]
1700 kPa
COMPR EXP [245 psi]
FC 62-103 kPa
[9-15 psi]
EXPANDER- FC
COMPRESSOR JT
20-62 kPa VALVE
[3-9 psi]
PC
-51°C
5500 kPa [-60°F]
[785 psi]
60°C SIDE
[-75°F] REBOILER
INLET DEMETHANIZER
GAS LC
GAS/
GAS
HEX -32°C 7°C
[-25°F] BOTTOM [45°F]
FC REBOILER
EXPANDER
INLET
SEPARATOR
DEHYDRATOR 5600 kPa
[800 psi] TC
PRODUCT ANAL
RAW HEATER
38°C PRODUCT
[100°F]
PRODUCT PUMP
TC FC
DEMETHANIZER
The main feed stream comes from the packing or liquid on each tray. Most of the
Expander Separator. A level control sys- C2 and heavier hydrocarbons in the gas are
tem on the Separator regulates the flow of condensed by the liquid on the trays, so
liquid. It enters the tower near the middle. that gas leaving the top tray is mostly meth-
The liquid portion of the stream enters the ane. It flows into the separator section on
tower and flows across the trays or pack- the top of the tower. The stream out of the
ing in the lower section of the tower. Expander also enters this separator. It is a
Upflowing gas on each tray boils the meth- mixture of gas and liquid. The gas combines
ane out of the liquid, so that by the time with gas from the top tray and exits the
the liquid reaches the bottom of the tower, tower at the top and flows through the Gas-
most of the methane has been boiled out. Gas Exchanger, and Compressors and
Heat to boil methane out of the leaves the plant. Liquid in the stream from
downflowing liquid comes from the Bottom the Expander falls to the bottom of the
Reboiler and Side Reboiler. Liquid enter- Separator and flows to the top tray of the
ing the Side Reboiler is withdrawn about tower. It serves as reflux to the tower.
1/3rd the way up the tower. It flows through 1. Demethanizer Bottom Temperature
the Reboiler, where it picks up heat from Control System
the inlet gas flowing through the tube side Methane is boiled out of the liquid en-
of the Reboiler. Some of the liquid vapor- tering the DeC1 by adding heat to the tower
izes when it is heated. The stream out of in the Side and Bottom Reboilers. The
the Reboiler returns to the tower below the amount of heat transferred in the Reboilers
tray from which it was withdrawn. is controlled by regulating the flow of heat-
Liquid from the bottom tray flows to the ing fluid (inlet gas) going through the
Bottom Reboiler, where it is heated by in- Reboilers. Different plant designers use
let gas, which results in some vaporization. various methods for controlling the flow of
The gas which forms flows up the tower, heating gas.
and liquid that remains is the bottom prod- The drawing on page 21 shows a tem-
uct which is cold. It is pumped through a perature controller in the bottom of the
Heater to recover the refrigeration in the Demethanizer that regulates flow of gas
stream. From the heater it flows to a pipe- which passes through the Demethanizer
line or to fractionation towers to separate it Reboilers. If the temperature in the
into ethane, propane, butane and gasoline. Demethanizer drops, the temperature con-
Product flow is regulated with a level con- troller will signal the control valve to open
trol system. so that more gas flows to the Reboilers,
The vapor portion of the stream from and vice versa. The temperature controller
the Expander Separator that enters the is set by the plant operator at the point that
DeC1 flows upward. It bubbles through the results in the bottom product having slightly
less than the maximum methane in the to the Demethanizer to provide heat for the
ethane portion of the product. tower. When this occurs, the Demethanizer
It is important to recognize that gas is not bottom temperature will fall. The tempera-
a particularly good heating medium, and ture control valve will be wide open.
several minutes will be required to notice any The pressure drop across the butterfly
change in temperature after the gas rate flow- valve is usually 70 - 140 kPa [10 - 20 psi].
ing through the Reboilers changes. This is the pressure required to force some
The Demethanizer bottom temperature of the inlet gas to flow to the Demethanizer
control system diverts a portion of the in- Exchangers. The pressure drop must be
let gas through the Demethanizer Bottom made up with the residue gas Compres-
Heater and Reboilers. The remainder of the sors, which requires additional fuel to the
inlet gas flows through the Gas-to-Gas Compressor driver. In order to keep the
Exchanger. The pressure drop across a recompression cost to a minimum, the but-
heat exchanger is usually 35 - 70 kPa [5 - terfly should be closed only enough to force
10 psi]. In other words, the outlet pressure gas to flow through the Demethanizer
is lower than the inlet pressure. The por- Reboilers. If it is closed too much, a high
tion of inlet gas which flows to the pressure drop will result, which will increase
Demethanizer Exchangers passes through the power (and fuel) required by
several exchangers, whereas the remain- Recompressors to make-up the pressure
der of the inlet gas may pass through only loss across the butterfly valve.
one Gas-to-Gas Exchanger. The net result The procedure to position the butterfly
is that the pressure drop of gas flowing valve in the main gas line is to fully open the
through the Demethanizer Exchangers is valve and then slowly close it until the DeC1
considerably more than that flowing temperature control valve is 50% open at
through the Gas-to-Gas Exchanger. Con- normal flow rates through the plant. It may
sequently, there must be some restriction be necessary to change the position of the
in the gas line to the Gas-to-Gas Exchang- butterfly valve at high or low gas rates.
ers in order to force gas to flow to the In some plants the Demethanizer bot-
Demethanizer Exchangers. tom temperature controller regulates two
This restriction is often a butterfly valve control valves as shown in the drawing on
in the gas line to the Gas-to-Gas Exchang- page 4. If the bottom temperature drops,
ers which is closed enough to force gas to the controller opens the control valve in the
flow through the Demethanizer exchang- gas line to the Reboilers, and closes the
ers. If the butterfly valve moves to a more control valve in the gas line to the Gas-Gas
open position, inlet gas will preferentially Exchanger. Reboilers and the Product
flow to the Gas-to-Gas Exchangers, and Heater may have by-pass lines in the heat-
there may not be enough volume flowing ing gas lines to manually by-pass some of
Problem 4
1. In what piece of equipment is methane removed from other hydrocarbons which con-
dense as gas is chilled? ______________________________________________.
b. The amount of chilling in an Expander depends upon: ________________________
__________________________________________________________________.
c. Most of the gas chilling occurs in what equipment? __________________________.
d. What fluid is used for process heat in the Demethanizer?______________________
__________________________________________________________________.
INLET DISCHARGE
GAS GAS
OUTLET SUCTION
GAS Shaft
GAS
Impeller
or Impeller
Wheel or
Wheel
EXPANDER COMPRESSOR
and exits the Expander at a lower pressure. The opposite flow diagram indicates a
The rotating speed of the Expander can typical Expander control system. The by-
be in excess of 50 000 rpm, depending pass valve is normally referred to as the JT
upon the volume of gas entering the unit, (Joule-Thompson) valve. Output pressure
and the pressure drop the gas takes in flow- from the pressure controller enters the vane
ing through the unit (inlet pressure minus dis- actuator, which operates at a pressure of
charge pressure). A high flow rate and high 20 - 60 kPa [3 - 9 psi]. In other words, the
pressure drop result in a high Expander vanes move from full close to full open over
speed and obviously a high power output. this pressure control range. The JT valve
The power developed at the rotating operates over a pressure control range of
shaft of the Expander is used to drive a 60 - 100 kPa [9 - 15 psi]. It does not start to
single impeller Compressor attached to the open until the adjustable vanes are fully
other end of the shaft. Low pressure gas opened. At this point, the Expander is fully
enters the center of the impeller and dis- loaded. If the gas flow with the Expander
charge gas is withdrawn from the tip of the fully loaded is not enough to maintain pres-
impeller blades at a pressure about 1.3 sure, pressure in the outlet line will drop,
times that of suction pressure. and the output pressure from the pressure
A. Expander Control controller will increase. When the output
pressure from the pressure controller ex-
The Expander is controlled to maintain
ceeds 60 kPa [9 psi] the JT valve will start
a constant pressure at some point in the
to open and gas will flow in the bypass line.
system by regulating the flow of gas to the
The pressure controller that regulates
Expander. Gas flow is increased by open-
the capacity of the Expander is often lo-
ing guide vanes located at the gas inlet side
cated at the Demethanizer, which is essen-
of the Expander impeller. In the drawing on
tially the same as that at the Expander out-
the next page, the pressure controller in
let line. Other plants control Expander ca-
the outlet line signals the adjustable vanes
pacity to hold a constant pressure at the
to open or close in order to maintain con-
plant inlet, or at the suction to the
stant outlet pressure. If the outlet pressure
Recompressor.
drops, the pressure controller opens the
Regardless of the location of the con-
vanes and allows more gas to flow through
troller, the system is a “split range” control
the Expander. Conversely, if downstream
in which half of the controller output pres-
pressure rises, the pressure controller closes
sure operates the Expander vanes, and the
the vanes and restricts the flow of gas enter-
other half operates the by-pass valve.
ing the Expander. In the event the flow of gas
As gas flows through the Expander, its
to the Expander is not enough to maintain
temperature is lowered and about 10% of
pressure, a bypass valve will open and allow
the stream condenses. The liquid which
the excess gas to pass through it.
SCREEN
GAS pressor may not be fully
20 - 60 kPa
[3 - 9 psi] loaded. In this situation, gas
60 - 100 kPa
[9 - 15 psi] flow to the compressor is in-
creased by recycling some
20 - 100 kPa Guide
[3 - 15 psi] J-T Vane Contr compressor discharge
By-Pass Line
Expander speed should not change than the energy the Expander is capable
when gas to the compressor is raised as of removing from the gas.
long as the compressor is not loaded. Flow The expansion curves on pages 16 and
of recycle is increased in steps until there 17 indicate the maximum energy that can
is no change in Expander outlet tempera- be removed from gas as its pressure is re-
ture, or the speed drops off. At this point, duced. As energy is removed from gas, the
flow of recycle is lowered until the speed gas temperature is lowered. Thus, as the
returns to normal. The compressor should Compressor is loaded by increasing flow
be fully loaded and maximum gas cooling of recycle gas, the temperature of gas out
(and C2 recovery) should occur. of the Expander will drop. The Expander
It may appear to you that the Expander outlet temperature will be at its minimum
speed should drop off when the gas flow when the compressor is fully loaded. At this
to the Compressor is increased. This is not point, increasing flow of recycle gas to the
necessarily the case as long as the energy Compressor will overload the Expander,
required to drive the Compressor is less and the speed will drop off.
INLET GAS
FROM SEPARATOR DISCHARGE
Raise set point in flow controller
GAS 1 until control valve opens.
20 - 60 kPa Then increase flow in small steps.
[3 - 9 psi]
60 - 100 kPa
[9 - 15 psi] SURGE
CONTROL
VALVE
Guide
J-T Vane Contr
By-Pass Line
SURGE
PRESSURE FLOW
CONTROLLER CONTR
SUCTION
GAS
OUTLET GAS
TO DEC1 RPM
EXPANDER COMPRESSOR
2 Observe Expander outlet temp & speed. Temp Repeat steps 1 & 2 until Expander outlet temp does not
should drop a few degrees, at each flow 3 drop, or speed decreases. When speed decreases,
increase step. Speed should not change if reduce by-pass flow until speed returns to normal.
Compressor is not loaded.
side. Mechanical seals are not used on the final tooth, it is at its lowest pressure and
Expander because oil to lubricate the seal largest volume. The clearance between the
could enter the Expander and solidify at teeth and shaft will allow only a small vol-
the low temperature and seriously damage ume of gas to flow. Thus, there is a con-
the machine. tinuous flow of gas through a labyrinth seal,
Labyrinth type seals are used on the but it is a small quantity. A slight amount of
Expander and Compressor to reduce the wear in the labyrinth teeth will obviously in-
flow of gas at high pressure that leaks to a crease the quantity of gas that leaks across
lower pressure point. A labyrinth seal is a the seal. Labyrinth seals are shown in the
series of teeth which are machined in the following drawing and tabulated below.
impeller and seal rings to a clearance be-
tween the end of each tooth and the shaft
of approximately 50 - 100 microns [0.002 -
0.004 in]. The labyrinth acts as a pressure
reducing device. Gas is at a higher pres-
sure on one side of the labyrinth than on
the other side. A small amount of the high
pressure gas leaks across each tooth in
the seal. As it passes from one tooth to
another, its pressure reduces, and its vol-
ume increases. By the time it reaches the LABYRINTH SEAL
As you can see in the drawing below, tween two labyrinth seals on the Expander
the lowest gas pressure is that in the hous- shaft. Since this pressure is higher than that
ing between the Expander and Compres- on the back side of the Expander impeller,
sor. Gas which leaks across the labyrinth some seal gas will leak through the laby-
seals on the Expander and Compressor rinth seal (number 2) and end up in the
flows into the housing. This gas enters the Expander outlet gas. This is a small quan-
lube oil reservoir, which is vented to the tity of gas which has very little detrimental
suction side of the Compressor. Thus, the effect on temperatures in the Expander.
pressure in the housing will be the same Some seal gas also leaks across the
as that at the suction to the Compressor. labyrinth seal (number 3) into the housing
If cold expander gas leaks into the between the Expander and Compressor.
housing, it can chill the lube oil to the point This gas flows to the suction side of the
that it would lose its lubricating properties. Compressor.
To prevent this from occurring, a seal gas Seal gas must come from a source at
system is used which serves as a barrier least 350 kPa [50 psi] above that of the
between the Expander gas and the lube oil. Expander outlet gas. The seal gas must be
Seal gas is clean dry gas at a pressure clean and dry and at approximately ambi-
about 350 kPa [50 psi] above that of Ex- ent temperature. A filter is usually included
pander outlet pressure. It is injected be- in the line to remove solid particles from it.
PRESSURE
REGULATOR
2100 kPa
[300 psi]
OUTLET SUCTION
GAS GAS
HOUSING Thrust
Contr Valve
EXPANDER
Lube Oil
Reservoir COMPRESSOR
Outlet gas from the plant is often used level to prevent bearing failure and serious
as a source of seal gas. Seal gas is intro- damage to the machine.
duced to the Expander before start-up, and The thrust force is due to the difference
maintained during operation. A pressure in suction and discharge pressure acting
regulator is included in the seal gas line for on the front and rear face of an impeller.
adjusting the pressure. Look at the Expander impeller in the fol-
D. Thrust Control lowing drawing. High pressure inlet gas
enters at the tip of the impeller, and leaks
In any type of centrifugal device, thrust
around the labyrinth impeller seal to the rear
forces develop which tend to move the shaft
face and exerts a force to the left. Low pres-
toward one end or the other. If it were to
sure outlet gas pressure is imposed on the
move laterally along its axis, the impellers
front or left side of the impeller. In order to
would touch the casing and quickly wear out.
neutralize the thrust in the Expander impel-
In an Expander-Compressor, thrust bearings
ler, gas which leaks around the labyrinth seal
on each end of the shaft prevent lateral move-
on the rear face of the impeller flows to the
ment. However, the thrust forces against the
outlet gas line, so that the pressure on the
bearings must be controlled at a moderate
rear face is slightly above outlet pressure. One
OUTLET SUCTION
GAS GAS
THRUST
BEARINGS
EXPANDER COMPRESSOR
THRUST
CONTROL
VALVE
manufacturer has holes in the impeller Compressor (to the right) is more than that
which allow gas under pressure behind the at the Expander, the shaft will move to the
impeller to flow through the holes to the right. Clearance at the right thrust bearing
outlet gas line. The holes in the impeller will decrease, and oil pressure at the bear-
are located such that the pressure behind ing will increase. At the same time, clear-
the wheel is about 175 kPa [25 psi] above ance at the left thrust bearing will increase,
Expander outlet pressure. Other manufac- and oil pressure will decrease. The net ef-
turers pipe the gas behind the wheel to the fect is that the piston actuator will open the
outlet gas line. In any event, the thrust force thrust control valve, which will release some
of the Expander impeller is partially neu- of the pressure behind the Compressor
tralized. The gas pressure behind the im- impeller, and lower its thrust force.
peller is slightly more than that on the front If the thrust control system should fail,
face, so that a moderate thrust force is and the control valve closes, a high thrust
exerted toward the Expander. force toward the Compressor end will re-
The thrust force on the Compressor sult, which could cause the Compressor
impeller is in the opposite direction. Suc- thrust bearing to fail. Any type of bearing
tion pressure is imposed on the front or failure in a machine rotating at 25 000 rpm
right face of the impeller and discharge or more can result in serious damage. Thus,
pressure acts against the rear or left face. the thrust balancing system should be care-
The thrust force is to the right. fully watched and properly maintained.
The thrust control system regulates the If the thrust neutralizing arrangement
thrust force on the Compressor end so that on the Expander end should fail due to
it is about the same as that on the Ex- plugging of holes in the Expander impel-
pander end. The Compressor thrust force ler, the thrust force developed will be far
is often regulated with a piston actuated greater than the thrust control system can
control valve in which pressure on each handle. A high thrust force toward the Ex-
side of the piston is that of thrust bearing pander will result, which can quickly dam-
pressure on each end of the shaft. If the age the Expander thrust bearing. A shut-
shaft moves lightly in one direction, thrust down from high thrust occurs in this situa-
bearing pressure will rise on one bearing tion to prevent damage to the machine.
and fall on the other, which will cause the E. Lubrication System
piston to move so that more or less gas
The Expander-Compressor has a bear-
behind the impeller flows through the con-
ing on each end of the shaft. These bear-
trol valve and thereby equalizes the thrust
ings must be continuously lubricated with
bearing pressures. The previous drawing
clean lubricating oil of the approved type
shows such a system.
at the proper temperature. Lubrication fail-
For example, if the thrust force at the
ure for a short period of time may result in
a bearing failure which may seriously dam- stant temperature. The oil then flows
age the machine. through one of two filters to remove solid
The lube oil system is shown in the particles and enters the bearings on each
drawing below. Pressures shown are typi- end of the shaft. The oil flows out of the
cal for a plant in which the Demethanizer bearings and drops to the bottom of the
operates at a pressure of 1750 kPa [250 housing and flows by gravity into the reser-
psi]. Flow is as follows: voir, and the cycle is repeated.
Oil from the reservoir enters one of the The control valve in the spillover line is
pumps which is able to raise its pressure positioned by a differential pressure con-
several thousand kPa [several hundred psi]. troller (∆P Contr) which is set to hold the
A control valve in the pump discharge line pressure of oil entering the bearings about
releases excess pressure through a 1050 kPa [150 psi] higher than the pres-
spillover line that returns to the reservoir. sure of oil flowing out of the bearings. This
Oil from the pump enters a temperature difference in pressure will assure adequate
control valve, which is positioned by a tem- flow of lube oil through the bearings. In-
perature controller that allows some of the creasing the differential pressure will raise
oil to by-pass the cooler to maintain a con- the flow of lube oil to the bearings, and vice
versa. A stand-by pump is
2700 kPa
provided which turns on
[385 psi]
Heat automatically in the event
Shield BEARINGS
pressure in the system
drops due to failure of the
primary pump.
SHAFT
The lube oil pumps are
COMPRESSOR
normally driven by electric
OIL
PRES-
motors. If a power failure
1650 kPa SURE occurs, the motors will ob-
EXPANDER [235 psi] TANK
viously stop, and the Ex-
∆P
Contr pander-Compressor will
HEATER ∆P
Contr FILTERS shut down from low oil
RESERVOIR Valve
pressure. In order to pro-
38°C
TEMP
[100°F] vide lubrication to the
CONTR
STAND-BY bearings during the run-
PUMP
down period, a pressure
tank filled with oil is pro-
PUMP COOLER
vided which will let oil flow
LUBRICATION SYSTEM from the tank to the bear-
ings when the oil pumps stop. into the reservoir should be higher than the
The pressure tank has a bladder which temperature of oil entering the bearings.
is inflated to a pressure slightly above that If the temperature of oil draining into the
of the oil reservoir. While the oil pump is reservoir is lower than the temperature of
operating, the oil tank will fill with oil at sys- oil entering the bearings, leakage of cold
tem pressure. The pressure will compress expander gas into the housing is indicated.
the bladder. If both lube oil pumps shut This can result from:
down, oil pressure will fall and oil will flow 1. Seal gas flow has stopped.
out of the tank to the bearings. 2. Excessive wear in the Expander impel-
The oil reservoir operates at the suc- ler labyrinth seal, which results in more
tion pressure of the Compressor. A vent gas leaking across the seal than the
line connects the reservoir to the Compres- holes in the impeller can handle. Pres-
sor suction line. Seal gas or Compressor sure behind the impeller will rise above
discharge gas which leaks through laby- seal gas pressure, and it will flow through
rinth seals into the housing around the labyrinth seals on the Expander shaft into
bearings, flows into the oil reservoir and the housing and cool the lube oil.
exits in the vent line to the suction of the If a low oil temperature is caused from
Compressor. stoppage of seal gas flow, the situation can
A heating coil is installed in the oil res- be corrected by returning the seal gas flow
ervoir for use in cold weather, or in the to its normal rate. The oil temperature
unlikely possibility of cold Expander gas should rise to its normal point if this is the
leaking into the reservoir. problem.
The heat shield shown in the previous Maintaining proper lubrication in the
drawing is a plastic plate behind the Ex- bearings in the Expander-Compressor is
pander-Impeller which insulates the metal essential for prolonged life of the machine.
housing from the low temperature gas The Manufacturer’s recommendations
passing through the Expander. Without the should be followed in selecting the type of
insulating shield, the temperature in the oil to use, and the oil temperature should
Expander bearing could cool to the point be carefully controlled by adjusting the
that lubricating oil would solidify and the amount of cooling in the cooler, or using
bearing would quickly fail. the heater in the reservoir. Oil filters should
The temperature of lube oil entering the be closely watched and elements changed
bearings should be about 38°C [100°F]. when the pressure drop across a filter in-
The oil not only lubricates the bearings, but dicates it is plugged with dirt.
also removes the heat of friction released The oil should be tested monthly for its
when the bearing faces rub against each lubricating qualities, and replaced when a
other. Thus, the temperature of oil draining 10% deterioration is reached. In the ab-
SEAL
GAS
OVERSPEED
HIGH
SCREEN
∆P
SHAFT
COMPRESSOR
VIBRATION
∆P
LOW Contr
OIL
TEMP
FILTERS
LOW
OIL
∆P
LOW
OIL ∆P TEMP
LEVEL CONTR CONTR
RESERVOIR VALVE
HIGH
OIL
TEMP
OIL PUMP
Problem 5
Match each item in the right column with the proper item in the left column.
_____ 1. Expander capacity control a. Clean, dry gas at pressure of 350 kPa
[50 psi] above expander outlet gas
pressure.
_____ 2. Compressor load control b. Shut down machine.
_____ 3. J-T valve open c. Compressor suction pressure.
_____ 4. Seal gas d. Compressor recycle gas.
_____ 5. Thrust control e. Gas flow is more than Expander can
handle.
_____ 6. Lube oil reservoir pressure f. Regulate pressure behind compressor
impeller.
_____ 7. Low oil pressure g. Guide vanes.
-87°C
SALES [-125°F]
GAS
RESIDUE GAS 90°C
COMPRESSOR [-130°F]
1700 kPa
COMPR EXP [245 psi]
FC 62-103 kPa
[9-15 psi]
EXPANDER- FC
COMPRESSOR JT
20-62 kPa VALVE
[3-9 psi]
PC
-51°C
5500 kPa [-60°F]
[785 psi]
60°C SIDE
[-75°F] REBOILER
INLET DEMETHANIZER
GAS LC
GAS/
GAS
HEX -32°C 7°C
[-25°F] BOTTOM [45°F]
FC REBOILER
EXPANDER
INLET
SEPARATOR
DEHYDRATOR 5600 kPa
[800 psi] TC
PRODUCT ANAL
RAW HEATER
38°C PRODUCT
[100°F]
PRODUCT PUMP
TC FC
said previously, the allowable methane con- of the Demethanizer is the lowest point that
tent of the DeC1 bottom product is usually results in a liquid product having the maxi-
1 - 2% of the ethane content. mum concentration of methane.
It may help in operating the In order to determine the methane and
Demethanizer to think of it as having two ethane contents of the bottom product,
products — methane out the top, and some means for analyzing the bottom prod-
ethane out the bottom. We would like to uct is necessary. A process chromatograph
have 0% ethane leaving in the methane is often installed which indicates the rela-
product at the top, and 0% methane leav- tive quantities of methane and ethane in
ing in the ethane product out the bottom. the bottom product. The methane concen-
However, we cannot economically operate tration should be held near its maximum
with 0% ethane in the top product. We can by adjusting the bottom temperature of the
minimize the quantity of ethane in the top Demethanizer. If the bottom product has
product by holding the maximum quantity too much methane, the temperature should
of methane in the bottom product. Thus, be raised.
the important point in operating the When the bottom product analyzer is
Demethanizer is to have the maximum not working, the relative density or spe-
quantity of methane in the bottom prod- cific gravity of the gas leaving the top of
uct, which is usually 1 - 2% of the ethane the Demethanizer is often used as an indi-
content of the bottom product. cation of the quality of the liquid product at
The methane content of the bottom the bottom of the tower. An increase in the
product is controlled by changing the set specific gravity of the overhead gas indi-
point in a temperature controller at the bot- cates an increase in the ethane content
tom of the tower which regulates the which results from a high bottom tempera-
amount of heat added to the tower in the ture. Conversely, a decrease in the relative
Reboilers. Raising the set point in the tem- density indicates less ethane, which indi-
perature controller will lower the methane cates a low bottom temperature.
content of the bottom product. It will also The effect of the ethane content on the
raise the volume of ethane flowing out the relative density of the overhead gas from
top of the tower. Thus, raising the bottom the Demethanizer is: a change of 1%
temperature lowers the methane content ethane in the gas will effect its relative den-
of the bottom product, and also lowers the sity 0.005. If the relative density of the over-
total volume of bottom product. Conversely, head gas increases from 0.610 to 0.615,
lowering the bottom temperature increases the ethane content of the gas has increased
the methane content and increases the 1%. This may seem like a small amount,
total volume of bottom product. but it actually amounts to 10 - 20% of the
The proper temperature at the bottom total ethane recovered. For example, if the
0°
250
that at which the residue compressor
0°
+3
is fully loaded.
0°
+2
225
0°
+1
F 0° DEMETHANIZER BOTTOM
,°
200 ge TEMPERATURE CHANGE WITH
an -10
°
TOWER PRESSURE CHANGE
Ch ° ENGLISH UNITS
u re -20
at
er
175
p ° ° Example: When pressure is lowered
m -30 -40
Te from 255 psi to 225 psi, bottom
150 temperature change is -10°F.
150 175 200 225 250 275
2000
STARTING DEMETHANIZER
FINAL DEMETHANIZER PRESSURE, kPa
SI UNITS
PRESSURE, PSIG
5°
0°
+2
5°
+2
+1
1800
0°
+1
°
+5
0°
C
1600
e,°
DEMETHANIZER BOTTOM g
a n -5°
TEMPERATURE CHANGE WITH Ch -1
0°
TOWER PRESSURE CHANGE 1400
ure
at °
SI UNITS
per -15
m °
-20
Example: When pressure is raised from 1200 Te
°
1200 kPa to 1700 kPa, bottom tempera- -25
ture change is +15°C.
1000 1200 1400 1600 1800 2000
Problem 6
Lowering the DeC1 pressure will result in (circle correct answer):
a. Volume of liquid product will increase / decrease / stay the same.
b. Residue Gas Compressor fuel will increase / decrease / stay the same.
c. Temperature in the Expander-Separator will increase / decrease / stay the same.
d. DeC1 bottom temperature should be increased / decreased / no change.
GAS-GAS
EXCHANGER
Close DeC1
4 Temp
Contr
Valve.
EXPANDER
SEPARATOR
Open level control valve and 6
partially close JT valve so gas LIQUID
flows through liquid line.
PRODUCT
PRODUCT
PUMP
PROCEDURE TO DRYOUT GAS-GAS EXCHANGERS
the entire system during dryout is gas. Thus, less time will be required to dry
Demethanizer operating pressure, which the plant at low pressure than would be
is usually 1500 - 2000 kPa [200 - 300 psi]. required at high pressure. If there is no
If normal inlet gas pressure was used dur- dryout line from the Residue Gas Compres-
ing dryout, it would be necessary to drop sor to the Dehydrator, inlet gas is used for
the pressure of gas entering the dryout. It flows through the plant in its nor-
Demethanizer to avoid popping the relief mal path. However, the gas pressure is re-
valve on the vessel. Lowering the gas pres- duced to the Demethanizer pressure be-
sure will result in cooling the gas, and if fore it enters the dehydrator.
moisture is present, hydrate may form and The Expander-Compressor unit is
block the flow of drying gas. blocked in and by-passed on both the Ex-
Another reason for using low pressure pander and Compressor ends during
gas during dryout is that low pressure gas dryout. The unit is purged and dried with
will hold more moisture than high pressure seal gas prior to start-up. The procedure is
2 Open
Valve.
JT
JT
GAS VALVE
DEHYDRATOR
EXPANDER
Close
2 main
gas
valve.
GAS-GAS
EXCHANGER
Open DeC1
1 Temp
Contr
Valve.
EXPANDER
SEPARATOR
Open level control valve and 6
partially close JT valve so gas LIQUID
flows through liquid line.
PRODUCT
PRODUCT
PUMP
PROCEDURE TO DRYOUT DEMETHANIZER EXCHANGERS
described on page 48. c. Open the valve in the gas line to the
There are three general phases of Gas-to-Gas Exchanger.
dryout: d. Close the temperature control valve
1. Dry the main gas flow system through in the gas line to the Demethanizer
the Gas-to-Gas Exchanger. Reboilers.
2. Dry the gas flow system through the e. Start the Residue Gas Compressor
Demethanizer Reboilers. and Dehydrator and circulate dry
3. Dr y the lower por tion of the gas through the system. All of the
Demethanizer. gas will flow through the Gas-to-Gas
The sequence for dryout is as follows: Exchanger.
1. Dry the main gas flow system through f. After gas flow is established, open
the Gas-to-Gas Exchanger. the level control valve on the Ex-
a. Close valve at the inlet and out- pander-Separator so that gas flows
let of the Expander and Ex- through the liquid line from the sepa-
pander-Compressor. rator to the Demethanizer. It may be
b. Fully open the JT valve. necessary to slightly close the JT
INLET
GAS OUTLET
GAS
JT
VALVE
GAS
DEHYDRATOR
EXPANDER
VENT
Open
drain
valves.
GAS-GAS
EXCHANGER 3
Open
1 Valves.
EXPANDER
SEPARATOR
Open
2 vent
LIQUID valve.
PRODUCT
PRODUCT
PUMP
PROCEDURE TO DRYOUT DEMETHANIZER
valve in order to force gas to flow ing the compressors so that it indicates the
through the liquid line from the Ex- moisture content of gas that has flowed
pander Separator to the through the plant during dryout. Dryout is
Demethanizer. completed when the moisture content sta-
g. Maintain gas flow through this por- bilizes at about that of the moisture con-
tion of the system until it is dry. tent of gas leaving the Dehydrator.
2. Dry the gas flow system through the 2. Cool Down
Demethanizer Exchangers.
When dryout is completed, tempera-
a. Open the temperature control valve
tures can be lowered and start-up can com-
in the gas line to the Demethanizer
mence. The temperature is lowered in two
Reboilers.
steps:
b. Close the valve in the inlet gas line
1. Partially cool with the Expander shut-
to the Gas-to-Exchangers. All of the
down and use the cooling effect from
gas will flow through the
the JT valve in the Expander by-pass
Demethanizer Reboilers.
line.
c. Maintain flow until the system is dry.
2. Start the Expander and bring tempera-
3. Dr y the lower por tion of the
tures down to normal.
Demethanizer.
On pages 16 & 17, we discussed the
Some plants have a drying line pro- temperature drop which will occur when
vided at the bottom of the demethanizer gas pressure is lowered. During the initial
which can be used to circulate gas through phase of plant cool-down, the pressure
the tower and dry it out. If such a line is not reduction which normally occurs across the
provided, the Demethanizer should be Expander takes place across the JT valve.
dried by venting gas from the bottom of the This will result in a significant drop in gas
Demethanizer, each of the side Reboilers temperature. In fact, the temperature drop
should be vented to remove any moisture is enough to condense about 30% of the
on the shell side of the exchangers. normal liquid production of that with the
Gas flow rate through the Expander operating.
Demethanizer during dryout should be only Cool-down commences immediately
a fraction of the total gas flow circulating. If after dryout is completed. The pressure
the entire gas flow stream were circulated controller the Demethanizer is put in ser-
through the Demethanizer, it could dam- vice to regulate the position of the JT valve.
age the packing or trays in the tower. Inlet gas continues to flow, and outlet gas
The moisture analyzer on the gas de- from the residue gas compressor is di-
hydration unit is used fro determining when verted into the sales gas line. At this point,
each dryout phase is completed. The ana- the inlet gas should flow through the Gas-
lyzer is connected to the residue gas leav- to-Gas Exchanger at the start of cool-down.
The temperature control valve in the gas boil out methane contained in the liquid
line flowing to the Demethanizer Reboilers product entering the tower. The Product
is closed. Temperature in the cold system Pump is also started.
will slowly start to decrease, and liquid will The temperature in the Expander Sepa-
start to form in the Expander Separator. rator is the guide for determining when to
When the level in the Separator rises start the Expander. The Expander is not put
to its normal point, the level control system in service as long as the temperature is
is put in service to allow liquid to flow into falling. However, when the temperature in
the Demethanizer. In a short time, a liquid the Separator levels out at its low point,
level will appear in the bottom of the maximum cooling using the JT valve has
Demethanizer. At this point, the tempera- been achieved. At this point, the Expander
ture controller on the bottom of the is put in service. Refer to the following
Demethanizer is put in service and some pages for the detailed procedure for start-
of the inlet gas is diverted through the tem- ing the Expander.
perature control valve to the Demethanizer The Expander and Expander-Compres-
Reboilers to provide heat to the tower to sor are slowly put in service until tempera
Open
se
se service. Start
Product
Pump.
5
2
Open main valve and
close temp contr. valve.
EXPANDER
SEPARATOR
Put level controller in 4
service when liquid
appears in Separator. LIQUID
PRODUCT
PRODUCT
PUMP
COOL-DOWN PROCEDURE
tures in the cold section reach their nor- long enough for it to warm up to ambient
mal operating point. At this time, all of the temperature. If the cool-down is performed
gas should be flowing through the Ex- too quickly, some damage may occur to
pander and none through the JT valve. The piping or insulation from sudden metal con-
plant is in its normal operating mode, and traction due to rapid cooling. On the other
instruments and controls should be hand, if start-up commences a few minutes
checked for final tuning. after a shutdown, and all equipment is cold,
The time required to start-up the plant no cool-down is necessary and the Ex-
may vary from a few minutes to several pander can be placed in service as soon
hours, depending upon whether or not the as the lube oil and seal gas flows are es-
plant is cold, the degree of automation, tablished.
whether dryout is necessary, etc. A longer
start-up time is required for cool-down if
equipment in the plant has been shut down
Problem 7
A 30 second power outage occurred which shut down the plant. Restart begins as
soon as power is restored.
a. Is it necessary to dryout the plant? ___________
b. Is it necessary to cool-down the plant? __________
COMPR SURGE JT
DISCH VALVE
VALVE CONTROL
4 VALVE
Open suction
and discharge
valves.
SURGE
FLOW
CONTR
COMPR EXPANDER
COMPR
SUCTION
VALVE Close Open
n
pe
O
Open case drain
se
lo
3
O
pe
DeC1
PRES
COOLER
CONTR
DEMETHANIZER
PROCEDURE TO PURGE EXPANDER/COMPRESSOR
AND ESTABLISH SEAL GAS FLOW
SEAL
GAS
COMPR SURGE JT
DISCH VALVE
VALVE CONTROL
VALVE
SURGE
FLOW
CONTR
COMPR EXPANDER
COMPR
SUCTION
VALVE
1. Crack open the case drain valves on 1. The lube oil system has two oil pumps,
both the Expander and Compressor each with a HAND/OFF/AUTO switch.
and drain liquid from each casing. Open During normal operation, one pump is
a vent valve on the lube oil reservoir. operating, with its switch in the HAND
2. Slowly open a valve in the seal gas line position, and the other pump is stand-
and allow seal gas to flow out the drain by with its switch in the AUTO position.
valves on the Expander and Compres- The stand-by pump will automatically
sor cases and the vent on the oil reser- start if the lube oil pressure drops dur-
voir. ing operation. It is a good operating pro-
3. After the casings and reservoir are thor- cedure to set each pump in the HAND
oughly purged, close the drain valves position and observe the pump dis-
on the Expander and Compressor cas- charge pressure after it turns on to be
ings, and then close the vent valve on sure that both pumps are operating
the lube oil tank. satisfactorily.
4. Open the Compressor suction and dis- 2. After lube oil circulation is established,
charge valves. check pressures and temperatures in
5. Set the seal gas flow at its normal rate. the lube oil system for normal opera-
tion. The temperature of lube oil flow- 1. At the Expander Loading Station back
ing from the housing to the reservoir off on the air pressure regulator so that
should be about 38°C [100°F]. If the its output pressure is zero. The vane
Expander is cold at the time of start- control pressure gauge, PG-1, on the
up, lube oil may be cooled below its drawing, should read 0. The DeC1 pres-
normal operating temperature. In this sure Controller output pressure
case, check to see that the heater in gauge, PG-2, should read between
the oil reservoir is on, and the lube oil 60 - 100 kPa [9 - 15 psi].
temperature controller is by-passing oil 2. Move the 3-way valve to MANUAL po-
around the cooler. Maintain circulation sition. At this point the position of the
long enough to warm up the lube oil to vanes on the Expander is regulated by
its normal operating temperature. adjusting the air pressure at the pres-
3. Crack open drain valves on the Com- sure regulator.
pressors and Expander cases to see 3. Open the Expander outlet valve.
that no lube oil is leaking into either end 4. Open the Expander inlet valve. At this
of the unit. point, a small amount of gas will flow
c. Expander-Compressor Start-up through the Expander because the vane
controller does not positively stop all gas
The suction and discharge valves on
flow into the unit.
the compressor should be open.
Open inlet valve.
EXPANDER 4 Some gas will flow
INLET GAS through Expander.
SEAL
GAS
VANE
Reduce
SURGE CONTR Instr 1
FLOW Air air pres
CONTR AIR to zero.
COMPR EXPANDER PRES
REG DeC1
COMPR EXPAND PRES
SUCTION OUTLET VANE CONTR
VALVE CONTR OUTPUT
VALVE PRES PRES
Open
3 outlet PG-1
valve. PG-2
MAN AUTO
EXPANDER LOADING STATION
2 DeC1
MOVE VALVE TO 6 PRES
COOLER manual. CONTR
When PG-1 & PG-2 read the
same pressure, move 3-way DEMETHANIZER
valve to AUTO.
EXPANDER-COMPRESSOR START-UP
closed.
7. As soon as the Compressor impeller
begins rotating discharge pressure will
rise and close the check valve in the
by-pass line, and the Compressor will
be in service.
The time required to bring the Expander
Front View Side View up to normal operating speed will depend
upon whether or not the plant is cold at the
EXPANDER LOADING STATION
time of start-up. If the plant is warm, the
5. Slowly increase the Expander speed by time to bring the Expander up to full speed
raising the air pressure to the vane con- should be several hours to allow for gradual
troller. This is done by raising the pres- cool down.
sure of air out of the air pressure regu-
d. Cold Expander Start-up Procedure
lator in the Loading Station.
A cold Expander start-up could occur
6. As the pressure to the vane controller
on re-start after a short power outage,
increases, more gas will flow through
which will stop the lube oil pumps and trip
the Expander and its speed will in-
the low oil pressure shutdown device on
crease. At the same time, flow of gas
the Expander. Special precautions must be
to the JT valve will decrease, and the
observed when starting a cold Expander
output pressure from the Demethanizer
to prevent serious damage to the machine.
pressure controller will decrease. The
If a power outage occurs, and lube oil
two pressure gauges indicating pres-
pumps stop, lubrication during rundown of
sure on the vane controller and output
the Expander comes from the pressure pot
pressure from the Demethanizer pres-
in the system. This will provide lubrication
sure controller are located in the Ex-
during rundown, but will not provide a con-
pander Loading Station. As the air pres-
tinuous flow of lube oil while the unit is shut-
sure to the vane controller increases,
down. With no oil flowing through the bear-
the output pressure from the pressure
ings, the cold Expander housing and im-
controller will decrease. When the two
peller will slowly cool the shaft and bear-
pressures are equal, the 3-way valve
ing on the Expander end of the shaft. In a
is moved to the AUTO position, and the
matter of a few minutes, the lube oil in the
Demethanizer pressure controller is
bearing may freeze so that no lubrication
regulating the position of the vane con-
oil will flow to the bearing when the lube oil
troller on the Expander. At this point,
pump starts. In this situation, it is neces-
all gas should be flowing through the
sary to warm the bearing with steam or hot
Expander, and the JT valve should be
water until the bearing temperature is high position. The capacity of the Expander
enough for lube oil to circulate through it. is now controlled with the pressure regu-
Following is a procedure for cold start- lator. As you lower the output pressure
up when the bearing temperature is 15°C from the pressure regulator, the vanes on
[60°F] or below: the Expander will slowly close, and less
1. Start the seal gas flow. Be sure the com- gas will flow through the unit. At the same
pressor discharge valve is open so that time, the pressure in the Demethanizer
there is an outlet for seal gas. will start to drop, which will increase the
2. Check to see that the heater in the lube output pressure from the pressure con-
oil tank has turned on if the oil, tem- troller and open the JT valve.
perature is below 35°C [95°F]. There is a time delay before the
3. Start the lube oil pump, and circulate oil until Demethanizer pressure controller reacts to
its temperature is at least 25°C [80°F]. a change in flow through the Expander. In
4. When the expander bearing tempera- other words, when the flow through the
ture rises above 20°C [70°F], start the Expander is reduced by dropping the pres-
Expander using the procedure de- sure to the vane controller, it may take sev-
scribed in the prior section. eral minutes for pressure in the
e. Manual Operation of Expander Demethanizer to drop so that the pressure
controller will signal the JT valve to open.
If the situation should arise that you
Thus, adjusting the pressure on the vane
want to operate the plant with some gas
controller should be done slowly to avoid
flowing through the Expander and balance
pressure fluctuations in the Demethanizer.
through the JT valve, it will be necessary
to operate the Expander on manual con- 4. Expander Shut Down
trol. The procedure to switch from automatic The Expander can be shut down by 2
to manual control is as follows: methods:
1. At the Expander loading station, adjust 1. Depress the STOP button on the con-
the pressure from the air pressure regu- trol panel, which closes the inlet valve
lator so that it is the same as the output to the Expander. The machine will run
pressure from the Demethanizer pres- down in a short time when gas flow is
sure controller (PG-1 equals PG-2). stopped. Pressure in the Demethanizer
2. Move the 3-way valve to the Manual
Problem 8
List the 3 phases of starting the Expander-Compressor Unit in proper sequence.
1. ___________________________________________________________________
2. ___________________________________________________________________
3. ___________________________________________________________________
will start to drop, and the pressure con- If restart after a shut down is expected
troller will signal the JT valve to open. within a short period of time, it is good prac-
Gas flow to the Compressor will pass tice to leave the lube oil pump running and
through the by-pass line when the com- seal gas flowing. As long as seal gas is
pressor impeller stops rotating. flowing to the unit, the compressor dis-
2. Put the Expander on MANUAL control charge valve must be opened, or some
using the procedure previously de- other means must be provided for dispos-
scribed and reduce the pressure to the ing of the seal gas that enters the unit. Oth-
vane controller to zero. At this point, the erwise, pressure in the Expander housing
vanes are closed, but some gas will may rise to that of the source of seal gas.
leak past the vanes and the Expander B. ROUTINE OPERATING CHECKS
will continue to turn at a low RPM. The
Routine operating checks of any pro-
inlet valve to the Expander is then
cess facility include observation of various
closed to stop rotation.
instruments and controls to see if a change
After the expander has stopped rotat-
has occurred from a prior reading. If a
ing, the lube oil pump is stopped and then
change is noted, the cause should be de-
seal gas flow is stopped. If the unit must
termined and corrected before the condi-
be opened for inspection or repair, valves
tion deteriorates into one that may result
in the Expander outlet line and compres-
in shutdown. The position of control valves,
sor suction discharge line should be
that is the percent the valves are open, is
closed.
another item which should be checked rou-
EXPANDER
SEAL
VANE
SURGE Instr
FLOW
AIR
COMPR EXPANDER PRES
DeC1
COMPR EXPAND PRES
SUCTION OUTLET VANE CONTR
CONTR OUTPUT
VALVE
PG-1 PG-2
MAN
EXPANDER LOADING
2 DeC1
Move 3-way valve to MANUAL PRES
and reduce expander speed
by lowering air output pressure. DEMETHANIZER
MANUAL OPERATION OF EXPANDER
tinely. Quite often, a change in the noise or plant can continue to operate and produce
sound that equipment makes is a better about one-third of the normal liquid produc-
indication of a problem than temperature tion. The pressure drop which normally
or pressure gauge readings on the equip- occurs across the Expander will take place
ment. Following are some of the more im- across the JT valve, and some gas cooling
portant routine observations to make in will occur. This situation is often referred to
cryogenic plants: as JT valve operation.
1. Inlet gas temperature, pressure, and Gas flow during Expander shutdown is
flow rate. shown in the opposite drawing. The main
2. Gas temperatures in and out of the Gas- difference between this flow and normal
to-Gas Exchanger. flow is that all of the gas flows through the
3. Temperature in the Expander Sepa- JT valve in the by-pass line around the
rator. Expander, and gas which normally flows
4. Level in the Expander Separator. to the compressor flows through the by-
5. Temperatures on the shell and tube pass line around the compressor directly
sides of the Demethanizer Reboilers. to the residue gas compressor. The tem-
6. Temperature at the bottom of the peratures throughout the plant will be at a
Demethanizer. higher point.
7. Level in the bottom of the The volume of liquid production will be
Demethanizer. about one-third of that with the Expander
8. Methane/ethane ratio in the liquid operating. This may require resetting level
product. controllers on the Expander Separator and
9. Demethanizer pressure. Demethanizer bottom.
10. Demethanizer top temperature. The Demethanizer bottom temperature
11. Expander lube oil pressure and tem- will have to be raised because the liquid
perature. product will contain lower quantities of
12. Expander seal gas pressure and flow. ethane and propane. If an analyzer on the
13. Expander thrust bearing pressures. bottom product automatically resets the
14. Expander-Compressor suction and dis- temperature controller at the base of the
charge pressures. Demethanizer, the control system will au-
15. Pressure drop across Expander lube oil tomatically change the bottom temperature
filter. to the point required to make the desired
16. Pressure drop across Expander inlet quality of bottom product.
screen. After an Expander shutdown, it may re-
C. Operation with Expander quire several hours for temperatures and
Shutdown levels to stabilize in the plant. One reason
When the Expander is shutdown, the it takes some period of time for tempera-
tures to stabilize, particularly in the pacity will be slightly lower because the resi-
Demethanizer is that heating gas flow in the due gas compressor power normally pro-
Reboilers is not a very good heat transfer vided by the Expander-Compressor must be
material, and considerable time is required made up by Residue Gas Compressors,
to stabilize temperatures after an upset oc- which will reduce their capacity. It may be
curs. necessary to raise the Demethanizer pres-
The plant can operate indefinitely with the sure to make up the pressure rise provided
Expander out of service. However, the ca- by the Compressor on the Expander.
Problem 9
Your plant is operating with the Expander-Compressor shutdown. Indicate how follow-
ing process conditions will change from their point with the Expander in service.
a. Expander Separator temperature. Warmer / Cooler / No Change
______________________________
b. Demethanizer bottom temperature. Warmer / Cooler / No Change
______________________________
c. Demethanizer top temperature. Warmer / Cooler / No Change
______________________________
d. Residue gas compressor fuel. More / Less / No Change
______________________________
e. Volume of liquid product. More / Less / No Change
______________________________
SALES
GAS
RESIDUE GAS
COMPRESSOR
COMPR EXP
FC 60-100 kPa
[9-15 psi]
EXPANDER- FC
COMPRESSOR JT
VALVE
PC
SIDE
REBOILER
INLET
GAS LC
DeC1
GAS/
GAS
HEX
BOTTOM
FC REBOILER
EXPANDER
INLET
SEPARATOR
DEHYDRATOR 5600 kPa
[800 psi] TC
PRODUCT ANAL
RAW HEATER
38°C PRODUCT
[100°F]
PRODUCT PUMP
TC FC
TRIM
HEATER
HOT FLUID
PRODUCT ANAL
RAW HEATER
38°C PRODUCT
[100°F]
PRODUCT PUMP
TC FC
SNOWBALLING TEMPERATURES
the piping and Reboiler is more than the inlet gas side and lower the quantity of liq-
height of liquid in the chimney tray, the liq- uid condensed and fed to the
uid level will rise around the chimney and Demethanizer.
overflow into the lower portion of the tower. One way of eliminating this problem is
The net effect of liquid overflowing in the to inject a stream of gas into the liquid line
chimney is to by-pass the Reboiler. This will out of the Reboiler. The gas lift action should
result in less heat input to the restore normal liquid flow to the Reboiler
Demethanizer, the methane content of the and stop overflow down the chimney. After
bottom product will rise. temperatures return to normal, which indi-
Another effect of a locked Reboiler is cates the gas lift action is working, the in-
that the inlet gas which provides process jection gas rate should be slowly reduced
heat in the Reboiler is not cooled as much until no gas flows.
as normal because some of the cold liquid Injection gas should be warm gas which
which normally passes through the ex- does not contain heavy hydrocarbons.
changer is overflowing in the chimney tray. Sales gas from the recompressor is often
This results in less chilling of the inlet gas the source of injection gas to a locked
stream, which will raise temperatures in the Reboiler.
CHIMNEY
Gas temp will rise
when Reboiler locks.
HEATING
GAS
OUTLET
REBOILER
INJECTION
GAS
HEATING DEMETHANIZER
GAS INLET
FLOW OF INJECTION GAS TO UNLOCK REBOILER
WARM COLD
GAS GAS
IN OUT
Pressure drop increases.
METHANOL
∆P
-87°C
SALES [-125°F]
GAS
RESIDUE GAS 90°C
COMPRESSOR [-130°F]
1700 kPa
COMPR EXP [245 psi]
FC 62-103 kPa
[9-15 psi]
EXPANDER- FC
COMPRESSOR JT
20-62 kPa VALVE
[3-9 psi]
PC
-51°C
5500 kPa [-60°F]
[785 psi]
DeC1
60°C SIDE
[-75°F] REBOILER
INLET
GAS LC
GAS/
GAS
HEX -32°C 7°C
[-25°F] BOTTOM [45°F]
FC REBOILER
EXPANDER
INLET
SEPARATOR
DEHYDRATOR 5600 kPa
[800 psi] TC
PRODUCT ANAL
RAW HEATER
38°C PRODUCT
[100°F]
PRODUCT PUMP
TC FC
SHAFT
COMPRESSOR
EXPANDER THRUST
CONTR
VALVE
∆P
Contr
FILTERS
∆P TEMP
CONTR
RESERVOIR
COOLER
PUMP
EXPANDER-COMPRESSOR
Problem 10
Match each item in the left column with the appropriate item in the right column.
_____ 1. Snowballing Temperatures a. Inlet gas dehydrator is not drying gas.
_____ 2. Locked Reboiler. b. Lower temperature in Expander
_____ Separator.
_____ 3. Freeze-up in Exchanger c. Low seal gas flow.
_____ 4. Surge in Expander- d. Drop in Demethanizer bottom
_____ Compressor temperature.
_____ 5. Low temperature of e. Worn Labyrinth teeth on Expander
_____ Expander lube oil. impeller.
_____ 6. High thrust. f. Low gas flow rate.
CRYOGENIC PLANT
EXPANDER- FC
2. Actual temp out of Expander is COMPRESSOR JT
VALVE
PC
-105°C. How much condensation
-57°C
SIDE
Expander? ________%. INLET
GAS LC
REBOILER
DeC1
SEPARATOR
PRODUCT ANAL
is _______°C. TRIM
HEATER
HOT FLUID
5. g 1. 6. a. Increase 7. a. No
d 2. b. Increase b. No
e 3. c. Decrease
a 4. d. Decreased
f 5.
c 6.
b 7.
10. b 1.
d 2.
a 3.
f 4.
c 5.
e 6.
is ________ °F.
FC 260 psi
EXPANDER- FC
COMPRESSOR JT
800 psi
GAS
EXPANDER
FC
BOTTOM
REBOILER
INLET
plant is operating on the JT valveDEHYDRATOR
SEPARATOR
815 psi
TC
Temperature in the Expander RAW
PRODUCT
HEATER
ANAL
PRODUCT
Separator is -40°F. Theoretical 100°F
PRODUCT PUMP
TC FC
temperature out of the JT valve 1/3 of Inlet Gas TRIM
HEATER
5. g 1. 6. a. Increase 7. a. No
d 2. b. Increase b. No
e 3. c. Decrease
a 4. d. Decreased
f 5.
c 6.
b 7.
10. b 1.
d 2.
a 3.
f 4.
c 5.
e 6.
305 WELLS FARGO DR., SUITE 4 • HOUSTON, TEXAS 77090 • (281) 444-7632 • FAX: (281) 586-9876
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