Third Topical Conference on Natural Gas UtilizationThird Topical Conference on Natural Gas Utilization

March 30 March 30 --April 3, 2003 New Orleans, Louisiana, USAApril 3, 2003 New Orleans, Louisiana, USA

Testing Criteria for 2 MW or Greater LNG ExpandersTesting Criteria for 2 MW or Greater LNG Expanders

Samuel A. AfolabiSamuel A. AfolabiRotating Equipment EngineerRotating Equipment Engineer

Nigeria LNG Nigeria LNG Bonny Island, NigeriaBonny Island, Nigeria

Samuel.Afolabi@nlng.comSamuel.Afolabi@nlng.com

Sukhi S. GillSukhi S. GillGeneral Manager General Manager

Ebara International Corp.Ebara International Corp.Sparks, Nevada, USA Sparks, Nevada, USA sgillsgill@@ebaraintlebaraintl.com.com

ChenChen--Hwa ChiuHwa ChiuLNG Technology Advisor LNG Technology Advisor

ChevronTexaco ChevronTexaco Bellaire, Texas , USA Bellaire, Texas , USA

chiuch@chevrontexaco.comchiuch@chevrontexaco.com

Yoshitsugi KikkawaYoshitsugi KikkawaSen. Engineering Consultant Sen. Engineering Consultant

Chiyoda CorporationChiyoda CorporationYokohama, Japan Yokohama, Japan

ykikkawaykikkawa@@ykhykh..chiyodachiyoda.co..co.jpjp

Hans E. KimmelHans E. KimmelVice President R&DVice President R&D

Ebara International Corp.Ebara International Corp.Sparks, Nevada, USASparks, Nevada, USA

hkimmelhkimmel@@ebaraintlebaraintl.com.com

Donald R. SmithDonald R. SmithDept. of MathematicsDept. of Mathematics

University of CaliforniaUniversity of CaliforniaSan Diego, USASan Diego, USA

drsmith@ucsd.edudrsmith@ucsd.edu

American Institute of Chemical Engineers 2003 Spring NatAmerican Institute of Chemical Engineers 2003 Spring National Meetingional Meeting

Origin of LNG Expander Origin of LNG Expander TechnologyTechnology

United States Patent 4,334,902United States Patent 4,334,902

Inventor: Henri ParadowskiInventor: Henri ParadowskiTechnip, Paris La Defense, FranceTechnip, Paris La Defense, France

Priority Date: Dec. 12, 1979Priority Date: Dec. 12, 1979France 79 30490France 79 30490

Method of and System for Method of and System for Refrigerating a Fluid to be Cooled Refrigerating a Fluid to be Cooled

Down to a Low TemperatureDown to a Low Temperature

United States Patent 4,334,902 June United States Patent 4,334,902 June 15, 198215, 1982

Inventor: Henri ParadowskiInventor: Henri Paradowski

Method of and System for Refrigerating a Fluid to be Cooled Method of and System for Refrigerating a Fluid to be Cooled Down to a Low TemperatureDown to a Low Temperature

LNG Expander EconomicsLNG Expander Economics

LNG ExpanderPower Output

Increase inLNG Output

Increase in RevenueFor LNG Price

$266.67/tonkW Tons/year $/year1

10050010002000

606,00030,00060,000120,000

16,0001,600,0008,000,00016,000,00032,000,000

MLNG Dua, Malaysia:MLNG Dua, Malaysia:

First generation LNG First generation LNG expander with airexpander with air--cooled cooled generator and rotating generator and rotating

shaft sealshaft seal19961996

(Flowserve Corp.)(Flowserve Corp.)

NLNG Nigeria:NLNG Nigeria:

First generation LNG and First generation LNG and HMR expanders with airHMR expanders with air--

cooled generator and rotating cooled generator and rotating shaft sealshaft seal

19991999

(Flowserve Corp.)(Flowserve Corp.)

ThreeThree--Stage Stage Liquid Expander Liquid Expander for Oman LNGfor Oman LNG

19991999(Ebara Intl. Corp.)(Ebara Intl. Corp.)

Oman LNGOman LNGLiquefaction Process Trains 1 and 2Liquefaction Process Trains 1 and 2

Libe

ral K

ansa

s U

SA

MR

Bin

tulu

Dua

LNG

Bin

tulu

Dua

MR

Bin

tulu

Tig

a

LNG

Bin

tulu

Tig

a

N-L

NG

Tra

in 1

& 2

M

R

N-L

NG

Tra

in 1

& 2

LN

G

Om

an L

NG

MR

Om

anLN

G L

NG

N-L

NG

Tra

in 3

MR

N-L

NG

Tra

in 3

LN

G

Woo

dsid

e Tr

ain

3 M

R

Woo

dsid

e Tr

ain

3LN

G

Ras

Laf

fan

Tran

3 M

R

Ras

Laf

fan

Trai

n 3

LNG

Krio

Pol

and

Dam

ietta

MR

Dam

ietta

LN

G

Sakh

alin

MR

Sakh

alin

LN

G

N-L

NG

4 &

5 M

R

N-L

NG

4 &

5 L

NG

Stat

oil H

amm

erfe

st M

R

Stat

oil H

amm

erfe

st L

NG

EIC Power kW

0

200

400

600

800

1,000

1,200

1,400

1,600

1,800

2,000

Size kW

Plants

Liquid Expander Installations LNG

EIC Power kW

Flowserve PowerkW

To be DecidedPower kW

ThreeThree--Stage Stage Liquid Expander Liquid Expander

for Ras Laffan LNGfor Ras Laffan LNG20022002

(Ebara Intl. Corp.)(Ebara Intl. Corp.)

Reasons for testing LNG expanders or LNG pumpsReasons for testing LNG expanders or LNG pumps

••Testing of all materials under cryogenic conditions for Testing of all materials under cryogenic conditions for thermal stress and shrinkagethermal stress and shrinkage

••Testing the hydraulic performance with LNG, the actual Testing the hydraulic performance with LNG, the actual cryogenic fluidcryogenic fluid

••Testing the rotordynamic performanceTesting the rotordynamic performance

••Testing the electrical performanceTesting the electrical performance

Testing of one LNG expander with 2 MW power generation requires two booster pumps with a total power input of 5 MW

One 2 MW LNG expander with 85% efficiency and 5 MW booster pumps with75% efficiency generate power losses equal to 1.55 MW

Power losses are converted into heat.

1.55 MW vaporizes 8.6 t/h LNG equivalent to 18,300 US $ per 8 hours of testing

Test stand for turbine testingTest stand for turbine testing

Two booster pumps for Two booster pumps for turbine testingturbine testing

Turbine test stand with LNG tankerTurbine test stand with LNG tanker

7 MW of additional power supply for booster pumps7 MW of additional power supply for booster pumps

Limitations of Conventional Testing of Large Limitations of Conventional Testing of Large LNG ExpandersLNG Expanders

••Number and size of booster pumpsNumber and size of booster pumps

••Power consumption for booster pumps is at least 2.5 times Power consumption for booster pumps is at least 2.5 times the power generation of LNG expanderthe power generation of LNG expander

••Heat losses vaporize high quantities of LNGHeat losses vaporize high quantities of LNG

••Costs for conventional testing increase by the factor 3 to 5 Costs for conventional testing increase by the factor 3 to 5 with the size of the expander dependent on the specified flow with the size of the expander dependent on the specified flow rate and differential head of the expanderrate and differential head of the expander

Proposed Method of Testing 2 MW or Proposed Method of Testing 2 MW or Greater LNG ExpandersGreater LNG Expanders

Testing of LNG expanders in the pump performance Testing of LNG expanders in the pump performance mode and converting the tested pump performance mode and converting the tested pump performance

to the related turbine performance.to the related turbine performance.

All reaction turbines can be operated as centrifugal All reaction turbines can be operated as centrifugal pumps, and all centrifugal pumps can be operated as pumps, and all centrifugal pumps can be operated as

reaction turbines.reaction turbines.

RotorRotor

Induction GeneratorInduction Generator

StatorStator

Thrust Equalization Thrust Equalization

Mechanism (TEM)Mechanism (TEM)

Turbine Nozzle VanesTurbine Nozzle Vanes

Turbine RunnersTurbine Runners

Turbine Draft TubeTurbine Draft Tube

RotorRotor

Induction MotorInduction Motor

StatorStator

Thrust Equalization Thrust Equalization

Mechanism (TEM)Mechanism (TEM)

Pump Diffuser VanesPump Diffuser Vanes

Pump ImpellersPump Impellers

Pump Suction TubePump Suction Tube

Turbine Nozzle Ring or Pump Diffuser RingTurbine Nozzle Ring or Pump Diffuser Ring

Turbine Runner or Pump ImpellerTurbine Runner or Pump Impeller

Complete Pump Complete Pump CharacteristicsCharacteristics

by by R.T.KnappR.T.Knapp

Trans.ASME Nov.1937 Trans.ASME Nov.1937

Rotordynamic Rotordynamic schematic of turbine schematic of turbine generator identical to generator identical to schematic of electric schematic of electric

motor pumpmotor pump

Rotordynamic parametersRotordynamic parametersidentical for turbine and pump operationidentical for turbine and pump operation

Vibration as a function of speed identical for Vibration as a function of speed identical for turbine and pump operationturbine and pump operation

Relation between motor and generator performance Relation between motor and generator performance for induction motor/generatorfor induction motor/generator

Ebara International Corporation Ebara International Corporation Headquarters and Factory Sparks, NevadaHeadquarters and Factory Sparks, Nevada

Proposed Method of Testing 2 Proposed Method of Testing 2 MW or Greater LNG ExpandersMW or Greater LNG Expanders

Thanks to Our Turbine Engineering ForefathersThanks to Our Turbine Engineering Forefathers

Thank YouThank You