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MAKORI GPF TURBO EXPANDER LOG SHEET
EXP. OUT PRESSURE (PIT-404) 280~295 - PSIG 293 293 293 292 293 293 291 293 293 292 292 293 293
COMP. IN PRESSURE (PI-0002) 260~270 250 PSIG 267 267 267 266 267 266 265 266 267 266 266 266 266
COMP. OUT PRESSURE (PIT-0303) 350~365 - PSIG 366 367 366 366 366 366 366 365 366 366 366 366 366
EXP. THRUST Pressure (PI-105) 270~280 - PSIG 290 293 292 290 290 288 292 288 290 293 286 287 290
COMP. THRUST Pressure (PI-104) 270~280 - PSIG 275 276 275 273 280 278 274 279 278 274 282 279 277
EXP. THRUST DIFF. Pressure (PDI-105) 0 ~ 50 200 PSID 16 14 16 17 10 9.9 18.36 9.38 12.11 19.54 4.3 8.79 13
EXP. WHEEL Pressure (PI-101) 335~350 - PSIG 338 338 338 336 338 336 337 336 337 337 337 338 337
SEAL GAS SUPPLY Pressure (PI-102) 380~400 - PSIG 385 385 386 385 387 387 385 385 387 384 388 387 386
TALL-60
EXP. BEARING Temperature (TI-101) 160~175 TAHH-200
0
F 166 165 166 166 164 165 167 165 166 169 167 168 166
EXP. ''X'' VIBRATION (VI-101A) 0.4~0.6 1.6 MILS 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.12 0.12 0.12 0.12 0.12 0.13
EXP. ''Y'' VIBRATION (VI-101B) 0.4~0.6 1.6 MILS 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.11 0.11 0.12
COMP.''X'' VIBRATION (VI-102A) 0.4~0.6 1.6 MILS 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.07 0.07 0.07 0.07 0.07 0.08
COMP. ''Y'' VIBRATION (VI-102B) 0.4~0.6 1.6 MILS 0..10 0.09 0.10 0.10 0.09 0.09 0.09 0.09 0.09 0.09 0.09 0.09 0.09
EXP/COMP. SPEED (SI-101) 22~23.5k 28400 RPM 22,205 22,190 22,234 22,344 22,153 22,198 22,285 22,234 22,197 22,293 22,168 22,183 22224
COMP. WHEEL Pressure (PI-103) 270~290 - PSIG 281 281 281 280 282 281 280 281 281 281 281 281 281
LUBE OIL FILTER DIFF. Pressure (PDI-108) 4~8 35 PSID 3.30 3.90 3.90 3.90 3.90 3.90 3.90 3.90 3.90 3.90 3.90 3.90 3.9
LUBE OIL RESERVOIR Pressure (PI-106) 260~270 - PSIG 269 270 269 268 270 269 268 269 269 269 269 268 269
LUBE OIL SUPPLY Pressure (PI-107) 400~424 - PSIG 426 426 425 424 426 425 424 425 424 424 424 424 425
LUBE OIL FILTER INLET Pressure (PI-108) 400~425 - PSIG 430 429 429 428 431 429 428 429 429 428 428 428 429
LUBE OIL DIFF. Pressure (PDI-106) 140~150 90 PSID 157 156 156 156 156 156 155 155 155 155 155 155 156
IGV CONTROL (XY-308-0101B) opening 75~85 - % 80% 80% 80% 80% 80% 80% 80% 80% 80% 80% 80% 80% 1
RESERVOIR LUBE OIL LEVEL 17~22 - IN 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18
LUBE OIL PUMP IN SERVICE P-101/102 - - - 102 102 102 102 102 102 102 102 102 102 102 102 -
LUBE OIL PUMP dishcharge pressure - - PSIG 455 455 455 455 455 455 455 455 455 455 455 455 455
Notes: (In line with VSM recommendation shared vide email dated July 31, 2019)
[1]
Thrust differential pressures shall not exceed the value of 200 psig.
[2]
Upper limit set for bearing temperature is 175 F.
[3]
Vibration shall not exceed value of 1.3 Mils
TE's Vibration & Cold Separator Temperature Curve
0.35
0.25
Mils
0.15
0.05
0800 1000 1200 1400 1600 1800 2000 2200 0
EXP. ''X'' VIBRATION (VI-101A) EXP. ''Y'' VIBRATION (VI-101B) COMP.''X'' VIBRATION (VI-102A) COMP. ''
170
160
150
140
F
130
120
110
100
0800 1000 1200 1400 1600 1800 2000 2200 0
Psig
11,000
300
9,000
7,000
5,000 250
3,000
1,000 200
2000 2200 0000 0200 0400 0600 0800 1000
160 120
140
100
120
Psig 80
100
F
80 60
60
40
40
20
20
0 0
2000 2200 0000 0200 0400 0600 0800 1000
0
0800 1000 1200 1400 1600 1800 2000 2200 0000 0200
EXP. THRUST Pressure (PI-105) COMP. THRUST Pressure (PI-104) LUBE OIL DIFF. Pressure (PDI-106)
0
0800 1000 1200 1400 1600 1800 2000 2200 0000 0200
SEAL GAS SUPPLY Temperature (TI-103) LUBE OIL SUPPLY Temperature (TI-105)
200
190
180
170
160 Psig
150
140
130
120
0000 0200 0400 0600
rves
emperature (TI-105)
1.6
1.4
1.2
1
ATA: 15~22 sep,2015
0.8
Mils
0.6
0.4
0.2
0
1-May-14 1-Sep-14 1-Jan-15 1-May-15 1-Sep-15 1-Jan-16 1-May-16 1
Expander "X" vibration (vi-308-101a) Expander "Y" vibr
TE's Vibration Historical Trend
2 sep,2015
ATA: 8~11 sep, 2017
ep, 2017
ATA: 27 June, 05 July, 2018
Re-
Expander Gas re- Re-
compressor Lube oil
thrust compressor compressure
thrust differential
Production Date differential discharge suction
differential pressure (DPi-
pressure (DPi- pressure (pit- pressure (Pi-
pressure (DPi- 308-106)
308-106) 308-0303) 308-109)
308-104)
Lube oil Lube oil Lube oil Seal gas Seal gas
Lube oil filter Lube oil drain
reservior supply supply supply differential
inlet pressure temperature
pressure (Pi- pressure (Pi- temperature pressure (Pi- pressure (DPi-
(Pi-308-108) (Ti-308-106)
308-106) 308-107) (Ti-308-105) 308-102) 308-101)
JT Valve OP
(%)
15.19
14.42
15.71
16.40
16.33
16.79
15.58
15.21
14.29
14.83
15.42
15.04
11.56
6.79
2.65
0.33
0.00
0.00
0.00
0.00
0.00
5.29
0.21
0.00
0.00
0.00
0.00
0.00
0
0.00
0.00
0.00
0.00
0
2.43
1.52
1.52
2.08
2.38
2.38
0.75
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
2.92
6.71
6.75
3.50
6.58
0.21
0.00
0.00
0.00
0.00
0.00
0.00
12.13
12.25
11.42
12.27
8.96
8.42
8.25
6.71
8.54
9.29
8.54
7.88
11.29
13.42
8.38
10.88
4.79
1.92
6.46
2.00
0.00
4.00
10.75
6.83
4.50
6.02
4.21
2.81
7.10
7.75
10.38
26.06
10.13
0.00
0.00
7.92
18.63
17.96
10.88
8.75
15.79
13.67
17.42
14.88
16.65
16.13
18.29
18.88
18.88
5.21
14.09
15.83
24.63
17.46
15.42
19.04
18.50
17.46
19.29
22.21
20.83
21.92
19.42
-
-
-
-
-
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
6.33
21.50
51.25
44.00
30.59
30.06
35.25
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.75
0.25
0.00
2.79
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
9.92
2.17
12.08
15.03
15.00
14.73
13.33
14.62
11.38
0.00
0.31
RPM reduced from 23500 to 21500, JT partially open
Gas load remained split on turbo expander and JT valve as per requirement to observe vibration at constant RPM.
Lube oil TCV set point changed from 100 deg. F to 95 deg. F.
Deep2 Commissioning
Gas load remained split on turbo expander and JT valve as per requirement to sustain vibrations within limits of 1.3 Mils.
Gas load remained split on turbo expander and JT valve as per requirement to sustain vibrations within limits of 1.3 Mils.
Gas load remained split on turbo expander and JT valve as per requirement to sustain vibrations within limits of 1.3 Mils.
1. Gas load remained split on turbo expander and JT valve as per requirement to sustain vibrations
within limits of 1.30 Mils.
2. 40 Liters of fresh TELLUS 100 charged into system after drainage of same amount of lube oil.
Gas load remained split on turbo expander and JT valve as per requirement to sustain vibrations within limits of 1.3 Mils.
Gas load remained split on turbo expander and JT valve as per requirement to sustain vibrations within limits of 1.3 Mils.
Gas load remained split on turbo expander and JT valve as per requirement to sustain vibrations within limits of 1.3 Mils.
Turbo Expander tripped at 0628 hours (25-12-2019) on low seal gas DP, reduction in vibrations is
observed after start up.
Seal gas heater set point increased from 60 to 65 0F to maintain supply temp. at 50 0F.
RPM remained slightly on lower side in lieu of feed curtailment due to 2 booster operation (0840 to 0940 hrs).
Seal gas heater set point increased from 65 to 75 0F to maintain supply temp. at 50 0F.
80 liters of Tellus-100 charged at 1200 hours on March 20, 2020.
Lube oil filter element B changed with A, DP dropped from 25psig to 3psig.
Expander stopped at 1024hrs (16-8-20) and started at 0100hrs (17-8-20), lube oil flushing, seal gas and lube oil filter replaced,
TE tripped on expander bearing high temperature at 1625hrs and restarted at 1910hrs.
TE tripped on expander bearing high temperature at 1234hrs and restarted at 2200hrs.
On 30th August, 100 liter of lube oil Shell Tellus100 was make up. At 1530 hrs load on TE increased by 10 MMscfd, increase in
On 1st September, TE was stopped at 1348 Hrs. as per OEM recommendation to test the functionality of ATE and purge the th
Unit started on 2nd September, at 0146 Hrs. Similar conditions of compressor high bearing temperature and thrust pressure p
Gas circuit shut down occurred at 0859 hrs on a/c of TIT-3080202 LL alarm activation, (attributed to feed flow). Sale gas flow r
In lieu of reduced offtakes from Maramzai sector (with only MRM-2 & 4 in service), dry out FCV took in service at 0215 hrs to m
Exp. Bearing high alarm (190F) logged at local PLC while DCS recorded 173.63 F at same time.
TE tripped on expander bearing high temperature at 0650 hrs dated Sep 24, 2020 and restarted at 0816hrs. (Loop simulation o
Exp. bearing temp spikes. Max. 190.86oF @ 0211hrs. IGV was reduced and JT taken in parallel. Load normalized at 0225hrs.
TE tripped at 0504hrs due to Exp. bearing high temp. Restarted at 0524hrs.
TE tripped at 2039hrs due to Exp. bearing high temp. Restarted at 2056hrs.
Tellus 46 Fresh = 50Litre & Tellus 68 Fresh = 85 Litre added to the system @1745hrs
Seal gas heater set point increased from 85 to 87 F at 0800 hrs.
Seal gas heater set point increased from 87 to 90 F at 1500 hrs. Exp. bearing temp spikes. Max. 192 OF @ 0557 hrs (not logge
High vibration alarm on comp Y side (1.846 Mils) observed at 17:21:18 hrs followed by normalization of same at 17:21:20 hrs.
Turbo expander tripped at 2138 hrs on expander bearing high temperature alarm followed by MGPF gas circuit shutdown on D
50 liters lube oil drained from LO reservoir and replenishment of same quantity with Shell Tellus-46.
100 liters lube oil drained from reservoir and replenished 50 liters of Shell Tellus-46.
onstant RPM.
hin limits of 1.3 Mils.
hin limits of 1.3 Mils.
hin limits of 1.3 Mils.
and lube oil filter replaced, expander bearing redundant RTD used. Temperature still on higher side.
by 10 MMscfd, increase in thrust pressure was observed from 120 psig to 180 psig. Load was accordingly reduced to maintain bearing tem
ty of ATE and purge the thrust pressure transmitters and impulse tubing. ATE was tested in workshop and found working OK. Turbo Expan
ture and thrust pressure persisted till 0445 hrs. At 0446 hrs. Compressor wheel back pressure suddenly dropped within few seconds resul
feed flow). Sale gas flow resumed at 2126 hrs followed by startup of TE at 2245 hrs and normalization of plant parameters.
k in service at 0215 hrs to maintain plant pressure which decreased from 985 to 930 psi.
0816hrs. (Loop simulation of expander bearing RTD. Verification of termination tightening. Spare RTD signal has been relayed to DCS system
normalized at 0225hrs.
2 OF @ 0557 hrs (not logged on DCS). IGV was reduced to 65 from 77%. Load normalized afterwards.
n of same at 17:21:20 hrs. No tripping occurred.
F gas circuit shutdown on De-ethanizer Hi pressure security at 2140 hrs. Sales gas flow resumed at 2156 hrs.
uced to maintain bearing temperatures and compressor thrust differential pressure below 120 psid.
ound working OK. Turbo Expander along with MCS was completely pressurized and depressurized twice via seal gas from normal operating
pped within few seconds resulting in increase in high compressor thrust differential pressure also compressor bearing temperature droppe
ant parameters.
has been relayed to DCS system via temperature transmitter (TIT-3081010-R). Now, redundant RTD display is also available at DCS with live
eal gas from normal operating pressure to atmospheric pressure towards close drain.
r bearing temperature dropped from 178 °F to 169 °F within a minute and the unit got stable. Unit was ramped up to the normal operatin
s also available at DCS with live monitoring and trending. Lube Oil TCV taken into service with 104 F Setpoint)
ped up to the normal operating conditions with the closure of in-parallel operating JT valve.
Turbo Expander Tripping History After MCS Replacement
Cause Remarks
1. On 27th August, Unit was started at 0455 hrs. and was stopped at
0550 hrs. in lieu of high compressor side bearing temperature. Started
again at 0635 hrs. on low RPM of 16000 for observation of bearing
Expander bearing high temperature temperatures, Comp/EXP. Bearing temperature was 180F/160F.
Increase in 600 RPM result in sudden surge of Expander temperature
and unit tripped at 0756 hrs.
2. On 28th August, Turbo expander started at 1324 hrs after lube oil
viscosity enhancement by blending of T-100 in the oil circuit. (Viscosity:
57.37 Cst) and left running at 15000 RPM. At 2025 hrs. turbo expander
Compressor Thrust High Differential pressure
tripped on Compressor Thrust High Differential pressure. Unit restarted
at 2310 hrs. with reduced throughput keeping in view compressor thrust
differential and Exp/Comp bearing temperatures.