COURSE OVERVIEW:

The integration of compressors and turbo-expanders is vital for cryogenic processes, gas processing, and energy recovery applications. This course provides an advanced technical study of these high-speed rotating machines, focusing on their thermodynamic interaction and mechanical design. Participants will explore how turbo-expanders convert the internal energy of a high-pressure gas stream into useful work, often driving a companion compressor on a single shaft.

The scope of this training includes the detailed analysis of aerodynamic performance for both centrifugal compressors and radial-inflow turbines (expanders). We will examine the specialized components required for cryogenic service, including magnetic bearings, specialized sealing systems, and variable inlet guide vanes. The course emphasizes the importance of managing the "Joule-Thomson" effect and the phase changes that can occur during the expansion process.

Coverage extends to sophisticated troubleshooting methodologies for turbo-expander-compressor units, including the diagnosis of rotor dynamic instabilities and thrust balance issues. Attendees will learn how to manage complex control strategies that balance refrigeration duty with power recovery. By the end of this course, participants will possess the expertise to operate, monitor, and troubleshoot these critical assets in demanding process environments.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the thermodynamic principles of isentropic expansion.
2. Identify the major components of a turbo-expander-compressor set.
3. Analyze the performance maps for both the expander and compressor sides.
4. Manage the impact of gas composition and mole weight on machine behavior.
5. Understand the operation and benefits of Active Magnetic Bearings (AMB).
6. Implement effective control strategies using Variable Inlet Guide Vanes (VIGV).
7. Execute safe startup and shutdown procedures for cryogenic expanders.
8. Monitor and troubleshoot dry gas seal systems in high-pressure service.
9. Identify the early warning signs of rotor instability and resonance.
10. Manage thrust balance and axial displacement in high-speed rotors.
11. Diagnose the causes of efficiency loss in the expansion process.
12. Troubleshoot auxiliary systems, including lube oil and seal gas skids.
13. Analyze the impact of liquid formation (condensate) in the expander discharge.

TARGET AUDIENCE:

Senior Operations Personnel, Mechanical Engineers, Rotating Equipment Specialists, and Maintenance Leads in LNG or Gas Processing plants.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.