AP P L I C A T I O N NOTE

Turboexpander-Compressor
Design Features
AN-PP-001 January 2002 Rev. 1

1.0 TURBOEXPANDER-COMPRESSORS

Mafi-Trench Corporation (MTC) turboexpander-compressors, or expanders are currently in operation around the
world in natural gas processing, dew point control, ethylene production, and power recovery applications. The
design speed and wheel diameters are selected to provide optimum aerodynamic performance for the turboexpander
as well as its booster compressor.

1.1 TURBOEXPANDER DESIGN

The expander compressor consists of three basic sections: (See Figure 1.1.)
1. The expander section with inlet and discharge flanges
2. The rotating assembly or center section.
3. The compressor section with inlet and discharge flanges.

FIGURE 1.1

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1.1.1 INLET GUIDE VANES

The inlet guide vanes regulate mass flow admission to the expander. They are designed to provide zero
blow-by, positive actuation and high efficiency over a broad operating range. This is accomplished by utilizing
a unique proprietary mechanism incorporating a pressure actuated sealing ring. This design eliminates side
leakage and prevents nozzle galling.

The mechanism is designed to withstand full expander inlet pressure and can be adjusted to control admission
over the range of approximately 0 to 125% of the design mass flowrate. A pneumatic actuator with integral
positioner controls the guide vane opening. A control air signal causes the actuator to adjust the inlet guide
vane opening to compensate for changes in process conditions.

KEY DESIGN BENEFIT:

Non-Galling design provides more reliable and accurate process control.

VIEW FROM BEARING HOUSING

VIEW FROM OUTLET FLANGE

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1.1.2 IMPELLERS

Mafi-Trench expander and compressor wheels are machined from solid

plate, bar or forgings for maximum strength and integrity. Brazed wheels
are not permitted in the Mafi-Trench design. Critical design parameters
such as stress and bore growth are computed in-house using Finite Element
Analysis software. Mafi-Trench has designed wheels for operating tip
speeds in excess of 1500 fps (457 m/s).

Expander stage performance is predicted using Computational Fluid

Dynamic (CFD) modeling. In addition, every Mafi-Trench wheel is
vibration tested for blade and disc resonant frequencies and tuned as required to prevent any damaging
interactions.

KEY DESIGN BENEFIT:

Greatly increased impeller life
No restrictions on operating speeds
High efficiency designs

Sample of CFD analysis on

compressor wheel design

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1.1.3 SHAFT / WHEEL ATTACHMENT

The expander-compressor shaft is designed to operate below the first bending critical speed and torsional
resonance. For oil-lubricated bearing designs, a flame plated band of aluminum alloy is applied to the shaft in
the area sensed by the vibration probes to eliminate the effect of electrical runout. This technique has been used
on hundreds of Mafi-Trench turbines with complete success. Wheels are attached to the shaft on a special
tapered profile, with cylindrical keys and keyways. This design avoids the stress concentrations associated with
splines, conventional square keyways, and tongue and groove wheel-to-shaft fits. In addition, wheels are
secured to the tapered ends of the shaft by a common center stretch rod which is pre-stressed during assembly.
This results in a constant preload on each wheel to insure contact between wheels and shaft at all extremes of
temperature and speed.

KEY DESIGN BENEFIT:

Fewer machine trips due to high vibration
Lower dynamic loads on bearings
Ease of assembly and disassembly

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1.1.4 ADDITIONAL DESIGN DETAILS

A spring-loaded Teflon lip seal is used for sealing of cryogenic cases. This highly reliable seal is also pressure
actuated. Therefore, effective sealing is not dependent on torquing of case bolts. Elastomeric "O" rings are used
for sealing warm process casings and warm internal parts.

The compressor incorporates a parallel wall, vaneless diffuser which yields excellent off-design performance.

The process conditions induce thermal growth and/or shrinkage in the expander and compressor housing.
Therefore, the expander case is center-line mounted and the compressor case is allowed to move along the
center line of the machine. Allowable flange forces and moments are three times NEMA SM-23 requirements.

All rotating parts are dynamically balanced to the requirements of ISO 1940 G2.5 on precise electronic
balancing equipment to ensure smooth operation over the entire operating speed range.

1.1.5 SPECIAL TOOLS

A "shaft seal ring and wheel puller" and a "shaft seal ring mounting tool" are part of the standard equipment
supply. These are the only special tools required for assembly and disassembly of the Mafi-Trench
Expander-Compressor.

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