A complete skid-mounted turboexpander unit

Abstract

The utility model relates to mechanical equipment field and disclose a whole set of pry installation's turbine expander unit, including the chassis, be provided with expansion refrigeration system, braking system, lubricating oil system, cooling water system, instrument gas system and electrical control system on the chassis, and expansion refrigeration system and lubricating oil system are relatively arranged in the edge place of chassis close to two sides, and cooling water system is located one side of lubricating oil system, the expansion refrigeration system, braking system, lubricating oil system, cooling water system, instrument gas system and electrical control system of expansion unit supporting are all integrated in the space in the chassis range, realize the whole assembly of turbine expander unit in a pry installation block, complete detection, paint, pressure test, debugging, heat preservation, cold preservation and instrument electricity etc. all installation work in advance, just transport to the specified position, can immediately put into use, has saved user's a lot of time and manpower, has reduced the cost significantly, has improved the economy of equipment.

Description

Technical Field

[0001] This utility model relates to the field of mechanical equipment, specifically to a complete skid-mounted turboexpander unit. Background Technology

[0002] The turboexpander is a key unit in air separation equipment, providing almost all of the cooling capacity. Its performance directly determines the energy consumption and reliability of the air separation unit. Currently, most turboexpanders used in air separation equipment employ oil bearing lubrication. This type of expander offers advantages such as convenient operation, stable running, high load capacity, and applicability to various operating conditions.

[0003] With the increasing scale of air separation equipment production, the working gas volume of oil bearing expander units has also increased, resulting in larger and larger machines. Furthermore, existing expander units are manufactured in several parts: the main expander, the oil supply system, the expander unit itself, and the instrumentation and control system. The inlet and outlet pipelines and equipment for the expansion and braking components are only installed on-site by the user. This leads to the current expander units being shipped in multiple boxes, requiring on-site installation for pipe insulation and heat protection. In particular, the measuring points of the expander units are relatively dispersed, and there is a considerable distance between the electrical control box and the equipment. This not only results in unsightly wiring but also affects the accuracy of operation and measurement data.

[0004] Therefore, currently, after the main unit skid-mounted blocks and oil supply unit skid-mounted blocks are transported to the user's site, the user needs to spend a lot of time and manpower to complete the on-site installation work. Then, they also need to complete installation work such as testing, painting, pressure testing, commissioning, insulation, cold insulation, and instrumentation. This not only makes it difficult to effectively control quality but also adds extra costs. Furthermore, the low-temperature components of the expander unit are generally located in a cold insulation box. If maintenance is required, the insulation material in the cold insulation box must first be removed, and after maintenance, the cold insulation box must be refilled with insulation material before startup. This method not only consumes considerable time and manpower but also inconveniences inspection work during operation. Utility Model Content

[0005] The purpose of this utility model is to overcome the shortcomings of the existing technology and provide a complete skid-mounted turbo expander unit. By adopting a complete skid-mounted block method, it is very convenient for users to change the location of the equipment. As long as it is transported to the new location, it can be put into use immediately, reducing the cost of on-site welding and installation.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A skid-mounted turboexpander unit includes a base frame. An expansion refrigeration system, a braking system, a lubricating oil system, a cooling water system, an instrumentation gas system, and an electrical control system are mounted on the base frame. The expansion refrigeration system and the lubricating oil system are positioned opposite each other near the front and rear edges of the base frame. The cooling water system is located on one side of the lubricating oil system. The instrumentation gas system and the electrical control system are located between the cooling water system and the expansion refrigeration system. All three systems are located near the edges of the base frame, and the braking system is located at the end of the expansion refrigeration system furthest from the instrumentation gas system and the electrical control system.

[0007] Optionally, the expansion refrigeration system includes an expansion host, the braking system includes a fan, the expansion host and the fan are mounted on the base frame via a bracket, and the expansion host and the fan are coaxially connected.

[0008] Optionally, the air inlet end of the expander is connected to an air inlet pipe, and the air outlet end of the expander is connected to an exhaust pipe. The air inlet pipe and the exhaust pipe are located on the side of the expander away from the braking system, and both the air inlet pipe and the exhaust pipe are parallel to the base frame.

[0009] Optionally, the air inlet of the fan is equipped with an inlet filter, and the air outlet of the fan is equipped with a silencer. The silencer is located above the lubricating oil system on one side, and the inlet filter is perpendicular to the base frame.

[0010] Optionally, both the air intake pipe and the exhaust pipe are equipped with expansion joints, and a pair of maintenance flanges are provided between the air inlet and the inlet filter.

[0011] Optionally, the lubrication system includes an oil supply device, the rear end face of which is flush with the rear side of the base frame, and the oil supply device is at least 800mm away from the expander.

[0012] Optionally, the cold end inlet and outlet of the expansion unit are insulated with polyurethane foam.

[0013] Optionally, the base frame is provided with four lifting rings for lifting the turbine expander unit, and the four lifting rings are arranged in pairs and symmetrically distributed on both sides of the base frame.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows: (1) In this utility model, the expansion refrigeration system, braking system, lubricating oil system, cooling water system, instrument gas system and electrical control system of the expansion unit are all integrated in the space within the base frame, so that the entire turbine expansion unit can be assembled in a skid block. All installation work such as testing, painting, pressure testing, debugging, heat preservation, cold preservation and instrumentation can be completed in advance. As long as it is transported to the designated location, it can be put into use immediately, saving users a lot of time and manpower, significantly reducing costs and improving the economy of the equipment; (2) In this utility model, the low-temperature part of the expander unit only needs on-site foaming insulation, which saves the cold storage box, not only saving maintenance time and labor costs, but also facilitating inspection during operation; (3) In this utility model, the entire skid-mounted block of the expander unit only needs one packaging box, which is convenient for transportation and saves transportation costs. Moreover, it can be put into use immediately as soon as it is transported to the new location, reducing on-site welding and installation costs. (4) In this utility model, a pair of maintenance flanges are provided between the air inlet and the inlet filter. In this way, during maintenance, only the flange near the brake end of the maintenance flange and its connected pipe need to be removed to maintain the expander. Compared with the existing direct welding method, this significantly improves the convenience of equipment maintenance. Attached Figure Description

[0015] Figure 1 This is a top view of the entire skid-mounted turboexpander unit in this embodiment of the present invention. Figure 2 This is a schematic diagram of the main structure of the entire skid-mounted turboexpander unit in this embodiment of the present invention; Figure 3 This is a side view of the entire skid-mounted turboexpander unit in this embodiment of the present invention. Figure 4 This is a rear view structural diagram of the entire skid-mounted turboexpander unit in this embodiment of the present invention; Figure 5 This is an isometric structural diagram of the entire skid-mounted turboexpander unit in this embodiment of the present invention; Among them, 1. Expansion refrigeration system; 101. Exhaust pipe; 102. Intake pipe; 103. Expansion joint; 2. Braking system; 201. Silencer; 202. Inlet filter; 3. Lubricating oil system; 4. Cooling water system; 5. Instrument air system; 6. Electrical control system; 7. Base frame; 701. Lifting ring. Detailed Implementation

[0016] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. These drawings are simplified schematic diagrams, which are only used to illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0017] Example 1, as Figures 1-5 As shown, a complete skid-mounted turboexpander unit includes a base frame 7, on which an expansion refrigeration system 1, a braking system 2, a lubricating oil system 3, a cooling water system 4, an instrument air system 5, and an electrical control system 6 are installed.

[0018] Existing oil bearing turbine expander units generally include a turbine expander main skid and an oil supply device skid. Based on their functions, they can be divided into six major systems: expansion and refrigeration system 1, braking system 2, lubricating oil system 3, cooling water system 4, instrument air system 5, and electrical control system 6. These systems ensure the safe and reliable operation of the machine.

[0019] This solution integrates all six major systems within the space of the base frame 7, allowing the entire turboexpander unit to be assembled in a single skid-mounted block. This enables the pre-completion of all installation work, including testing, painting, pressure testing, commissioning, insulation, cold insulation, and instrumentation. Once transported to the designated location, it can be put into use immediately, saving users significant time and manpower, significantly reducing costs, and improving the economic efficiency of the equipment.

[0020] Among them, such as Figure 1 As shown, the expansion refrigeration system 1 and the lubricating oil system 3 are positioned opposite each other on the front and rear edges of the base frame 7. The cooling water system 4 is located to the right of the lubricating oil system 3. The instrument air system 5 and the electrical control system 6 are located sequentially between the cooling water system 4 and the expansion refrigeration system 1. The cooling water system 4, the instrument air system 5, and the electrical control system 6 are all located near the right edge of the base frame 7, and the braking system 2 is located at the end of the expansion refrigeration system 1 furthest from the instrument air system 5 and the electrical control system 6 (left end). With this structural layout, all six major systems can be integrated into a single integrated skid block. The expander inlet and outlet pipes and the equipment and inlet and outlet pipes of the braking section are also installed in the skid block. Before the equipment leaves the factory, all pre-installation work, including testing, painting, pressure testing, debugging, insulation, cold insulation, and instrumentation, can be completed, allowing the equipment to be put into use immediately after being transported to the designated location.

[0021] To facilitate the overall lifting of the skid, four lifting rings 701 are provided on the base frame 7. All four lifting rings 701 are used to lift the turbine expander unit, and they are arranged in pairs, symmetrically distributed on the left and right sides of the base frame 7.

[0022] Example 2, as Figures 1-5 As shown, based on Embodiment 1, this utility model also proposes the connection relationship between the various systems.

[0023] The expansion refrigeration system 1 includes an expansion host, an air inlet pipe 102 connected to the air inlet end of the expansion host, and an exhaust pipe 101 connected to the air outlet end of the expansion host. The air inlet pipe 102 and the exhaust pipe 101 are located on the side of the expansion host away from the braking system 2, and both the air inlet pipe 102 and the exhaust pipe 101 are parallel to the base frame 7.

[0024] Working principle of expansion refrigeration system 1: Gas with a certain pressure and temperature first enters expansion refrigeration system 1. The gas first flows into the volute of the expander. Inside the volute, the gas is guided to the adjustable nozzle. By adjusting the opening of the nozzle, the gas is accelerated, and pressure energy is converted into kinetic energy, causing the gas to impact the expander impeller at high speed. The gas continues to expand in the impeller, driving the impeller to rotate at high speed. During this process, the internal energy of the gas is converted into the mechanical energy of the impeller, and its own pressure and temperature are significantly reduced, achieving a refrigeration effect and producing low-temperature gas for subsequent processes.

[0025] As mentioned above, both the intake pipe 102 and the exhaust pipe 101 are equipped with expansion joints 103, which are corrugated compensators. They are used to compensate for the displacement and deformation of the pipeline caused by thermal expansion and contraction, vibration, etc., to relieve pipeline stress, ensure the stable operation of the pipeline system, and play the role of flexible connection and shock absorption compensation in the pipeline connection of the turbine expander unit.

[0026] Furthermore, the cold end inlet and outlet of the expansion unit are insulated with polyurethane foam. The cold end refers to the low-temperature area after the gas expands and cools down after passing through the expansion unit.

[0027] The cold end inlet of the expander refers to the inlet pipe (inlet pipe 102) interface before the gas enters the expander; the cold end outlet of the expander is the outlet interface after the gas has expanded and done work through the expander impeller, located downstream of the expander impeller, that is, at the connection between the volute outlet and the exhaust pipe 101.

[0028] The turbo expander skid in this invention does not require a cold box. It only needs to use polyurethane foam insulation at the cold end inlet and outlet of the expander, without the need to fill with perlite insulation, which saves costs and facilitates maintenance during equipment operation.

[0029] The braking system 2 includes a fan. An inlet filter 202 is installed at the air inlet of the fan, and a silencer 201 is installed at the air outlet of the fan. The silencer 201 is located above the side of the lubricating oil system 3. The inlet filter 202 is perpendicular to the base frame 7, and a pair of maintenance flanges are provided between the air inlet of the fan and the inlet filter 202. That is, in the connecting pipe between the inlet filter 202 and the fan, one section is connected by a pair of maintenance flanges.

[0030] In existing technologies, many brake-end inlet pipes installed on-site do not take into account the needs of expander maintenance. They are directly welded together with pipes between the inlet filter 202 and the brake inlet flange. When the expander needs maintenance, the inlet filter 202 must be removed first, then the inlet pipe fittings must be disassembled and lifted away, and then the brake-end inlet and outlet flanges must be removed, which is a lot of work.

[0031] In this invention, a pair of maintenance flanges are directly installed on a horizontal pipe about 1000mm away from the inlet flange at the brake inlet. During maintenance, the expander can be repaired simply by removing the flange closest to the brake end and the pipe connected to it. This is a simple, quick and efficient method.

[0032] The expander and fan are mounted on the base frame 7 via a bracket, and the expander impeller and the fan impeller in the braking system 2 are mounted on the same shaft, meaning the expander and fan are coaxially connected. When the expander impeller rotates, it drives the fan impeller to rotate synchronously. The fan impeller performs work on the surrounding gas, increasing the gas pressure. This process consumes the mechanical energy output by the expander, preventing damage to the expander due to excessive speed. The fan load can be changed by adjusting the opening of the fan outlet regulating valve, thereby controlling the expander speed and enabling the unit to operate stably under different operating conditions.

[0033] The core component of the expansion refrigeration system 1 (expander impeller) and the core component of the braking system 2 (fan impeller) are coaxial (sharing the same rotor), connected by a main shaft and rotating synchronously. The mechanical energy output by the expander impeller is directly transferred to the fan impeller and consumed by the fan. The oil outlet pipe of the lubricating oil system 3 is directly connected to the bearing cavity of the expander, providing a lubricating oil film for the high-speed rotating rotor bearing. After lubrication and cooling, the lubricating oil flows back to the oil tank of the lubricating oil system 3 through the return oil pipe, forming a circulation. Since the fan impeller and the expander impeller are coaxial and the rotor bearing is shared by both, the piping of the lubricating oil system 3 also provides lubrication for the bearing on the fan side.

[0034] The instrument gas system 5 connects to the pneumatic actuators such as the inlet regulating valve and emergency shut-off valve of the expansion refrigeration system 1 via branch pipelines, providing power for valve opening and closing and degree adjustment. Sealing gas enters the sealing sleeves at the expansion end and fan end through pipelines to isolate the process gas from the bearing lubricating oil, while simultaneously maintaining coldness at the cold end. The inlet / outlet pressure sensors, temperature sensors, and rotor speed sensors of the expansion refrigeration system 1, the inlet / outlet temperature sensors and inlet / outlet differential pressure transmitters of the braking system 2, and the sealing gas pressure sensor of the instrument gas system 5 transmit real-time data to the PLC or control cabinet of the electrical control system 6 via cables. Simultaneously, the electrical control system 6 controls the operation of the expansion compressor's inlet regulating valve through output signals, thereby regulating the cooling capacity.

[0035] The fan outlet regulating valve of the braking system 2 is either electric or pneumatic. If an electric valve is used, it is directly driven by the signal of the electrical control system 6. If a pneumatic valve is used, it is powered by the instrument air system 5, and the electrical control system 6 indirectly regulates it by controlling the opening and closing of the instrument air valve.

[0036] The lubricating oil system 3 is equipped with an oil cooler in its oil supply device or oil outlet pipeline. The low-temperature cooling water from the cooling water system 4 enters the cooler and exchanges heat with the high-temperature return oil to reduce the lubricating oil temperature and prevent the oil temperature from being too high, which would cause the viscosity to decrease. The cooling water after heat exchange returns to the cooling water system 4.

[0037] The oil supply pressure sensor, oil tank level sensor, oil temperature sensor, etc. of the lubricating oil system 3 transmit data to the electrical control system 6; at the same time, the electrical control system 6 controls the start and stop of the lubricating oil pump to ensure stable oil supply pressure.

[0038] Example 3, as Figures 1-5 As shown, based on the user's requirement for ambient temperature cooling of the expander, the braking end needs to be equipped with valves, filters, and a silencer, while the expansion end needs to be equipped with valves, filters, and expansion joint 103. To ensure the manufacturing and installation quality of this expander unit, and also for its aesthetic appearance, all six systems of the oil bearing expander unit are integrated into a single skid-mounted block. Furthermore, the expander's inlet and outlet pipes, as well as the equipment and inlet / outlet pipes of the braking section, are also installed within the skid-mounted block as much as possible. This design allows all measuring points on the pipeline to be manufactured in-house, ensuring the quality of equipment manufacturing. Simultaneously, the instrument control box and electrical control box are combined into one control box, and all the dispersed transmitters are concentrated on the control box and the bracket next to it.

[0039] Considering the limitations of transportation dimensions, the dimensions of the entire skid-mounted block will be controlled within the allowable limits: height limited to 3.2m, width limited to 3.2m, and length limited to 8m. Based on the above requirements, the final dimensions of the skid-mounted block will be 4400×3000×2800 mm. It will be shipped unloaded and completely covered with plastic film to prevent rain.

[0040] The main purpose of this expander unit is for air conditioning and food freezing in summer. Therefore, the outlet design temperature of the expander only needs to be above -50℃. The low-temperature part of the expander and the inlet and outlet pipes of the expansion end only need to be insulated with foam on site. The outlet of the brake fan end is marked with anti-scalding label to ensure the safety of workers during operation.

[0041] With proper layout, taking into account operating space and convenience, the main equipment of the entire skid-mounted turboexpander unit is arranged as follows: (1) The expansion host is placed at a position 650mm from the front of the base frame 7 for easy installation and operation. Correspondingly, the inlet filter 202 of the blower is set at a height of 1.8m from the ground, the inlet pipe of the blower is 2600mm from the ground, and the silencer 201 for venting the blower outlet gas is set at a height of 2200mm, so that the sound at the air inlet is about 1m away from people and the sound at the air outlet is about 0.6m away from people, thus reducing noise pollution. (2) Secure the inlet and outlet valves, filters, and expansion joint 103 at the expansion end to the base frame 7 with the brackets, and then guide all the pressure measuring points to the instrument box and the brackets on the side after the instrument pipes are centrally wired, so that the overall piping is aesthetically pleasing. (3) Install the oil supply device of the lubricating oil system 3 flush with the rear side of the base frame 7. This ensures that there is at least 800mm of operating and maintenance space between the oil supply device and the expansion host. Set all the drain ports of its oil tank and accumulator on the rear side, and install inlet and outlet valves and return water sight glasses at the inlet and outlet of the oil cooler. (4) The instrument control box (electrical control system 6) and the instrument panel (instrument air system 5) are all located on the right rear side, with a 50mm gap between the operating surface and the rear plane to facilitate wiring and maintenance operations.

[0042] Through reasonable layout, the entire expander unit is perfectly arranged in a limited space. Most importantly, the manufacturing and installation quality is guaranteed. After the entire unit is manufactured, radiographic testing can be carried out to improve the welding quality; the whole machine is tested for airtightness to reduce the workload on site; and the whole unit is painted to make the equipment look uniform and beautiful.

[0043] All instrumentation and electrical testing points were installed in the workshop, and an overall test run was conducted. The instrumentation and electrical testing points and pneumatic valves were tested to ensure their correctness and accuracy. The unit was transported as a whole skid, which ensured the installation quality and reduced the cleaning and transportation costs of the pipelines.

[0044] In summary, this utility model proposes a complete skid-mounted turbo expander unit, which can be assembled entirely within a single skid block. All piping, valves, and measuring points between the six systems are manufactured in-house. After assembly, pre-installation work including testing, painting, pressure testing, commissioning, insulation, cold insulation, and instrumentation is completed, saving users significant time and manpower, reducing costs, and improving equipment economics. The entire skid block is then hoisted into the commissioning workshop for convenient mechanical and simulated performance testing. Furthermore, the skid block can be customized by the user for various applications, including adjustable refrigeration and refrigeration / freezing of food and vegetables.

[0045] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0046] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0047] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0048] Based on the preferred embodiments of this utility model described above, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A complete skid-mounted turboexpander unit, characterized in that: The system includes a base frame on which an expansion refrigeration system, a braking system, a lubricating oil system, a cooling water system, an instrument air system, and an electrical control system are mounted. The expansion refrigeration system and the lubricating oil system are positioned opposite each other at the front and rear edges of the base frame. The cooling water system is located on one side of the lubricating oil system. The instrument air system and the electrical control system are located between the cooling water system and the expansion refrigeration system. All three systems are located near the edges of the base frame, and the braking system is located at the end of the expansion refrigeration system furthest from the instrument air system and the electrical control system.

2. The complete skid-mounted turboexpander unit according to claim 1, characterized in that: The expansion refrigeration system includes an expansion host, and the braking system includes a fan. The expansion host and the fan are mounted on the base frame via a bracket, and the expansion host and the fan are coaxially connected.

3. The complete skid-mounted turboexpander unit according to claim 2, characterized in that: The air intake end of the expander is connected to an air intake pipe, and the air outlet end of the expander is connected to an exhaust pipe. The air intake pipe and the exhaust pipe are located on the side of the expander away from the braking system, and both the air intake pipe and the exhaust pipe are parallel to the base frame.

4. The complete skid-mounted turboexpander unit according to claim 3, characterized in that: The fan has an inlet filter installed at its air inlet and a silencer installed at its air outlet. The silencer is located above the lubrication system on one side, and the inlet filter is perpendicular to the base frame.

5. The complete skid-mounted turboexpander unit according to claim 4, characterized in that: Both the air intake pipe and the exhaust pipe are equipped with expansion joints, and a pair of maintenance flanges are provided between the air inlet and the inlet filter.

6. The complete skid-mounted turboexpander unit according to claim 5, characterized in that: The lubricating oil system includes an oil supply device, the rear end face of which is flush with the rear side of the base frame, and the oil supply device is at least 800mm away from the expansion host.

7. The complete skid-mounted turboexpander unit according to claim 6, characterized in that: The cold end inlet and outlet of the expansion unit are insulated with polyurethane foam.

8. The complete skid-mounted turboexpander unit according to any one of claims 1-7, characterized in that: The base frame is equipped with four lifting rings for lifting the turbine expander unit, and the four lifting rings are arranged in pairs, symmetrically distributed on both sides of the base frame.

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