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Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Authors: Ramin Taheri Seresht & Hassan Khodaei Jalalabadi
Presented by: Ramin Taheri Seresht
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
The objectives of presentation:
 Introduce the conventional natural gas pressure reducing station.
 Introduce the turboexpander & its applications.
 Express thermodynamically difference between throttle valve and
turboexpander.
 Select case study.
 Exergy analysis on the selected case study.
 Simulate the using of turboexpander in the selected case study.
 Economical analysis.
 Conclusion.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the conventional natural gas pressure reducing station
The different types of the conventional station:
1.
City gate station (C.G.S.).
2.
Town broad station (T.B.S.).
3.
Combinatory station (C.G.S./T.B.S.).
4.
Station for industrial consumptions.
5.
Station for domestic consumptions.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the conventional natural gas pressure reducing station
Comparing the different types of conventional station on the base of pressure:
Type of Station
Inlet Pressure
Outlet Pressure
psi
MPa
psi
MPa
C.G.S.
1000
6.8
250
1.7
T.B.S.
250
1.7
60
0.4
C.G.S. / T.B.S.
1000
6.8
60
0.4
Industrial
1000
6.8
Domestic
60
0.4
60
0.4
Home Regulator
60
0.4
0.25
0.0017
Desired Pressure
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the conventional natural gas pressure reducing station
The main components of a conventional station:
1.
2.
3.
4.
5.
6.
7.
Ball / Globe valves.
Filter.
Regulator (Throttle valve).
Relief valve.
Safety shut off valve.
Meter.
Heater.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the conventional natural gas pressure reducing station
Please pay attention:
All of types of gas stations just differ in size, inlet & outlet pressure, capacity
and exitence of some components.
But all of them reduce the gas pressure by using throttle valves (regulators).
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the conventional natural gas pressure reducing station
Most important roles of the regulator in a conventional station are:
1.
Reducing pressure.
2.
Adjusting pressure.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the conventional natural gas pressure reducing station
How does a regulator (throttle valve) reduce the pressure?

In the throttle-valve gas pressure is reduced in result of the isenthalpic
expansion.

In this process not only no energy is produced but also the energy of
high-pressure gas is lost.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Could the energy of high-pressure gas be recovered?
Yes, of course.
Why not?
$
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
How could the energy of high-pressure gas be
recovered?
It is so easy just by using the turboexpander.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the turboexpander & its applications
What are turboexpanders?
1.
2.
3.
4.
5.
6.
Turboexpanders are expansion turbines, rotating machines similar to
steam turbines.
Commonly, the terms “expansion turbines” and “turboexpanders”
specially exclude steam turbines and combustion gas turbines.
Turboexpanders can also be characterized as modern rotating devices
that convert the pressure energy of a gas or vapor steam into
mechanical work as the gas or vapor expands through the turbine.
If chilling the gas or vapor stream is the main objective, the mechanical
work so produced is often considered a byproduct.
If pressure reduction is the main objective, then heat recovery from the
expanded gas is considered a beneficial byproduct.
In each case, the primary objective of turboexpanders is to conserve
energy.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the turboexpander & its applications
The different designing types of turboexpanders:
1.
Axial Type.
2.
Radial Type.
That the each of types has three typpes itself:

Impulse.

Reaction.

Complex.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the turboexpander & its applications
The different power absorption methods in turboexpanders:
1.
Direct-connected compressor.
2.
Gear and generator.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Introduce the turboexpander & its applications
Turboexpander applications:
1.
2.
3.
4.
5.
6.
7.
8.
Recovering high pressure gas energy & power generation.
Cryogenic process.
Chemical & Petrochemical industries (included: FCC process and
producing Nitric acid, Acetic acid, PTA & Terephtalic acid.).
Oil & gas industries (included: LPG & LNG processes.).
Separating air components.
Liquefaction gases (like Helium).
Separating condensable components of natural gas.
Power generation from geothermal energy.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Express thermodynamically difference between throttle valve & turboexpander
As thermodynamically point of view:

In the throttle-valve gas pressure is reduced in result of the isenthalpic
expansion.

In the throttle valve not only no energy is produced but also the energy
of high-pressure gas is lost.

In the turboexpander the gas pressure is reduced in the isentropic
expansion.

But in the turboexpander the energy of high-pressure gas is recoverd.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Express thermodynamically difference between throttle valve & turboexpander
On the other hand:
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Select case study
The C.G.S. No. 2 of Tehran was selected as case study for following
reasons:
1.
2.
3.
4.
5.
6.
Existing enough space for turboexpander installation.
Existing three heaters that they could be heated the entering gas to
turboexpander if it was needed.
In this station, the changes of inlet pressure gas is less than the other
stations in the country.
In this station, the changes of passed flow rate gas is less than the
other stations in the country.
In this station, just for a few days in the year the passed flow of gas is
cut off when the annual maintenance operations are done.
This station is next to some residential areas and a few industrial
manufacture so that, it might be used of power generation directly if it
was needed.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Select case study
The chemical compounds of
gas that is passed
through the C.G.S. No. 2
of Tehran are as table:
Chemical Compounds
No.
Name
Chemical
Formula
Mole Percent
1
Nitrogen
N2
3.70
2
Methane
CH4
89.80
3
Dioxide
Carbon
CO2
1.10
4
Ethane
C2H6
3.70
5
Propane
C3H8
0.98
6
Iso Butane
C4H10
0.22
7
Normal
Butane
C4H10
0.29
8
Iso Pentane
C5H12
0.10
9
Normal
Pentane
C5H12
0.07
10
Hexane
C6H14
0.04
Tatol
100.00
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Select case study
The physical properties of gas that is passed through the C.G.S. No. 2
of Tehran are as following table:
No.
Physical Property
1
Calculated Average Molecular Weight
2
Calculated Gas Specific Gravity, Air = 1.000 (MW of Air = 28.964 gr/mol)
3
Calculated Gas Density (P = 1013.25 mbar , T = 15 °C)
4
5
Unit
Quantity
gr/mol
17.93
---
0.619
Kg/m3
0.758
MJ/m3
34.4
Btu/ft3
920.4
MJ/m3
38.2
Btu/ft3
1020.1
Calculated Net Calorific Value (P = 1013.25 mbar , T = 15 °C)
Calculated Gross Calorific Value (P = 1013.25 mbar , T = 15 °C)
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Select case study
The monthly average quantities
of inlet pressure, outlet
pressure, outlet temperature &
flow rate of gas that is passed
through the C.G.S. No. 2 of
Tehran (in 1385) are as table:
Monthly Average Quantities
Months in
1385
Inlet
Pressure
Outlet
Pressure
Outlet
Temperature
Flow Rate
MPa
psi
MPa
psi
°C
°F
Nm3/hr
Kg/sec
Farvardin
4.4
644
1.7
250
7.7
45.9
176,880
37.24
Ordibehesht
4.6
670
1.7
250
10.7
51.3
104,105
28.31
Khordad
4.9
726
1.7
250
8.0
46.4
170,514
35.90
Tir
5.3
775
1.7
250
8.7
47.7
154,239
32.48
Mordad
5.3
775
1.7
250
8.8
47.9
132,929
27.99
Shahrivar
4.9
726
1.7
250
10.2
50.4
184,663
38.88
Mehr
4.2
619
1.7
250
10.4
50.6
178,689
37.62
Aban
3.9
566
1.8
259
10.4
50.6
262,381
55.25
Azar
2.4
350
1.8
270
10.8
51.4
346,470
72.95
Day
2.3
337
1.7
257
10.9
51.7
427,071
89.92
Bahman
3.2
470
1.8
271
10.3
50.5
398,845
83.98
Esfand
3.0
445
1.8
267
10.4
50.8
355,395
74.83
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Select case study
The curves of monthly average inlet & outlet pressure profiles in 1385
for C.G.S No. 2 of Tehran are as follow:
1000
900
800
4
700
Pressure (psi)
5
3
6
2
1
7
600
8
500
11
12
400
300
1
2
3
4
5
6
8
7
9
10
9
10
11
12
200
100
0
1
2
3
4
5
6
7
8
Months of Year
Outlet Pressure
Inlet Pressure
9
10
11
12
6.8
6.4
6.0
5.6
5.2
4.8
4.4
4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
0.4
0.0
Pressure (MPa)
The Curves of Average Inlet & Outlet Pressure Profiles in the Year of 1385
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Select case study
The curves of monthly average outlet temperature profiles in 1385 for
C.G.S No. 2 of Tehran are as follow:
The Curves of Average Outlet Temperature Profiles in the Year of 1385
20
68.0
Temperature (C)
56.0
12
2
8
7
6
10
11
12
50.0
5
4
3
1
9
8
44.0
4
38.0
0
32.0
1
2
3
4
5
6
7
8
Months of Year
Outlet Temperature
9
10
11
12
Temperature (F)
62.0
16
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Select case study
The curves of monthly average flow rate profiles in 1385 for C.G.S No. 2
of Tehran are as follow:
570000
532000
494000
456000
418000
380000
342000
304000
266000
228000
190000
152000
114000
76000
38000
0
120.00
108.00
96.00
10
84.00
11
12
9
72.00
60.00
8
48.00
1
6
3
4
2
2
7
36.00
5
24.00
12.00
0.00
1
2
3
4
5
6
7
Months of Year
Flow Rate
8
9
10
11
12
Flow Rate (Kg/sec)
Flow Rate (Nm3/hr)
The Curve of Average Flow Rate Profiles in the Year of 1385
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Exergy analysis on the selected case study
At definition:
Exergy is maximum work (shaft work) can be obtained from a specified
quantity of energy.
And exergy is equal to summation of all its components:
ex  exK  exP  exPh  exDi  exCh
Where:
exK = kinetic exergy.
exP = potential exergy.
exPh = physical (termomechanical) exergy.
exDi = diffusion exergy.
exCh = chemical exergy.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Exergy analysis on the selected case study
In the selected case stydy:
exK = exP = exDi = exCh = 0.
And:
exPh


T

 C P T  T0    T0 ln

 T0

  
 P
    RT0 ln

  
 P0



CP  a  bT  cT  dT
2
For calculating CP:
CPmix   xi CP i
3
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Exergy analysis on the selected
case study
With substituting the monthly
average quantities in
the recent relations is
obtained:
Months in 1385
Calculated Monthly Average Exergy
KJ/Kgmole
KW
KWhr
Farvardin
2,158.452
4,483.031
3,335,375
Ordibehesht
2,277.888
3,596.599
1,812,686
Khordad
2,406.358
4,818.085
3,584,655
Tir
2,591.160
4,693.858
3,492,230
Mordad
2,591.866
4,046.087
3,010,288
Shahrivar
2,420.588
5,248.882
3,905,168
Mehr
2,066.357
4,335.548
3,121,594
Aban
1,768.406
5,449.216
3,923,436
Azar
660.584
2,687.652
1,935,110
Day
691.912
3,469.981
2,498,386
Bahman
1,314.629
6,157.422
4,433,344
Esfand
1,167.514
4,872.566
3,391,306
Annual Summation
38,443,578
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Exergy analysis on the selected case study
The curves of monthly average exergy profiles in 1385 for C.G.S No. 2 of
Tehran are as follow:
The Curves of Average Exergy Profiles in the Year of 1385
3000
6500
11
2500
5700
6
3
2
8
6
1
7
2000
3
12
4900
4
8
1
7
1500
4100
5
11
2
12
10
1000
3300
9
9
10
500
2500
1
2
3
4
5
6
7
8
9
Months of Year
Exergy (KJ/Kgmole)
Exergy (KW)
10
11
12
Exergy (KW)
Exergy (KJ/Kgmole)
5
4
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Simmulate the using of turboexpander in the selected case study
Simulation has been done by using the Thermoflow software at two
following states:
1.
2.
One turboexpander is installed so as parallel with the station.
Three turboexpanders are installed so as parallel with each unit
of the station.
So that each of these states has two other states:
1.
2.
Without gas preheating.
With gas preheating.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Simmulate the using of turboexpander in the selected case study
The state of one turboexpander and without gas preheating:
3
10
2
1
68.0
25.0
126
68.0
25.0
42.0
13 15
17 16
68.0 68.0
25.0 25.0
42.0 42.0
10
68.0
25.0
0
11
12
68.0
25.0
0
12
14
68.0
25.0
0
9
68.0
25.0
42.0
21
2
17.0
-60.8
126
68.0
25.0
126
9
11
68.0
25.0
42.0
20
4
14 18
8
68.0
25.0
126
Q+
19
68.0
25.0
0.013
68.0
25.0
0
15 20
13
68.0
25.0
42.0
19
22 21
68.0 68.0
25.0 25.0
0 0
16
3
68.0
25.0
0
5
Q+
17
4
68.0
25.0
0
6
Q+
24
17.0
25.0
0
18
5
68.0
25.0
0
THERMOFLEX Version 13.0 Ramin Taheri Home
1130 File = H:\Final Project\Work\Modified Typed Files\Simulation Files by Thermoflow\Case 7-1-1-1.tfx 01-12-2009 15:55:03
8
23
17.0
25.0
0
25
17.0
25.0
0
7
17.0
-60.8
126
7
6
17.0
25.0
0.013
1
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Simmulate the using of turboexpander in the selected case study
The state of one turboexpander and with gas preheating:
4
10
2
1
68.0
25.0
126
68.0
25.0
42.0
13 15
17 16
68.0 68.0
25.0 25.0
42.0 42.0
10
68.0
25.0
0
9
68.0
25.0
42.0
19
Q+
3
2
17.0
-44.1
126
3
68.0
45.0
42.0
68.0
45.0
126
5
11
12
68.0
25.0
0
11
68.0
25.0
42.0
20
Q+
4
68.0
45.0
42.0
14
68.0
25.0
0
13
68.0
25.0
42.0
21
Q+
8
68.0
45.0
126
15 20
5
68.0
45.0
42.0
8
7
17.0
-44.0
126
23
17.0
45.0
0
19
68.0
45.0
0.013
68.0
45.0
0
6
12
16
14 18
9
22 21
68.0 68.0
45.0 45.0
0 0
17
24
17.0
45.0
0
18
25
17.0
45.0
0
THERMOFLEX Version 13.0 Ramin Taheri Home
1130 File = H:\Final Project\Work\Modified Typed Files\Simulation Files by Thermoflow\Case 7-1-1-2.tfx 01-12-2009 00:53:44
7
6
17.0
45.0
0.013
1
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Simmulate the using of turboexpander in the selected case study
The state of three turboexpanders and without gas preheating:
3
13
13
68.0
25.0
0
2
1
68.0
25.0
126
68.0
25.0
42.0
16 18
20
68.0
25.0
42.0
19
68.0
25.0
42.0
14
15
68.0
25.0
0
15
17
68.0
25.0
0
2
17.0
-60.8
42.0
68.0
25.0
42.0
17 21
12
68.0
25.0
42.0
23
22
68.0
25.0
0
6
Q+
20
5
68.0
25.0
0
24
68.0
25.0
0
3
17.0
-60.8
42.0
7
Q+
26
68.0
25.0
0
8
Q+
10
17.0
-60.8
42.0
28
17.0
25.0
0
5
4
17.0
-60.8
42.0
68.0
25.0
42.0
19 25
16
68.0
25.0
42.0
25
11
21
6
68.0
25.0
0
9
17.0
-60.8
42.0
27
17.0
25.0
0
4
68.0
25.0
42.0
18 23
14
68.0
25.0
42.0
24
10
12
22
7
68.0
25.0
0
THERMOFLEX Version 13.0 Ramin Taheri Home
1130 File = H:\Final Project\Work\Modified Typed Files\Simulation Files by Thermoflow\Case 7-1-2-1.tfx 01-12-2009 01:25:57
29
17.0
25.0
0
11
17.0
-60.8
42.0
9
8
17.0
-60.8
126
1
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Simmulate the using of turboexpander in the selected case study
The state of three turboexpanders and with gas preheating:
3
13
13
68.0
25.0
0
12
68.0
25.0
42.0
23
Q+
2
17.0
-44.1
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42.0
16 18
6
19
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5
68.0
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42.0
9
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1
68.0
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Q+
17
6
68.0
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68.0
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68.0
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9
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28
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18 22
7
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THERMOFLEX Version 13.0 Ramin Taheri Home
1130 File = H:\Final Project\Work\Modified Typed Files\Simulation Files by Thermoflow\Case 7-1-2-2.tfx 01-12-2009 01:58:37
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1
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Simmulate the using of turboexpander in the selected case study
The results of simulation has been summarized as following:
The States of Simullation
Produced Power (KW)
Produced Annual Energy (KWhr)
One Turboexpander without Gas Preheating
19,347.6
164,841,552
One Turboexpander with Gas Preheating
20,728.1
176,603,412
Three Turboexpanders without Gas Preheating
19,347.6
164,841,552
Three Turboexpanders with Gas Preheating
20,728.5
176,606,820
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Economical analysis
Tuboexpander price is obtainable by using following relation or figure:
Price (million$)  0.005312 Output (kW)
0.7294
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Economical analysis
The local price of electrical energy is as the following table:
Local Price of Electrical Energy (KWhr / Rls.)
Year
Domestic
General
1383
104.20
151.41
1387
773.00
1123.22
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Economical analysis
The global price of electrical energy is obtained by the following curve:
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Economical analysis
The results of economical calculations is summarized into the tables:
Table Legend:
A = The Installation & Commissioning Cost (mil. Rls.).
B = The Maintenance Cost (mil. Rls.).
C = The Investment Cost (mil. Rls.).
D = The Annual Income of Produuced Electrical Energy with Considering Local Price (mil. Rls.).
E = The Annual Income of Produuced Electrical Energy with Considering Global Price (mil. Rls.).
F = The Time of Investment Payback with Considering Local Price (Years.).
G = The Time of Investment Payback with Considering Global Price (Years).
Turbine
Numbers
The Price of One
Turbine (mil. Rls.)
The Price of Total
Procurement
(mil. Rls.)
A
B
C
D
E
F
G
1
75,000
75,000
1,500
750
76,500
43,181
46,132
1.8
1.7
3
34,000
102,000
2,040
1,020
104,040
43,181
46,132
2.5
2.3
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Conclusion
According to that was mentioned, using turboexpanders at natural gas
pressure reducing stations not only is economical but also its
produced electrical energy in compare of other sources has
following advantages:
1.
For producing that doesn’t need to very high investment like
power plants & water dams systems.
2.
For producing that doesn’t need to consumption of fossil fuel.
3.
Producing that doesn’t emit any pollutant in environment.
4.
Maintenance cost of its facilities is so less than a power plant or a
water dam.
5.
For producing that doesn’t need to a lot personnel.
6.
For producing that doesn’t need to occupy a lot space.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Last Word
Using the turboexpanders at the natural gas
pressure reducing stations could be a
historical opportunity.
And if we don’t apply them now, perhaps
tomorrow would be too late.
Retrofit of Tehran City Gate Station C.G.S. No.2 by
Using Turboexpander
Yasun Farayand Company & K.N. Toosi University of Technology
Any Question?
Thanks for your attention.
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