In the world of midstream natural gas liquid (NGL) operations, turboexpanders play a vital role in liquid recovery by utilizing high-pressure gas to power compressors or generators. However, maintaining the integrity of these systems requires precise, reliable bearings, particularly Active Magnetic Bearings (AMBs), which ensure correct rotor positioning without the use of oil.
When an NGL processing company sought to replace its outdated analog AMB controller, the challenge was finding a solution that would avoid significant downtime and the high costs of a full system upgrade. Enter L.A. Turbine (LAT), a subsidiary of Chart Industries, which specializes in turboexpander design and aftermarket services. LAT, in partnership with Waukesha Magnetic Bearings, was able to retrofit a modern controller for the company’s existing AMBs, offering a cost-effective and efficient alternative.
The existing controller, housed in an obsolete cabinet, could no longer be repaired. The original equipment manufacturer (OEM) recommended replacing the entire system, but the NGL company faced a substantial capital expenditure and extended downtime to get engineering support. In contrast, LAT proposed the retrofitting solution, leveraging a successful past collaboration with Waukesha Magnetic Bearings.
Waukesha’s Zephyr® controller, designed to be “bearing-agnostic,” proved ideal for retrofitting. Its high configurability made it compatible with various sensors and magnets, and its simple operation, along with modern features such as remote monitoring and adjustment, met the customer’s needs. The controller’s advanced diagnostics, including web-server interfaces and automatic balancing, significantly improved upon the outdated analog system.
Both LAT and Waukesha worked to ensure minimal downtime, with a dedicated onsite commissioning engineer and careful preparation. This collaboration led to a seamless integration, allowing the NGL company to resume operations with a state-of-the-art solution in place. The Zephyr controller’s long-term reliability, supported by predictive maintenance and an extended warranty, provided the customer with peace of mind regarding future performance.
In conclusion, LAT and Waukesha Magnetic Bearings delivered a superior upgrade that not only saved the customer from costly system replacement but also enhanced the overall performance and reliability of their NGL turboexpander operations.
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