COMPRESSORCONTROLS REcIP MODELING RUB PROBLEmS MARCH 2014 REAL-TIME SOLVING IMPELLER GE Buying Cameron’s Recip Line Frigid Winter Tests Gas Industry WWW.COMPRESSORTECH2.Com Dearing’s Marcellus Business Booms THIS ISSUE DRIVEN BY Click on company logo to see ad page n n Customers: Challenge: Result: Global oil and gas producers. Changing compression requirements as fields mature and production peaks. n Flexible, reliable compressor designs for extended, cost-efficient operations. They turned to Elliott for reliable compression solutions. From Aberdeen to Rio de Janeiro, Calgary to Jakarta, Elliott compressors, turbines, and expanders deliver the reliable, efficient performance that producers and processors require. And every piece of Elliott equipment is backed by our unmatched global service network. Customers throughout the world turn to Elliott for critical turbomachinery and service because our resources are global and our execution is local. Who will you turn to? C O M P R E S S O R S n T U R B I N E S n G L O B A L S E R V I C E The world turns to Elliott. www.elliott-turbo.com or Ariel7-2Go.com . arielcorp.arielcorp.0311 | 35 Blackjack Rd Mount Vernon. Choose Ariel and have your package designed around the most reliable and best supported compressor available.com. OH 43050 | www. Contact Ariel today through one of our distributors. and let us help you specify the right compressor for your application.There’s A Reason Why It’s Called A Compressor Package Compressor packages are designed around a compressor. KBZ/6 COMPRESSORS WORLD STANDARD 740.397. . . it is the rich that provide the engine for economic growth through their investments and risk taking.President & CEO ....... Advertising Manager Gabriele Dinsel.Michael Brezonick Page What’s Yours Is Yours........ On the contrary......................... Brent Haight Associate Publisher . at my level of wealth............ we must avoid politicizing both poverty and wealth....Chad Elmore Copy Editor .. DE6 1LH.. Suite 220 Waukesha... There is a huge cavern that separates generosity from miserliness... May the Lord hold you in the hollow of His hand throughout the rest of 2014.. But..............” Government is limited..Carla Lemke Graphic Artist . though wealth and poverty have huge political implications.. Associate Publisher 44.......... Regional Manager/Editor Linda Cameron.. Jack Burke Associate Editor ...... United Kingdom Telephone: +44 20 31 79 29 79 Fax: +44 20 31 79 29 70 UNITED KINGDOM OFFICE Roberto Chellini. Alyssa Loope JoE KaNE CompREssoRtech2 Founder PUBLICATION HEADQUARTERS 20855 Watertown Road. I won’t have to deal with this ideology....... in my opinion.... My belief is that it is our right to be wealthy if we so desire to be — to keep the fruits of our labor. Michael Brezonick Senior Editor .. despite our envy. Suite 225 Houston.. Editor Mike Rhodes. Then.. the poor remain poor and the wealthy either are lowered to poverty or relocate.. Advertising Manager Niemöllerstr. 231-0824 Japan Telephone: +81 45 624 3502 Fax: +81 45 624 3503 JAPANESE OFFICE S. someone who likes to dispose of other people’s money makes these decisions.... CT2 ... It is through their efforts that society in general progresses and is the best hope for lifting up the bottom rung of society. Ohio Mauro Belo Schneider ..... Italy Telephone: +39 0464 014421 Fax: +39 0464 244529 Bo Svensson.... 21a I-38062 Arco...... On the contrary................................ Texas Norm Shade .....................Roberto Chellini Editor ...” I’m not sure of the source of this quote........ Italy Telephone: +39 055 50 59 861 Fax: +39 055 57 11 55 ITALIAN OFFICES Roberta Prandi Via Fitta...... The poor will always be with us and they should be the target of our generosity regardless of our level of wealth..... Branch Manager Rm 1405............ So what should be our attitude towards having wealth.....H................ Our lens must always be moral rather than A Member of the Diesel & Gas Turbine Publications Group COMPRESSOR PUBLICATION STAFF 4 CT2 Founder ....... Mike Rhodes Associate Editor . Mok... Field Editor/Business Manager Dunderbacksvagen 20 612-46 Finspong...... Advertising Manager 40 Premier Avenue Ashbourne. we must never idealize poverty and see wealth as a bad thing in itself... Derbyshire....... Kowloon Building 555 Nathan Road Kowloon....... pure and simple. Generally speaking. it doesn’t manage its vast economic power very well and try and try as it does from time to time. Sweden Telephone: +46 70 2405369 Fax: +46 122 14787 SCANDINAVIAN OFFICE Akiyoshi Ojima... Naka-ku Yokohama... Amanda Ryan Graphic Artist ......... Branch Manager 51-16-301 Honmoku Sannotani....................... Always. Senior Editor 12777 Jones Road. Sarah Yildiz Circulation Manager . both as it pertains to the very rich and as it pertains to us? First..... In the process. a major portion of the population had to be eliminated. dangerous to the soul and dangerous to society....Sheila Lizdas Production Manager ...... Bill Gates Sr..... Michael Osenga Executive Vice President .. It is very inefficient..... Joseph Kane Publisher ... but. DJ Slater Senior Editor ... What’s Mine Is Yours A lot of flack seems to be appearing in the mainstream media of late having to do with redistribution of wealth......... you have to be wealthy in order to be subjected to this seemingly appealing exercise of justice — to lift up the poor among us.............. We adore the rich and famous.... it is how we use it and what it can do to us as authentic human persons that can be bad...Patrick Crow Executive Editor .... Publisher Patrick Crow.. but also in an honest accounting of society’s substantial investment in creating fertile ground for wealth-creation. Wisconsin 53186-1873 Telephone: (262) 754-4100 Fax: (262) 754-4175 Jimmy Patterson ... “The poor aren’t poor because Bill Gates and Warren Buffett are rich.......... I’ll give credit to Kathleen Parker............. Brazil Brent Haight.............. Via Delle Forbici I-50133 Firenze... 9 73760 Ostfildern............ This is rooted not only in most religious traditions......... History reveals some prime examples of where to gain compliance.... someone or some bureaucracy determines if you have too much or too little....... Hong Kong Telephone: +852 3118 7930 Fax : +852 3110 3572 CHINESE OFFICE political..... Texas 77070 Telephone: (281) 890-5310 Fax: (281) 890-4805 CONTRIBUTING EDITORS HOUSTON OFFICE Lisa Hochkofler........... the wealth-distribution ideology often morphs into despotism if the perpetrators aren’t thrown out of office....Brenda Burbach Graphic Artist . we grant them their due..... puts it..Catrina Boettner Advertising Manager ..... in solving the problem of poverty.. History does not reveal any success with the attempt at wealth distribution...........Cambridge.. In my favor..... “Society has an enormous claim upon the fortunes of the wealthy...... depending upon the power of the decision-makers.Midland............ Marisa Roberts Graphic Artist ................. and in the end..Rio Grande du Sul....... Germany Telephone: +49 711 3416 74 0 Fax: +49 711 3416 74 74 GERMAN OFFICE Ian Cameron. The position of wealth is not a bad thing of itself.............. how should we view being rich from a moral perspective? We have been warned that riches are dangerous...... an opinion writer for The Washington Post. Jerry Karpowicz Digital Content Manager... Fortunately..... it always fails in its effort to eliminate poverty...... critical components lubrication systems field services reconditioning services evolving solutions around your world www.com .c-p-i. . ON L2E 6V2. Materials protected by U. Box 456.S.S. Safety Predictions For Control Panels COMPRESSORtech2 (ISSN 1085-2468) Volume 19. October. U.00 per year/$10. Unauthorized duplication and publication is expressly prohibited. POSTMASTER: Send address changes to: Circulation Man ager. WI 53186-1873 U. April. WI 53186 and at additional mailing offices. November. Waukesha.O.compressortech2. July. March.00 per copy worldwide. Niagara Falls. LNG Exports Remain On The Back Burner 56 Featured Products 73 Recent Orders www.A.S. EControls Assimilation Pays Dividends 26 Motortech Adds High-End Ignition Controllers 28 Dresser-Rand Makes Major Move Into Gas Liquefaction 32 Custom Packager Strikes Gold In The Marcellus Shale Cover Designed By Alyssa Loope Dedicated To Gas Compression Products & Applications 22 The Importance Of Motor Dynamics In Reciprocating Compressor Drives 42 Flowmeter Can Be Sized For Any Engine 62 Recip Compressor Performance. Subscription rates are $85. 20855 Watertown Road. August-September.A. Return Undeliverable Canadian Addresses to: P. What’s Mine Is Yours 8 Global Perspective — EOR Could Revitalize Middle Eastern Oil Industry 10 Meetings & Events 12 About The Business — Frigid Winter Challenges U.S. Waukesha. All Rights Reserved. Canadian Publication Mail Agreement # 40035419. and international copyright laws and treaties. No. June. Copyright © 2014 Diesel & Gas Turbine Publications. Suite 220.S. Gas Industry 14 Monitoring Government — U.S.com Follow Us @ COMPRESSORtech2 MEMBER OF … 73 Web Headlines 74 Prime Movers 84 Scheduled Downtime 85 Marketplace 86 Advertisers’ Index 88 Cornerstones Of Compression — The Heart Of The High-Speed Recip MEMBER OF BPA WORLDWIDE® PRINTED IN THE U. December) by Diesel & Gas Turbine Publications.com.A.March 2014 COMPRESSOR Featured Articles 16 GE Acquiring Cameron’s Recip Division 18 Murphy. E-mail: slizdas@dieselpub. 20855 Watertown Road. May. TECHcorner 36 Motor Dynamic Influence On Torsional Vibration Analysis 46 Friction-Surface Coatings In Dry-Running Recips 58 Solving Compressor Impeller Rub Problems During Mechanical Run Tests 76 Case Study: Intake/Exhaust Silencer Redesign Mitigates Noise Departments 4 Page 4 — What’s Yours Is Yours. WI 531861873. Periodicals postage paid at Waukesha. 2 — Published 10 issues/year (January-February. Compressortech2. Canada. And a plant operation shutdown is never a good thing. Catalyst elements work hard under extreme conditions. a failure is always possible.WHEN CATALYST ELEMENT FAILURE PUTS YOU IN A BIND. A quick replacement with top quality DCL Metalcor® products is the key to getting you out of trouble. and even with regular maintenance. 877. So you won’t be on the spot – we will. We stock a wide range of products in our Dallas warehouse.9759 dcl-inc. ready for rush delivery anywhere in the U. DCL WILL BE ON THE SPOT.897.S.com D A L L A S • H O U S T O N • L O S A N G E L E S • O K L A H O M A C I T Y . MARCH 2014 . it should sustain oil production at around 100. The final sanctioned project. etc. mature oilfields have pushed national oil companies to reconsider their investment plans.000 bbl/d and extend field life. but it also can extend the commercial life of the oilfield. but the terms of the new agreement require Total to take additional steps to maximize oil output. Despite the slowing investment in Qatar’s upstream. polymers or steam. An exploration and production sharing agreement signed with the Qatari government requires at least three exploration wells to be drilled this year. Oman has somewhat taken a lead in EOR in the region and the United Arab Emirates has implemented a project. Because of these efforts. This research into subsurface chemistry and fluid flow relationships in carbonate structures will be essential to sustaining Qatar’s longer term oil output. BMI expects Qatari oil production (including NGLs and other liquids) will be sustained above 1. CT2 8 COmPrESSOrtech2 dvanced enhanced oil recovery (EOR) has not been widely applied in the Middle East due to continuing strong levels of production and the additional costs of installing of high-pressure compressors. Perhaps of greater importance is Qatar’s drive to move its oil and gas sector to the forefront of technology. is due to come on stream in two phases this year and in 2015. the high price of crude and steep depletion rates at giant. The first is due to spud soon.Global Perspective BY Roberto Chellini Associate Publisher A EOR Could Revitalize Middle Eastern Oil Industry > Qatar Pushes Ambitious Program As a result of reduced oil and gas activity. steam. No redevelopment plans have been announced. the government has maintained a moratorium on new developments pending a study on field optimization and the geological impact of gas extraction. Meanwhile. water. Both tactics could make a major contribution to increasing reserves and sustaining production over a longer period. Qatar’s hydrocarbon industry is heavily centered on the resources in the largest single deposit of gas in the world. The US$3 billion project will add 200 production and injection wells. on Block BC. Historically. Qatar Petroleum is budgeting US$13 billion to maximize production from Bul Hanine oilfield. pumps and other equipment. Increased output is due in 2018.000 bbl/d of output. underground in order to maintain pressure in the formation and/or fluidize the heavy hydrocarbons to enable their flow toward the production wells. Maersk Oil opened a digital core laboratory in Doha. often bypassing the target oil zone and reducing the efficiency of the EOR sweep. This should develop better technologies for reservoirs like Maersk’s Al Shaheen oilfield on offshore Block 5. The company secured a 25-year extension to its license at Al Khalij field effective in January 2014.. Qatar is moving forward aggressively. The Middle East is the world’s largest carbonate oil-producing region. In some oil-rich nations. it has been challenging to apply the same techniques to carbonate reservoirs as they are generally more naturally fractured than sandstone. the nation is placing substantial focus on maximizing production from existing fields and exploring EOR opportunities. which is one of the most complex carbonate structures in the world.7 million bbl/d over the next 10 years. However. Fractures in a formation act as conduits to injected water. While the project is only expected to add 50. since 2005. carbon dioxide. it will extend production life by 25 years. While the development is not expected to increase production. French major Total remains upbeat about prospects offshore Qatar and this year will conduct exploratory drilling with partner China National Offshore Oil Corp. In mid-January. Occidental Petroleum is working on a sixyear project to redevelop the Idd El Shargi field after signing an agreement with Qatar Petroleum in mid-2013. Total is also involved in Qatar’s production optimization drive. Redevelopment efforts are already underway. Not only can this increase the rate of production. Business Monitor International (BMI) expects Qatar’s hydrocarbon sector to stagnate and its contribution to the nation’s economy to continue to decline. the North Field. the country still has plenty to offer. the Barzan Gas Project. The facility will put particular focus on researching EOR in carbonate formations and the marine environment. However. as Qatar’s oilfields begin maturing. where they have largely been successful due to the relatively standard porosity throughout the geology. with results expected to be available before the end of the year. In particular. EOR technologies have been applied to sandstone formations. Total’s efforts could therefore bring welcome upside potential to the country’s reserves and production outlook. EOR injects associated gas. most efficient. There may be a proud old name on the outside. Cooper-Bessemer is a registered trade name of Cameron Corporation. The heritage name. echoes the engineering excellence that has earned Rolls-Royce an unparalleled reputation for quality. but the driving force within the world’s best-engineered. the unsurpassed engineering experience of the past makes Rolls-Royce the compressor name of the future.com It’s all in the name. Cooper-Bessemer. in a business where productivity and dependability mean so much. Today.rolls-royce. still carried by older machines. used under license by Rolls-Royce plc A proud past leads to a new future. Trusted to deliver excellence . pipeline gas compressors is Rolls-Royce. Texas Tel: +1 (972) 518-0019 Web: www.com aPriL April 7-9 *Gas Compressor Association Expo & Conference — Galveston.turoge.com March 24-27 *Gastech — Seoul.cn/2014/en March 23-27 Sour Oil & Gas Advanced Technology 2014 — Abu Dhabi.leading operators and OEMs confirm: Emission impo The BCD packing ring has proven its outstanding performance in numerous applications worldwide.hoerbiger.gascompressor.com April 13-16 *Gas Processors Association Annual Convention — Dallas Tel: +1 (918) 493-3872 Web: www.BCD Packing Ring . reduced emissions and cost savings. United Arab Emirates Tel: +971 2 674 4040 Web: www.org April 15-16 *Gas Compressor Institute — Liberal.blackseaoilgas. Energy and Infrastructure Conference — Tbilisi.com April 28-May 2 *Gulf South Rotating Machinery Symposium — Baton Rouge.sogat. Kansas Tel: +1 (620) 417-1171 Web: www.indd 1 Meetings & Events *Indicates shows and conferences in which COMPRESSORtech2 is participating 2/17/14 9:18 AM MARCH March 19-21 *China International Offshore Oil & Gas Exhibition — Beijing Tel: +86 10 5823 6555 Web: www. Many compressor operators have installed the HOERBIGER BCD packing ring and leading OEMs have confirmed its high lifetime and superior sealing efficiency. Romania Tel: +44 203 615 2988 Web: www.org March 24-25 *Gas Transport & Storage 2014 — Berlin Tel: +44 20 7202 7690 Web: www. Georgia Tel: +44 207 596 5135 Web: www.gpaglobal.com MARCH 2014 10 COmPRESSORtech2 . Gas.giogie.gtsevent. ask for the BCD packing ring: ringsandpacking@hoerbiger. Their compressors now run more efficiently and with less fugitive emissions. Turkey Tel: +44 207 596 5147 Web: www. Korea Tel: +44 203 615 2872 Web: www. For extended lifetime.com March 26-27 Georgian International Oil.ciooe.com.gascompressor. please visit our website at www.org April 9-10 Turkish International Oil and Gas Conference 2014 — Ankara.info April 28-30 Black Sea Oil and Gas Forum — Bucharest.gastechkorea.com www.compressortech2. Louisiana For a complete listing of upcoming events.com Hoerbiger. com MARCH 2014 11 COmPRESSORtech2 .com June 10-12 *Global Petroleum Show — Calgary.energyexposition.powergeneurope.compressortech2. Germany Tel: +1 (404) 847-0072 Web: www.com Tel: +1 (403) 209-3555 Web: www. Uzbekistan Tel: +44 207 596 5144 Web: www.otcnet.org/ TE2014 June 24-26 Sensors Expo & Conference — Rosemont.org JUNE June 3-5 *Sensor+Test 2014 — Nuremberg. Germany Tel: +49 5033 9639 0 Web: www.com June 3-6 Caspian Oil & Gas 2014 — Baku.asmeconferences.oguzbekistan.de June 3-5 *Power-Gen Europe 2014 — Cologne.sensorsmag. Azerbaijan Tel: +44 207 596 5000 Web: www.indd 2 2/17/14 9:19 AM *Indicates shows and conferences in which COMPRESSORtech2 is participating Tel: +1 (225) 578-4853 Web: www.org May 13-15 Uzbekistan International Oil & Gas (OGU) Exhibition — Tashkent.globalpetroleumshow. Are you satisfied with the effectiveness of your compressor packings? Are you happy with leaking gas? Are you satisfied with the durability of your packing rings? Are you comfortable with the impact your compressor may be having on the environment? ssible Hoerbiger. please visit our website at www.egcr.org May 13-15 *Eastern Gas Compression Roundtable — Moon Township. Alberta.com For a complete listing of upcoming events. Illinois Tel: +1 (617) 219-8375 Web: www.com June 16-20 *ASME Turbo Expo 2014 — Dusseldorf.gsrms.com/ sensors-expo June 25-26 MAY May 5-8 *Offshore Technology Conference — Houston Tel: +1 (972) 952-9494 Web: www. Germany Tel: +44 1992 656 617 Web: www.caspianoil-gas. Canada Energy Exposition — Billings.sensor-test. Montana Tel: +1 (307) 234-1868 Web: www. Pennsylvania Tel: +1 (412) 372-4301 Web: www. More underground gas storage or local liquefied natural gas storage facilities also may have to be considered to meet power generation demand peaks. If the Marcellus Shale region were a nation. has driven increased demand for natural gas.. Speakers said conversions and repurposing of gas pipelines are proceeding very quickly. output of “tight oil” will grow significantly.90 on Feb. after Russia and the rest of the U. new infrastructure Industry > Production driving compression demand infrastructure challenges were discussed during the Gas/ Electric Partnership conference in Cypress.S.50/MMBtu range since January and spiking to US$7. showed 65 gas pipeline projects under construction. new laterals are taking longer. Despite the surging winter demand. Those Norm Shade is senior consultant and president emeritus of ACI Services Inc. MARCH 2014 12 COmPRESSORtech2 . net withdrawals from storage in the eastern U. Appalachian production from the Marcellus and Utica will continue to displace gas coming from the southwest.About The Business BY Norm shade Frigid Winter Challenges U.4 x 108 m3/d) earlier this year.S. slightly exceeded the previous record noted during the 2002-03 heating season. Even at the low end of the price range. much of the recent high demand and the resulting strain on the pipeline system have been in the eastern U. upstream capital investment. Texas. all of which is good news for the gas compression industry. The EIA reported production from the Marcellus region reached 12 Bcfd (3.55 x 1013 m3) of unconventional gas could be economically produced. The pipeline infrastructure to take away all the Eagle Ford and Bakken associated gas currently is insufficient and flaring is prevalent. 40). Meanwhile.S. p. A presentation by the Wood Mackenzie consultancy showed that U. This burst of production and pipeline growth is driving the need for new compressors as well as the refurbishment and resizing of existing pipeline stations in these regions. It said that by 2020. CT2 A n exceptionally cold winter in much of the U.S. A presentation by McKinsey & Co. Large quantities of Marcellus gas will flow out of the Northeast while associated gas from the Bakken Shale in the Williston Basin will increasingly displace Canadian gas that historically has supplied the Midwest market. driven by demand for home heating and power generation in the eastern U. Gas growth. 5.S. inferring that significant demand increases can be accommodated without requiring a substantially higher price. Volumes from both will potentially flood Chicago and the Gulf South. McKinsey projects that Appalachian shale gas and associated gas elsewhere in the nation will drive U.S. is almost 25% of the global total. more than six times the 2009 production rate. inadequate oil and gas infrastructure continues to cause problems. long-haul pipelines from the Gulf Coast to the Northeast and Canada are underutilized.S. the report said that about 900 Tcf (2. With supplies growing in new shale gas regions. hovering in the US$4. gas production through this decade. with the largest supplies coming from the Eagle Ford Shale. Since October. some areas experienced low gas pressures and near brownout conditions as pipelines strained to deliver enough gas to heat homes and produce electricity. Williams Partners had reported record natural gas flows on its Transco interstate gas pipeline system. the long-established.S. Those included a mix of expansions and laterals. IHS Cambridge Energy Research Associates predicted in January that shale production would restrain natural gas prices to the US$4 to US$5/MMBtu range for at least 20 years. of Cambridge. Energy Information Administration (EIA) data shows that gas storage levels have been below the recent five-year average since the beginning of January. Henry Hub spot prices reached the highest level in four years. A 44-year veteran of the gas compression industry. Bakken Shale and Permian Basin. January-February 2014. Some of those may be reversed or converted to liquid or ethane lines. When a polar vortex struck the upper Midwest and Northeast in January.50 to US$5. its natural gas output would rank third in the world. led by oil development. McKinsey predicts that the Permian gas flow will also be bottlenecked by next year. Ironically. 5-6. on Feb. the region that has developed into the most prolific producer of gas in the nation. principally in the Appalachian region or routes to New England and the Midwest from the Marcellus area (See COMPRESSORtech2. he has written numerous papers and is active in the major industry associations. approved.S. filed or proposed in the U. In December. Ohio. This oil production also will boost the gas flow since those shales produce large volumes of associated gas. Maximize the Performance of your Spark-Ignited Natural Gas Engine with Murphy’s new Intelligent Ignition Control System The IntelliSpark system is a microprocessor-based capacitive discharge ignition control system. Ensure the health of your spark-ignited natural gas engine with Murphy’s IntelliSpark ignition controller and components. 2014. TX Booth #320 www. Galveston. Visit us at GCA April 6-9. Ultimate control is achieved via true ignition energy measurements while offering users an intelligent view of engine operations and increased programming capabilities. EICS utilizes IntelliSpark technology to provide integrated spark and diagnostic capabilities as part of a comprehensive Engine Management solution.fwmurphy. Keep the spark going in your engine by running Murphy’s Engine Integrated Control System (EICS).com/intellispark-ct2 1311251 12-13 Contact us today to find out how to ignite your engine: 918-317-2627 . Over the years. In the House of Representatives. sponsors are clamoring for DOE approvals now. switched to the chair of the Finance Committee. Landrieu supports the “Our Energy Moment” gas-export campaign.” Committee Chairman Fred Upton (R-Mich. “In essence we’re sending a friendly shot across the bow for DOE to take it up. LNG Exports Remain On The Department’s permitting Back Burner > Energy continues at leisurely pace BY PATRICK CROW The report said. Department of Energy (DOE). It said exports would help reduce the U. this column discussed the glacial pace in approvals for liquefied natural gas (LNG) export permits at the U. therefore the committee is urging the Department of Energy to approve all remaining export licenses by the end of the year and is considering legislative action to modernize the process and remove barriers. Murkowski recently issued a white paper urging the administration to lift the ban on crude oil exports and expedite LNG permitting. So from outward appearances. due to the mushrooming supplies now recoverable at low production costs.” Two key senators seem to be firing shots aimed at the bow. Landrieu recently ascended to the chair when Ron Wyden (D-Ore. and affordable supply of natural gas. much to the delight of the chemical industry and other hydrocarbon-intensive manufacturers (who predictably oppose LNG exports). “Our friends and allies around the globe desperately need a more stable. It argued exports would have little impact on domestic prices. and Lisa Murkowski (R-Alaska). the new chairman of the Senate Energy and Natural Resources Committee. DOE has approved only five permits. especially with the congressional midterm elections approaching in November. entrepreneurs have proposed a number of projects to export domestic LNG into a thirsty world market. economy is partially due to surge in cheap shale gas production. Both represent major producing states and hold key positions. The recovery of the U. The Obama administration recognizes that fact and has every incentive to keep natural gas supplies plentiful and cheap. Perhaps the market will be able to accommodate a half dozen. it might seem that momentum is building in Congress to force faster action at DOE.) said. the department has cleared six projects in the key category. Given the long lead times required to build liquefaction plants. No matter what House Republicans bluster. exports to non-Free Trade Agreement nations. trade deficit by as much as US$27 billion. MARCH 2014 . Well.S. Although associations representing gas producers have been pressing for LNG exports. and American consumers and manufacturers need continued robust demand to bring additional resources into competitive production. businesses and state economic development organizations.S. CT2 14 COmPrESSOrtech2 T welve months ago.). nor what Landrieu and Murkowski can push through their energy committee. where much of the surplus gas productivity is pooling. an ad hoc coalition was launched in February with the same goal objective. all 30 export projects won’t go forward. With even greater shale gas production in prospect. Senate Democratic leaders can be expected to keep the lid on legislation to expedite LNG exports. the Energy and Commerce Committee recently issued a report urging the Obama administration to approve all of the pending LNG export applications by the end of the year.S. The shale gas boom has bestowed ample natural gas and gas liquids supplies upon the nation at bargain prices. In the past 12 months. “This window of opportunity will not remain open indefinitely.MONITORING GOVERNmENT U. the Senate panel has been the most influential entity in the national energy policy realm. They are mostly based in Texas and Louisiana. The “Our Energy Moment” alliance is a convergence of producer associations. whose cautious resistance toward gas exports constituted passive opposition. In reality. maybe a few more.S. Little has changed since then. and that of course continues to be the problem. The Landrieu-Murkowski duo is a Washington energy lobbyist’s fantasy team.S. Proponents argue that’s not the point: DOE should approve the permits and let the market determine which projects bloom in the right place at the right time. and about 25 are pending. not really. reliable.000 jobs. The group said LNG exports could generate up to US$47 billion in net benefits to the U.). So far. the senior Republican on the panel. economy and create up to 450. They are Mary Landrieu (D-La. ∙ • • • • • • Very durable design High resolution stepper motor Operated by VariStep stepper motor card H2S resistant Modbus RTU and CAN 2.com . MOTORTECH offers an air/fuel ratio control system that will allow you to successfully operate engines on lean gas. Phone: 1-800-436-9190
[email protected] WPI Phone: 1-888-458-0448 www.de | www.C.motortech. like landfill or biogas.wpi.com Cypress Engine Accessories Phone: 1-281-256-9100 www.The Perfect Mix The Mixing Solution for a reliable Performance and NOx Control For gas engines up to 1 MW.cypressengine.com Distribution partner for DENSO spark plugs MOTORTECH Americas.com Reagan Power & Compression LLC Toll free: 1-800-264-7767 www.0b interface Very flexible for changing gas qualities Designed and manufactured in Germany Call your nearest MOTORTECH Sales Partner: Martin Machinery L. LLC | www.reaganpower. flexible and precisely to any changes in gas quality for a maximized efficiency while complying with current emission limits. It uses an electronically controlled mixer concept that reacts fast.L.motortechamericas. too BY PATRICK CROW n Cameron employees assemble Superior compressors at the company’s Houston plant. GE noted that high-speed recips are used in applications from gas gathering. The division. has 900 employees and operates from 20 global locations.” COMPRESSORtech2 MARCH 2014 . The development of shale oil and gas fields. such as Asia and South America. The company’s recip business provides reciprocating compression equipment and aftermarket parts and services for oil and gas production. regulatory agencies approve. gas lift and injection. particularly in North America. which focuses on low-horsepower units that are used predominately in gas lift applications. It said that as shale continues to develop in other regions of the world. the acquisition will position GE to serve the industry globally. gas distribution and independent power industries.S. gas processing. which generated sales of about US$355 million in 2012. as well as 16 transmission and storage. the acquisition is expected to close during the third quarter. has increased demand for high-speed reciprocating compressors. Cameron’s recip portfolio will enable the company to offer higherhorsepower models used in gas gathering. president and CEO of GE Oil & Gas. was considering the sale of its centrifugal compression business.GE Acquiring Cameron’s Recip Division > Cameron may sell centrifugal business. Lorenzo Simonelli. GE said the acquisition complements GE Oil & Gas’ existing highspeed reciprocating (HSR) business. C ameron has agreed to sell its reciprocating compression division to GE Oil & Gas for US$550 million and. said. processing and transmission. If U. “The new (Cameron recip) business positions GE to more effectively focus on key downstream industry trends and to better anticipate customer needs. at press time. Cameron chairman and CEO.8 billion. and we anticipate that this trajectory will continue with the support of GE Oil & Gas. Hasan Dandashly. DTS also will include the newly acquired Salof product lines of small-scale. higher margins and market leadership. which had sales of US$365 million in 2012. CO and HCs Superior performance. the Standard in Catalytic Converters: TM Reduce 99% of NOx. which will supply equipment and services to the US$10 to US$11 billion downstream and distributed gas industry segments — including unconventional oil and gas activities.5 million in 2012. trucking and industrial industries. GE said oil and gas is one of its fastest-growing businesses.2125 / www. Citi is helping Cameron evaluate options for its centrifugal compression business. Revenues were a record US$9. “Exploring strategic alternatives for the centrifugal compression business is part of our ongoing effort to optimize our asset base with a focus on our core markets. Cameron reported 2013 net income of US$724. blowers.320.” Cameron’s recip operations will become part of GE Oil & Gas’ recently formed Downstream Technology Solutions (DTS) business. CT2 Johnson Matthey Modulex. said. The business also provides maintenance services and remote monitoring and diagnostics.5 billion in the prior year.2 million. valves and distribution systems. “We have achieved good growth over recent years. president of Cameron’s reciprocating compression division. The proceeds from the transaction will provide us with greater financial flexibility and afford us the opportunity to drive additional value for our shareholders. modular liquefied natural gas plants for the rail.Cameron said its after-tax proceeds from the sale would be US$400 million. The recip business had sales of US$355 million for the year ended Dec. pumps. “These actions will streamline the company’s operations and are consistent with our strategy of building on our strong sales and order momentum in our core markets while selectively expanding product and service offerings in strategic growth areas. DTS offers technologies and services including steam turbines. Headquartered in Houston. Jack Moore. said. up 16% from US$8. Its services and geographic presence will expand our distributed gas portfolio and enhance our shale capability and services expertise for our customers. 31.jmsec. In late January. We are committed to directing resources to businesses where we have the best opportunities to achieve sales growth. marine. said. 2012.” Richard Stegall. quality and durability backed by 100 years of experience Multiple silencer options Local availability and service Competitive pricing Want to know more? Contact us today! 484. compared to US$750. “Cameron’s reciprocating compression division will become an important part of our downstream offering to customers. distributed gas solutions.” In addition to Cameron’s reciprocating compression division. reciprocating compressors. with orders rising from less than US$1 billion per year in 1994 to nearly US$20 billion today and profits growing at an average 16% over the past three years. DTS vice president.com / MARCH 2014 17 COMPRESSORtech2 . power generation and agriculture. Board member Patrick W. Cavanagh is president and CEO. Enovation Controls is positioning itself as a global provider of engine and engine-driven equipment management and control products and services. to deliver improvements in engine management.” In order to facilitate the company’s approach to engine control. performance Dividends > One systems for gas compressors n Enovation Controls’ Engine Integrated Control System helps companies meet emissions standards as well as optimize performance for their natural gas engines driving compressors. drivability and emissions. “Although we officially merged four years ago. “The Enovation Controls name now represents our fully integrated company as a single. Murphy added that Enovation Controls would continue to promote and utilize the Murphy and EControls brands while strengthening the company’s positioning in the market. Enovation Controls executive chairman of the board. and Engine Controls and Fuel Systems business segments. Texas. With the introduction of EICSequipped engines. The system incorporates everything needed in one high-tech package designed specifically for selected engine models. EICS is a full-authority engine control system that incorporates ignition. and EControls. “The goal in creating integrated teams of the company’s product design and development engineers is for Enovation Controls to develop and deliver solutions to customers faster 18 than its competitors. Display and Power Controls. “By capitalizing on our synergies. along with the more fully integrated solutions our markets demand. EControls Assimilation Pays example: meshed emissions.” A recent example of Enovation Controls’ approach to engine governance is its Engine Integrated Control System (EICS) to optimize emissions compliance and performance for natural gas compressors. “The Solution Groups are focused on the development of more integrated and tailored solutions for customers. customers have continued on page 20 COMPRESSORtech2 MARCH 2014 . The system includes the company’s engine control modules. The privately held company employs 1000 people worldwide and was on track to exceed US$250 million in revenue in 2013. off-highway. Enovation Controls is realigning its technical resources into Solution Groups to work more closely with the company’s Natural Gas Production Controls. fuel efficiency.” Murphy said.” said Frank Murphy III. PowerView displays and related proprietary software that displays critical engine information. San Antonio. material handling. chief technology officer. Oklahoma. air/fuel ratio and speed control along with diagnostics. The system is precalibrated to meet emission and performance requirements for the application and typically requires no field calibration or adjustment. natural gas commercial vehicles. focused team. T he business formed by the 2009 merger of FW Murphy. Tulsa. Enovation Controls delivers the same products and services our customers have always known. The company serves markets that include natural gas compression and liquids.Murphy. we wanted to be very careful and deliberate with our integration process in order to make sure we truly preserved the strengths both companies brought to the table. reliability. recreational and commercial marine. protection and monitoring. sensors and catalyst into one package designed for specific engine models. “Enovation Controls combines Murphy’s line of controls and instrumentation with EControls’ engine control expertise to go beyond components to a fully integrated engine control and instrumentation provider. has taken the name of Enovation Controls to reflect the now fully integrated company.” said Kennon Guglielmo. air handling and aftertreatment to make alternative power a reality. IN 47202-3005 U.A. filtration. Cummins is leading the way in providing power from alternative fuels – part of our commitment to being a global power leader. Box 3005. fuel systems. Naturally. Visit cumminsengines. ©2014 Cummins Inc.. We have been pioneering the design and use of integrated subsystem technology such as combustion. we are producing a broad range of natural gas power and our dual fuel engines provide seamless transitions from diesel fuel to dual fuel operation.com to see how we could help you make the move to economical and reliable natural gas.Making Alternative Power a Reality Innovation you can depend on.S. Today. Columbus. controls. . a capability made possible by the merger. Another benefit of the merger. and said it will continue to expand and invest its international operations. Enovation Controls has used this combination of capabilities to launch a generation of PowerView color and monochrome displays with new capabilities and price points. more than 170. the merger has resulted in other synergies. Enovation Controls will be positioned to support the expected growth in the natural gas vehicle sector. The customer also can program these components as a single integrated system by using the proprietary PowerVision Configuration Studio development software. It is spending another US$4 million (in addition to more than US$15 million already invested in China) in an engine development center in Hangzhou. are now used to improve the quality.. China. which include in-house. said Terry Baldwin. “At Enovation Controls. adding that over 1500 natural gas compressors have been retrofitted with the EICS. In addition to EICS. shown above.n The EControls manufacturing and assembly operations in San Antonio.” Cavanagh said. EControls’ electronics manufacturing capabilities. at midyear. “The integration of the engine control. Guglielmo said Enovation Controls expects the number of natural gas-powered vehicles to grow significantly in the U. The combination of intellectual property from the two companies is also yielding value for Enovation Controls customers. “However. we’re leveraging our synergies in order to expand our offering so that more customers can experience the benefits of a total engine control and instrumentation solution. China.” CT2 n China is a major target for Enovation Controls’ global marketing effort. Guglielmo said. surface-mount assembly lines. Texas. Enovation Controls has invested in the relocation and significant upgrades of its engine development facilities in San Antonio.000 are found on heavy-duty natural gas fueled buses and trucks. electronic qualityinspection equipment and direct relationships with electronic parts suppliers. experienced short installation times with improved engine performance and fuel economy in the presence of load swings and changes in natural gas well flow. MARCH 2014 20 COMPRESSORtech2 .” Baldwin said. The company has sales and manufacturing facilities in North America. China and worldwide. With these investments. Guglielmo said.S. “The ability to cross over the boundary between vehicle systems and engine control is a unique Enovation Controls’ capability. These new modules have been combined with the next generation PowerView displays to form a package that is designed to work as a single system. “Our customers are reporting a 20 to 30% savings in fuel and operating costs by utilizing the EICS system. Of the more than 1 million engine control systems Enovation Controls has shipped to date. Europe and India.” Some of Enovation Controls’ most promising growth opportunities are in providing control and fuel system solutions for natural gas powered vehicles. vehicle systems and dashboard displays can yield performance advantages that a collection of components from a variety of vendors cannot match. cost and lead time of Murphybranded products. It has an application engineering and sales operation in Shanghai and will expand its plant at Hangzhou. we remain committed to providing our customers with the quality and service that earned us the business in the first place. Baldwin said EICS’ ability to monitor all integrated system components could simplify troubleshooting and reduce engine downtime while enabling customers to meet emissions regulations. To that end. Murphy said.” he said. have been expanded and upgraded. vice president of the Natural Gas Production Systems segment. is that Enovation Controls has taken engine control module designs from EControls and transformed them into general-purpose controllers and I/O modules for off-highway and marine applications. that is scheduled to open at midyear. We’ll help you reduce the uncertainties. WE DO THE SAME FOR YOUR RISKS. March 24-27 Bringing energy and the environment into harmony. and our installed liquefaction compressors currently represent approximately one-quarter of all LNG trains above one MTPA in production worldwide.LIQUEFYING NATURAL GAS GREATLY REDUCES ITS VOLUME. Stand G260.com Compressors–Turbo & Recip / Steam Turbines / Gas Turbines / Engines / Control Systems / Expanders » www.com . Reduce your risk. Ours were the first compressors used in liquefaction plants driven by large. Risky decisions have no place in this business. Visit us at Gastech 2014. by testing at full scale with variable geometry before you make your investment decision. speed project execution and lower cost of ownership—with the kind of experience only Dresser-Rand can offer. That’s why Dresser-Rand helps ensure your investment before you make it.® The Americas: (Int’l +1) 713-354-6100 / EMEA: (Int’l +33) 2-35-25-5225 Asia-Pacific: (Int’l +60) 3-2093-6633 /
[email protected]. and increase your LNG production with Dresser-Rand. heavy-duty gas turbines. South Korea. We were the first to be awarded a contract to supply large aeroderivative gas turbine-driven floating LNG compressors. • improved uptime due to increased equipment reliability. including this 10. Contact him at: ssubramanyam@ neuman-esser.500 hp (7. The need for highly accurate torsional analyses to produce the most reliable drivetrain is paramount to achieving best-in-class uptime. Germany. The paper reviewed the analysis and decisions that NEA takes to ensure that torsional designs for motor driven applications minimize unforeseen downtime.knop@neuman-esser. proper torsional dynamics and system analysis should lead to: • improved uptime due to much lower maintenance time. including motor dynamics. When utilizing motor-driven drivetrains. made at the 2012 International Rotating Equipment Conference in Düsseldorf. Contact him at: gerhard. He is a member of the GMRC Torsional Analysis subcommittee. He holds a master’s degree in mechanical engineering and has more than 20 years of experience in compressor application engineering and design of reciprocating gas compressor packages and associated equipment. all undergo detailed torsional analyses.8 MW) compressor train for natural gas storage.de. with a focus on drivetrain vibrations. emissions regulations and the strategies of end users. a trend which is primarily being driven by availability of electricity. head of development projects for Neuman & Esser (NEA). The impact of using a motor Because of their enormous torque variations. ed torsional issues — coupling alignment. cost of electricity. He is member of the GMRC Torsional Analysis sub-committee and has a Dipl.com. I nvestments in further developing the North American natural gas supply continued at a strong pace in 2013. transmit and store the new gas supplies. • improved uptime due to decreas Swamy Subramanyam is vice president of technical management and procurement at Neuman & Esser USA Inc. reciprocating compressors introduce torsional vibrations into the drivetrain that must be thoroughly continued on page 24 COMPRESSORtech2 MARCH 2014 22 . Major investments are being made to process.-Ing. The following technical summary is based on a presentation that Gerhard Knop.(FH) degree in mechanical engineering. Gerhard Knop is head of development projects at the Neuman & Esser Machine Factory in Übach-Palenberg. He has more than 18 years of experience in numerical and analytical calculations. The use of electric motor-driven compression continued to increase 2013. Germany. resonance and vibration alarms.The Importance Of Motor Dynamics In Reciprocating Compressor Drives > Exacting torsional analyses can ensure reliable drivetrains BY SwamY SUbramanYam and GerHard KnOP n NEA’s products. com www.prognost.Trust the #1 online monitoring system for mission-critical equipment Who monitors the most reciprocating compressors? When you look at the numbers. Our dedication ensures that your system remains best-in-class.com . reply@prognost. it all adds up to PROGNOST Systems: • Largest installed base of online diagnostic systems on reciprocating compressors • The world’s top refiners and HPI producers trust PROGNOST® systems • Over 20 years of experience in monitoring reciprocating machinery PROGNOST has one focus – reciprocating machinery. • Control of the rotational speed fluctuations.1. Why to consider motor dynamics in drivetrain simulations The introduction of motor dynamics into the drivetrain simulation is increasingly important and requires precise calculations and sophisticated simulation models for the following reasons: • Higher compressor rotational speeds are being used. This diverse behavior was modeled with a focus on induction motors. When properly chosen.6). • avoid rotor and stator mechanical overloading. but interestingly. It should be noted that the number of coupling or shafting failures due to complete simulation models (with motor dynamics) has gone down to practically zero. Both quantities. MARCH 2014 24 COMPRESSORtech2 . Electric current fluctuations must be limited to: • avoid excessive loading and flicker.7 and 7. In order to reduce speed variations. Therefore. • Setting the control very slow so that no fluctuations are controlled down. which are quite rigid. The motor reactions on torsional vibrations can create highly amplified or attenuated shaft torque variations. only with different frequency and voltage supply. which increases the probability of torsional resonances.2. • semiconductor malfunction. Torque dynamics must be limited in order to: • avoid coupling overloading or early rubber wear. similar to compressor torque. Negative damping When using all-steel disc couplings. investigated by simulation before these machines are put into operation. In recent years. advanced analytical design approaches reveal that coupling and motor shaft torque variations go up significantly without much external excitation. • As with connecting directly to the main power network. however. negative damping would amplify the vibrations due to unfortunate phase shift between excitation and vibration. which are much more frequently used than synchronous motors. Soft coupling and motor — two friends The most amazing influence on the torsional vibration behavior of the motor dynamics can be observed at drivetrains being equipped with high flexible (rubber in shear type) couplings. paragraphs 7. which reduces compressor main bearing load. Motors react on torsional vibrations. which results in resonant conditions that need to be properly investigated. The options are: • Control of motor current fluctuations. • avoid shaft fractures. Variable-frequency drives If a frequency converter is used. • More complete and sophisticated drivetrain simulations lead to increased reliability. crank shaft bending load and lateral vibration tendency.1. The resulting motor air gap torque variations represent an external excitation. they would even attenuate the shaft torque loading to an almost constant value. Where positive damping results in attenuation of vibrations in resonance near condition. the motor air gap torque would be constant as well. the motor air gap torque is smoothened in the same way as the motor current. • The use of speed controls continues to increase. If the torque of the compressor were constant. for variablefrequency drive (VFD) drives it is • Improved drivetrain simulations allow reduction of flywheel size and weight.n This cutaway drawing shows a high flexible (rubber in shear) coupling. smooth speed is achieved by varying current and shaft torque. the fluctuating compressor torque produces angular deflections of the rotor within its magnetic field and causes the motor air gap torque to change its height. • avoid thermal overloading of the frequency converter. This assumption most often leads to completely incorrect shaft torque dynamics and gives no information on electric current fluctuations. the motor air gap torque must vary accordingly. In this case the motor behaves in the same way as if connected directly to the main power network. Whether during start-up or steadystate. the behavior approaches that of a constant motor air gap torque. In this case. sometimes even today. If the control is fast enough. the reacting torque of the driving induction or synchronous motor was considered to be constant at steady-state operation. and influences the torsional vibrations of the drivetrain. the motor air gap torque is affected by the respective frequency converter control methods. these self-induced vibrations are driven by feedback of the motor. are the key design features of a drivetrain (API 618.1. The coupling type has an immense effect on the motor air gap torque which reduces or increases torsional vibrations and shafting torque load depending on the given drivetrain configuration. However. Neuman & Esser has developed expertise in evaluating motor dynamics for drivetrain simulations (especially motor electromagnetic characteristics). OK COMPRESSORtech2 . As a compressor and motor can only be simulated in a single combined model. When using torsionally soft couplings. Therefore. When torsionally rigid couplings like all-steel. At VFD. Motor and soft coupling represent a very good combination and produce robust systems that show only small torque pulsations at coupling and shafts. as modern compressor installations provide a stronger demand on calculation accuracy. coupling. due to better strength utilization. CT2 MARCH 2014 25 Innovator in State-of-the-Art Pipe Supports & Clamps Inventor of Flywheel Lock Leaders in Field Machine Work Pioneers in Casting Rapair PRODUCTS: n Pipe Supports & Clamps n Epoxy Grout n Anchor Bolts n Flywheel Locks n Temperature & Vibration Sensors n Spark Plugs SERVICES: n Field Machining n Casting Repair n Crankshaft Machining n Machine Shop n Broken Bolt Removal n Frame Reinforcement n Alignment Services 918-252-7545 www.com Tulsa. the motor electromagnetics should always be included into the calculations. depending on the individual requirements.com info@r-f. increasing the reliability of high-pressure reciprocating compressors used in gas applications. This has become even more important today. The inclusion of motor dynamics in drivetrain simulations has increased equipment reliability. the frequency converter control method must be thoroughly chosen in order to promote or reduce the motor magnetic field influence. compressor manufacturers must understand the dynamic motor behavior. flywheel and crankshaft designs.Recognized Leader n This is an all-steel. not only the dynamic shafting torque but also the motor electric current fluctuations that have to be considered during the drivetrain design. disc-type coupling. disc-type couplings are used. allowing them to optimize the drivetrain on every relevant aspect such as proper motor inertia. The resulting shaft and coupling torque variations can be multiples of the calculated values due to the false assumption of constant motor torque.r-f. the torque loading value can become quite low due to the motor reaction. Conclusions It could be demonstrated that the motor dynamics represent the major influence on the torsional vibrations of drivetrains — especially on the shaft torque loading and on electric current pulsations. self-induced vibrations may occur with sometimes harmful amplitudes. Germany-based company said that high ignition energy. wellhead or mine and it employs a high precision stepper motor drive with a reprogrammable controller board called VariStep. accurate spark timing and diversified online diagnostics can combine to improve engine efficiency.youtube. Based on different design sizes and different flow bodies in the Venturi nozzle. The Celle. Based on the suction vacuum of the engine. wood. it is possible to achieve various volume flows. The controller is fully customer configurable via a laptop. according to the company. landfill. This way. To see a video of the SparkView application. Series 100. The Venturi effect produces an underpressure at the narrowest point. It allows the engine to operate at its most efficient point. Coupled to an air/ fuel ratio controller. In the VariFuel2. variable Venturi-type mixer that can constantly adjust to any fuel changes. gas and air are mixed based on the Venturi effect. a greater range of application areas. it precisely regulates the mixture and. They are the MIC3. sucking the gas in through the gas inlet. Another recent Motortech product launch was a handheld device to support gas engine mechanics who are trouble shooting engine problems or going through preventive maintenance procedures. which has 12 ignition outputs and 200 mJ of primary energy for small and mid-sized gas engines. SparkView monitors the high voltage required by the spark plug when firing. gas and air are mixed and released at the Venturi outlet.Motortech Adds High-End also expands offerings of Ignition Controllers > It fuel mixers By IaN CamERON n This is a grouping of VariFuel2s available from Motortech. biogas. The main task of the gas mixer is to mix the fuel (gas) and air so that the gas engine achieves optimal combustion. lean-burn or stoichiometric. or respectively overlap. including natural. MARCH 2014 M The VariFuel2 is a high-tech. Motortech said the decisive optimization parameters are a high degree 26 of efficiency and low emissions that comply with relevant regulations. spark plug life and availability of the equipment under the strict emissions regulations.com/ watch?v=YcC94wnhzQc. and the MIC5 with 20 ignition outputs and 500 mJ primary energy for engines with up to 670 hp (500 kW). 200 and 250 VariFuels are available for engines with an air requirement up to 176 Mcfh (5000 m3/h). go to: www.140. sewage. the air is sucked through the air inlet into the Venturi nozzle. Various flow bodies and flexible inlet and outlet configurations allow fully flexible cross section adjustment. is suitable for applications with constant changes in the calorific value of fuel. otortech has extended its range of high-end ignition controllers with two new series. Motortech has also extended its VariFuel2 air/fuel ratio mixer series with two new sizes to cover. It can be used with nearly all gas types. CT2 COmPrESSOrtech2 . Features and BeneFits FEATURE BENEFIT _________________________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________________________________ Carbon or stainless steel construction DBG Sealing Technology Industry’s longest lasting housings. Our hinged “Quick Cover” designs afford fast and easy access to catalysts.Leading the way in … stationary engine emissions ParaLLeL FLow Based on its more than 60 years of catalytic converter manufacturing expertise.CatalyticCombustion. WI 715-568-2882 GILLETTE.com . OK 715-933-4154 www. TX 715-933-1559 TULSA. built to customers’ specifications 12 possible combinations of rectangle catalyst configurations All installation hardware included Improved emission control using three rectangular catalysts in strategic placements Fastest installation on the market for parallel flow application Easiest catalyst element change No field assembly or modification required Innovative Double Bulb Gasket provides the best seal for removal and bypass prevention Hinged “Quick Cover” catalyst access panel Two lifting eyes pre-installed Catalytic Combustion manufacturer’s “Quality 4” plate Catalytic Quality Craftsmanship Guarantee Validates date of manufacture and quality assurance with full tracking capabilities Industry-leading 12-month craftsmanship warranty BLOOMER. Catalytic Combustion offers best-in-class Parallel Flow housings. WY 715-933-2641 FORT WORTH. saving time and money during in-the-field service. D resser-Rand has announced the successful operation of its newly developed small-scale liquefied natural gas (LNG) production system. According to Charles Ely.” Dresser-Rand designed.712 L) of LNG per day. The first phase of cooling is accomplished by the mechanical chiller. The integrated ammonia chilling system consists of an evaporative condenser and screw compressor that removes the heat of compression from the methane prior to expansion. which allows for very small stand-alone plants that are portable and can be moved to support changing requirements and needs. which in December reached a milestone with the initial production of LNG. The conditioning module. “We are very excited about this technology for small-scale LNG production. which uses an ammonia refrigerant loop and evaporative cooler.” President and CEO Vincent Volpe Jr.Dresser-Rand Makes Major Move Into completed for small-scale LNG Gas Liquefaction > Tests production system BY JOE KANE uefaction process piping to drop the pressure and reduce the temperature of the natural gas. “The standard LNGo plants are sized to produce approximately 6000 gallons (22. extended performance and endurance tests are being performed as the final step prior to full market release. and is fitted with a gas seal and anti-surge control systems to assure reliable operation. Now. cleans and continued on page 30 n The compressor module contains a four-throw Dresser-Rand 7MOS4TM reciprocating compressor to provide all stages of compression and the interconnecting pipe to the process module. New York. The advantage of this first stage is lower cost and smaller footprint. constructed and commissioned its demonstration plant. JouleThomson valve. The process module contains a mechanical chiller. It is used to supply the final cryogenic heat exchanger with cooling medium. the LNGo system operates on the open-loop methane concept. The expander wheel uses variable inlet guide vanes to control inlet gas flow and maximize efficiency. named LNGo. The second phase of cooling is accomplished with the turboexpander. brazed welded plate heat exchangers and liq- n The LNGo system is shown with threedimensional CAD software created by the development team at Painted Post. MARCH 2014 28 COmPrESSOrtech2 . The process is identified as a methane letdown cycle. said. turboexpander. Final subcooling is accomplished with a Joule-Thomson valve that rapidly expands natural gas and reduces temperature to below -250°F (-157°C). general manager of midstream SBU. also known as the molecular sieve. stainless-steel. . now free of H2O or CO2.800 to 42. CO2 and heavier hydrocarbons that are not permissible for making LNG. and is a tribute to our internal processes.74/2.5/281. The product stream. (160 x 175 mm) giving a displacement of 3436 cu. (172 mm) stroke and bore sizes (C1/C2/C3/C4) of 10. Dresser-Rand currently offers the LNGo system for direct sale but is evaluating other market strategies such as rental or lease options with market channel partners. as well as routine operations. The purge stream is essentially a waste stream that contains H2O. Bore and stroke are 6.35 L) and a compression ratio of 9. turbocharged and aftercooled. “Our development process began in earnest less than one year ago. Depending upon the nature of the application.1/0. We are proud of our people and their outstanding efforts. For direct sale. rich-burn engine (rated 870 kW at 1800 rpm and bmep of 151 psi or 10. operations.870 kJ/m3). Fuel gas is a blended mixture of mole sieve purge (waste) gas and feed natural gas. the power module provides power for the entire LNGo system. A fan-driven ambient air cooler is used to cool engine jacket and lube oil circuits. as well as to the men and women of our development team. The compressor features Dresser-Rand’s Magnum XF series valves for proven combination of efficiency and durability in high-pressure ratio applications. on-site fuel supply for n The liquefaction process module does all the cooling and subcooling of the natural gas in the system. (267/267/444. New York. The compressor module satisfies all four stages of gas compression re- quired by the LNGo liquefaction system.n Dresser-Rand’s Guascor generator set takes natural gas and converts it into electrical energy for the rest of the system to operate. four-cycle. in.4 bar). the company has been talking to potential clients for several months. It uses nonlubricated cylinders to avoid process contamination and eliminate lube oil consumption.5/11. The power module contains a Dresser-Rand Guascor.85.13/0. is fed to a Dresser-Rand MOS compressor to begin the liquefaction process.2/0. sep arates the incoming gas into two streams. With an engine configured to handle natural gas within a lower heating value (LHV) range of 800 to 1150 Btu/ cf (29. 16-cylinder. Compression ratios of the four stages are (C1/C2/C3/C4): 3. avoiding additional gas treatment or cleanup. A waterglycol coolant is used to cool compressor cylinders.27/0. among others. Rated emissions are 0. Dresser-Rand’s Enginuity PLC-based control system serves both the power module and the LNGo process. with a target capacity of 6000 gpd (2. three-phase WEG induction motor rated for 750 hp (559 kW) at 480V. For all users. It is blended with makeup natural gas and used to fuel the Guascor engine. rod packings and the crankshaft and rod bearings lube oil is fed by a mechanically driven pump during normal operation and electric motor-pump during start-up.3:1.9 in. The power module also contains the motor control center (MCC).” On the commercial side.27 g/kWh) for NOx/CO/ HMHC. (56.2 g/bhph (0. Upstream applications include. “In this time frame. MARCH 2014 30 COmPrESSOrtech2 .5/17. monitoring and maintenance contracts to ensure ongoing reliable and available operations. the monetization of flared gas to increase revenues for oil companies and reduce their environmental impact. It includes VFD with harmonic filter. a power module and full turnkey installation and commissioning. This development cycle time to market is amazingly short.25/3. Dresser-Rand can provide full turnkey installation and commissioning services.6 mm).5/2. Dresser-Rand provides the liquefaction process and associated ancillary gas processing equipment.2 kpd). these potential opportunities are broadly classified as modules that would either be for sale or for lease. The compressor is driven by a 12pole. and our Painted Post. the production of stranded natural gas fields that are not close to existing pipeline infrastructures. Dresser-Rand’s four-stroke model 7MOS4 reciprocating compressor has a 7 in.5/10. built and commissioned an entire plant.5 in.” Volpe said.3 x 6. our or- ganization has taken the process and designed. Dresser-Rand said orders booked for LNGo in the next several months will convert to shipments in 2014.ACIServicesInc. Dresser-Rand believes that its approach to short cycle time will enable LNGo plants to be installed and operating in months rather than years. shipping and delivery companies. allowing LNG to compete effectively with diesel fuel on a cost-per-energy-content (Btu) basis. The short cycle times will allow owners to see quick returns on their investment. smallscale LNG production plants will grow from early adopters in North America to a broad.n A simple schematic representation of the process shows the progress from input natural gas to the output of LNG. www. industrial mining equipment. transportation fleets and retail fueling stations along the United States interstate highway system to LNG fuel. CT2 Don’t Just Go With The Flow Exceed Your Expectations ACI provides a robust line of performance control devices to help you optimize the operation of your reciprocating compressors. Further. drilling and hydraulic fracturing equipment converted to run on LNG and applications for coal bed methane for fueling mining vehicles. The substantial price disparity between diesel fuel and low-priced natural gas has oil-field service operators. as is the practice today. the technology eliminates the need for the costly trucking of LNG long distances from large. Downstream applications include the production of vehicle-grade LNG. North America is the most rapidly growing market. As those units are placed into service and gain operating experience and runtime. As LNGo plants enable the “distributed” production of LNG on a small scale. centralized plants to LNG fueling depots. as well as matching the supply and demand of LNG as local markets develop. Driven by rapidly expanding global shale gas development and continued price differentials between natural gas and oil. oil and gas companies. the company expects the incoming stream of orders to grow over time. Dresser-Rand predicts that the market for distributed. and downstream fuel distributors/marketers across the region converting drilling rigs.com 740-435-0240 . robust market for users around the world. Albin P. has found itself in the right place and the right time to supply the Marcellus and Utica shale plays. who sold and serviced Gardner Denver industrial air compressors. joined the company in 1985 after receiving petroleum engineering and MBA degrees. 32 earing Compressor and Pump Co. The family owned company’s introduction to the oil and gas business came in 1960 by working on Gardner Denver oil rigs and compressors. chief financial officer. This later led to an expansion into the natural gas compressor market within Ohio. She joined the company in 1981. Until August 2006. D MARCH 2014 Dearing Compressor has served the Appalachian Basin since 1945 By Norm ShadE Richard (Rick) H. Dearing operated in a 26. Ariel JGD/4 inlet gas compressor. the current president and grandson of the founder. “The company has grown steadily since we purchased it from our father in 1996. “But customers demanded that we be able to do it all or we wouldn’t get any of their other business. The large package in the foreground includes a Waukesha 9390 gas engine.Custom Packager In The Marcellus Shale StriKEs GoLd n Dearing’s plant has eight fabrication bays with 180 tons (163 tonnes) of crane capacity and is being expanded to 12 large bays in 2014. (2416 m2) facility with limited crane capacity. packages in the 100 to 300 hp (75 to 224 kW) range were common.ft. and 500 hp (373 kW) was a big unit for the company.000 sq. “Business COmPrESSOrtech2 .” Rick Dearing said. sister and co-owner with Rick. A 10. Ohio. “Dearing is established as a leader in the engineering. packaging and installation of quality compressor equipment. And then the Marcellus Shale emerged. (929 m2) expansion helped the Appalachian Basin packager continue several years of steady growth. Rebecca Dearing Wall is the executive vice president.” Rick Dearing said until about 2005. Dearing Jr. so we kept expanding to larger and larger units. Dearing III.000 sq.ft.” Dearing Wall said. of Youngstown. formed Dearing in 1945. and AXH air cooler.. com .COMPRESSOR Dedicated To Gas Compression Products & Applications PACKAGER GUIDE 2014 www.compressortech2. Texas. Type of compressors: centrifugal. marketing and michel. Calgary. Principal contact: Peter Kourkoubes. vice president of sales and marketing. Principal contact: Brian McDonald. • ABC Compressors. Types of compressors: reciprocating and rotary screw. Types of compressors: reciprocating and rotary screw. Principal contact: Eric McKendry.com. liquid rings and blowers. USA and Latin America. sales. • GEA Refrigeration Italy. E-mail: tkerbo@arrowengine. Bucharest.500 kW). Capacity range: up to 4024 hp (3000 kW). president. com.com. • Enerproject SA. Spain. • ANGI Energy Systems LLC.000 hp (7456 kW).pierce@alegacy. • Compressor Systems Inc.000 kW).mcdonald@flatrockcompression. reciprocating and centrifugal.000 to 120. Capacity range: 95 to 5000 hp (71 to 3728 kW). Florence. E-mail: kbright@agequipmentcompany. general manager. E-mail: jhightower@angienergy. vice president. Principal contact: Javier Cuevas. Houston. • Bidell Gas Compression. E-mail: cdejong@dresser-rand. Capacity range: 26 to 500 hp (19 to 373 kW). Italy. Principal contact: Vito Notari. E-mail: sales@abbyservicesinc. • Dresser-Rand.com. vane and rotary screw. E-mail: tbrown@elliott-turbo.. Principal contact: Jared Hightower. Compression and Process.com. Capacity range: 250 to 9000 hp (186 to 6710 kW). Pennsylvania. Type of compressors: screw. E-mail: sdouglas@compasscompression. E-mail: Mike. E-mail:
[email protected]. and reciprocating. Capacity range: up to 13. Wisconsin. Principal contact: Terry Kerbo. vice president. blowers and liquid ring. Houston. their locations and package capacity ranges is an important service to the end users of this equipment. E-mail:
[email protected] to 95. manager. Principal contact: Bo Pierce. • Flatrock Compression Ltd. Texas.com. Capacity range: 10 to 6800 hp (8 to 5000 kW). Jeannette. • FIMA Maschinenbau GmbH. Principal contact: Jack Motley.000 hp (15 to 7456 kW).000 hp (7456 kW). axial. Principal contact: Ivano Camaggi. gas and steam turbines. director of marketing and sales. Oklahoma. E-mail: vito.teodorescu@comoti. Principal contact: Sara Hassett. E-mail: philm@brahmacompression. sales manager. Capacity range: 25 to 300 hp (19 to 224 kW). Oklahoma.de.100 to 181..000 kW). E-mail: COMPRESSOR Dedicated To Gas Compression Products & Applications . • Comoti – Romanian Research and Development Institute for Gas Turbines. Capacity range: 3 to 500 hp (2 to 373 kW).notari@enerproject. Type of compressors: reciprocating. Capacity range: 20 to 10. Types of compressors: rotary vane. Principal contact: Colman DeJong. • Arrow Engine Co. Principal contact: Scott Douglas. Obersontheim. Canada.com. Types of compressors: reciprocating and rotary screw.. Principal contact: Michel Bezemer.000 hp (15.com.com. Communications Leader. compression. Capacity range: 5 to 400 hp (4 to 298 kW). Alberta. Power Technology Center. • Abby Services Inc. Types of compressors: centrifugal and seal-less.bezemer@conpacksys. Netherlands. Oklahoma City. Capacity range: 30 to 8000 hp (22 to 5965 kW). Romania. E-mail: jackmotley@compressorpackaging. Type of compressors: centrifugal and axial compressors. Types of compressors: reciprocating. Principal contact: Mike Gerzina.hassett@ge. Capacity range: 5 to 8000 hp (4 to 5965 kW). Types of compressors: centrifugal. Buffalo.Gerzina@c-a-m.
[email protected]@exterran. Capacity range: 30 to 2448 hp (22 to 3280 kW). sales and applications.412 hp (10. with expanders and turbine-generator sets. • AG Equipment Co. reciprocating. Capacity range: 70 to 1600 hp (50 to 1200 kW). please let us know. • Exterran Compression. Capacity range: 26 to 8500 hp (19 to 6338 kW). • ConPackSys. Types of compressors: reciprocating. sales engineer. E-mail: ivano. president. E-mail: roger. reciprocating. • GE Oil & Gas. E-mail: rick@dearingcomp. Romania. Canada.. Ohio. sales. Tulsa. Type of compressors: reciprocating. Capacity range: up to 10. Louisiana. screw. Janesville. E-mail: hank. centrifugal and blowers. centrifugal. Odessa. Alberta. Italy.com. • Com-Pac Systems Inc. president. Houston. Types of compressors: rotary screw.wachter@eurogassystems. as it will be updated on a regular basis. Capacity range: 25 to 4000 hp (19 to 2983 kW). Principal contact: Drake Andarakes. Sales. Canonsburg. Type of compressor: reciprocating. Dordrecht. types of compressors offered and the capacity range of the packages they produce. Capacity range: 20.com.065 kW). Email: pkourkoubes@enerflex. Calgary.com. • Elliott Co. Type of compressors: centrifugal. turboexpanders and hot gas expanders. • Dearing Compressor & Pump Co.com. E-mail: jcuevas@abc-compressors. E-mail: susan. E-mail: m. Capacity range: 44 to 9383 hp (33 to 7000 kW). Waller. Principal contact: Trevor Hunt. Sales.ro. sales. This addition of our services to the industry is based on several inquiries we received regarding compressor packagers. Germany. E-mail: sara.000 to 70.com.. Types of compressors: blowers. • Cobey Inc. Principal contact: Bob Carter. E-mail: b. Broken Arrow. • Custom Compression Systems.nl.com. Houston. Principal contact: Kent Bright. sales manager.000 kW).com.. Principal contact: Michael Loercher. Capacity range: 40 to 800 hp (30 to 597 kW). reciprocating. Principal contact: Richard H. VP of sales – The Americas. lube oil systems. Types of compressors: reciprocating and rotary screw.com. Eibar.Packager Guide 2014 Establishing a comprehensive listing of compressor packagers. Calgary.. • Flogistix. An important note — if your company is missing from this listing. general manager. rotary screw. • Euro Gas Systems SRL. Principal contact: Phil Meloche.. Capacity range: 30 to 400 hp (22 to 298 kW). E-mail: sales@flogistix. Capacity range: 20 to 800 hp (15 to 597 kW). Alberta. domestic CNG Sales. Mezzovico. • Alegacy Equipment. Principal contact: Roger Wachter.sheeran@compressor-systems. New Iberia. • Cameron.com. Texas. integrated electric motor driven compressors. • Brahma Compression. along with contact information. rotary screw and rotary vane. Capacity range: 10. E-mail: bcarter@customcompressionsystems. Type of compressors: reciprocating. A listing of packagers follows. president. Capacity range: 148 to 9000 hp (110 to 6711 kW). Switzerland. E-mail: marius. marketing/ communications. New York. Capacity range: up to 30. • Enerflex Ltd. Types of compressors: reciprocating and rotary screw. Principal contact: Susan Nelson. E-mail:
[email protected] hp (22.com. Calgary. reciprocating and highspeed reciprocating compressors. Capacity range: 100 to 5000 hp (75 to 3728 kW).com. vice president. Principal contact: Marius Teodorescu. Midland..000 to 135. manager. Principal contact: Hank Sheeran. Types of compressors: rotary screw. Types of compressors: reciprocating and screw. Targu Mures.. Principal contact: Don Fulmer. Type of compressors: rotary screw. rotary screw and vane. Canada. Principal contact: Tom Brown. Canada.biz.com.com. Principal contact: Mat Clark. president.. Capacity range: up to 10.200 hp (15. vice president. com. Types of compressors: reciprocating.com. Types of compressors: reciprocating. Houston. Youngstown. Alberta. Capacity range: 20. Castel Maggiore. • Compass Compression Services Ltd. Dearing Jr.000 hp (7456 to 89. E-mail: brian. Types of compressors: rotary screw. marketing manager.. Types of compressors: reciprocating and rotary screw.loercher@fima. Types of compressors: reciprocating. Texas. E-mail: mseeliger@valerus. Capacity range: up to 75 hp (56 kW). regional senior sales leader for Latin America. Oklahoma. Beni. E-mail: mmaggi@palmero. • Natural Gas Compression Systems Inc. Compressor Division sales manager.niss@siemens. • Solar Turbines Incorporated. Capacity range: 670 to 10.de. Type of compressors: reciprocating. Capacity range: 5 to 8000 hp (4 to 5965 kW).net COMPRESSION TECHNOLOGY SOURCING SUPPLEMENT . Bergamo. rotary screw and vane.000 kW).com.com. Ohio.097 to 77. Alberta. S. E-mail: rogerio. Capacity range: up to 2500 hp (1864 kW).com. Calgary.com. E-mail: mtearoe@startec. • G.petraccone@safe-ita. Oklahoma. Principal contact: sales department. Type of compressors: horizontal..p. Germany. sales. reciprocating and scroll. E-mail: info@pse-eng.. Sable. Farmington..100 kW). Type of compressors: reciprocating. Duisburg.. • Valerus. Capacity range: up to 6705 hp (5000 kW). Principal contact: Michaela Niss. centrifugal. Alberta.eu.o. Netherlands (packaging). E-mail: tim@mcclungenergy. Principal contact: Tomasz Grzegolkowski. Renfrew. Energy. Principal contact: Jeffrey B. Colorado. export. • Startec Refrigeration Services Ltd..000 hp (75 to 7456 kW). Principal contact: Vickie L. Principal contact: Michele Petraccone. E-mail: jeffrey.000 hp (15.com. E-mail:
[email protected]. Type of compressors: reciprocating. Capacity range: up to 6500 hp (4846 kW). • S&R Compression LLC. Principal contact: Rogerio Freitas da Fonseca. Broussard. Principal contact: Thompson Speir. Capacity range: 100 to 10.. E-mail: trent. Longview.kollenbach@vpt-kompressoren. Principal contact: Steven Tyler. sales engineer.com. screw (gas and electric motor driven). Secco S. Calgary. vertical and V-type reciprocating. Principal contact: Ron Delisle. Argentina. McBride. Houston. • Henry Production Inc. com. Capacity range: up to 10. Types of compressors: vapor recovery.grzegolkowski@siemens. director of sales. E-mail: rdelisle@propaksystems. Capacity range: 30 to 5000 hp (22 to 3728 kW).. Type of compressors: reciprocating.707 hp (9800 to 57. Type of compressors: reciprocating.aftersales@howden. Capacity range: up to 5000 hp (3728 kW).000 hp (7456 kW).com. E-mail: mauro_acquati@siad. owner. Types of compressors: natural gas and reciprocating. • Siad Macchine Impianti S. sales and marketing director.b. New Mexico. Capacity range: 5 to 1000 hp (4 to 746 kW). • SEC Energy Products & Services. Email: valdir@hbrarcomprimido. Principal contact: James R. Irving. Capacity range: up to 250 hp (186 kW).com.com.A.vocca@gie. Oklahoma.ca. E-mail: styler@uecompression. Hengelo. Type of compressors: centrifugal.com. screw.br. • Siemens AG. Capacity range: 75 to 5000 hp (56 to 3728 kW). Capacity range: 6635 to 40. Types of compressors: reciprocating. E-mail: tomasz. Type of compressors: turbocompressors. Barr. • J-W Energy Co. Capacity range: up to 20. director. U.. vapor recovery. Principal contact: Donatello Vocca. E-mail: forso@reaganp ower. • Neuman & Esser U.com. Sao Paulo.com.com. Capacity range: 5 to 5000 hp (4 to 3728 kW).com. • UE Compression LLC. • Kingsly Compression Inc. compression systems. Michigan. Traverse City.A. Capacity range: 25 to 4500 hp (19 to 3355 kW). Canada. • HBR Equipamentos ltda. Principal contact: G. Germany.. Types of compressors: rotary vane. Types of compressors: reciprocating. reciprocating. Capacity range: up to 6500 hp (4846 kW). Type of compressors: reciprocating.com.ca. Porto Recanati. San Diego. Rio de Janeiro. E-mail:
[email protected]. Turbo Equipment. Texas. Okemah. E-mail: powergen@solarturbines. • Safe. Types of compressors: rotary screw and reciprocating. Katy. E-mail: michele. Italy. Capacity range: 60 to 7200 hp (44 to 5371 kW). Principal contact: Valdir Zuffo.com.com. rotary vane. Hugoton. Type of compressors: high-speed reciprocating. Type of compressors: rotary screw. Buenos Aires. E-mail: sales@OTACompression. Argentina. • SAGE Energy Corp. Type of compressors: reciprocating. high spec. • McClung Energy Services. • PSE Engineering GmbH.it. Alberta. Italy. & E.. sales. vice president.I. Principal contact: Mauro Acquati.. Principal contact: Dirk Heyer. Principal contact: Tim McDonald. Principal contact: Bill Jenkins. Kansas.• GE Oil & Gas do Brasil Ltd. Louisiana.K. E-mail: c.de. Principal contact: Trent Bruce. Principal contact: Mike Tearoe. Hannover. • Sertco. Principal contact: Terry R. Types of compressors: rotary screw and reciprocating. • Palmero San Luis S. Canada. Types of compressors: reciprocating. • Reagan Power and Compression Inc. E-mail: (new systems) hpc@ howden. Okemah. Capacity range: 20 to 200 hp (15 to 149 kW). San Giovanni in Persiceto (BO). Texas. Capacity range: 50 to 10. Capacity range: 27 to 3220 hp (20 to 2400 kW). Poland. production manager.. Principal contact: Carsten Kollenbach. rotary. Rosario. Types of compressors: rotary screw. Capacity range: 67 to 4700 hp (50 to 3500 kW). Brazil. Capacity range: up to 400 hp (298 kW). Texas.000 hp (7456 kW).. corporate development. Saxonburg. Type of compressors: reciprocating. Pennsylvania.com. Remscheid. Type of compressors: reciprocating and rotary screw.S.000 hp (37 to 7456 kW). applications engineering. Principal contact: Scott DeBaldo. (service and parts) hpc. E-mail: thompson@speircompression. Canada. sales and marketing.348 hp (4950 to 30. Types of compressors: reciprocating. Email: sdebaldo@neuman-esser. • OTA Compression LLC. CTSSnet.A. vice president of sales and marketing.com.sable@kingslycompression. Capacity range: up to 10.ar.900 kW).A Inc. E-mail: donatello. z o. Durland. Orso. E-mail address: michaela. Types of compressors: reciprocating. Types of compressors: reciprocating.. rotary screw.bruce@sageenergy. • Howden Process Compressors. Houston.. • VPT Kompresssoren GmbH. Principal contact: Francis A.fonseca@ge. Airdrie. Capacity range: 50 to 400 hp (37 to 298 kW). Capacity range: up to 100 hp (75 kW). E-mail: matt@sertco. Tulsa. E-mail: abeni@jfsecco. screw and reciprocating. • Industrias Juan F. Principal contact: Maggie Seeliger.com. director of marketing. • Great Plains Gas Compression Inc.A. blowers. and electric. Principal contact: Matt Smith. E-mail: fnorthup@sec-ep. Principal contact: Matias Maggi.700 hp (500 to 8000 kW).com. vice president. Type of compressors: screw. Types of compressors: rotary screw and reciprocating. vice president. E-mail: jenkins@ngcsi. Principal contact: Sam Henry. Capacity range: 13. Types of compressors: reciprocating and rotary screw. • Speir Energy Solutions. Type of compressors: reciprocating. Elblag. Germany (rotating equipment). E-mail: samh@hpi1. CNG fueling stations.com. Capacity range: 50 to 7500 hp (37 to 5592 kW). sales. Cambridge. Capacity range: 7 to 5365 hp (5 to 4000 kW). • Propak Systems Ltd. Henderson. Italy. Principal contact: Augusto F. division manager. Capacity range: 70 to 7000 hp (50 to 5000 kW). compression and process division. rotary screw. Dallas. Gage-Tims. Type of compressors: screw. Principal contact: Frank Northup. Oil & Gas. rotary screw and reciprocating. • Siemens Sp. E-mail: jbarr@jwenergy. has skyrocketed since companies started drilling in earnest in the Marcellus Shale,” Dearing Wall said. The company received its first Marcellus Shale compressor order for 15 units in early 2009. That year, it built 64 units averaging 868 hp (647 kW), with 45% of them electric motor-driven. Seeing demand growing rapidly, Dearing nearly tripled its plant space with a 60,000 sq.ft. (5574 m2) addition that was completed in July 2010. This Waukesha P9390 and Ariel JGD/4 package was shipped in late 2013 to a Marcellus site in West Virginia. The engine was removed to reduce the shipment weight and height, which is a common requirement for large packages going to remote Appalachian Basin destinations. It provided 50,000 sq.ft. (4645 m2) of shop space and 10,000 sq.ft. (929 m2) of office and break area. The expansion quickly enabled more business as typical order sizes of four to six units were replaced with orders of eight to 15 units. In addition, there were more engine driven units, 69 and 79%, respectively, in 2010 and 2011, with average size growing to 1383 hp (1031 kW) in 2010 and 1530 hp (1141 kW) in 2011. In 2012, the company built 92 units averaging 1881 hp (1403 kW). Even though a number of large Caterpillar G3616 engine driven packages were built, electric motor-driven fuel gas boosters and gas plant residue compressors for the western Marcellus and Utica Shale resulted in a mix of 58% engine and 42% electric drive. “We continued to see more continued on page 34 COmPrESSOrtech2 n n This Ariel KBZ/6 reciprocating compressor package was installed at a Marcellus wet gas-processing facility near Washington, Pennsylvania, in 2010. The cryogenic gas processing residue compressor is driven by a 5000 hp (3729 kW), 900 rpm, 4160V GE VFD capable electric motor. MARCH 2014 33 n electric-driven units in 2013 for Utica Shale gas plants,” Rick Dearing said. Dearing’s primary market covers western Pennsylvania, West Virginia, Ohio, western New York, Virginia, Kentucky and Tennessee. “In 2012, we packaged units ranging from 40 to 5000 hp (30 to 3729 kW),” Dearing Wall said. “We don’t want to box ourselves out of any market. We want small units too. We build air skids, and we see growing markets in vapor recovery units (VRUs) and compressed natural gas (CNG) compressors.” With the acquisition of adjacent properties, the company now has 125,000 sq.ft. (11,613 m2) under roof on 16 acres (6.5 ha). Current capacity is 100 large units per year. Seeing more demand, the company is adding 20,000 sq.ft. (1858 m2) in 2014 to expand the parts warehouse and package pipe welding areas, moving them from the current fabrication plant to free more packaging space there. The facility has eight fabrication bays, although multiple small units can be built in a single bay. When the new MARCH 2014 addition is complete, fabrication capacity will grow to 12 large bays with 180 tons (163 tonnes) of crane capacity. The company has 190 employees. Other parts of the complex include an ASME coded pressure vessel shop, a hydrostatic test shop, a quality department and inspection area, a paint line for prepainting many items prior to assembly on the packages and a skid fabrication area. Some skids are subcontracted. Dearing offers packaged compressors for field gas gathering, gas processing plants, pipeline transmission, gas storage, VRU and CNG, including complete CNG stations with the dispensers and fuel management systems provided by a partner company. It also assembles air starting systems, including complete buildings, air drilling primary and booster compressor packages, and blower and vacuum packages for environmental services. In addition, the company provides pump packages for well servicing, salt water disposal and high pressure hydraulic applications. It delivered its first sour gas units last year. 34 This modular building, shown nearly complete at the Dearing plant in late 2013, contains a complete air system for a compressor installation. Included is a Gardner Denver rotary screw compressor, drier, controls, and all HVAC equipment and environmental controls. Dearing is a distributor for Ariel, LeROI and Gardner Denver compressors. The company has packaged other compressors when specified by the customer. An engineering team of 14 to 16 provides custom designs for many applications. Packages are completely designed on Autodesk Inventor 3-D CAD. The company’s factory-trained technicians provide assistance with installation, startup and training. “We have based our reputation on service, reliability, integrity and innovation, and we have responsibly served our industrial and energy customers with dependable equipment and systems for compressed air, gas, process gas and hydraulic applications,” Rick Dearing said. “We match quality compressors, drivers and other equipment with engineering, design expertise, installation experience and quality service.” CT2 COmPrESSOrtech2 BLUESTROKE COMPRESSOR SYSTEMS NEUMAN & ESSER USA.neuman-esser. Texas www. and we have local engineering.THINK GERMAN. Located in Katy. Inc. service and parts to deliver reliable. ACT LOCAL. That’s why for NEA it is mandatory to include motor electro-magnetic characteristics in drive drain simulations. VIBRATIONS TROUBLING THE NATURAL GAS MARKET? NEA UNDERSTANDS MOTOR DYNAMICS TO REDUCE DRIVE TRAIN VIBRATIONS Motor dynamics have a major impact on torsional vibrations especially on shaft torque and electric current pulsations. packaging.com Contact me for Latin and North America: Swamy Subramanyam Vice President of Technical Management and Procurement
[email protected] Direct Phone: +1 713-554-9636 NEA GROUP Headquarters in Germany . NEA compressors are made in Germany. vibration free solutions. one above and one below the single mode frequency.. Knop’s paper was examined.com) n Figure 1. as shown in Figure 2. British Columbia. with an additional spring and damper between the rotor and stator. kM ≥ kC. Edmonton. BiLL ECKeRt aND BRiaN HOWes Editor’s Note: This article is based on a paper given at GMRC’s Gas Machinery Conference in Albuquerque. If the rotor has a torsional vibration superimposed over the steady rotation. corner T he steady-state torque and power output of a polyphase induction motor are the result of electromagnetic fields that act across the air gap between stator and rotor. estimation of the resulting transient motor torques. 2013. Howes recognized the problem matching actual torsional natural frequencies with predicted TNFs. He has Bachelor of Science and Master of Science degrees in mechanical engineering from the University of Calgary. The additional spring and damper add a second vibrational mode. This difference could not be explained until Dr. Such unsteady em effects have nevertheless been extensively studied in the past by direct numerical integration of the differential equations representing stator and rotor currents and their mutually induced stator and rotor mag- Ed Hauptmann is director of engineering development for Lo-Rez Vibration Control Ltd. These additional electromagnetic (em) effects are not usually included in standard torsional vibration analyses. the same electromagnetic fields across the air gap can produce additional torques on the rotor. and dynamic effects such as limit cycles and drive instabilities (“negative” damping).com. As an example. Calgary. This is an idealized two-mass model of a motor-compressor drive. Canada. He has a Bachelor of Science and a PhD in mechanical engineering from the University of Alberta. The importance of em effects can be shown by first referring to simpler mass-elastic models.com. Past studies have typically included start-up of drive systems. Since coupling stiffness is often chosen to place the coupling mode frequency below the operating speed range (heavy line a in Figure 2). 36 COmPrESSOrtech2 MARCH 2014 . Contact him at: beckert@betamachinery. so that the system now has two natural frequencies. Eckert has extensive experience in finite element modeling of flexible rotors. The authors wish to thank Andrew Mancini for his help in rerunning past analyses and Fabian Claussen for translating several references from German to English.. Canada and a PhD in applied mechanics from the California institute of Technology. 6-9. Hauptmann has 35 years of experience as a torsional vibration consultant. the additional em spring could well raise the higher natural frequency into the operating range (the right-hand dashed lines b in Figure 2). and depending on the ratio of motor to compressor inertias. Contact him at: ed@lo-rez. Bill Eckert is principal engineer for Beta Machinery Analysis Ltd. As important as these past works are. Contact him at: (bhowes@betamachinery. Brian Howes is chief engineer for Beta Machinery. Vancouver. Figure 3 shows that for a coupling with stiffness lower than that of the em spring. New Mexico. Canada. He has a Bachelor of Science in mechanical engineering from the University of Alberta. as no analytical methods for estimating their magnitudes have been available to date.TECH Motor Dynamic Influence On Torsional Vibration method of estimating electromagnetic damping magAnalysis > A nitudes and their effect on torsional vibration response BY ED HaUptMaNN. netic fields. which act in the same way as a torsional spring or damper. Figure 1 shows an idealized two-mass torsional model of a compressor and motor rotor. the direct em effects on torsional vibration in a drive train have not been extensively explored. Oct. Alberta. with the addition of an em “spring” and “damper” acting between the rotor and stator. single frequency. For example. The numerical examples given by Knop (ratio of rotor to compressor inertias. Knop [1].indd 1 . analytical expressions continued on page 38 MARCH 2014 n Figure 3. JM / JC. Shown here are the torsional natural frequencies of a twomass model: curve (a). Figure 3 shows that the (upper) natural frequency in this case would be raised by about 6% above that without including the em effect. In the following we present a way to develop estimates of em spring and damping magnitudes.testo350. The effect of including an em spring in the two-mass model (neglecting damping.5 times higher than normally estimated. less than 1. the ratio of motor to compressor inertia is approximately 1. but are not as common in North American installations.8.com 37 COmPrESSOrtech2 1/22/2014 3:54:00 PM testo340-half-island. the upper natural frequency could be as much as 1. JM / JC. ratio of em stiffness to coupling stiffness. The Ultimate in Engine Tuning. with the higher natural frequency possibly raised into the system operating range. testo 340.0.n Figure 2.0) are found in many European compressormotor drivelines. curves (b) including em effects. Estimating electromagnetic spring and damping values In the earlier reference cited. kM / kC. and taking kM as constant) is demonstrated. and no em effect. 1200 rpm motor driving a fourthrow compressor through a steelspring coupling. and consider their effect on torsional vibration response for a range of typical North American motorcompressor installations. These unsteady em motor effects were described by Knop [1] in a 2012 EFRC presentation. suggested that by linearization of the differential equations for the stator and rotor currents. greater than 1. • • • • • Four-gas capability for complete analysis NO plus NO2 for fast lean-burn setup High range CO for rich-burn tuning Highest measurement ranges for NOx & CO Simple to use and built for the field O2 • CO • NO • NO2 (NOx) 800-227-0729 • www.85 and the ratio of em spring to coupling stiffness is approximately 0. Keep in mind that the above remarks are based on a simplified twomass model. with a constant value of em spring stiffness and no accounting of damping effects. for a 1200 hp (900 kW). TL = a motor circuit electrical constant with units of time. For torsional frequencies. Figure 4 shows estimates made using Equation 3 for two types of motors. 1250 hp (932 kW). TB = breakdown motor torque. 450 hp (340 kW).14 seconds for motors in the range of 670 to 2000 hp (500 to 1500 kW). 2. Case studies Equations 5 and 6 have been used to make estimates of kM and dM in order to find how important em effects may have been in past torsional vibration studies based on conventional mass-elastic models (Figure 5). COmPrESSOrtech2 . we have derived the following approximate equations for MSt and TL: with: TR = rated (full load) motor torque. which summarizes the results for three types of installations: 1. As a result. With the further substitution of: x = (vTL). then: TL ≈ (1/Ωs)[1/(2sR)]( TR / TB ) … Equation 3. and dM = kM / (v2TL) = kM (TL) / (x)2 … Equation 6. Knop [1] proposed that the em spring stiffness kM. mid-speed (720 rpm). however practical estimations of torsional response in a wide range of driveline installations might still be made. No further information was given in Equation 1 or regarding how the expressions MSt and TL could be evaluated. MSt = a motor circuit constant with dimensions of torque. Equations 1 and (2) become. This shows the estimated time constant TL for typical induction motors. but the time constant TL requires a further evaluation of Equation 3. soft (rubber) coupling. data taken from published information [4]. kM = (# stator poles)( TB )[ x2 / (1 + x2) ] … Equation 5. dM = (MSt /Ωs){1 / [1 + (vTL)2] } … Equation 2. The dashed line is for reference only. (1200 rpm). This would not allow study of certain dynamic aspects (limit cycles. the frequency effect on kM. “negative” damping). stiff coupling. and interested parties should contact the lead author for details. MARCH 2014 38 n Figure 4. where: v = frequency of the superimposed torsional vibration. the variable x2 = (vTL)2 in Equation 5 can vary from approximately 20 to 2000. for very soft couplings between large motor-compressor setups. and MSt /(ΩsTL) ≈ (# stator poles)(TB ) … Equation 4. can be significant and should not be neglected. mid-range power. sR = slip at rated load. TR and sR are either tabulated or readily available. (450 to 900 rpm). 5000 hp (3728 kW).07 to 0. and damping dM \ could be expressed as: kM = (MSt /Ωs){(v2TL) / [1 + (vTL)2] } … Equation 1. nor was further information made available to us. but the quantity [x2/(1+x2)] is always within a few percent of 1. with the addition of an em spring and damper acting on the rotor. This involves considerable algebraic manipulation not worthy of inclusion here. Drive B. shown in Equation 5.0 and in such cases can be neglected. However. To uncover the meaning and get estimates for the variables MSt and TL in Equations 1 and 2. high power. Drive A. The main motor torque characteristics TB. low power. and have also carried out a further linearization analysis of expressions for spring and damping effects used in their studies. Using Equations 3 and 4 in Equations 1 and 2 will allow ready estimations to be made of the em effect on torsional vibration in a range of drive installations. 3]. with time constants TL ranging from 0. A representative sample of these studies is shown in Table 1. [5].could be generated for em spring and damping values. Drive C. we have referred to the fundamental analysis and equations in Jordan et al [2. This is the conventional mass-elastic model used for the torsional vibration case studies in Table 1. v of interest from 10 to 60 Hz. Ωs = electrical supply frequency. steel spring coupling. n Figure 5. 3. 05 1.com www.8 0.HahnMfg.25 rad/s for drive A. The variable stiffness characteristics of rubber couplings are a particularly important influence on the wide range of frequency estimates for this type of system. USA 16329 Hermitage.92 651.507 0.ellwoodcrankshaftgroup. These results are also shown in Figure 6.40 0.15 1.086 15.86 times that without the em effects in the model. cylinders. MILLING.7 0.55 3.com 3.03 9.002 We Manufacture and Remanufacture the World’s Largest Crankshafts Ellwood Crankshaft Group Irvine.92 651.66 3. the coupling mode frequency can be as much as 90% higher. v0 – Hz Motor Rated Power (kW) Line Frequency (Hz) Number Of Poles Rated Torque.indd 1 Housings.07 0. TAPPING AND GRINDING ON FERROUS AND NON FERROUS MATERIAL UP TO 30. xE = (vETL)* xE2 / (1 + xE2) kM – kNm / rad dM – kNms / rad kM / kC 136 5.593 0. This is a summary of em effects on some previous torsional vibration studies.40 0.% Breakdown Torque. that is.Drive A Compressor Speed Range (rpm) Ariel JGC/6 450-900 Drive B Ariel JGK/4 1185-1192 SteelSpring Drive C Cameron MH64 716 Stiff: Disc pack Coupling Soft. n Table 1. kM >> kC.75 Reliance 900 60 6 7.80 1. For this case.com PRECISION BORING. connecting rods … Let our skilled craftsmen get to work for you! Visit our website at www.8 2.230 1. PA.036 72 4.210 0. em effects are relatively unimportant. rubber-in shear Cold Nominal Warm kC – kNm/rad 1st TNF.40 0. TB – Nm Time Const. the natural frequency was up to 1. TL – sec.117 77.991 98. PA.4 0. sR .86 10.8 2.93 Toshiba 3728 60 8 40. the torsional natural frequency was shifted enough to result in resonance at 1 x shaft speed at the lower end of the run speed range.92 651. where kM in the abscissa is calculated from Equation (5). vE = 94. Intermediate systems like B are modestly affected. kM << kC.04 124 14.56 8948 0. DRILLING.88 0. Table 2 shows a summary of the torsional natural frequencies compared to the orders of run speed. On the other hand for systems like A with soft couplings.98 WEG 336 60 10 4474 0.0058 1. continued on page 40 MARCH 2014 39 Hahn_AugSept. The effect is pronounced for higher power installations with ultrasoft rubber couplings.8 2. USA 16148 1-800-247-1326 or 724-347-0250
[email protected] 106 4. Certified Quality Management System ISO 9001:2008 COmPrESSOrtech2 8/19/13 10:01 AM . much as predicted by Knop [1].000 LBS.79 1.67 16.67 88.987 88.089 v / v0 * Main excitation harmonic assumed to be 1 x run speed. Results of em effects on natural frequency (coupling mode) — Table 1 indicates that for systems like C with stiff couplings.118 8.. As previously noted the largest shift in torsional natural frequency was for the Ariel JGC/6 with a very soft rubber coupling.03 4. TR – Nm Rated Slip.133 0.03 6. Compressor Vibratory Torque. the addition of the em stiffness and damping was insignificant for the design operating conditions. lbf-in.61 (Rigid Body Mode) 7. the predicted torques.71 51.00 0. The addition of the em stiffness results in the coupling mode being resonant at 1 x run speed. upper left. B. In this case.2 Upset Operating Conditions (Single Acting Cylinders) 512. Coupling Heat Load (HP) Motor Shaft Stress Design (Bagci) Factor n Figure 7. there is very little 1 x torque demand from the compressor due to the staging and double acting loading for the MARCH 2014 40 n Figure 8. with the power off.19 4. the authors are not aware of any actual cases where that has occurred. em effects are present.given design operating conditions.500 125. In this case. if single acting conditions are considered (possibly as a result of a cylinder valve failure). the coupling heat load is approaching the manufacturer’s limit during the upset conditions. including em effects. Proximity to the 45° dotted line indicates good agreement.04 (Coupling Mode) With em Stiffness 2. Open markers are for predicted TNF without em effects. The added em stiffness does have the potential to cause a resonant condition with resulting failures of driveline components during upset operating conditions.3 n Table 3.27 Orders Of Run Speed At 450 rpm 900 rpm Comparison with field data n Table 2. such sweeps produce significantly different results: during run-up. while during rundown (with power off). Design Operating Conditions No em Effect With em Effect No em Effect With em Effect 516. Field measurements of torsional resonance are made conveniently during start-up or shutdown sweeps of a system.730 28. Results of em effects on system stress and torque levels — For each of the previous design cases A. During run-up a TNF is indicated at 615 rpm.67 11. In many cases.300 77.900 516.17 0. versus predicted TNF. This is a summary of how em effects alter the predicted response of drive A (soft rubber coupling). although the system is now resonant with the coupling mode at run speed. lbf-in.50 0.720 27. COmPrESSOrtech2 .5 54.440 513. but important for upset conditions (particularly on the coupling vibratory torques and heat load). Coupling Vibratory Torque. The inertia ratio lines are taken from the two-mass model and are shown for reference only.35 1. A summary of em effects on the predicted torsional natural frequencies of drive A (soft rubber coupling) is given. Predicted Natural Frequencies (Hz) Without em Stiffness 4. design factors and heat loads for drive A (soft rubber coupling).090 0.77 0.51 (Coupling Mode) 0. C. This graph shows measured TNF during run-up (with em effects present). with em effects present. This difference is graphically illustrated in Figure 7. The representative em effects for the three different types of drives are described in Table 1. which shows rpm measured on a 1000 hp (746 kW) motor driving a four-throw compressor through a steel spring coupling. Table 3 shows a comparison of the predicted torques. At this point. they are not. n Figure 6. stress design factors and coupling heat loads did not change to any significant degree during design operating conditions.54 0.980 3.3 15. This is because. while during rundown the TNF is shown at approximately 500 rpm. lower right. However. This shows rpm versus time for a 1000 hp (746 kW) motor driving a four-throw compressor through a steel-spring coupling. the coupling vibratory torques and heat loads are predicted to be much higher when including em effects. . particularly during upset conditions. Systems with “very soft” couplings can be extremely sensitive to the em effect. Wiss. Müller. while “stiff” couplings are not significantly affected. 5. very soft couplings might have much greater frequency shifts and in those cases. technical catalog for IEC motors EN.. Seinsch. “About Electromagnetic and Mechanical Transient Processes with Three-Phase Drives” (translated from German).” Catalog D 84. [3] Jordan. Conclusions The electromagnetic stiffness and damping effects on torsional vibration can be estimated by Equations 5 and 6.. Figure 8 shows that the predicted and measured values fall close to the dotted 45° line. H. G. 2012. The authors plan to carry out such work. The solid symbols show measured versus predicted results when em effects are included in the analysis. “The Behavior of Three Phase Asynchronous Motors in Torsionally Elastic Drives” (translated.O. 3. H. Further field measurement of the coupling mode natural frequency for fixed speed induction motors is needed to confirm the validity of the approach used to develop Equations 5 and 6. calculate kM from Equation 5.We have compiled a few field measurements made during run-up (with em effects) and compared them with predictions made.. including em springs and dampers. 2. September 2011-3. Reasonable preliminary estimates of the importance of em effects in a particular system can be made by taking the following steps: 1. that is. “The importance of motor dynamics in reciprocating compressor drives. “Three-phase induction motors. in a full torsional analysis of the system. AEG-Telefunken 53. which will be reported in a future paper.. CT2 References [1] Knop. Such field work requires advanced measurement and data processing techniques. Seinsch. Düsseldorf.O. J.” EFRC. [5] ABB HV induction motors.1. [2] Jordan. 1980. [4] Siemens. H. Ber. J. # poles x breakdown torque/coupling stiffness. from German). This is a very conservative estimate. 1979. AEG-Telefunken 53. 3. . indicating good agreement. Wiss. Evaluate the abscissa in Figure 6. 2009. Steel spring couplings may have their coupling mode frequency shifted upward by 8 to 10%. Müller. Ber. The predictions agree reasonably well with field measurements in a few cases known to us. H. The omission of em effects is particularly significant with very soft couplings. Enter these values on Figure 6 to find how much the natural frequency might be affected. Combine the inertias on either side of the coupling to form a simple two-mass model and note the inertia ratio. The basic design of the FM 50 remains the same. The device provides a true mass flow calculation that corrects for temperature or pressure inconsistencies. while new small natural gas-fired turbines would need to meet a limit of 1100 lb. The 8 in. New coal-fired units would need to meet a limit of 1100 lb.000 hp (75 to 7457 kW). and a turndown ratio up to 20-1. (5 cm) inlet pipe rather than having to re-pipe the inlet and find a way to fit a larger meter in around existing equipment. is shown installed on a gas engine application. Modbus. or through the included 2.to medium-sized gas turbines. Ethernet. They are due by June 1. days or months. backlit display built into the body. as well as measurements either averaged or totalized over a period of hours. and operators would have the option to meet a tighter limit if they choose to average emissions over multiple years. The FM 50 comes with a heated. In such a case. a response time under 10 ms. (454 kg) of CO2 per MWh. (499 kg) of CO2 per MWh. new large natural gas-fired turbines would need to meet a limit of 1000 lb.3 cm) device can be dropped into a 2 in. the FM 50 is useful for applications where a compressor is using a bi-fuel gas substitution system. C ontinental Controls Corp. the company said. COmPrESSOrtech2 MARCH 2014 . CCC also calibrates the meter.S.14 bar). The venturi-based FM 50 provides near instant flow momentary measurements. Environmental Protection Agency standards issued last September to reduce carbon dioxide emissions from new and existing power plants. no matter the size engine or turbine it is installed on. According to the proposed rule. (499 kg) of CO2 per MWh. allowing the device to operate in extreme subzero temperatures. which was specifically designed for single engines. In addition to environmental com42 n The FM 50 flowmeter is designed to measure flow and fuel consumption for gas engine and turbines. the FM 50 provides measurements of the fuel flow and cost-saving estimates. the company said. resulting in an accuracy of 3% of reading or 0.6 GHz wireless radio. CT2 n The FM 50 flowmeter from Continental Controls Corp. The release of the CCC product follows proposed U. and the unit is sized to match the needs of a particular engine. which automatically makes adjustments to re-zero the transducers each time the meter is powered down. The agency is also developing standards to address carbon emissions from existing power plants. satellite or cellular modem. a flowmeter that can be sized to measure flow and fuel consumption for nearly any reciprocating gas engine or small. (CCC) has introduced the FM 50. works with engines and gas turbines from 100 to 10. Features of the flowmeter include a pressure drop of 2 psi (0.5% of full scale. (20. For a gas turbine with a low NOx combustor. Data can be stored locally on a USB portable drive or can be communicated via CAN J-1939. whichever is greater.Flowmeter Can Be Sized For Any Engine > New CCC tool will help operators comply with emissions rules pliance. The measurement tool. the FM 50 can measure the flow to each part of the combustor and provide that data to the turbine control system for determining efficiency. It offers limitless combinations of data acquisition channels for pressure. What’s more. vibration. 6320 analyzers and RECIP-TRAP�analyzers. it shares industry-leading Windrock MD software – giving you one.com www. familiar user interface for all your online and portable monitoring systems.cookcompression. online machine protection and condition monitoring that acquires and filters data just like proven Windrock portable analyzers.com +1 865-330-1 100
[email protected]: Windrock Platinum Online Monitoring System The ultimate platform to protect and assess the health of your reciprocating and rotating machinery Integrating the latest technology from Windrock OnGuard� .com See What’s Happening at Cook Now . temperature and proximity – plus ultrasonic. Windrock Platinum gives you best-in-class. Turning Data Into Performance New Windrock Platinum www. as well as smart features such as self-monitoring diagnostics and redundancy of critical components.windrock. You get real-time data and event playback. kbdelta. Quality COMPRESSOR VALVE PARTS Metallic Plates|Thermoplastics|Springs|Buttons|Poppets|Kits|Center Bolts|Pins|Lift Washers|O-Rings KB Delta Manufacturing Manufacturing and Delivering Excellence. . Discover the industry leader in aftermarket compressor valve parts.Begins on the inside. KB Delta makes no representation that the parts we manufacture are OEM parts.com 800-632-3994 Torrance. California USA KB Delta Inc. is an aftermarket supplier of compressor valve parts. • On-site manufacturing for fast turnaround • 95%+ orders ship the same day • OEM quality. OEM specifications are adhered to on all of the parts we manufacture. every time • Engineering support www. every part. however to our best knowledge. . 3 in. also to be considered in the case of oil-free compression is the suitability of the friction surface’s coating for dry-running operation with a broad spectrum of filled plastic materials. MARCH 2014 . about one-third of the me46 COmPrESSOrtech2 Norbert Feistel has a degree in mechanical engineering from the University of Karlsruhe and a doctorate from the University of Erlangen-Nuremberg. To mitigate this drawback. Germany. Corrosion resistance Coatings of the highest possible chemical resistance are used to avoid damage to the metallic friction surfaces inside the cylinder and the piston rod during compression of corrosive gases such as chlorine. gas mixtures and impurities. however. API 618 [1] recommends wear-reducing coatings for piston rods. too. High corrosion resistance and/or high wear resistance are required depending on the specific application. Bench tests with dry-running sealing systems have revealed notable changes in surface texture. To be taken into account furthermore is the large bandwidth of parameters influencing production of the desired coating quality. hard-metal coatings are being used increasingly for compression of corrosive media. coatings are now also being used increasingly in the absence of corrosive media to protect surfaces subjected to tribological loads. he joined the R&D group of Burckhardt Compression in Winterthur. the chemical resistances of the various coatings appear to be an important factor influencing the formation of transfer film. 2012. hydrogen sulfide.96 in. Finally. The maximum permissible layer thickness which already precludes individual coating processes or at least necessitates use of a special intermediate layer is of importance depending on whether a new coating or repair of a worn component is involved. the interactions taking place between the friction pair and ambient medium must be considered. Coatings requirements A sound knowledge of materials as well as detailed information regarding the load parameters involved are needed to determine the most appropriate combination of coating material and procedure for a given application. In the most common variant of friction-surface coating comprising tungsten carbide in a cobalt matrix. all coatings recommended for use in corrosive media achieved poorer wear rates compared to nitrided-steel piston rods. Especially with high-pressure loads. This paper was presented at a conference of the European Forum for Reciprocating Compressors on Sept. in Düsseldorf. or a presence of abrasive contaminations in the gas. despite high hardness values significantly in excess of 1000 HV. measures to protect the counter-body surfaces of the sealing and rider rings are becoming increasingly important. In addition to surface topography. 27-28. Especially in the case of dry-running reciprocating compressors. (1 m). are met through numerous combinations of coating materials and processes. In addition to ceramics. a use of piston and rider rings with abrasive fillers. the influences of different coatings on the processes involving dry-running friction contact are not clear. etc. In addition to the piston rod’s outer coating. regardless of the base material. Introduction The application of coatings to prevent damage during compression of corrosive gases has proven successful over many years.Friction-Surface Coatings In Dry Running Recips > An assessment of the benefits and risks BY NoRbeRt FeiSteL TECH corner D ue to increasing demands on the reliability of process gas compressors. hydrogen chloride. Due to ever-increasing demands on the reliability of process gas compressors. The coating’s surface texture. Especially ceramic coatings such as chromium (III) oxide (Cr2O3) have proven suitable for such applications for many years. the diameter of the cylinder to be coated on the inside can range from less than 1. In this regard. in particular. (50 mm) to more than 39. the base cobalt constitutes a weakness in terms of corrosion resistance. of importance to stable dry-running conditions. Today’s complex set of requirements concerning the use of coatings in process gas compressors and involving. typically accompanied by severe wear of the sealing elements after just 500 hours of testing in the case of some coatings. In 1988. a diversity of gases. also raises questions about optimal parameters and feasibility. A wear-resistant coating inside the cylinder might also become necessary in case of a high load exerted on the sealing system. or use of a dense. these WC/CoCr coatings quickly proved successful in many applications involving corrosive media. Though a hard metal comprising 88% WC and 12% Co has a hardness of just 1300 to 1400 HV. and is also used now as a friction-surface coating in compressors. thermal spray coatings always exhibit a porosity whose degree is influenced. which stipulate agreed limiting values for the layer’s composition. To prevent this kind of underlying corrosion. Thin layers deposited using the PVD or CVD process. porosity. The well-known titanium nitride layers are specified to have micro hardness values of over 2000 HV. tensile adhesive strength. for example. Through these pores and microcracks in the spray coating. this wear-resistant layer has performed well in the chemical and aerospace industries. hardness. and possessing a maximum thickness of only a few micrometers. In fact.COM · 713. however. the wear resistance limits MARCH 2014 of even high quality nitrided steel are rapidly exceeded [7]. The porosity ranges from 0. nickel-chromium-molybdenum alloys or chemically deposited nickel are employed as diffusion barriers. however. Coating quality Requirements for the quality of a friction-surface coating are described by coating specifications. corrosion-resistant intermediate layer between the base material and coating. The highest possible degree of hardness. if requirements for bonding strength are not met so that the layer fails by flaking during operation. etc. Even hard chrome coatings offer no protection here. for example. in particular. for example. by the type of process employed. thickness. The only remedy in this case is to use a coating with a significantly higher wear resistance. In the case of thermal spraying. some hard-metal coatings have proven themselves superbly during operation with the aforementioned alumina particles present in the gas flow.tallic cobalt matrix is replaced with chromium. Wear resistance Dry-running materials with abrasive fillers such as ceramics. theoretically offer a very good performance. corrosive media can penetrate as far as the substrate. If abrasive gas contaminations such as aluminum oxide are involved additionally. in which repeated spraying and annealing of a ceramic suspension followed by sealing also makes it possible to create a layer almost free of pores.5% in the case of very dense layers to more than 2%. is usually favored during selection of this kind of wearprotection coating. The extremely hard diamond-like carbon (DLC) coatings have significantly higher micro hardness values of 4000 to 6000 HV. Suitable especially for hightemperature applications. in particular. high hardness values alone are no guarantee of adequate protection for the base material. it is necessary to implement additional measures such as surface sealing. Our dual sampling system allows simultaneous testing.663. Intermediate layers comprising. glass or carbon fiber can already cause severe wear-related damage on counterbody surfaces made of cast iron. In addition to ceramic coatings with a high hardness of about 2000 HV. spray gun. the coating’s quality is also influenced to a large extent by the process. Our Team Commitment: Tuning Recommendations State of the Art Equipment Final Reports within 5 Business Days Emissions Management Program LEARN MORE HERE ENGINE TRYCECO. which saves you time and money.com COmPrESSOrtech2 . a coating’s properties depend on a variety of further parameters. Another very corrosion-resistant variant of a hard-metal coating is chromium carbide in a matrix of nickel and chromium. continued on page 48 47 TRUST OUR EXPERTS CECO’s stack emissions experts work with your mechanics to tune your engines on-site to comply with EPA and state requirements. fuel. In reciprocating compressors. Due to the nature of this process. Available finally as an alternative coating process is high-temperature CVD.1668 · emissions@ceconet. the heterogeneous structure of this sintered composite of hard carbides in a soft metal matrix has proven to be wearresistant even in the presence of very hard gas impurities. thermal aftertreatment by means of self-fluxing alloy powders. However. Ceramics and hard metals suitable for corrosion protection are usually applied through thermal coating. An optimal roughness range instead of an extremely smooth surface has proven successful during dry-running [7]. is required after the application of the coating. From a critical value onward. spray gun or powder particle size optimal for a piston rod’s outer coating. At present. the internal coating of a cylinder of a small diameter can no longer be applied using the process. significantly influencing friction and wear. carbon-based coatings exhibit significantly better values. the coater selects a powder of the most appropriate particle size. exhibits a very fine structure with carbide sizes ranging from just 4 to 5 µm [9]. Despite a constant powder composition. with carbide sizes ranging from 10 to 25 µm (Figure 1.application rate. To achieve reproducible coating qualities.. WC/Co coatings applied using a detonation process (bottom). adequate empirical data regarding tribochemical interaction with a variety of combinations of filled plastic materials and gases are not available for all coatings. The coating applied using a detonation process has a much coarser structure. Suitability for dry-running Practice has shown that cast iron or nitrided steel as the counter-body material in dry-running applications achieves a very good service life for the sealing and rider rings. Appropriate precise surface finishing by means of grinding. However. etc. it is therefore essential that all process parameters. such as silicon carbide. to insulators (e. and therefore do not advance the process of transfer film formation. bottom).g. lapping. such as hard chrome and composite materials made of nickel-phosphorus with embedded PTFE particles. Key requirements for friction-surface coatings intended for dry-running can generally be described as follows: •R esistance to local. as well as coatings with pronounced anti-adhesive properties. and using high-velocity oxygen fuel spraying (HVOF) [9]. The requirement to produce a functional friction pair from various available dry-running materials is therefore a key criterion that significantly restricts the choice of available coatings. high temperatures above 572°F (300°C) • Highest possible thermal conductivity • Favorable properties for formation of a stable transfer film • Favorable influence on tribochemical processes The thermal conductivity values of eligible friction-surface coatings might differ notably from those of conventional metallic counter-body materials. At least the same expectations are placed on friction-surface coatings. In dependence on these boundary conditions. as Figure 1 already shows in terms of the differences between the structures of two WC/Co coatings applied using different processes. and whether the resultant combinations have optimal effects. For instance. whereas a WC/Co coating of a nearly identical composition applied by high-velocity oxygen fuel spraying (HVOF). but instead can affect it negatively. for example. defined by means of a spraying instruction. it is necessary to note that they are not identical to the tribochemically modified transfer film formed during operation. for example.. Process-specific variations in the coating quality are not always avoidable in practice. the preparation of the substrate surface and the aftertreatment of the coating are MARCH 2014 . in addition to defining a coating specification [2. significant differences to conventional metallic counter-body materials can be expected. Friction-surface coatings in practice The aforementioned requirements for friction-surface coat48 COmPrESSOrtech2 n Figure 1. Especially in the case of ceramics with a low chemical activity. honing etc. Particularly with regard to coatings containing PTFE. any change to these parameters can significantly affect coating quality. it is unclear whether proven roughness values for metallic counter-body materials can be implemented for specific coatings. zirconia). Ceramics range from materials with excellent thermal conductivity. through formation of a protective layer on the sealing elements’ running surface [6]. 3]. Attention must also be drawn to the fact that tribochemical processes take place during dry frictional contact. and can thus have a positive effect. WC/Co coatings also have a very good thermal conductivity. Thus. the wear rate deteriorates continuously despite constant conditions for assembly and operation of the packings. which were still widespread until a few years ago. until premature failure of the fourth sealing system. However. An alternative process to thermal coating of cylinders with small diameters is the high temperature CVD method. coated piston rods are increasingly replacing nitrided piston rods. especially in terms of increased wear protection compared to uncoated friction surfaces. practical experiences with the performance of dry-running packings in practice have been mixed. their lower impact sensitivity compared to ceramics has a positive effect highly valued during everyday handling. especially in dry-running applications involving low loads. For instance.. Evidently. the application of friction-surface coatings in reciprocating compressors has increased significantly. In applications involving pressure differences in excess of about 290 psi (20 bar). n Figure 2.ings in dry-running reciprocating compressors are now met mainly by hardmetal and ceramic layers applied by a thermal spray process. achievable by plasma processes. very smooth surface areas. however. Despite the additional costs. smaller spray-gun dimensions here also make it possible to realize internal coatings of cylinders with a diameter of slightly less than 1. we can protect your critical downstream processes.. Parker Hannifin Corporation 500 S. Optimized multicomponent systems are also continually broadening the scope of applications for ceramic coatings. lowporosity layers. Each packing was operated on the same continued on page 50 J-Series • • • • • Robust Construction Up to 5000 psig Connections ranging from 1/4” to 2” Temperatures up to 350°F Flows up to 26. (50 mm). In addition. customers expect added value in the form of notably longer lifespans of the coated components. This method offers the greatest variation in terms of coating materials as well as layer properties and thicknesses. For example. Figure 2 shows the average wear rate of all sealing elements forming part of dry-running packings of a hydrogen compressor with a pressure difference of 783 psi (54 bar). Hard metals are handled differently than ceramics. the piston rod exhibiting conspicuous. However.parker. Others know they do! Some companies hope they have enough filtration for their compressors. thereby holding a lot of potential. especially for the repair of worn friction surfaces. When investing in such surface finishing. Operational experience with coatings has shown that demands placed on them. MI 48371 Finite Airtek Filtration Division 248-628-6400 www.96 in. Spraying of ceramic layers requires higher temperatures. Glaspie Street Oxford. packings occasionally had a very short service life.com/finitefilter MARCH 2014 49 COmPrESSOrtech2 . however. are usually fulfilled in a most excellent manner.000 SCFM at 5000 Together. hard metals are now favored increasingly as piston-rod coatings. hard-metal powders applied using the HVOF technique can be used to produce very dense. Average wear rates of four sets of packing rings for sealing a piston rod coated with hard metal. Figure 3 therefore only shows the temperature profile of the piston Detonation HVOF 1156 0.487 0.840 0.47 1279 0.933 0. In this case. A suction pressure of 232 psig (16 barg). For this purpose. Each test was to have a duration of 500 hours. Such steep rises in temperature to values above 212°F (100°C) were not observed in the other tests. though this was not possible with the WC/CoCr-coated piston rod.957 0.4 fps (3. The PTFE/PPS polymer blend selected for the packing rings and filled with graphite and carbon fiber [7] has proven to be nonabrasive in many applications. Finally. Here.rod with a hard metal coating. is clearly visible in comparison with the surface in its new state (Figure 4). (550 mm) long tail rod with a diameter of 1. chromium oxide. An arithmetical mean deviation of the profile Ra in the range from 0. for piston rods coated with WC/CoCr and WC/Co using the HVOF process. zirconium oxide and titanium oxide was included in the test series. to ensure clearly defined conditions during subjection of the piston rod to friction power.12 n Figure 3.793 0. n Table 1. (50 mm) was coated with the hard metal WC/Co using both the detonation as well as the HVOF process.477 32. A piston rod made of nitrided steel served as a reference for a metallic counter-body surface. Hardness and roughness values of the tested counterbody materials.430 31. The piston rod’s friction surface was polished smooth and glossy (Figure 4. Interactions Insights into the phenomena observed on coated piston rods in practice were to be provided by bench tests on a dry-running compressor.86 WC/ CoCr Ceramic Plasma 926 0. test had to be interrupted due to a sudden rise in the temperature of the sealing element’s chamber (Figure 3).237 1.667 0. and the test eventually had to be cancelled after 424 hours due to high leakage.18 m/s) were specified as the load parameters for the tests conducted with dry nitrogen.093 0. the roughness in the region of the sealing element’s friction surface had declined significantly.263 2.20 to 0. Used in each case was only one sealing element comprising PTFE/PPS polymer blend in a cooled packing.29 HVOF 1128 0. this MARCH 2014 50 COmPrESSOrtech2 .797 0. For comparison with the two chromiumfree coatings. final pressure of 580 psig (40 barg) and average piston velocity of 10.773 0.122 82. bottom). which was in excellent condition except for a low roughness along the packing rings’ friction path. the compressor’s 216 in. Counter-Body Material Coating Process Hardness HV0. There was another temperature rise later on.303 0. a quaternary ceramic consisting of aluminum oxide. the hard metal WC/CoCr containing chromium was applied to another piston rod.30 µm was specified for all surfaces (Table 1).401 46.3 Ra [µm] Rz (DIN) [µm] Rk [µm] Ratio Rk / Rz Rmr [%] Nitrided WC/Co WC/Co Steel 731 0. On the piston rod. the chamber temperatures remained stable in the range between 140° to 158°F (60° to 70°C) after running in.15 n Figure 4.372 53.96 in.280 2. after an operating period of 270 hours (center) and after 424 hours (edge length 300 x 225 µm).223 1. The removed sealing element had been thermally damaged by the excess temperature. Temperatures measured in the sealing element’s chamber.277 1. and therefore had to be replaced with a new one. also using the HVOF process. even in combination with cast iron of a low hardness. Friction surface of a piston rod coated with WC/CoCr in the new condition (top). Especially during the running-in period of a dry-running friction pair.com MARCH 2014 51 +1 740-326-1007 info@ucginc. On this coating. The two chromium-free. To learn more or to schedule a consultation. compared with the original finish in each case. Ignored in this case is the known fact that the arithmetical mean deviation of the profile Ra is totally unsuitable for characterizing surfaces. not your expectations. The wear rates of the sealing elements are also significantly lower than that of the nitrided steel surface. except the ceramic coating (Figure 5). Ra values measured on the friction surfaces of different counter-body materials. continued on page 52 Solutions Beyond Expectations UCG offers control system solutions with unparalleled quality. The lowest value was obtained in the test of the ceramic-coated piston rod. even on extremely hard counterbody materials. Comparing the thus obtained arithmetical mean deviation of the profile Ra to the values in the original state reveals a reduction in the case of all surfaces. Because these effects can vary highly along the friction surface. visit unitedcontrolsgroup. Influencing parameters Although a functional design of counter-body surfaces is of particular importance for the dry-running friction pair comprising soft and hard. although it turned out to have the highest hardness values (Table 1). Very good results were also obtained with the two chromiumfree. n Figure 5. Especially evident is the reduction in roughness on the WC/CoCr-coated piston rod. Lower your risk. Consequently. hard-metal variants. the surface of the hard counter-body material is usually described only by specifying a permissible range for the Ra value. zones exhibiting minimal roughness were sought and evaluated on the surfaces of all piston rods. Peaks and valleys are treated equally during determination of the Ra value. and revealing the greatest drop in the Ra value.rod coated with WC/Co (HVOF process) for the purpose of comparison. roughness measurements in this region usually provide results that fluctuate greatly. The arithmetical mean deviation of the profile is therefore only suitable as a quality control parameter if the character of the roughness is known. flexibility. as it does not permit any distinction between different profiles.com . surface topography is altered through breakage of roughness peaks. hard-metal coatings and even the nitrided steel exhibit a much smaller drop in Ra values. and support — providing you increased value and improved operational efficiency. The highest wear rate was established in the test of the WC/CoCr-coated piston rod involving high chamber temperatures at times. deposition of wear particles and reorganization of surfaces. A further result shown in Figure 6 comprises the wear rates of the sealing elements operated on the various surfaces under otherwise identical conditions. formation of the transfer film even led to a slight increase in the Ra value. the upper limit of the permissible Ra value is often exceeded by this kind of surface.25 in terms of this ratio have also proven successful in dry-running if their Ra value exceeds the permissible upper limit (Table 1). However. for example [8]. and only slightly higher than the n Figure 7. the material ratio was determined with a reference line c0 shifted by about 2% with respect to the highest peak at an profile section level of c1 = Rz/4. Several surface texture parameters permit a characterization of surfaces and therefore serve to supplement the results of an Ra measurement.e. This is achievable. it is not necessarily a drawback in the case of a plateau-like roughness profile. In each case. Wear rates of a single packing ring in dry nitrogen on various counter-body materials. A comparison between the Rmr values of the three hardmetal layers reveals that the material ratio of the WC/CoCrcoated piston rod is significantly lower than that of the two chromium-free variants.n Figure 6. surfaces achieving a value of less than or equal to 0. In practice. MARCH 2014 52 COmPrESSOrtech2 . While an inadmissibly large Ra value of a profile with a pronounced proportion of peaks leads to high abrasive wear on the soft dry-running sealing element. for example. A quick initial conclusion about the nature of the roughness profile can be drawn from the ratio between the core roughness depth Rk and the average roughness depth Rz (DIN) [8].. whether a fissured or plateau-like surface is involved. Conclusions about the characteristics of the various piston rod surfaces can also be drawn from the material ratio of the profile Rmr indicated in Table 1. i. Porous surface of a ceramic applied using a plasma process (bottom) compared to a nitrided steel surface (edge length 300 x 225 µm). the surface after comple- tion of processing might be characterized by a plateau-like roughness profile comprising a high proportion of valleys attributable to the pores (Figure 7). by means of the following parameters: • Ratio of core roughness depth Rk to average roughness depth Rz (DIN) • Ratio of average peak-to-valley height Rp to average roughness depth Rz (DIN) • Relative material ratio of the profile Rmr Especially in the case of the porous ceramic coatings applied using the plasma process. Different surfaces after processing of a WC/Co coating and a WC/CoCr coating (bottom) [9]. n Figure 8. thereby creating a surface with a dominant proportion of valleys. Plateau-like structures can be realized. An analysis of the test results obtained with the ceramic coating and the two chromium-free WC/Co coatings shows that plateau-like surfaces with the greatest possible material ratio offer favorable conditions for dryrunning. bottom).170 0. continued on page 54 53 COmPrESSOrtech2 . and is supplemented there by a chromium content of 4% by weight. Influence of coatings on the performance of dry-running sealing systems The single-ring test results conMARCH 2014 Counter-Body Material Coating Process Rmr.36 0. for example. and resulting in the observed coarse surface topography [9]. it drops to 10% by weight in the WC/CoCr-powder. The highest value of 82.227 0.89 0. The chromium content has a negative effect on the composite’s toughness. friction surface [µm] Nitrided Steel 33. roughness parameters as average from 6 measurements by profile method [4. but rather by the different composition of the matrix material and the resultant material properties. by levelling the roughened profile’s peaks using a suitable superfinishing process. Hardness as average from 10 measurements.58 0. the carbides present in the WC/ CoCr coating and sized about 3 µm were slightly smaller compared to the sizes of 4 to 5 µm in the chromiumfree coating.minimum value of 31.60 0.3% ascertained for the nitrided-steel piston rod. A comparison of the surface topographies of both layers applied by means of the HVOF process reveals that the piston rod coated with WC/ CoCr has a coarser structure (Figure 8. cerning the influence of various coatings’ surface texture on the performance of dry-running sealing sys- tems were studied in more detail in a hydrogen compressor.157 WC/Co WC/CoCr HVOF 64. 5]. original finish [µm] Ra. The differences in surface topographies observed after processing can therefore hardly be explained by their structure. original finish [%] Ra.1% was obtained with the ceramic coating.140 HVOF 40.237 0.077 n Table 2. Whereas the cobalt content of the chromium-free variant is 12% by weight. Roughness values of the counterbody materials tested in dry hydrogen.102 CrC/NiCr HVOF 43. apparently making it difficult to produce a surface profile with a high material ratio.220 0. as a result. Powder with a particle size of -45 +15 µm was employed for both hard-metal variants. Though the average wear rate of the sealing elements operated on this CrC/NiCr-coated piston rod is somewhat lower than the result obtained for the WC/CoCr coating. The quaternary ceramic that successfully passed the single-ring tests also has an excellent corrosion resistance. the average wear rate of the six packing rings was more than twice that of the chromium-free variant. Table 2 shows that this was achieved more successfully with the chromium-free coating. investigations carried out using energy dispersive X-ray analysis (EDX) and micro-probe analysis (WDX) revealed no differences. In addition. A conventionally finished piston rod made of nitrided steel again served as a reference for a metallic surface. (50 mm) were coated with both hard-metal variants with and without a chromium content using the HVOF process. Though the test in this case did not pose any problems. final pressure of 580 psig (40 barg) and average piston speed of 1.077 µm (Table 2). MARCH 2014 . In this series of tests. this coating was to subsequently prove its dry-running suitability under a significantly higher load comprising a suction pressure of 580 psig (40 barg) and a final pressure of 1450 psig (100 barg) in the hydrogen compressor’s second stage. Nor was there any change in the layer structure near the surface. Average wear rates of packings in dry hydrogen on various counter-body materials. is highly resistant to corrosion. Silver-colored layer on the friction surface of a dryrunning packing ring after operation on a CrC/NiCr-coated piston rod. This poor result was confirmed in a repeated test. conducted in the first stage of a horizontal compressor that was operated with dry hydrogen with dew point of about -85°F (-65°C). This loss of surface roughness was accompanied by formation of a striking.5 fps (3.41 m/s) were specified for the tests. An operating period of 500 hours was planned for each test. it is still significantly higher compared with the values obtained for the chromium-free hard-metal variant and the nitridedsteel piston rod. To counter the conspicuously high roughness loss on the WC/CoCr-coated piston rod. between the coatings’ used and original areas. Already during the test.15 to 0. such as a depletion of oxygen or chromium. the friction surface of the CrC/NiCr-coated piston rod exhibited a significant decrease in Ra value from 0. The test series was nonetheless supplemented by a further hard-metal coating that. like WC/CoCr. 54 COmPrESSOrtech2 n Figure 9. despite the higher material ratio Rmr.25 µm were selected for all surfaces. The sealing system employed here comprised a cooled packing with a total of 10 packing rings made of a PTFE/PPS polymer blend and optimized for this application. n Figure 10. However.237 to just 0. Accordingly.For this. but also the different compositions of the two hard-metal variants via tribochemical interactions between the friction pair and the ambient medium [9]. unfavorable operating characteristics were indicated by conspicuously high temperatures on the piston rod’s surface and at the outlet for leakage gas and cooling water. too. and higher by about one-third even compared to the result obtained for the nitrided-steel piston rod (Figure 9). The average wear rate of the sealing elements operated on the ceramic coating is more than twice the value obtained for a conventional piston rod made of nitrided steel (Figure 11). slightly lower Ra values in the range from 0. silver-colored layer on the sealing elements’ friction surfaces (Figure 10).96 in. and their surfaces furnished with highest possible material ratio Rmr in an additional superfinishing process. the WC/CoCr-coated piston rod’s behavior was conspicuous. the piston rods possessing a diameter of 1. The piston rod sealing system in each case comprised a cooled packing of six packing rings made of a PTFE/ PPS polymer blend. Due to the very good results obtained at a final pressure of 40 barg. A suction pressure of 203 psig (14 barg). laboratory analyses were conducted to reveal whether friction and wear are influenced not only by different surface topographies. Variable gas mix and EOS based thermodynamics . The tests showed that plateau-like surfaces with the highest possible material ratio Rmr offer favorable conditions for dry-running.Advanced compressor modeling . For example.compressormap.Advanced gas and compression thermodynamic based on EOS .com Tedom STACIO INZ EN 79x121 _25496.com. powdery particles on the ceramic coating’s surface. IPC. Cmap .Operative parameters continuous monitoring .Performance predictions under variable gas mixture and variable process conditions .tedomengines. hard-metal coatings with a pure cobalt matrix exhibited a considerably smaller decline in roughness than those with a matrix material containing chromium. +420 483 363 642 www.Auto-diagnostic: calculation of actual performance and efficiency comparison with design values adjusted to actual conditions. CBM gas and others
[email protected] µm in the region of the sealing element’s friction surface after only 500 hours.Expected performance in Real time .indd 1 COmPrESSOrtech2 3.At variance to the compact structure of the transfer film observed in all other tests. Biogas. Coating composition turns out to play an influential role here too. Differences in roughness loss indicate an influencing role played by the composition and structure of the hardmetal composite. Summary and conclusions Despite high hardness values significantly in excess of 1000 HV.indd 1 12/9/13 10:51 10:15 AM GAS ENGINES n Figure 11. LPG. These WC/Co coatings possessing a high material ratio continued on page 56 MARCH 2014 55 Reliable heart for your unit Power range: 80 .210 kW Fuels: NG.com Cmap is a software tool designed to perform easily and quickly centrifugal compressors performance evaluations. Another important factor influencing roughness loss is the counter-body surface’s topography. thereby confirming the observations made in practice. both tests here revealed a large amount of loose. Wellhead gas.Off design performance calculations .Advanced centrifugal compressor aero-mechanical modeling .Compressor performance analysis www. a generation of such surfaces with the highest possible material ratio Rmr being more successful in the case of WC/Co coatings than in the case of the two hardmetal variants WC/CoCr and CrC/NiCr. Average wear rates of two packings operated on a ceramic coating in comparison to a nitrided-steel piston rod. CENTRIFUGAL COMPRESSOR Performance Software CENTRIFUGAL COMPRESSOR On-line Monitoring System IPC Monitoring Systems embed all Cmap capabilities: .14 10:56 . the arithmetical mean deviation of the profile Ra of some hard-metal coatings dropped by more than 0. besides reducing roughness losses. This change in surface texture was typically accompanied by high wear rates on the packing rings. 27 in. Users can view the live feed of the scope through a flip-up LCD display screen. A quaternary ceramic tested as an alternative to hard-metal coatings.11 in. however.: Rauheitsmessung Beuth Verlag GmbH. N. medical grade camera MARCH 2014 56 technology. 20005.4 ft. p. and possessing a significantly higher material ratio Rmr yet due to its porous surface topography. (4 mm) scope. It has the same features as the original 0. including four-way joystick-controlled camera articulation. Berlin. U. In addition to surface topography. has released the VJ-Advance video borescope. R. B.rfsystemlab..Rmr also exhibited lower wear rates compared with the tests of a conventional piston rod made of nitrided steel. Large amounts of loose particles on the counter-body surface suggest that the corrosion-resistant ceramic coating adversely affects a formation of transfer film. fith EFRC-Conference. “Reciprocating Com- pressors for Petroleum. Prague. the ascertained wear rates were reproducibly worse compared to the result obtained for the nitrided-steel piston rod. (6. 51-62 [8] Volk. variations in chemical resistance among the coatings therefore also appear to be an important factor influencing wear characteristics. Berlin Wien Zürich.: Verschleißverhalten von Trockenlaufwerkstoffen für Abdichtelemente in Kolben-kompressoren Dissertation Universität Erlangen-Nürnberg. CLA) Rz (DIN) Average roughness depth Rk Core roughness depth Rp Average peak-to-valley height (Rpm) Rmr Relative material ratio of the profile c0 Reference level c1 Profile section level References [1] American Petroleum Institute. Definitionen und Kenngrößen der Oberflächen-beschaffenheit Beuth-Verlag GmbH. [2] DIN EN 15311 Thermisches Spritzen – Bauteile mit thermisch gespritzten Schichten – Technische Lieferbedingungen B euth-Verlag GmbH. all coatings recommended for use in corrosive media achieved poorer wear rates than a nitrided-steel piston rod. Berlin. despite higher values for the material ratio Rmr. Fifth Edition. The device can be used in any industrial application that requires a sub-0.” API Standard 618. 2005 [9] Kühnert. CT2 Notation PTFE Polytetrafluorethylene PPS Polyphenylensulfide CVD Chemical vapor deposition PVD Physical vapor deposition HVOF High velocity oxygen fuel DLC Diamond-like carbon Ra Arithmetical mean deviation of the profile (AA. and Gas Industry Services. Berlin. achieved the best test results with a final pressure of 580 psig (40 barg).C.com continued on page 72 COmPrESSOrtech2 . D. The 0.15 in. Czech Republic 2007. Juni 2007 [3] D IN EN 15648 Thermisches Spritzen – Bauteilbezogene Verfahrensprüfung Beuth-Verlag GmbH. a nondestructive testing technology provider. 1995 [7] “Dry-running sealing systems in practice — new challenges by new materials. After the load pressure was increased to 1450 psig (100 barg). Juli 2010 [6] Tomschi.8 mm) VJ-Advance is a diagnostic device for various applications including oil and gas and chemical processing. April 2009 [4] DIN EN ISO 3274 Geometrische Produktspezifikation – Oberflächenbeschaffenheit: Tastschnitt-verfahren – Nenneigenschaften von Tastschnittgeräten Beuth-Verlag GmbH. Especially with high-pressure loads. and trigger activated image capture.” Feistel. Chemical.9 mm) VJ-Advance. (2. Berlin. (5 m). www. Most of these scopes from RF System Lab are available in lengths up to 16. April 1998 [5] DIN EN ISO 4287 Geometrische Produktspezifikation – Oberflächenbeschaffenheit: Tastschnitt-verfahren – Benennungen.: Schichtbeurteilung von Kolbenstangen FEATURED PRODUCTS Video Borescope RF System Lab. December 2007. Washington. You’ll buy more because we deliver: Can do and Will do – since 1954.Harsco Air-X-Changers. you might buy your first cooler from us because of what we say – or because of what you’ve heard about us. Call 918-619-8000 (USA) today. Reliability. Service. Quality.™ .com Insight onsite. OK. Or visit harscoaxc. Performance. Using a fishbone analysis tool after this failure. First incident The subject was undergoing a four-hour mechanical run test as per end user approved and API 617-based procedure. super-duplex alloy material. The horn shape of the peak at critical speed suggests a possible rub as shown in Figure 1. Some end users insist that a partial vacuum be used to ensure that fluid medium does not influence the results. A recent issue changed this philosophy regarding running of a mechanical run test. During this test. All were found to be correct.3. another mechanical run test was conducted on rotor No. These included setup. it even reached 80 µm pk-pk (higher than the trip limit set). 2. (630 mm) for stages 4. Alarm and trip settings were correct to prevent incipient rub. During rundown. the test validates the critical speed calculations and amplitudes in steady state (four hours at maximum continuous speed) and transient conditions (while passing through critical speed). The common understanding was that mechanical run tests are to be conducted in partial vacuum by a leading OEM and some of the more capable end users. The machine in question is a single-shaft multistage centrifugal compressor handling hydrocarbon gas in a back-to-back design. vibration amplitude shot up from 7 to 40 µm at NDE side. 7th Edition. Some OEMs follow this procedure using a partial vacuum as a medium. Damage occurred in the impeller eye labyrinth area. when approaching maximum continuous speed. compressor speed is 10. This article investigates the issue in simple form and provides a means to mitigate the problem with technical backup. impeller expansion limited Run Tests > Heat by shifting molecular weight of compressed medium o validate the rotor dynamic design of centrifugal compressors. The agenda generally follows clause 4. This is the phase-amplitude plot during rub. Second Incident After the replacement and subsequent modification.2 in. It has three impellers at each section with a suction impeller of high-quality. the chemical and mechanical properties of the impellers. 2 and 3 and 24. It was decided to dismantle the bundle as telltale evidence of rub was shown in the form of a phase-amplitude Mantosh Bhattacharya is a rotating equipment technical specialist for Petrofac in the United Arab Emirates. Interstage labyrinths are stainless steel because of the presence of mercury and CO2 in the process gas.Solving Compressor Impeller Rub Problems During Mechanical dissipation improved. 5 and 6. mechanical run tests generally are conducted in OEM test facilities.1 of chapter 2 in API 617.800 rpm.6 of chapter 1 and clause 4. He has 22 years of experience with rotating equipment. (540 mm) for stages 1. The calculated efficiency was now just at the guaranteed point. continued on page 60 58 COmPRESSORtech2 MARCH 2014 . The gas handled is a hydrocarbon gas with molecular weight of 18. The intent of this test is to ascertain rotor stability without it being influenced by process gas. The OEM undertook the replacement of the subject impeller and in parallel increased the clearance between impeller eye and labyrinth by 100 µm to avoid rub. TECH corner BY Mantosh BhattachaRYa T plot taken during that period.8 in. it was shown that rotor-stator clearance was correct as per API 617 requirements. n Figure 2. In a nutshell. impeller diameters are 21.3. n Figure 1. post-weld heat treatment procedures of impellers and measured rotor and gas path radial and axial clearances. 2014.fwmurphy. Visit us at GCA • April 6-9.CO N O VAT I controller with The Centurion BY ENO NT Murphy’s Centurion™ configurable controller now with New and Improved MView display. crisp characters for increased readability • Vivid backlight and contrast adjustable for all conditions • Plug-and-play upgrade for existing Centurion systems The Centurion controller with the new MView display is just one more reason to standardize your control strategies with Murphy solutions. TX • Booth #320 For more about Murphy’s Centurion Configurable Controllers product line . RO LS BY NT ENO VAT I O N CO RO LS visit: www.com/ad/ezview Phone: 918-317-2611 1311383 1-2-14 MUR MUR PH PH Y Y MView display enhances the user experience! • More content on display reduces scrolling and searching for information • Sharp. Galveston. d0 is the original diameter and dt is the temperature differential. if the local temperature (at impeller area) goes up to B.1 x 10-6 mm/°C.A))x 13. RCV analysis and vibration amplification factor showed that even at trip level. the DE vibrations were higher than NDE side due to high centrifugal forces of comparatively high diameter impellers (540 mm/630 mm). It was observed in both cases of damage. An analysis of failures with observations that were probably overlooked by the OEM: 1. too. operating mode shape is a linear combination/ interpolation of the first and second critical speed mode shapes. Hence. air being at higher pressure than partial vacuum.Similar rub was observed at maximum continuous operating speed. For example.7 in. If the second critical speed was getting excited due to some unknown reason. 4. Air. Super duplex alloy material has a mean coefficient of thermal expansion a of 13. they tend to come closer. In reality. This shows the test medium and seal-gas path with windage location. Only an unexplained local heating and thermal expansion could have lessened the clearance and initiated rubbing. The test was aborted. This part is lightly loaded with respect to the drive end part.025 flow coefficient.027 in. as shown in Figure 3. The bearing pad temperatures record did not show any local heating (Morton Effect).) During the witnessed mechanical test. So. Local windage can cause high local heating. 0. Diametrical clearance between impeller neck and labyrinth were 0. This observation led to further calculation. still the impeller eye can rub with the labyrinth if the COmPRESSORtech2 . Both stages of super duplex alloy material impellers have the same diametrical clearances.00X m if measured in ambient temperature of A in °C. which is far less than the API 617 criteria of 25 µm.027 in. The OEM procedure was to use a partial vacuum media and lubricant media used for dry-gas seals was air. 19. 3. similar rub with a lower severity was observed. The final diameter after circumferential expansion may be calculated as: d1 = d0 (dt a + 1) = 0. the second stage suction impeller should have rubbed before the first stage suction impeller based on mode shape and their comparative amplifications. The ratio of clearance shown in the lateral critical speed analysis did not suggest any probability of rotor rub at the first critical speed. in °C due to windage and improper heat dissipation. it could easily ingress into the clearance between labyrinth and impeller eye and cause a windage effect. Consequently. which was confirmed in test run-up mode and orbit plots.1) + 1] = Z mm Where d1 is the final diameter after thermal expansion. Upon dismantling the rotor.X [(B . balance drum and coupling half. Y — DE side of compressor rotor. 0. most severe was the first stage. During the test. (It has three 630 mm diameter impellers. rotor rub occurred in the NDE side only. In a vacuum. if the shaft displacement reading at the probes is M microns. n Figure 3. (500 mm) diameter impeller. (700 µm) for all impellers. the rotor cannot rub on stationary close clearance parts. Second stage impeller — 630 mm diameter. Expansion was substantially higher for the first-stage impeller (higher flow coefficient) and was higher than that of the second-stage suction impeller (lower flow coefficient). The high flow coefficient clearly indicated that eye opening diameter was bigger in the first suction impeller than the second stage suction impeller. is a poor conductor of heat. It is known that 70% of seal air goes to the process stage based on differential pressure. Graph shows rotor mode shape X — NDE side.065 flow coefficient. This leads to thermal expansion of the impeller hub and labyrinth. (700 µm). MARCH 2014 60 n Figure 4. The geometrical differences between the first stage impeller and second stage suction impeller were: First stage impeller — 540 mm diameter. the initial outside diameter of the impeller eye is X mm = 0. heat dissipation is much less by convection. In spite of comparatively high vibration at the DE side. 2. 0. The attention shifted to close clearance labyrinth seals as the interstage HC seal was found new and intact. L is representative dimension of a conduit/pipe. Nu.5 psia (1 bara) and discharge pressure of 23. impeller diameter.2 psia (1. a complete set of four compressors were tested with the same modified procedure and tests were successful in all aspects to the satisfaction of the OEM and end user. the power and density ratio is in the very lower side. MW. Measured values were a very close match with FEA calculation results. and l is the thermal conductivity of the fluid.6 bara) was selected. suction pressure and flow is so low that it will not affect the rotor behavior. the OEM conducted an FEA of the first stage suction impeller using the mechanical properties measured in an experimental test. Hence it will not affect the rotor by aero cross coupling forces. is the dimensionless parameter for fluids characterizing convective heat transfer. There will be no shift in rotor critical speeds (minimum to maximum bearing stiffness). The rest of the parameters are based on rotor construction and fixtures. it was evident that localized heat generated must be removed. This was to be done by using a medium which does not influence the rotor behavior by damping and the intent of the mechanical run test is not compromised. Girtz is an innovator in the packaging of large industrial equipment. Hence a gas mixture of molecular weight in MRT — 8. To confirm that local heating and subsequent thermal expansion has an undesirable effect. CT2 A standard solution for your stationary packaging needs: GUARD ® Protect your investment with Girtz post and panel style of enclosure.8 was conducted. 3. Contact our sales team for more information on this or other custom turn-key solutions. Alford Forces are a function of power. clearance of labyrinth and kinematic viscosity and density of gas. Later. L / l. It was successful in all aspects. The gas mixture entrapped between labyrinth and impeller eye had a higher Nusselt number than air so heat generated due to windage dissipates faster.805 (80% He + 20% N2) with suction pressure of 14. Where a is convective heat transfer coefficient. minimum width of gas passage in bundle and rpm. This innovative enclosure style is designed with ‘use’ in mind. The Nusselt number. an internal test with 80% He and 20% N2 with molecular weight of 8. Force coefficients are a function of shaft diameter at labyrinth. which suggested that bore/eye radial deformation does not occur that might have led to impeller/labyrinth rub.indd 1 61 COmPRESSORtech2 2/19/14 9:29 AM . 2. MARCH 2014 Girtz. As mentioned in point 2. density ratio.shaft vibration amplitude plus thermal expansion is greater than “as built” clearance. The unit shown in only one example of our highly engineered products. We specialize in custom packaging of all major gensets and industrial equipment. This was done to evaluate the possibility of radial deformation at the impeller eye during full speed and over speed in a bunker. Solution/corrective action Based on the previous. a premium stationary power generation unit offering the perfect balance of technology. dependability and service in today’s power applications. width of labyrinth. Nusselt number is a measure of the ratio between heat transfer by convection (a) and heat transfer by conduction alone (l/L). There was almost no change in compressor loading from the previous test. Based on the above understanding. Regarding the rotor dynamic changes due to use of this gas mixture it was concluded that: 1. The gas mixture. It is defined as: Nu = a. The Covers 90% of Concerns method involves more calculations regarding unit performance and safety. transmission and gas-gathering applications. BY DWAYNe A. HicKmAN R eal-time modeling of performance and safety allows the PLC to predict healthy unit performance and to identify where it is safe to run that unit ahead of time.” This simple method typically does not preestimate interstage pressures before load steps are changed. this approach is not completely without some merit. He taught university math and computer science courses for 13 years and has been in the reciprocating compressor industry for the past 20 years. control panels could effectively ignore those issues and just concentrate on overload. or look ahead to determine if changing unit speed creates pin reversal issues. As such. Compressor station supervisors need to know which method is implemented in each control panel (UCP). Here. There are three general methods of modeling reciprocating compressor performance and safety prediction commonly used in unit control panels: Fast and Easy. thermodynamics are considered. This method is often implemented by System Integrators (SI) whose programmers curvefit a handful of calculated points. single-stage. While this seems like the obvious choice to implement. Furthermore. It is commonly implemented in UCPs for many slow-speed. gas boosting. and is the most frequently used method by experienced end users and their selected experienced SIs. withdrawal and even some process services. The real problems begin when this Fast and Easy method is applied to more generic units and/or wider operating ranges with the belief that this simple method is actually safe to use for all applications. as anything inferior to the OEM method could lead to compressor damage.Recip Compressor Performance. degrees of pin reversal and crank pin forces. and then apply a few generic rules (such as maximum pressure differentials and maximum compression ratios) to keep units running and “safe. For slow-speed units. Hickman is director of software development with ACI Services Inc. static (gas force) rod loads. Covers 90% of Concerns. how can one expect a low-level (and computationally slower) PLC to handle the complex mathematical methods that take even a high-end desktop PC a few seconds to compute? Fortunately. Unfortunately. a higher level of modeling complexity may come with a premium price. better understood and are based on actual modeling equations that calculate performance in real time versus a static curvefit approach. the second is desired. One approach is via unit-specific continued on page 64 COmPRESSORtech2 MARCH 2014 62 . The calculations and methods for determining safe operating limits are more robust. the industry does offer a couple approaches to satisfy these concerns. legacy compressor manufacturers typically reviewed the operating ranges (often indicated on unit’s nameplating) for complex issues like internal rod loads. The OEM-based method covers unit performance and safety according to all OEM limits and methods. and Covers Everything according to the Compressor Manufacturer (OEM).com) under Featured Articles. transmission.compressortech2. Safety Predictions for Control Panels > Real-time monitoring is often not enough Editor’s Note: This was derived from a paper published on the COMPRESSORtech2 website (www. Dwayne A. The problem with this method begins when it is applied to high-speed units under the belief that a slowspeed method is generically valid for high-speed units. pin loading forces. low volumetric efficiencies and high discharge temperatures. it’s not. injection. interstage pressures are reasonably predicted rod loads are better predicted. how does one model unit performance and safety for each OEM’s line of compressors if that knowledge is not readily available? And. and the ability to model both double-acting and single-acting compressor modes is standard. This approach works well for gas gathering. Many compressor stations have UCPs based on the Fast and Easy method. Real-time monitoring reviews unit performance based on actual unit operations (healthy or damaged) but generally provides no insight of what actions as safe to take — other than announcing alarms and shutdowns. It’s not. high pressures. The first is required action. For simple. doubleacting units that operate over narrow ranges without having too much cylinder clearance applied. aavolyn. engineered materials. AAVOLYN TY 480 PRESSURE BALANCED PISTON RINGS Engineered piston ring installations for all types of gas services. 207 Bogden Blvd. Used throughout the compressor industry for high pressure and wear applications where no other packing ring can perform satisfactorily. pressures and operating conditions. NJ 08332 Ph: 856-327-8040 • Fax: 856-327-9595 www. PACKING CASES For all gas services and pressures – designed to maximize sealing performance using highest quality materials and manufacturing features.Parts that perform beyond manufacturer’s specifications State-of-the Art Sealing Solutions Aavolyn provides innovative design engineering and advanced.com . including: REPLACEMENT PACKING RING KITS Available for all standard field gas compressor models. TYPE 260 PBU PACKING ASSEMBLES The original pressure balanced packing ring design. Millville. suction gas temperatures vs. end clearance settings vs. That is. Areas that lead continued on page 66 MARCH 2014 64 COmPRESSORtech2 . when in fact. all combinations of pressures vs. Another approach is via use of an add-on micro-controller that computes complex performance in real time using the actual OEMspecified equations and methods. to shut down the driver if serious issues are identified. high-power reciprocating engines and motors usually include an OEM designed. and gas thermodynamics. Consequentially. it is quite possible for two complimentary and interactive control panels (one for the driver and one for the compressor) to coexist with the UCP. Its warranty is based on its modeling methods. For some situations (e. performance prediction. This OEM control panel maximizes the driver’s ability while also maintaining proper safety based on current operating conditions — and it can also act independent of the UCP. The UCP calculations indicate that certain areas in the operating map are safe. The equivalent of a driver OEM control panel does not readily exist for reciprocating compressors. speed vs. With today’s open distributed control architectures. Since two very expensive pieces of equipment must be coupled together (a driver with a compressor) along with other numerous auxiliary items. This is likely the common case for many current PLC implementations of compressor performance and safety in UCPs — limiting the available operating map on one hand and unknowingly exposing the unit to cumulative and potentially catastrophic damage on the other hand. warranty and optimization. • The results allow the unit to operate in unsafe areas. suction pressure regulators and recycle valves. OEM-X does not warranty its units based on OEM-Y’s method of modeling mechanical issues like rod loads. • The results are conservative in some areas of the operating map while allowing unsafe operations in other areas. control concepts necessary for a wide variety of reciprocating compressor applications makes it difficult for a single set of control logic to address all situations. low suction pressures. Nevertheless. This leaves control. the calculations prevent the unit from running in areas that it could safely operate. since operators can still manually adjust manual variable volume clearance pockets (VVCP) to set head end clearances. if the wrong OEM method is applied. ends deactivated must be reviewed beforehand. are automated and thus controllable by a control panel. the packager or a thirdparty automation company. the potential outcomes are: • The results closely match the OEM’s results. add/ remove valve spacers or pull valves to deactivate ends. However. according to the OEM. and crank pin forces (as specified by OEM). gas gathering) only a few system elements. This means that the unit is likely not always optimized and thus not delivering maximum flows and revenues. This chart shows safety based on rod loads determined by dynamic internal gas pressures and inertia. crank pin forces.g. Some standardized UCPs are encoded with generic control logic for these three basic devices. such as speed governors. This is required to make sure that running the unit in one of the potential hardware configurations cannot lead to mechanical failure.. developed and approved control panel with the purchase of the driver. This type of solution works well when the only issues of concern are overload. Today’s modern. two or all three types of devices to keep the unit running within the end user’s requirements. safety prediction and dynamic compressor reconfiguration left to the end user. • The results create a conservative operating map. Good luck. Using the correct OEM methods for performance and safety is important for safety.n Figure 1A. PLC algorithms based on OEM performance and safety limits programmed directly into the UCP. allowing the UCP to adjust one. operating the unit in those areas results in specific safety limits being exceeded — the worstcase scenario for safety. this is a very reliable approach. high discharge pressures and maintaining desired flow rates. head to Las Vegas and buy a lottery ticket — but even a broken clock has the correct time twice each day. if necessary. ” 210 E.m. April 14 • Exhibitor setup—8 a.62 nd Annual Gas Compressor Institute Seward County Event Center 810 Stadium Rd. The Gas Compressor Institute has provided unique educational opportunities for the petroleum and natural gas industry. • Welcome Reception—6–8 p.m.m.–2 p.–4 p. call 620-417-1170.gascompressor. • See the latest equipment and services in the extensive exhibit hall with over 100 exhibitors.–12:30 p.m.m. • Compressor Packing/Seals • High Speed Round Table .Engines/Emissions 101 Sponsored by: Petroleum Industry Education . Wednesday. KS For 62 years.m. • • • • • • • • Alignment Gas Lift High Speed Round Table—Engines/Emissions 101 Kansas/Oklahoma Air Regulation Kansas Updates Screw Compressor Maintenance Vapor Flash Recovery Social Networking Reception—4:30–6 p. 2014 Seward County Event Center u 810 Stadium Road u Liberal.edu or visit www.m.info. • Share practical information and experiences with specialists and colleagues. Liberal. • Test your golf skills at the 11th Annual Breeze Masters Scramble Golf Tournament. Hugoton.m.–6 p. April 16—7 a. Register NOW at only $79 ($89 after April 4) For more information or registration.m.m. Great Plains Gas Compression “Crawfish Boil. exhibitor and sponsorship opportunities. • 11th Annual Breeze Masters Scramble Tee times—10 a. Schedule of Events Monday. email b&i@sccc. 2014 Why Attend? • Attend cutting-edge technical programs designed expressly for field-level employees. KS—sponsored by Great Plains Gas Compression APRIL 14-16. 1st St. KS APRIL 14-16. April 17—7:30 a. Tuesday.. or work with an OEM-approved. Consider a typical two-stage. 800 to 1100 psig (5516 to 7584 kPag) discharge pressure. then damage can occur. or the compressor OEM? It is not in the best interest for any MARCH 2014 party associated with the design. rods. high-speed unit running from 50 to 150 psig (345 to 1035 kPag) suction pressure. installation and operation of the compressor to have that unit fail. an SI must: go to the OEM for guidance. compressor performance expert.4° to 32. Unless the UCP has been reviewed for all possible combinations before it was allowed to control the unit. 1100 to 1500 rpm. Many OEMs have openly released sanitized versions of their modeling equations. loss of station operations and even injury or loss of life. However. to violations of the OEM’s safety limits must then be “locked out” from allowable operations.n Figure 1B. Reciprocating compressors often run under conditions of high stress on the components.This is a good start. but SI programmers still do not have all of the data and methods to be 100% compliant with that OEM’s safety requirements. While OEM manuals provide a lot of useful information in regards to lubrication rates. 66 safely operate it and properly shut down the compressor according to the OEM’s specifications. the station and personnel. an explosion. Most compressor OEMs provide high-end. degrees of pin reversal. suction gas temperatures ranging from 40° to 90°F (4. all mechanical systems have limits.2°C). pin loading forces. Thus. especially the operators. pistons or even crankshafts? And if those fail. That is not a good situation for anyone.. Windows-based performance modeling software for determining if a specific condition is safe or not. Typical critical methods not released by OEMs are equations or methods related to: thermodynamics. who would accept responsibility: the end user for not requiring the prechecks across their entire operating range. the packager for not requiring the checks from the UCP provider. Specifications are given for three-stage compressor tested. then there exists the possibility of a fire. the unit may fail later even when it is running within OEM specifications — effectively making the unit’s safety unpredictable. End users and packagers certainly expect that any installed UCP would act to protect the compressor unit. expected interstage pressures. OEMs build robust hardware to meet the challenges of end user applications. warmup time periods. acquiring actual OEM equations and methods is not so straightforward. SI programmers are being asked to fully incorporate OEM safety limits for each OEM based on that OEM’s developed methods to determine unit safety. VVCPs on both stages and a need to pull suction valves from the first stage’s head end at times. ask the end user what methods they want to implement. Nevertheless. they do not generally provide all of the actual equations and modeling methods for others to duplicate the OEM’s calculations and methods. And if such failures were to occur. Consequently. continued on page 68 COmPRESSORtech2 . twothrow. But if the unit is operated in conditions that exceed allowed limits. actuate unloading hardware or change speed in such a manner that the mechanical forces acting on rods and pins exceeded allowed OEM limits — damaging or potentially destroying the compressor. dynamic cylinder end internal pressures and internal gas force plus inertia rod loads. Therefore. the control panel provider. A review should be made that covers approximately 2 to 16 million distinct operating points before any UCP is allowed to arbitrarily adjust speed or suction pressure. and not arbitrarily adjust control valves. Continued running of the unit under excessive forces weakens the components. etc. However. SIs want their installed UCP to be able to properly start up the unit. OEMs design their units to handle those high stresses. how can one be confident that there are no areas where the panel may turn down the driver speed in an effort to control low suction pressure only to put the unit in pin nonreversal conditions that burn up bushings and possibly destroy crossheads. end users and packagers must make sure that their expectations are clearly specified in UCP requests (via in-house or third party): provided UCPs must protect the unit according to all of the OEM’s specifications for safe operations. org to register today! GSRMS/LSU Continuing Education Attn: Lisa Graves 1225 Pleasant Hall | Baton Rouge. Hytorc. RuhRPumpen. The GSRMS Symposium provides education and training to improve the compression and rotating machinery industry though workshops. Ariel Corp. Who should attend: Rotating and static equipment engineers Maintenance managers. Sinor Engine. coordinators and planners Engineering managers Equipment operators Technical specialists Reciprocating machinery analysts View the full agenda at gsrms. Learn.org Follow us on Twitter @GSRMS2014 Visit www.. Inc.gsrms. & Bi-fuel Engines Generation Control Systems Diagnostics & Reliability Emissions Alignment Compressor Auxiliary Equipment & Components Course presenters include representatives from the industry’s leading companies. Solar Turbine. Conoco Phillips.lsu. John H.—Crowne Plaza Executive Center Experience. M&J Valve. Ludeca. Hands-on technical course training and tutorials covering topics. Gas. FW Murphy.Gulf South Rotating Machinery Symposium April 28 – May 1. and Total Specialties.. LA. CPI. Grow. including Southwest Research Institute. LA 70803 225-578-4853 Sponsorships available! Contact gsrms@outreach. . Carter. Cameron Compression Systems. Inc. 2014 Baton Rouge. Simmons Plating & Grinding. including: SEMS (Safety Environmental Management Systems) Turbo Machinery Reciprocating Engines & Compressors Cranes Pumps Centrifugal Compressors Diesel. Governor Control Systems.edu for information. hands-on technical courses and tutorials. OEMs also need to protect their proprietary methods (developed via costly R&D) that may give them certain advantages over their competitors in select areas (e. the unit can fail due to crank pin forces being exceeded at various speeds for various load steps.n Figure 2A.. works better with slow-speed units (less than 500 rpm) as end users have had many years of experience with slow-speed units to develop and perfect how they want those units modeled. and they know how to predict interstage pressures and safety issues for all hardware unloading configurations (load steps) before any physical hardware is changed. A compression expert will know the calculation differences between the various OEMs’ rod load and pin load calculation methods.g. some items. and all suction gas temperatures. inappropriate rod load methods). They can review thousands to millions of operating points so as to prereview where the compressor may experience problems. This table shows safety based on rod loads based on static gas pressures (using old. Green area represents all load steps predicted to be safe at all speeds. consulting with compressor experts. as the OEM knows more about its equipment and safety limits than anyone else. process markets). This table shows safety based on rod loads based on static gas pressures (using old. Furthermore. asking the end user for guidance. The second option. inappropriate rod load methods). the majority of the “predicted safe” area is not always safe. end-user performance gurus have retired. The third option. In this case. As such. But even reapplication of slow-speed units to different operating ranges from which they were originally applied causes concern. asking for OEM guidance can be awkward since while OEMs want end users to control their compressors safely. MARCH 2014 68 The first option makes the most sense. and the OEM may not even have access to the complex source code for those routines to provide the automation programmers. many of the slow-speed. is what most end users are opting for in today’s highspeed compressor era. end users often direct packagers and/or automation specialists to consult with specific experts to create appropriate models for the UCP. They can calculate valve losses similar to each OEM’s method. such as gas thermodynamic routines used in OEM software. However. cannot run efficiently on PLCs. The end-all expert for a compressor’s performance and safety is the COmPRESSORtech2 . Also. When overlaid on actual OEM’s safety map. n Figure 2B. leaving a void in many end users’ knowledgebase of compressor performance and safety prediction. Why? To keep the modeling equations as simple as possible. As expected. That is. a growing number of current OEMs (Cameron/ Ajax. UCP logic should not be equations and safety check methods confused with compressor performance so that the micro-controller add-on provides similar results when calculatcontinued on page 70 Water Contamination Reliable_Layout 1 1/21/2014 4:09 PM Page 1 Water contamination levels of over 500 ppm Synthetic Lubricants Water Contamination? RELIABLE in your compressor’s lubricant can cause the the bearing life.OEM of that compressor. any selected compressor expert should have an excellent working relationship with the compressor OEMs.. the methods for predicting forces and stresses. UCP to best meet the needs of the Most other major high-speed OEMs station can lead to optimal use of the have provided many of their modeling equipment. the OEMs can work with a few trusted companies with whom they maintain secrecy agreements. at least that’s the way it has been up until about 2012. The main drawback is that this approach can potentially reduce the size of the allowed safe operating map.749. LeROI Gas Compressors and Arrow Engine) have incorporated their full set MARCH 2014 ing performance and safety limits for of compressor performance and safety those OEMs. This approach works well for many PLC programmers as it reduces the number of calculations needed to model the unit. That is.. forming free water. and the modeling equations used. often the worst cases are considered when creating the array of constraint equations needed to keep the unit safe. and all methods for calculating those limits. now achieve the exact same perforHaving an approved third-party SI mance and safety checks that those handle the controls of the compressor OEMs’ Windows-based performance makes sense. These select companies can then employ the correct methods and limits and develop simplified equations and methods for the PLC programmers on a per-job basis. Well. Thus. yet without disclosing proprietary OEM methods. Customizing the actual modeling software packages provide. However. Thus. the UCP limits into an actual micro-controller add-on also provides methods for a add-on for UCPs. In regards to performance and safety modeling. Summit’s PGS Series gas formation of free water in your oil and shorten compressor lubricants have the ability to hold up to 20. GE Oil & Gas.5823 www. they cannot reasonably expect anyone to be able to model and safely control their compressors without full disclosure of all limits involved in protecting the unit. Overly conservative constraint equations can effectively reduce the allowed operating map. as the OEM determines the limits. Save the bearings in your lubricants for the compression of hydrocarbon.000 ppm of water in solution without compressor by using Summit PGS Series CO2 and H2 gases. where does the compressor OEM’s responsibility begin and end? In short. the UCP can host of legacy OEMs.klsummit. the prospective operating map where the compressor can safely run may be reduced by 5 to 50%. we can help! Summit Industrial Products 800. Now. these disclosures do not necessarily have to be made public thus revealing proprietary information. Call us for Free Technical Support.com 69 COmPRESSORtech2 . providing the desired safety for that specific unit. Knox Western. and hence the operational flexibility often needed by the end user to fully achieve its goals. in favor of simpler modeling equations and limiting constraint equations. COmPRESSORtech2 . does the compressor need to be shut down for any safety reasons? SIs of reciprocating compressors are challenged to design.and highpressure limits. that issues would be caught by those sensors — a bad and potentially dangerous assumption. n Figure 3B. and all suction gas temperatures. safely operating them across a defined operating map. the unit can fail due to crank pin forces being exceeded at various speeds for various load steps.n Figure 3A. Very few reciprocating compressors actually have real-time internal pressure sensors. These are useful for checking against low. actuation of unloading hardware and control of recycle valves. When overlaid on actual OEM’s safety map. MARCH 2014 70 and safety. The latter is a basic necessity for the former. packing and rings will fail. which is inappropriate since the calculation method is not appropriate for the limits used). temperature and vibration sensors installed throughout the system. 400°. Often. what hardware configurations would be safe? And for the ones that are safe. and properly shutting them down. Eventually. but only if the discharge valves open and release the hot gas. code and test the control logic for properly starting compressors. Part of most control logic involves adjustments to operating speed. In this case. adjustments to suction pressure regulators. 500°F (175°/204°/260°C) and hotter. micro-controller add-on provides answers to the UCP questions: If the compressor were to run under the proposed operating conditions. valves. The green area represents all load steps predicted to be safe at all speeds. Discharge temperature sensors can catch high discharge temperatures. the majority of the “predicted safe” area is not always safe. which is inappropriate since the calculation method is not appropriate for the limits used). SIs and end users assume that because there is a plethora of pressure. This table shows safety based on rod loads based on adjusted static gas pressures (using another OEM’s method. As such. Standard pressure sensors only measure the suction and discharge pressures nearby the cylinder flanges. UCP logic deals with “what do I want to achieve?” and “what sequence of events. This table shows safety based on rod loads based on adjusted static gas pressures (using another OEM’s method. actions and time delays are required to try to achieve those goals?” Calculating compressor performance and safety predictions by a real-time. internal temperatures can climb to 350°. but not directly useful for OEM models that base rod loads on dynamic internal pressures. how much load is required? How much flow is predicted? How efficient is the unit at those conditions? And. Deactivated ends and ends operating in very low suction volumetric efficiencies do not lead to hot gases exiting out the discharge valves. The key issues noted on the graphic are: C: Crank Pin Forces Exceeded.5 million distinct operating points using the OEM’s exact methods for calculating safety issues. Yellow areas reflect where some combinations of load step and speed can be used to safely operate the unit while other com- binations remain unsafe. The Safe Operating Map is generated after reviewing over 8. The blue boundary line helps to highlight where the alternate-OEM method would indicate to the end user and the UCP that the unit is safe even though the unit may very well be under excessive stresses. areas marked as rod load concern (R) are quite different than those indicated in Figure 1A. the unit is safe. crosshead and even crankshaft. R: Rod Load Forces Exceeded. end users held high hopes that UCPs could keep their units safe. generic method would indicate to the end user and the UCP that the unit is safe even though the unit may very well be under excessive stresses. Since the earliest control panels. but knew. and O: Unit is Overloaded. Again. Figure 1A shows the Safe Operating Map of an OEM’s three-stage compressor (see specifications in Figure 1B) across a suction pressure range of 0 to 100 psig (0 to 690 kPag). Thus. but this time it is being modeled by a different OEM’s equations and safety limits. or in older compression theory textbooks. And. notice that Figure 3A shows no areas of excessive crank pin forces. Figure 3A shows the same compressor. The blue boundary line helps to highlight where the non-OEM. for some combinations of load step and speed. due to limitations in computing power. a discharge pressure range of 100 to 1000 psig (690 to 6895 kPag). but this time it is being modeled by standard compressor performance and safety calculations one would find by searching the Internet. six load steps and suction temperatures for the three stages varying from 100 to 140°F (38° to 60°C). That is. Notice that Figure 2A shows no areas of excessive crank pin forces. and excessive rod loads can damage the piston. Excessive crank pin forces can damage the crankshaft. a speed range of 700 to 1000 rpm. Red areas are where the unit cannot safely operate regardless of what load step is used and regardless of what speed the unit is running. Figure 2A shows the same compressor. Figure 2B overlays Figure 2A over Figure 1A with some translucency. Either one can lead to catastrophic damage to the unit. And. while for other combinations of load step and speed the unit is unsafe. areas marked as rod load concern (R) are quite different than those indicated in Figure 1A. Green areas reflect when all load steps are safe at all speeds. a few sensors cannot make up for not implementing the correct performance and safety models in the PLC — any expectation otherwise can be a dangerous choice. Figure 3B overlays Figure 3A over Figure 1A with some translucency. that some safety items were not being continued on page 72 . rod. U: Gas is Throttling through one of the stages.leading to consequential and potentially catastrophic damage. The tab@lign app runs on Apple and Android mobile devices. trend the data. Unknowingly operating them in unsafe areas also is unacceptable.e-inst. more shutdowns. the company said. The device can be configured with low-range NOx sensors with 0. handheld fiber optic temperature measurement system.ludeca. Ask for it. which combines the Prüftechnik laser measurement technology with a tablet and smartphone devices.092-28 is compatible with Caterpillar gas engines G3508.motortech.com COmPRESSORtech2 . Bluetooth capability. as well as its 24-hour battery life (in continuous use mode) allows the user to move while taking measurements.) is better. However. End users expect maximum use of their compressors. any new UCP is expected to correctly know when it is safe and unsafe to operate the unit being controlled. Three steps — enter dimensions. www. CO2. the company said. G3516B and G3520B. just like automation companies. but not ideal. An internal pressure sensor is designed to allow the analyzer to measure pressure and stack draft. too often inappropriately applied equations are used. make sure that your selected vendor applies the correct OEM safety and performance methods when modeling the unit. The portable nature of the device. CO. The standard EGAS software package offers the ability to save and graph data in real time in the field with a laptop or in a laboratory with a PC. compare to historic values and generate reports. G3512. G3512B. Operating a compressor by implementing that compressor’s OEM methods is ideal.01°C).checked. are standard features.02°F (0. Motortech has developed a new temperature sensor compatible with Caterpillar GS3500 series gas engines. Finally. rotate shafts and display measurement result — are all that’s needed for the app to align horizontal machines. Anything short of full implementation of the OEMapproved performance and safety methods is not an acceptable best practice for today’s control panel. These service-based companies take operating data from the field.photon-control. The sensor is an alternative to Caterpillar’s P/N 3832989/2419591 and serves as a replacement without modifications. It can be downloaded free from the Apple App Store or Google Play. a portable. thus potentially rendering the information from those reports anywhere from meaningless to misleading. NO. G3516. The PalmSense2 can be paired with both contact and immersion temperature measurement probes. run the data through a series of calculations. The concluding rule to use for end users is clear and simple: When automating a unit. The PalmSense2 features a temperature range up to 842°F (450°C). www. more wasted energies from pressure throttling and recycling. or adding it to a monitoring service. according to Motortech. The temperature sensor P/N 56. www. has released the PalmSense2.de Alignment Application The user can choose several electrochemical gas sensors — O2. Other features include active clock measurement mode.09°F (0. accuracy of ± 32. a tablet-based application for pumpmotor alignment. If the bidding vendor cannot provide it. If the unit is going to be controlled by a UCP.com 72 Temperature Measurement System Photon Control Inc. running the unit most efficiently and accurately predicting load. since at least 2004. Knowingly operating compressors in unsafe areas is unacceptable. the ability to measure.05°C) (probe dependent) and resolution of ± 32. and even possibly dangerous. However. Temperature measurements for flue gas and air. the company said. then select a vendor that can. flow and unit safety. The PalmSense2 is designed for high temperature RF environments or EMI applications in labs and field service. which includes safely covering the widest operating map.com Ludeca has introduced tab@lign. CT2 MARCH 2014 FEATURED Temperature Sensor PRODUCTS Emissions Analyzer E Instruments has released the E5500 portable emissions analyzer for industrial flue gas. potentially higher emissions. as well as the differential temperature. Operating a compressor by using overly conservative methods and thus restricting its operating map (lost revenues.1 ppm resolution.01. NOx and SO2. correct and save soft foot results. live mode for realtime corrections and preassembled brackets for quick mounting. then automation specialists should be required to integrate into their control logic the proper OEM-approved methods for determining unit safety. etc. Gas velocity can be measured using the differential pressure and an optional pitot tube. many optimization and/or monitoring service companies provide valuable information and insight into the fleet of compressors being modeled. www. G3508B. power generation and distribution and station instrumentation and controls. WEB HEADLINES FEATURED PRODUCTS Fluid Ends The stories listed below recently appeared on the COMPRESSORtech2 internet page. which is building the Ivar Aasen platform. The order for Ivar Aasen consists of a multistage radial compressor (1x100%) arranged in tandem configuration around a centrally positioned 12. the holding company of the Kentz engineering and construction group. construction and commissioning of two compressor stations in Doddridge County.catoilandgasinfo. are scheduled for completion in 2014. The Marcellus Shale facilities.axh. Kentz Corp. each rated at 120 MMcfd (3.000 SF on 53 acres (918) 283-9200 Fax (918) 283-9229 www. The HOFIM unit will be delivered to the module packager SMOE Pte Ltd. These fluid ends are compatible with all Cat XD Series components. procurement. The turnkey compressor stations will together include more than 35. Benefits of the stainless-steel fluid ends include improved corrosion resistance.compressortech2.000 hp (26 MW) of compression.5 MW) highspeed electrical motor.com to read the complete articles. In 2016.4 x 10. gas dehydration.740 hp (9. inlet separation and filtration.. Reliability. The remaining Valerus contract services and aftermarket service businesses have been renamed Axip. in Singapore. provided the integrated active magnetic bearings. which MAN acquired in early 2012. Now with three plants totaling over 400. GE To Acquire Cameron’s Reciprocating Compression Division Cat Issues Upgrade For G3516 LE Engines Emerson Introduces Vapor Recovery Units Valerus Gets Work On Two Stations Bolivia To Get GE’s ICL Compressors GE Starts Downstream Tech Solutions Valerus Compression Services Renamed ‘Axip’ Compressor Stations Lambasted At Meetings Cameron May Sell Centrifugal Business MAN Compressor Set For Norway Field U.com continued on page 82 Valerus Field Solutions Valerus Field Solutions has received a US$62 million contract to provide engineering.Recent Orders MAN Diesel & Turbo MAN Diesel & Turbo’s first hermetically sealed compressor to be installed in the North Sea will go to Det Norske Oljeselskap’s Ivar Aasen production platform.6 m3/d). integrated motor (HOFIM) compressor unit is similar to MAN’s subsea compressors currently under system integration tests in Norway. oil-free. the module will be towed to the Norwegian North Sea. The high-speed. CT2 MARCH 2014 Experience.. Subscribers to the digital magazine can simply click on the headline.. for Crestwood Midstream Partners. www. Gas Storage Withdrawals Set Record Caterpillar Global Petroleum has added stainless-steel fluid ends to the Cat XD line of well stimulation pumps and fluid ends. Visit www. completed its US$435 million purchase of Valerus Field Solutions in January. Ltd. the company said.com 73 COmPrESSOrtech2 . West Virginia. MECOS.S. Integrity. reduced incidents of cracking due to corrosion and improved durability. director of Business Development for Southeast Asia. Web Attachments & Bragging Rights ( just in case they missed it) Contact Mary Graesing for pricing and details Phone: 262-754-4100 E-mail: mgraesing@dieselpub.. Detechtion Technologies Detechtion Technologies has received an undisclosed investment by Element Partners. in the development of its compressed air energy storage (CAES) site near Larne. as well as hydraulic and electrical service. China. Malaysia.com . India. the £300 million Larne facility will comprise a 268 MW FS-Elliott FS-Elliott Co. Smith was formerly CEO of Cygnet Software. headquartered in Covington. Dresser-Rand Dresser-Rand has joined Gaelectric. Led by Greg Baldwin. Texas. FS-Elliott also has offices at Basingstoke. Shanghai. will become chairman of the board.. has expanded into Southeast Asia by establishing an office in Selangor. The facility provides service to the San Antonio metro area and the Eagle Ford Shale market. and Taipei. Houston. Conroy was vice president of global products at P2 Energy Solutions. a renewable energy firm.K.2 ha) facility has a 15 ton (13. They also formed an alliance to develop other European CAES projects. Northern Ireland. Roger Markwardt heads the division. Jubail. LES provides service for all makes of diesel and gas engines and enginedriven equipment.608 kg) overhead crane capacity. previously president and CEO. Detechtion founder Brian Taylor.ft. has opened a division — Laborde Equipment Services (LES) in San Antonio. It also stocks and provides parts for a broad range of support. Saudi Arabia. Louisiana. 3 acre (1. Laborde Products has also operated a branch location in Channelview. He has more than 30 years of experience in the diesel engine and rental industries. Texas. The 18. Concurrent with the investment. a manufacturer of oil- Custom Reprints From COMPRESSORtech2 Perfect For Brochures. Los Angeles. free centrifugal air and gas compressors.PRIME MOVERS Laborde Products Laborde Products Inc. the office will seek to expand partnerships. Mangalore. Andrew Miles will continue as senior vice president of operations. for the past seven years. (1672 m2). Chris Smith joined the company as president and CEO and Gerry Conroy in the newly created role of senior vice president of products and portfolio.. U. When completed. a growth equity fund focused on energy and industrial technology companies. Detechtion provides software-based optimization and fleet monitoring serv ices for about 20% of the active compression horsepower in North America and manages assets for 15 major gas producers.000 sq. a provider of natural gas SCADA products and services. with 12 spent in customer service for aviation gas turbine engines. air fuel ratio control (AFRC) and a NOx sensor. Wood Group GTS Wood Group GTS has appointed Mike Fisher as president of its U. The upgrade kit allows operators to modify existing engines to a lower emission configuration. field service and the completion of special configuration projects. processing and pipeline solutions and aftermarket field services globally. Axip is focused on delivering service-based offerings for customers. including front end engineering and design in 2014. Existing engines must have the ADEM A3 engine control module. contract production and processing solutions. minimally invasive solution that allows the engine to offer the same MARCH 2014 75 Einstruments. the Venezuelan national oil company. M. Dresser-Rand will provide project management. Centaur 50 and Taurus 60 gas turbines. performance and uptime of the Solar and Siemens turbine fleets on Lake Maracaibo for PDVSA. He will oversee phone support. gas shutoff valve and software. turbochargers. following the sale of Valerus Field Solutions LP. The current Valerus Compression Services management team will continue with Axip and oversee the transition and growth of the company. Target commissioning date is 2017. Caterpillar Oil & Gas Caterpillar Oil & Gas has released a low-emission upgrade kit for select G3516 LE petroleum engines used in gas compression applications. Centaur 40. Axip also retains the Command performance optimization offering. which was released to the market in late 2013. and fuel tolerance while increasing altitude and turndown capability. Axip’s 700 employees include Valerus contract services and aftermarket services personnel plus relevant support services personnel. gas and industrial services (OGIS) business. which are used primarily by the oil and gas industry.indd 1 COmPrESSOrtech2 3/7/13 9:49 AM . fee-based gathering. 3. Saturn 10. repair and overhaul for Solar Mars. Upgrade kits also are available to bring engines up to this configuration. 1340 bhp (1 MW) at 1400 rpm. Fisher Fisher joined Wood Group in 2005. Monico Monico Inc. including contract compression.PRIME MOVERS twin powertrain storage and electricity generation facility.0 g/bhp-hr NTE NOx levels. New components in the kit include a two-stage aftercooler. working initially in Venezuela where he managed a two-year project to increase the reliability. oil cooler. Axip Energy Services Valerus Compression Services LP selected Axip Energy Services LP as the new name for its Contract Services and Aftermarket Services business. power.5 or 1. which began operating as a stand-alone company on Jan. has promoted Bill Dicken to technical support manager. Dicken has 17 years of experience working with RollsRoyce engines. air cleaners. Caterpillar said the upgrade is an economic. scheduling and technical support services through the planning phase of the Larne project. He subsequently served within the operations group for power plant services and most recently has been vice president of Solar operations within OGIS. venture fuel mixer.S. This is a new position for the Houston-based business that provides maintenance. oil. enabling operation at 0. Contact him at: ray. Contact him at: engineerbaldwin@ satx. The noise measurements were made in engineering units of Pascals due to the low pressure levels. This article presents field testing activities to verify the excitation sources. 6-9. Ray Durke is a senior research engineer with SwRI. He has a bachelor’s degree in mechanical engineering from Texas A&M University and a master’s from the University of Texas at San Antonio. In summary. corrosion. He has been involved with reciprocating compressor pulsation control research work since 2004.org. 2 KVS and turbine operating. and reliability problems in plant systems.com n Figure 1. Field testing to identify problem sources In an effort to characterize the local complaints. 2013.5 Hz. One Pascal (Pa) is equal to 0.5 to 13 Hz at the residences and near the compressor building as seen in Figure 1. but was considered a likely source of rattling. Contact him at: eugene. cabinets. Gas Machinery Research Council meeting at Albuquerque. New Mexico. from residents near a gas transmission station.5 Hz corresponded to 2. In order to identify the sources of the airborne pulsations. The subject problem is somewhat unique in that the complaints of rattling are vibration-related.
[email protected] Case Study: Intake/Exhaust Silencer Redesign Research Institute solves Mitigates Noise > Southwest problem of airborne pulsations from compressor station BY EUgeNe ‘BUDDY’ BroerMaN. He has more than 30 years of experience with vibration-related problems. but the primary driving source is inaudible pulsations produced in the engine intake and exhaust manifold piping. This frequency is below the range of human hearing. it was found that ground-borne vibration was not
[email protected] times (2. Field measurements showed that the elevated pulsations near 12. S outhwest Research Institute (SwRI) was contracted to investigate complaints of rattling and shaking of windows. and follow-up field tests for verification. Eugene Broerman is a senior research engineer with Southwest Research Institute (SwRI). vibration. Compression at the station was provided by two models of integral compressors: Ingersoll Rand KVG (10-cylinder) and KVS (12-cylinder) units and by two gas turbine-driven centrifugal compressors. He has a bachelor’s degree in engineering from Trinity University and a master’s from Georgia Institute of Technology. 76 COmPrESSOrtech2 MARCH 2014 . testing was conducted with various units operating over a range of conditions to track the pulsations near 12. doors.000009 bar). He holds a bachelor’s degree in mechanical engineering from Texas A&M University-Kingsville. Airborne sound pressure measurements identified a peak occurring near 12.org.5x) the running speed of the KVG units. Field tests were conducted to identify the sources of the neighbors’ complaints and to aid in development of modifications to reduce complaints. Richard Baldwin retired from SwRI in 2012 and is an engineering consultant. a pulsation analysis to develop modifications for reducing offending pulsations. etc. sound pressures and vibration measurements were recorded at nearby home sites and outside the compressor building as the operating conditions of each type of compressor was varied. Graphs show sound pressure data recorded at residence with 4 KVG. Vibration measurements were recorded on the foundation of the residences as well as in the ground near each home to assess the potential of vibration transmitted from the compressor station. RaY DUrke aND RicharD BaLDWiN corner Editor’s Note: This article is based on a paper given by the authors at the Oct. He has experience with pulsation.000145 psi (0. The indication is that at least a portion of the noise at the residences originates from the inlet duct. n Table 1. the 2. n Figure 4. pk-pk) Detected near 2.5x energy and eliminated the KVS units and the turbine-driven units as potential sources. MARCH 2014 77 n Figure 5.5x at various test locations. Noise Pressures (Pascals.5 multiple pulsations. n Figure 2. Pulsation data recorded in Unit 4 intake duct showing 2. Schematic shows engine exhaust manifold. From the summary of pulsation amplitudes in Table 2. note that the 2. This graph shows the pulsation spectra recorded in the exhaust manifold.5x pulsations measured in the exhaust manifold.5x pulsation amplitudes measured in the exhaust piping are thousands of times more than that measured at the residences.When the engine running speed was varied over the operating range of 300 to 330 rpm. The pulsations at 2. A summary of those pulsation measurements near 2.75 Hz. The engine intake manifold schematic is shown. n Figure 3.5x the running speed and much lower amplitudes at several harmonics of running speed as displayed in Figure 2.5x the running speed dominated the spectrum and reached a maximum at the capped end of the manifold.5x pulsations and to provide data for correlation with an acoustic model of the intake/exhaust manifolds.5 to 13. n Table 2. as seen from the data in Figure 4. A schematic of the exhaust system is provided in Figure 3.5x component in the sound and pulsation data tracked speed and varied from about 12. This is a summary of maximum 2. Airborne sound pressure measurements near the inlet duct to the engines could not distinguish whether the source was from the intake or the exhaust. continued on page 78 COmPrESSOrtech2 . Field testing to map air intake and exhaust pulsations A separate testing effort was conducted utilizing high temperature transducers to measure pulsations in the engine inlet and exhaust manifolds in order to define pulsation characteristics contributing to the high 2. The testing effort identified the KVG units as the primary source of the elevated 2.5x is presented in Table 1. location P9. A pressure measurement taken inside the inlet duct shows high pulsation at 2. The extent of the piping included in the modeling is summarized in Figures 3 and 5. n Table 3. Modifications to reduce pulsations by changing the manifold length. A pulsation maximum was predicted at the capped end of the header and lower amplitudes near the stack. show good correlation with the model and field data. The pressure transducer installed at the end of the manifold (test point P5). which is similar to the pulsation data measured in the exhaust system. Field measurements acquired at four locations in the manifold piping. (Reference Figure 3 for test point locations. Exhaust manifold model The pulsation model of the exhaust piping indicated that an acoustic response was present in the system near 12. The spectrum is dominated by the response peak near 12.) n Figure 6.The inlet manifold is represented in Figure 5 and is a somewhat more complex piping system. The field measurements identified a strong acoustic response at 2.5x engine running speed and higher harmonics. indicated by stars.5x running speed that contains a pulsation maximum at the capped end of each cylinder bank (test locations P5 and P8). Figure 6 shows an example installation of a pressure transducer in the intake manifold at the capped end of the cylinder bank near cylinder one. and a minimum near the header between the cylinder banks (between test points P3 and P6).5x pulsations present over the speed range. It was assumed that the primary coupling of the excitation energy near 2. The pulsation amplitudes in the intake manifold are lower than those in the exhaust by about a factor of three. The important aspect of the design is the predicted amplitudes in the exhaust stack are reduced by a factor of about eight with the new silencer installed. This exhaust piping pulsation summary gives predictions and field data.5x pulsations measured in the inlet air manifold. Spectra pulsation plots of data recorded inside the intake manifold show the 2. which was an acoustic filter designed into the silencer to attenuate pulsations associated with 2. The graph shows predicted pulsations in the exhaust stack. This is a summary of maximum 2. A summary of the maximum pulsation amplitudes near 2. adding orifice plates. near 2. and providing an acoustic filter installed as part of the silencer were investigated.5 Hz predicted by the model in red for the existing manifold and in blue with the new silencer installed. test point P5. n Figure 8.5x is provided in Table 3. A summary of model results are presented in the following sections.5 Hz n Figure 7. Data from the field studies was used for calibration of an acoustic model of the manifold systems.5x running speed to COmPrESSOrtech2 .5 Hz.5x running speed and to investigate potential modifications for pulsation mitigation. The red plot in Figure 7 shows model predictions of the pulsation in the stack for the existing piping system. Pulsation model An acoustic model of both the inlet and exhaust manifolds was developed to explore the sources of the energy MARCH 2014 78 Figure 8 shows pulsation amplitudes near 12. The operating company desired the most reliable solution. Comparisons of the field measurements with the model predictions are included in subsequent sections. 5x pulsations. results in predictions of significant reduction of 2.5x running speed. The model predictions (shown as a red line) match the field data (plotted as red stars) fairly closely and show a pulsation maximum at the closed end of the cylinder bank and a minimum near the inlet. n Figure 10. the blue line in Figure 11.5x running speed pulsations in the piping downstream of the filter. This gives the predicted pulsations at the intake manifold. However. MARCH 2014 . the key pulsation data is at the inlet to the intake system. The predicted pulsation spectra at the 10 in. A more reliable modification to provide pulsation attenuation for airborne pulsations from the inlet piping was developed. which included orifices to damp the resonance.the atmosphere occurs at the exhaust stack outlet. The acoustic mode shape of the pulsation response in the inlet manifold model is provided in Figure 11 for the cylinder bank of cylinders six through 10. The acoustic resonance is associated with the length of piping from the capped end of the cylinder six through 10 bank to the capped end of the cylinder one through five bank. where the red line is the model prediction of pulsations with the original silencer and the blue line is the predicted amplitude with the new silencer installed.5x pulsations at higher running speeds.5x pulsations. and the addition of side branch resonators to absorb the pulsations. The acoustic filter was designed to attenuate the 2. Pulsation predictions within the intake piping with the silencer installed.) Acoustic modifications were investigated to mitigate the 2. Therefore. A spectral plot of pulsation predicted in the stack is shown in Figure 7. Inlet manifold piping The pulsation analysis of the engine inlet air piping indicated that an acoustic response should be expected in the system near the top range of 2. therefore. The response predicted at the inlet to the original intake system is given in red in Figure 10. inlet piping can best be seen in Figure 10 for both the original piping (in red) and with the new silencer installed (in blue). A drawing of the new inlet silencer design is provided in Figure 12. installation of the new silencer should reduce the pulsations that couple into the atmosphere at the end of the stack. Drawing shows the new exhaust silencer to attenuate 2.5x engine pulsations upstream of the silencer that would pass into the atmosphere. n Figure 11. a piping length change to shift the frequency of the response. showing higher 2.5 Hz.5x that pass into the atmosphere. The design utilized an acoustic filter with an inlet silencer similar to that developed for the exhaust system. (Reference Figure 5 for test point locations. Field data matches relatively well with the model predictions. This intake piping pulsation summary shows predictions and field data. do not vary significantly from pulsations in the original manifold model (the red line in Figure 11). n Figure 9. Adding the new silencer to the acoustic model results in a reduction of continued on page 80 79 COmPrESSOrtech2 Replacing the existing silencer with the silencer presented in Figure 9. the objective of the new inlet silencer is to attenuate the pulsations near 2. the response amplitude is significant from approximately 11 to 15. As shown. the 2. Figure 13 shows spectral plots recorded at Home 2. and about 6:1 at Home 3. n Figure 12. This shows sound pressure spectra at the compressor station. and also show the presence of more random low-level sound pressures present over the lower frequency band. These sound pressures were at 2. With the lower levels present. These predictions are an indication that the pulsations transmitted into the atmosphere at the engine intake will be significantly reduced. A reduction of at least 2:1 was measured at the compressor station. as predicted in the pulsation modeling. This graph is of the sound pressure spectra at Home 2. This drawing is the new inlet silencer. were significantly reduced after the new silencers were installed. The data distinctly indicates that the new silencers attenuate the 2. Field test to verify model prediction Field measurements were recorded with the recommended inlet and exhaust silencers installed on one unit to verify performance prior to installation on all six units. n Figure 13. Field sound measurements were recorded at locations similar to those recorded in the previous field tests with microphones located outside the compressor building and at Homes 2 and 3 to assess the effects of the new silencers.5x sound component. while Figure 14 shows sound pressure measured in the compressor station. It is not clear why the noise measured at one of the nearby 80 COmPrESSOrtech2 n Table 4.5x at noted test locations. Sound data was measured at the station and at two home sites. n Figure 14. respectively. MARCH 2014 . Based on the results of the tests. Table 4 provides a summary of the measurements and shows a significant decrease in the 2. The test results indicate that the sound pressures at 2. and a reduction of approximately 5 to 30% at the second residence.5x are lower with the new silencers by factors of about 3:1 near the compressor building. A follow-up field study was performed to evaluate the system when all six units were fitted with the new silencers. a reduction of more than 6:1 at one home site.5x pulsations with the silencers installed. Pulsation amplitudes at the inlet and outlet of the intake and exhaust systems. the sound pressure measurements are more erratic and can be affected by local noises. 2:1 at Home 2.5x pulsations by approximately 2:1 at the inlet to the intake system. the decision was made to install the silencers on the remaining units. Field measured pulsations in the intake and exhaust piping systems are summarized by the blue stars in Figures 8 and 11. 5x pulsations transmitted into the atmosphere were reduced significantly by the installation of the newly-designed silencers. pulsation analysis.indd 1 81 COmPrESSOrtech2 2/4/14 3:34 PM . • Field tests conducted with the new silencers installed on all six units revealed that the sound pressure spike near 2. At a second home site. • Field measurements conducted with the new silencers on one unit revealed that the sound pressure spike near 2.5x pulsations was predicted at the inlet. • Pulsation measurements inside of the engine intake and exhaust manifold piping revealed strong pulsations at 2.5x pulsation amplitudes varied from a factor of 2:1 to 6:1 as measured near the compressor building and at two nearby homes.home sites was not significantly reduced by the installation of the new silencers. the most reli- able option for reducing the pulsations transmitted into the atmosphere was replacement of the existing silencer with a low-pass acoustic filter type silencer designed to attenuate the 2.5x pulsations similar to that of the exhaust system.5x running speed of one type of compressor unit. this lone peak in the sound spectrum was considered the most likely cause of the rattling and shaking complaints.5x running speed and was shown to be the source of the elevated sound pressure energy detected at the local houses. Since the sound pressure spike was eliminated in the compressor station and at one home site. a 2. CT2 MARCH 2014 EGCR. it is clear that the 2. Summary The key points of the field investigation. and follow-up testing were: • Initial field tests to address community annoyance complaints identified airborne sound pressure peaks occurring at homes near the compressor station that corresponded to 2.5x sound pressure spike remained.5 to 14 Hz frequency was well below the range of human hearing. Although the 12. • Acoustic modeling of the engine intake manifold indicated that a half-wave acoustic resonance existed in the system near the 2. The measured reduction of the 2.5x was eliminated at measurement locations in the compressor station and at one of the home sites.5x frequency.5x pulsations as measured in the exhaust stack.5x running speed pulsations (and higher frequency pulsations). however. Of several potential design modifications. This design was predicted to provide a reduction of about 8:1 in the 2.5x was eliminated. •A n acoustic model of the exhaust gas manifold identified a quarter wave pulsation response in the piping system. A maximum reduction of about 2:1 in the 2. A low-pass silencer was designed to attenuate the 2. questions remain regarding another potential sound source. The field data provided correlation for acoustic models of the air ducts that identified acoustic responses in both the intake and exhaust manifold piping. www. platforms and other oil. these outputs provide an early warning of bearing defects such as cracked races. lowering vibration and increasing efficiency in vertical and horizontal pumps. the company said.FEATURED PRODUCTS Bearing Fault Detector IMI Sensors has launched the bearing fault detector PLUS. the SafeSite LED linear fixture is available in 2 and 4 ft. the company said.com Protective Shield Global Sales Group has introduced its engine oil drain valve for industrial engines and construction equipment. has released its Graphalloy bearings and wear rings. LNG and CO2.com Bearings And Wear Rings Oil Drain Valve Graphite Metallizing Corp. which is a sensor designed to monitor rolling element bearings and provide a 4 to 20 mA signal to plant monitoring and control systems for early fault alarms. galling or seizing of the pump. The model 649A03 contains an accelerometer and 4 to 20 mA transmitter in a single housing and has multiple specialized outputs. The bearing fault detector PLUS is designed for applications with critical rotating machinery requiring continuous monitoring. When used with a control system.dialight. gas. designed for Class I Div. which are designed to address pumping problems caused by low viscosity. looseness and spalling. users only have to turn the lever to drain oil. and turn it again to close it. light hydrocarbons can be difficult for metallic bearings because the hydrodynamic film provided by these lowlubricity fluids is unable to provide enough lubrication. Featuring 106 lumens per watt. Building on the company’s experiCOmPrESSOrtech2 . the company said. (5 kg).clark-reliance.imi-sensors.and offshore drilling rigs. (0. petrochemical and hazardous loca82 Analytics Software Visage Information Solutions released Visage 2014. The fixture is intended to replace traditional fluorescent and HID lighting fixtures. 2 certified hazardous applications such as on. self-lubricating features of Graphalloy allow pumps to continue working even when experiencing run-dry. brinelling. light hydrocarbon liquids such as natural gas liquids (NGL). flashing or cavitation. The SafeSite is L70 rated for more than 100. and can be retrofitted to Jerguson brand level gages. has released a new protective shield for use on armored glass.ezoildrain. which can lead to metal-on-metal contact. liquid level gages. www. A hose may be attached to the nipple end to drain the oil away from the engine. www. the company said. Using Graphalloy bearings and wear rings allows tighter clearances. Once installed. www. improving reliability.com tion facilities. According to Graphite Metallizing. Made of Lexan polycarbonate.6 and 1. The nickel-plated valve features a ball valve mechanism for leak-proof operation. which is designed for analyzing oil and gas data. the company said. chemical. Safe View shields are available in lengths to fit flat glass gage styles. and is also available for nonclassified general purpose industrial applications.com MARCH 2014 LED Fixture Clark-Reliance Corp. a new version of its visual analytics software.2 m) models with a weight of 11 lb. as well as many others.graphalloy. The 100 to 277 Vac linear fixtures also feature an integrated wiring box to provide access for making electrical connections in a separate compartment. Graphalloy bearings are used in horizontal and vertical pumps. It is also a simple drop-in replacement for traditional vibration transmitter units as it uses the same loop power and 4 to 20 mA output. www. Safe View shields protect nearby operators from high-pressure leaks. The EZ Oil Drain Valve replaces the traditional oil drain plugs.com Dialight revealed its latest LED linear fixture. an O-ring seal and rubber lever cover. The nongalling.000 hours and features a T4a temperature rating of 40° to 65°C (-40° to 149°F). com Turbine Filters Champion Laboratories (Europe) Ltd.framindustrial. FRAM-Clench. along with internal relay contacts for set-point control of an alarm or annunciator. an inner and outer clenched liner that provides a mechanical lock without damaging the liner surface.recip. four-digit Featuring a 100% synthetic media constructed from polyester and polyethylene.02. It also features the ability to retransmit a 4 to 20 mA analog signal to a control system or data logger. has launched its FRAM Industrial E10 filter line.Austria CONFERENCE FOCUS: The Reciprocating Compressor and the Environment: Why Recips are the Better Answer to Compression Problems SPECIAL FEATURE: Compressor Training: “Foundation Design for Reciprocating Compressors“ September 10. www. The M-100 meter comes with peak-hold functions standard. Schaevitz LLC Alliance Sensors Group has expanded its line of sensor support electronics with the release of the M-100 series singlechannel digital process meter. Digital Process Meter H.2014 18:13:58 9th EFRC CONFERENCE . (7 mm). and FRAM-Bead. www. 2014 For Programme and Online Registration: www. The M-100 digital meter is designed for measurement applications that display an analog sensor’s output or the output of most types of thermocouples. G. Vienna . It offers a 0. or temperature in Fahrenheit or Celsius. It also can be calibrated to display an analog sensor’s dc voltage or current output in engineering units.alliancesensors.indd 1 83 2/13/14 9:39 AM 2 COmPrESSOrtech 11.visageinfo. the software provides thousands of ways to examine data and generate analyses to inform better decision-making and increase competitive edge. a technology that maximizes dust-release space to prolong the life of the filter. 2014 ● Hofburg. the filter has been in- LED display with 16-bit resolution in a 1/32 DIN size that can be mounted. www. Key features include interchangeable components.com 9th EFRC CONFERENCE September 11-12.FEATURED PRODUCTS ence in the oil and gas industry.indd 1 MARCH 2014 EFRC_Advert. the company said.com dependently tested and certified to EN1822:2009. designed for gas turbines.3 in.org EFRC. 2 3 4 6 5 Scheduled Downtime Locating Packagers DJ Slater. PUZZlemaster Visit www. The words used in this puzzle are locations found in the Packager Guide 2014 insert.compressortech2.com for answers. 7 N W O T S G N U O Y H O A A W A L L E R D I E R A B I E D T M F L O R E N C E B D A A R I U D L E I A A D A N A C V E Z R B L E F E Z M S C D R A S S U O R B N X O U L R N N O S E D M G H E N G E L O O N S C A O E A A S N I N U N A L D F T G I O A H S I R J R A N H A M B A E P S E S K I R A B G K E L G H O L U G O I U I N E R T I R R G V D T F A N D R D N O D O M D U R O E B A I O G W I T U E O H N C A R L E K W S R M N I R O Y B L S U A S H I S S E H Y T P L B R R R S L R G S I J E A N N E T T E M E T U A N I E O K W R O K L A H O M A C I T Y G O V D T T H C E R D R O D C A K R I S L N S N O G R D O B E R S O N T H E I M A A E E N G N I V R I O S A O P A U L O C C N H N T E X A S T W T M E Z Z O V I C O A P D Y V V E H D I E H C S M E R F N Q J L N N X S W E I V G N O L A F F U B J P I Q Airdrie Bergamo Broken Arrow Broussard Bucharest Buenos Aires Buffalo Calgary Cambridge Canada Canonsburg CastelMaggiore Dallas Dordrecht Eibar Elblag Farmington Florence Hannover Henderson Hengelo Houston Hugoton Irving Janesville Jeannette Katy Longview Mezzovico Midland New Iberia Obersontheim Odessa Okemah Oklahoma City Osimo Porto Recanati Remscheid Renfrew Rio de Janeiro Rosario San Diego Sao Paulo Targu Mures Texas Traverse City Tulsa Waller Wisconsin Youngstown . DIV . Rate is $130. couplings • steady-state and time-transient simulation • simulation software (ARMD 5.00 per column inch.com For Marketplace Rates Contact Sarah Yildiz at
[email protected]) Int’l Seminar ROTOR DYNAMICS & BEARINGS Cologne.indd Display or non-display classified advertising accepted. Mary Graesing •
[email protected] . U. These reprints can be produced to your specifications in one or multi-color formats on selected paper in standard 8 x 10 1/2 or DIN A4 sizes. GERMANY Internet: www. Payment must accompany order. Sarah Yildiz E-mail: syildiz@dieselpub. trade show distri bution and many other sales development activities.com Phone: 262-754-4147 • Fax: 262-754-4177 ARLA Engineering Service to Simulate Vibrations in Drive Systems • torsional and lateral vibration analysis • rotordynamics & bearing analysis (fluid-film) • considering complete drivelines with motors.com 1-724-527-3911 3/11/03 2/17/14 8:4 11:06 For an immediate price quote fax or e-mail your ad copy to: Flexware_Classified. gears.indd 1 9/9/13 10:33 AM AC&DC ENGINE STARTING SYSTEMS EXPLOSION PROOF • STARTER MOTORS • ALTERNATORS • SWITCHES • CLASS I.Aero Design . Layout and film production services are also available.com Fax: (262) 754-4175 Phone: (262) 754-4146 1 Condition Monitoring Software . one inch minimum. compressors. Photographs not accepted. ANAHEIM.Consulting Services .S. EnergyFlexware. Germany: October 6-10.Rerates Sleeve Seals . GROUP D UNITED STATES ENERGY CORPORATION (714) 871-8185 • (714) 871-9229 FAX WWW.com 2014 CLASSIFIED AD RATES Arla_2014. 2014 ARLA Maschinentechnik GmbH. Contact Reprint Manager for information. engines. Corp 1k x 1" sales@flexwareinc. No charge for typesetting.arla-online. CA 92801 .COM 1600 MISSILE WAY.Wireless Instruments Inc.Marketplace Custom Reprints Available Articles in COMPRESSORtech2 can be re printed at a very reasonable cost and used for effective direct mail purposes. answering inquiries. 1&2. ....... WI 53186 2014 ............... Do you wish to receive COMPRESSORtech2 Magazine FREE of any charges? 74 77 70 72 75 73 76 91 95 97 54 n NEW n RENEW 3.................................. The ...........................Advertisers’ Index *Further information on this company’s products can be found in the 2013 Edition of the Global Sourcing Guide (at GSGnet..... 29 Gulf South Rotating Machinery Symposium 2014 ......................... 63 ACI Services........compressortech2.................................................... ............................ 10-11 IPC Industrial Plants Consultants ............. (Please Check One) Natural Gas Production Gas Gathering Company Natural Gas Process Plant Operations Gas Transmission Pipeline Compressor Operations Natural Gas Storage Company Chemical or Petrochemical Process Company Refinery Operations Consulting Engineers or Contractor Research and Development.................................... 21 EFRC 2014 .... Technical Support Organizations................................ 27 CECO ...................................... Second Cover *Ellwood Crankshaft Group ......................... Inc....................... 35 Parker Finite ... 5 Cook Compression ... My company’s business is YES Digital or Print OP AD 99 NO OT 4.... 2-3 Tedom a............................................................................... 7 *Dresser-Rand ................... 62nd Annual Gas Compressor Institute ............................................................net).............................................................................................................. 75 Eastern Gas Compression Roundtable 2014 ......... – Engines Division ............. 25 *Rolls-Royce .................................................................................................... Inc.. 51 COMPRESSOR 1............................................................................................................ 49 PROGNOST Systems GmbH . 57 Hilco Division – The Hilliard Corporation ... 37 United Controls Group ..... ...... Third Cover Gas Compressor Association 2014 .... 43 *Cummins Inc................ 13........... 47 *Compressor Products International .......................... 41 *Hoerbiger Kompressortechnik ... 2............... SIGNATURE (REQUIRED) ______________________________________________ DATE (REQUIRED) ______________________ E-MAIL (REQUIRED) _________________________________________________________________________________________ PLEASE SIGN & DATE CARD Web: www....................... ................... 53 *Catalytic Combustion Corporation .................... Accessories & Control Systems None of the above............ 23 Reynolds French . 9 Summit Industrial Products ............................. 83 E Instruments International ........ 67 Hahn Manufacturing Company ...................................................................................................................................................................................................... 55 *Testo..........net) and/or 2014 Compression Technology Sourcing Supplement (at CTSSnet.................................................................................... 39 Enerflex Ltd.............. Suite 220............... 1 BG Service Co.............................. Technical Universities and Libraries Students Distributing............... 73 *ARIEL .......... 59 & Fourth Cover Neuman & Esser Group ................................................................ MY COMPANY’S PRIMARY BUSINESS IS............................................. 69 *Tech Transfer...................................................... 71 Girtz ............................................................................................................. 31 Air-Cooled Heat Exchangers .... 81 *Elliott Group ...................... ............... Servicing and Overhauling Engines & Compressors 63 65 40 41 62 Manufacturing Compressors Manufacturing or Packaging Compression Sets and Systems Manufacturing Natural Gas or Dual-Fuel Engines Manufacturing Gas and Steam Turbine Engines and Gas Expanders Manufacturing Industrial Power Transmission Products & Compressor Components............com • Phone: 262-754-4121 • Fax: 262-754-4175 E-mail: slizdas@dieselpub... ..............s........................... ..... MY JOB FUNCTION IS: EN PR Engineering Production/ Purchasing Operating/ Maintenance Administrative/ Marketing Other (describe) Dedicated To Gas Compression Products & Applications COMPLETE THE 4 BOXES FOR YOUR FREE SUBSCRIPTION................................................................................... 55 Johnson Matthey ....... 61 GUARDIAN Engine + Compressor Control ....................................... 15 Murphy by Enovation Controls .............. 39 Harsco Industrial Air-X-Changers .... 19 DCL International Inc................................................ 17 *KB Delta Compressor Valve Parts Mfg................................................................ 44-45 MOTORTECH GmbH .......... Inc.. Inc....................................................... .............. NAME ______________________________________________________________________ TITLE ______________________ COMPANY _________________________________________________________________________________________________ IMPORTANT You must check BOTH ADDRESS __________________________________________________________________________________________________ a Business and Job Function box for your CITY & STATE/OR/COUNTRY___________________________________________ POSTAL/ZIP CODE ______________________ subscription to be processed.. Waukesha......................com • Address: 20855 Watertown Road.......... 65 Aavolyn ......................................................................... Cornerstones Of Compression story continued from page 88 CT Valve Application Limits Size Range (Relates to diameter of the seat land area) 2.65 to 8.70 in. 5075 psig 2175 psi 0.11 in. 65 to 221 mm 350 bar 150 bar 2.8 mm 2000 rpm Maximum operating pressure Maximum differential pressure Maximum lift Maximum speed Compressor suction and discharge valves are highspeed check valves that seal gas inside the cylinder during gas compression and expansion. The valve plates open when the gas pressure on one side overcomes the spring forces and the pressure on the other side. Conversely, the plates close when that pressure is no longer high enough to resist the spring force and the pressure on the back side of the plates. This action happens many times each second (e.g., 5 at 300 rpm and 30 at 1800 rpm). Early compressors operated at low speeds using valves with concentric rings, reeds, channel plates or other approaches with multiple coil springs. Most U.S. compressor manufacturers at the time, e.g., Ajax, Cooper-Bessemer, Superior, Worthington, Clark and Ingersoll Rand (IR), made their own valves. As higher-speed gas engines were developed, compressor manufacturers responded with separable compressors to match these newer, more cost-competitive drivers. HCA supplied high-speed plate valves 800 rpm IR RDH and RDS frames, as well as the Knight KOC and the EI and Gemini compressors. These were mostly called CGD valves, which employed metal plates with a unique double damping system. But the incumbent valve technology threatened to limit the size and speed of compressors. The valve lift (plate opening distance) for steel plate valves was limited by a number of factors including impact forces during opening and closing events where two hard and rigid surfaces collide. The high cost of steel valve plates also made them increasingly unattractive to compressor operators. Another problem was that when the steel plates failed, broken pieces could damage the valve seat and render it unrepairable. While steel valve sealing elements (plates, rings, channels, strips) had served as workhorses for valve plate technology since the early 1900s, in the late 1970s and early 1980s (then) relatively new nonmetallic valve plates, were proving to be much better and more reliable. The nonmetallic valve plates not only cost less, they were more resistant to fatigue and could accommodate higher lifts that increased the valve flow area and reduced valve losses. And the likelihood of severe valve seat damage was much less in the event of failure of the nonmetallic plates. U.S. reciprocating compressor manufacturers were beginning to embrace the separable compressor concept and were looking to push from the “high speed” of 800 rpm to unheard of speeds as high as 1800 rpm to match the emerging gas engines. This new requirement pushed the MARCH 2014 87 Hoerbiger R&D group in Vienna to investigate alternative valve designs, taking advantage of the new nonmetallic valve plate materials. The result was a compressor valve concept never before seen by the reciprocating compressor industry. The valve, designated CT, was designed from the ground up. It was never intended to be used with steel sealing elements and because of this the valve designers were able to offer significant increases in “valve lift area.” The new design used a thin 0.079 in. (2 mm) polyether ether ketone (PEEK) plastic plate with a steel cushion plate and a wafer spring that also helped eliminate the phenomenon then recently recognized as stiction. Stiction is a phenomenon that can occur in lubricated compressors when the valve plate comes into contact with either the seat lands or the guard and where a film of lubrication can cause a delay of the opening or closing event of the valve plate. This delay can result in the premature failure of the valve plate due to higher impact forces. The wafer spring, fitted between the guard and the steel cushion plate in the CT valve, worked beautifully in breaking the stiction effect. The CT valve had another very unique feature. Rather than having the closing springs dispersed throughout the valve guard, all the springs were arranged very close to the outside diameter of the valve guard. This allowed the valve plate to deflect from the inside out, keeping the valve plate in a flatter opening position and stabilizing the opening impact as the outside diameter of the valve plate tended to see the highest opening impact. The design lessened these typical high opening impacts, allowing the valve plate to last longer under extreme operating conditions, especially in the new short-stroke, highspeed compressors. Few people understood the impact that this breakthrough would have on the compressor industry. Hoerbiger put some out on test and sold a few. Cooper was developing a new 1200 to 1500 rpm Superior RAM compressor in 1985 and first applied the new CT valve. At about the same time Ariel, which was developing ever-larger compressors, started applying them in its JGR and then the newer JGK models. Soon the valves were being used in Gemini and EI compressors as well. A number of developments occurred as the CT valve evolved over the years. Plate thickness was increased to 0.157 to 0.236 in. (4 to 6 mm), and the steel cushion plate was eliminated. PEEK was brittle in cold weather startups, so nylon plates were offered. Soon, taking advantage of new material technologies, a special MT material was developed that was closer to the strength and high temperature capability of PEEK and the low temperature flexibility of nylon. Truly a game changer that enabled the successful application of modern high-speed separable compressors, the CT valve remains the “heart” of most natural gas compressors operating today. It is produced in a range of sizes and used in most gases, including sour gas. CT2 COMPRESSORtech2 C ornerstones Of Compression n The CT valve is a critical component for tens of thousands of high-speed separable compressors operating today. The Heart Of The HighSpeed Recip > Hoerbiger CT valve was a game changer BY NOrm ShaDE I n 1895, Hanns Hörbiger developed an innovative valve for reciprocating compressors. His steel plate valve overcame all the disadvantages of other common valve designs at the time. In 1900, Hörbiger, together with engineer Friedrich Wilhelm Rogler, founded an engineering office in Budapest, which they relocated to Vienna in 1903. Hanns Hörbiger devoted himself to continually enhancing the steel plate valve he had invented and patented. His office issued licenses for use of the technology to business partners domestically and abroad. In 1925, the engineering office became Hoerbiger & Co. trading company. In 1931, Alfred Hörbiger, oldest son of Hanns, started the in-house production of valves. 88 Between 1925 and 1945, 171 patents were granted for Hoerbiger & Co. for inventions and developments in the field of compressor valves and controls. After the destruction of the Vienna production plant during the last year of World War II and the sudden passing of Alfred Hörbiger, his wife, Martina, managed to rebuild the plant. Martina Hörbiger was a take-charge entrepreneur who oversaw the development of a worldwide company over many decades. Hoerbiger Co. expanded sales throughout much of the world and by the end of the 1950s had developed its own distribution system in North America. Hoerbiger Corp. of America (HCA) was founded in 1963 and the development of a production operation followed, led by Hubert Wagner. continued on page 87 COMPRESSORtech2 MARCH 2014 THE SHORTEST DISTANCE FROM WELLHEAD TO MARKET SHOULD BE A STRAIGHT LINE. TO ENERFLEX. We provide the flexibility of custom energy processing solutions from a single source. From wellhead to market. Compression to full-scale processing plants. Now, who are you going to trust your business with? The Single Source www.enerflex.com TX • Booth #320 1311382 1-2-14 Contact us today to find out how to get your gas compressor under control: 918-317-2612 . Galveston. 2014.com/ad/1311382_ct2 Visit us at GCA • April 6-9. We put the control back in your hands.fwmurphy.CONTROLLERS AND PANELS COOLANT LEVEL SWITCHES SWICHGAGES® LUBE LEVEL SWITCHES DUMP VALVES SCRUBBER LEVEL SWITCHES LUBE LEVEL MAINTAINERS Save time and money with Murphy products. SHOCK & VIBRATION SWITCHES www.