GE COMPLETESMETEM ACQUISITION EMERGING MARKETS EYE LNG MAY 2016 WWW.COMPRESSORTECH2.COM/SUBSCRIBE/ SULLAIR ROTARY SCREW COMPRESSORS n Customer: n Challenge: n Result: Vertically integrated global petrochemical company, Texas. Build a world-scale olefin plant to process plentiful, low-cost shale gas. Three trains of reliable, efficient Elliott steam turbines and compressors ensure the customer’s competitive advantage in world markets. They turned to Elliott for a long-term partnership and long-term service. World-scale olefin processors turn to Elliott for steam turbines and compressors that deliver unmatched reliability, efficiency and value over the life of their investment. 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 ARIEL’S TORQUE REFERENCES AT YOUR FINGERTIPS With the all new Ariel Torque Guide App 20855 Watertown Road. WI 531861873. Canada. All Rights Reserved.O. POSTMASTER: Send address changes to: Circulation Manager.S. Copyright © 2016 Diesel & Gas Turbine Publications. Box 456. August-September. Printed in the USA. March. October. Waukesha. ON L2E 6V2. No. www.May 2016 COMPRESSORtech2 is the premier resource for gas compression news and information. Niagara Falls. Featured Articles 12 GE Completes Metem Acquisition 14 Test Facilities Improve Compressor Reliability. Waukesha. and international copyright laws and treaties. May. Suite 220. July.com. WI 53186-1873 USA. COMPRESSORtech2. December) by Diesel & Gas Turbine Publications. Unauthorized duplication and publication is expressly prohibited. November. Return Undeliverable Canadian Addresses to: P.com Follow @COMPRESSORtech2 on: 34 RMS Expands Its Footprint 42 Analysis: Valve Performance On Booster Primary Compressor For LDPE 48 Inlet Cooling For Gas Turbines Driving Gas-Gathering Compressors Departments 4 Page 4 — Australia Leads The LNG Export Race 6 Global Perspective — Emerging Markets Eye LNG 8 About The Business — Domestic Oil & Gas Downturn Continues While Political Stances Threaten Its Survival 10 Events & Meetings 26 Featured Products 41 Literature 46 Prime Movers 52 Scheduled Downtime 53 Marketplace 54 Advertisers’ Index MEMBER OF … 56 Cornerstones Of Compression — Sullair Rotary Screw Compressors . 4 — Published 10 issues/year (January-February. Canadian Publication Mail Agreement # 40035419.00 per copy worldwide. Periodicals postage paid at Waukesha. April. WI 53186 and at additional mailing offices. 20855 Watertown Road. USA Subscription rates are $85. REP Approved Cover Designed By Alyssa Loope COMPRESSORtech2 (ISSN 1085-2468) Volume 21. June.00 per year/$10. Materials protected by U. Email:
[email protected]. Performance Predictability 24 Active Magnetic Bearing System For Large Machines 30 GE Tested. Brazil www.from the initial drawings to complete life-cycle service.com Contact me for Central and South America: Marcos Rihan Sales Manager marcos. NEA's team works as the single-contact provider for: Sales. This includes care for the entire reciprocating compressor system . we are here to serve you.com. NEUMAN & ESSER América do Sul is the expert for any compression needs in Central and South America.THINK GERMAN.rihan@neuman-esser. LOOKING FOR AN ALL-IN-ONE COMPRESSION PROVIDER? OVER 30 YEARS OF EXPERIENCE IN BRAZIL FROM CONCEPT TO SERVICE. LNG. air and more.br Direct line: +55 (31) 2126-9503 NEA GROUP Headquarters in Germany BLUESTROKE COMPRESSOR SYSTEMS . Engineering. technical and natural gases.neuman-esser. ANY APPLICATION. ACT LOCAL. Hydrogen. Located in Brazil. Packaging and Service. NEUMAN & ESSER América do Sul Ltda Located in Belo Horizonte. .......... Japan accounts for the largest share of contracted liquefaction output... Via Delle Forbici I-50133 Firenze..... The Gorgon project includes a domestic natural gas plant... Italy Telephone: +39 0464 014421 Fax: +39 0464 244529 SWEDEN Bo Svensson................. 03011 Korea Telephone: +82 2 391 4254 DIESEL & GAS TURBINE PUBLICATIONS President & CEO . according to the U. Margaret Pieper Production Manager .. Sales Manager Dongmyung Communications Inc.. Sweden Telephone: +46 70 2405369 Fax: +46 122 14787 JAPAN Akiyoshi Ojima.. Derbyshire.. Jerry Karpowicz 4 Digital Content Manager .... The U.. Wisconsin 53186-1873 Telephone: (262) 754-4100 Fax: (262) 754-4175 CONTRIBUTING EDITORS Norm Shade – Cambridge. Italy Telephone: +39 055 50 59 861 Fax: +39 055 57 11 55 Roberta Prandi..... Michael J. If the additional LNG capacity currently under development is fully operational as planned by 2019..2 Bcfd (157 x 106 m3/d)..S. Australia’s LNG export capacity currently stands at 6. Brezonick Associate Editor ...Catrina Carne Advertising Manager ..... Wheatstone and Ichthys — are still under construction..3 Bcfd (65 x 106 m3/d)..1 Bcfd (59 x 106 m3/d)....... shipped its first cargo this spring.Carla Lemke Graphic Artist . Jack Burke Associate Editor ....... The U..... Osenga Executive Vice President ........ Alyssa Loope PUBLICATION HEADQUARTERS 20855 Watertown Road. cutting costs and travel time from the U.... LNG Vessels Will Run Through It...... Chai.... Suite 220 Waukesha. Mark Thayer Associate Publisher ......Brenda Burbach Graphic Artist .. bound for Brazil.. DJ Slater Senior Editor ...... the country’s LNG exports capacity would likely increase to the largest in the world....8 Bcfd (79 x 106 m3/d) and are expected to come online between 2016 and 2018. Most new Australian liquefaction capacity is already contracted on a long-term basis to countries in the Asia Pacific region. is the world’s most expensive LNG project to date..... Marisa Roberts Graphic Artist .. Associate Publisher 44... equivalent of one-third of global LNG trade in 2014..... at 11.... with contracts for 79% of output from the existing liquefaction projects (in operation prior to 2014) and 35% from the new projects............... China is the second-largest destination.... Associate Publisher 12777 Jones Road......... will benefit from the US$5......4 Bcfd (96 x 106 m3/d).. But the infrastructure required to meet Asia’s thirst for LNG is lacking in the U... with 15% of contracted LNG from the existing liquefaction projects and 23% from the new projects. The first train was commissioned in March. Jongno-gu Seoul....Roberto Chellini Senior Editor ... is quickly losing ground to Australia in the race to become a global LNG supplier... Three projects in eastern Australia have been fully or partially commissioned since 2014.5 Bcfd (325 x 106 m3/d)... a carbon dioxide injection project and an LNG export facility... Among destinations for Australian LNG. Once fully completed. Australia’s Gorgon project....Michael J........ Field Editor/Business Manager Dunderbacksvagen 20 612-46 Finspong.... 38)... Ohio Mauro Belo Schneider – Rio Grande du Sul............... p.. Advertising Manager 40 Premier Avenue Ashbourne........Chad Elmore Associate Editor ........... mired in red tape and facility delays..... 82 Pyeongchangmunhwa-ro. Energy Information Administration (EIA). The U.3 billion Panama Canal expansion set to open this year.. Asia is the LNG prize.. CT2 ... 231-0824 Japan Telephone: +81 45 624 3502 Fax: +81 45 624 3503 KOREA D.. Queensland Curtis commissioned its two trains in 201415..... Regional Manager/Editor Via Fitta....S.............. Joseph M.. Katie Bivens Circulation Manager .... Gorgon LNG is the first of the four new projects off the northern coast of Western Australia to be partially commissioned..... Branch Manager 51-16-301 Honmoku Sannotani.S.... they will have a combined capacity of 3.... Brezonick T he country that introduced latex gloves. Its three liquefaction trains have a combined capacity of 2. Including the first train from Gorgon. Germany Telephone: +49 711 3416 74 0 Fax: +49 711 3416 74 74 UNITED KINGDOM Ian Cameron........S.. located on Barrow Island off the coast of northwestern Australia.......... Ultimately.S. strengthening the lead of the Land Down Under in the global LNG export race. But the sheer size and scope of the Gorgon Project quickly negated any strides gained by Sabine Pass......S..... Three other projects in the northwest — Prelude............... The Gorgon project..... Gulf Coast to Asia by 11 days (See November 2014 CT. Kane COMPRESSOR A Member of the Diesel & Gas Turbine Publications Group PUBLICATION STAFF Australia Leads The LNG Export Race Associate Publisher ......... These three projects have a combined capacity of 2............... Michael J..... 9 73760 Ostfildern. made headlines in February when Cheniere Energy dispatched the first shipment of LNG from its facility at Sabine Pass..Art Aiello Copy Editor ..... Naka-ku Yokohama........Page CT2 Founder .......... USA Mark Thayer...... Suite 225 Houston.. Gladstone commissioned its first train in October 2015 and Australia Pacific sent its first cargo in January of this year. Louisiana.. United Kingdom Telephone: +44 20 31 79 29 79 Fax: +44 20 31 79 29 70 ITALY Roberto Chellini....to nine-month intervals.. Advertising Manager Niemöllerstr.S.. Regional Manager/Editor Linda Cameron.. 21a I-38062 Arco.. DE6 1LH. Advertising Manager Gabriele Dinsel...... All three projects process coal bed methane into LNG and have a current combined capacity of 2.. taking more than six years to develop at a cost of US$54 billion.... Texas 77070 Telephone: (281) 890-5310 GERMANY Lisa Hochkofler.............. with the second and third trains to follow at six....... Brazil HOUSTON.... vegemite and Crocodile Dundee is now home to one the largest LNG projects in the world........ com/us | 1-800-675-6646 an EnPro Industries company . Together.com | 1-800-675-6646 CPIstrong. it’s the power of a single phone call for all of your oil & gas compressor needs. For Compressor Products International. manufacturing efficiencies and product innovations that arise from the unification of the 16 companies we’ve acquired since 2007. CPIstrong. it’s the global footprint. we are CPI. Together. we are stronger. For our customers.WHAT IS THE POWER OF ONE? The power of one is what happens when many individuals join forces toward a common goal. It’s the greatness that can be achieved through a shared purpose. Lower costs of LNG supply and infrastructure support the view that more regasification projects will move forward on top of those under construction. Nontraditional LNG import markets in Asia — such as Bangladesh. The acquisition places SembCorp in a good position to capitalize on the growing need for flexible LNG solutions in the Asia-Pacific region. especially as firms operate with smaller capex budgets amid the current low oil price environment. Some countries have already moved to explore the possibility of installing Gravifloat terminals to meet rising demand from the power sector. floating storage regasification units will be cheap as shipyards are looking for business amid a slowdown in the shipbuilding industry. (15 to 20 m). as well as stepwise expansion of storage. it secured the right to raise its share by an additional 44% to take full ownership through an equity purchase at the same price. A sustained period of weak LNG prices will create an environment whereby countries and companies that perhaps did not have sufficient financial resources are able to consider investing in LNG for the long term. or US$27. CT2 roliferation of innovative and cost-competitive liquefied natural gas (LNG) terminal solutions within the Asia-Pacific region will facilitate more-efficient LNG deliveries to its emerging markets. In addition. Pakistan. lower than the US$13/MMBtu average over 2013 to 2015.3 Tcf (36. which will include an LNG depot. Con Dao. The design utilizes a modular concept. which allows for flexible adjustment of capacity. Singapore’s marine and offshore engineering firm SembCorp Marine has increased its stake in near-shore LNG terminal specialist Gravifloat AS to 56%.8 x 109 m3) of annual import capacity. Furthermore. or at least 1. The low prices will place buyers in a strong bargaining position to secure favorable long-term contracts. Myanmar. Many of those markets are forecast to see substantial growth in LNG import requirements over the coming years. Furthermore. Gravifloat’s flexibility to cater to a wide range of market sizes offers it a competitive edge over standard floating facilities. Many of the emerging markets are projected to see considerable growth in gas demand and have proposed plans to increase LNG imports over the coming years. as oversupply in the regional LNG market drives investors away from large-scale LNG projects. the Philippines.Global Perspective BY ROBERTO CHELLINI ASSOCIATE PUBLISHER Emerging Markets and cost-competitive LNG Eye LNG > Flexible terminals provide regasification to emerging Asia-Pacific markets P generation module and berthing platforms. Myanmar is also reviewing a proposal from Gravifloat to construct a 127 MW LNG-fueled power plant offshore the Thilawa Special Economic Zone. Thailand and Vietnam — could add in excess of 15 new LNG regasification facilities. benefitting LNG suppliers who are looking for export markets. Weak LNG prices for at least the next five years and robust demand for gas will support long-term investments in LNG.5 million. based on need and investment plans. Given that many of these projects are either in the proposed phase or pending final investment decision. Gravifloat’s near-shore terminal can be situated at water depths as shallow as 50 to 65 ft. Thailand is currently mulling over plans for a US$45 million LNG-based power plant in Ben Dam Bay. BMI forecasts the price of Asian benchmark Japan Korea Marker (JKM) to remain below US$5/MMBtu over the period from 2016 to 2020. and be constructed in two to three years. a port and an 18 MW LNG power plant. power MAY 2016 6 COMPRESSORtech2 . BMI Research (BMI) believes there are opportunities for Gravifloat to offer a cost-efficient alternative to procuring LNG. For instance. Its lower cost structure increases its attractiveness relative to a conventional onshore import terminal. which in turn will create opportunities for suppliers to sell into these markets. . Total 2015 imports were slightly higher than 2014. explained that solar and winds aren’t as green Norm Shade is senior consultant and president emeritus of ACI Services Inc. Instead. In March. Solar cells. A 46-year veteran of the gas compression industry. Uninformed. a fact rarely reported by the press and ignored by the anti-hydrocarbon lobby. on fracking. as individuals in the oil and gas industry. thought to be the greenest of energy sources. And. solar. And even green energy has environmental consequences.S. In the first week of April.energynation. Well-organized opponents of oil and gas are energetic. But natural gas production continues to climb due to the large inventory of drilled wells yet to enter production and to the amazing productivity of new Marcellus and Utica Shale wells. and North America energy needs for the foreseeable future. he has written numerous papers and is active in the major industry associations. significant environmental issues have been reported from mining and manufacturing them.90/MMBtu. Not only is that a strategic concern. In the midst of the worst U. negative messaging risks turning most of the public off from listening to us. Baker Hughes reported that U. The Silicon Valley Toxics Coalition (SVTC). MAY 2016 8 COMPRESSORtech2 . Energy Information Administration (EIA) data shows that after a 23% decline from 2010 to 2014. Really?” pointed out that the fabrication of solar panels requires toxic chemicals and uses large amounts of water and electricity. Make yourself — and your extended network — familiar with them! CT2 . and turbine generators rely on components that contain rare earth metals found outside North America.S. For example.org/energylink). There are many good information sources including the American Petroleum Institute’s (API) Energy Nation (www. highest ever for that point in the season. government agencies and politicians continue to push agendas that endanger the very survival of the industry that drives the gas compression market. relatives and neighbors to factual information that favors our industry. pointing out that the industry “has allowed the United States to increase its oil production faster than at any time in its history. encouraging positive conversation. These problems undercut solar’s benefits.S. oil and gas industry. Talking only among our business associates is not enough. low costs and security — are obvious to all of us. ingaa. This has kept the Henry Hub price below $1. although some of the nastier environmental facts associated with green energy should be more widely publicized. and even bans. but the average citizen rarely hears that message except in some paid advertisements. crude oil imports actually started increasing again in late 2015. the practical matter is that it cannot meet demand for decades. and January 2016 imports soared to 20% higher than the same period last year. Although green energy development should not be discouraged. As this column has advocated. reported that the solar industry is focused more on survival and growth than on tackling the dirtier side of an otherwise clean energy source. rigs drilling for oil and natural gas reached a new low of 443 (354 oil and 89 gas).S.” Yet. of Cambridge. oil production is falling as low prices have stifled new development. U. especially in China. The benefits — jobs. we should concentrate on constantly educating the public on the positives of fracking and domestic oil and gas production to sustain the U. some politicians and environmental activists ignore this fact and push to essentially destroy the U. Yet we. Ohio. misinformed or misguided presidential candidates are proposing severe restrictions. a San Francisco-based nonprofit that has tracked the environmental impact of the high-tech industry since 1982.S. Speaking at the Gas Compressor Association’s Expo in March.About The Business BY NORM SHADE Domestic Oil & Gas Downturn Continues While Political Stances Threaten grass roots conversation is Its Survival > Informative needed to counter the negative oil & gas messaging from environmental advocates U and strategically friendly as generally portrayed. Dr. oil and gas downturn in decades. A November 2014 National Geographic article. environmental advocates. it’s up to us to direct our friends. director of the TCU Energy Institute. Ken Morgan. do little to counter their messaging and make our story heard.S.org) and the Interstate Natural Gas Association of America’s (INGAA) new Energy Link (www. “How Green Are Those Solar Panels.S. passionate and increasingly effective at influencing public opinion and politicians. has some serious baggage. The EIA reports that gas storage at the traditional end of the heating season was 54% higher than the five-year average. batteries. comes from fracking. an EIA report said that over half of the energy production in the U. burckhardtcompression. The Redura® Oil Sealing Systems consist of a combination of different ring types. REDURA® Longest MTBO at lowest leakage Highest availability Lowest life cycle costs The heterogeneous design of Redura® Piston and Rod Sealing Systems stands for a unique selection of rings. packings as well as specifically in-house developed. Switzerland Tel. provides optimized distribution of the dynamic and static pressure differences. The product line includes standard rings. reduces wear on each element and increases the overall sealing performance. UPGRADE YOUR RECIPROCATING COMPRESSORS NOW Burckhardt Compression AG.DISCOVER OUR NEW WEBSITE! www. +41 52 262 55 00 aftersales@burckhardtcompression. DURable and Advanced sealing systems for reciprocating compressors.com PUSH THE LIMITS! FORMING THE WINNING TEAM OF RINGS – REDURA® SEALING SYSTEMS REDURA® – REliable. ensuring enhanced sealing efficiency while fulfilling the requirements of dynamic tightness. designed and patented products.com REDURA® OIL SEALING SYSTEM REDURA® ROD SEALING SYSTEM REDURA® PISTON SEALING SYSTEM . caspianoil-gas.com June 21-23 Sensors Expo & Conference San Jose.com/sensors-expo June 21-23 Developing Unconventional Gas (DUG) East Conference & Exhibition Pittsburgh +1 (713) 260-6492 www.com June 7-9 Global Petroleum Show Calgary.org May 31-June 1 Gas Africa Sandton.egcr. Nigeria +234 706 911 7347 www.html COMPRESSORtech2 .asme.ingadaevents. Azerbaijan +44 207 596 5147 www. 23-25 Power-Gen Natural Gas Columbus. 12-15 Turbomachinery Symposium/ Pump Users Symposium Houston +1 (979) 845-7417 http://turbolab.dugeast.za JUNE June 1-4 Caspian Oil & Gas Baku.co. Italy +44 1992 656 637 www. South Korea +1 (800) 843-2763 www.southerngas.com June 13-16 Nigeria Oil & Gas Conference MAY 2016 Abuja.edu/outreach/engr/ gascompressor_home.sensorsmag.indd All Pages Boldface indicates shows and conferences in which COMPRESSORtech2 is participating MAY May 24-26 Eastern Gas Compression Roundtable Pittsburgh +1 (412) 372-4301 www.cwcnog. 13-15 Gas Compressor Short Course Conference Norman.globalpetroleumshow.Don’t replace. Alberta. South Africa +27 11 234 1196 www.org/events/turbo-expo June 21-23 Power-Gen Europe Milan. Gauteng. Events & Meetings Altronic_HHsprd_Mar16_CT2. Canada +1 (403) 209-3555 www.powergeneurope. California +1 (617) 219-8300 www.org AUGUST Aug.edu Sept.com SEPTEMBER Sept.tamu. Ohio +1 (918) 831-9160 www. Oklahoma +1 (405) 325-3136 www.ou.power-gennaturalgas.com June 13-17 ASME Turbo Expo Seoul.com 10 JULY July 25-27 SGA Operating Conference Houston +1 (972) 620-8505 www. org Sept.Rebuild.0 Secondary Spark Plug Lead System gives you the ability to fully rebuild spark plug leads in the field. 14-15 European Forum for Reciprocating Compressors (EFRC) Hofburg. 20-22 Power-Gen Asia Seoul.introequipcon. 17-19 Saudi Arabia International Oil & Gas Exhibition (SAOGE) Dammam.com MAY 2016 11 Nov. and the performance that are critical to minimize downtime.ibp. or grommets/terminal pins acquired directly from your Distributor’s inventory or your own. or locally by your own personnel.com Nov. Wyoming +1 (307) 258-4708 https://wyogasfair.recip. wires.innotrans. Germany +49 69 66 03 12 82 www.org Sept. 2-5 Gas Machinery Conference Denver +1 (972) 620-4026 www. South Korea +44 1992 656 656 www. Germany + 49 2267 6585-0 www. This system offers accessibility.altronic-llc. leads can be serviced/rebuilt when necessary with moderately priced.com OCTOBER Oct. Saudi Arabia +39 06 3088 3030 www.org. HOERBIGER Engine Solutions Find a distributor near you at www. Austria +49 69 6603 1286 www. United Arab Emirates +971 2 6970 518 www.org Oct. 24-27 Rio Oil & Gas Rio de Janeiro +55 21 2112 9079 www.com 2/17/16 9:44 AM For a complete listing of upcoming events. easily installed replacement components. The Altronic Flashguard 2. 11-13 HHP Summit 2016 Chicago +1 (888) 993-0302 www.com COMPRESSORtech2 . 20-23 InnoTrans 2016 Berlin +49 30 30 38 2376 www.br Sept.hhpsummit. including new O-rings. multiple wire styles. 7-10 ADIPEC Abu Dhabi.adipec. including special extensions for the Caterpillar 3300 and 3400 engines. 10-13 International Seminar Rotor Dynamics & Bearings Cologne. boots.com NOVEMBER Sept. you can cost-effectively specify a lead for manufacture by your local Distributor.powergenasia. and an assortment of lead accessories.saoge. 14-15 International Rotating Equipment Conference Duesseldorf. reliability.com/events/ Oct.compressortech2. Contact your Altronic Distributor for all the details. 13-15 Wyoming Natural Gas Fair Casper. In either case.de Sept. 2-4 EP Shanghai 2016 Shanghai + 852 2811 8897 www. please visit our website at www. Incorporating custom Teflon extensions.gmrc. Vienna. while driving the necessary cost-control and serviceability that are so crucial to twenty-first century operation.org Oct. a range of primary and secondary connections.epchinashow.com Oct.arla-online. . . n This closed-loop at Solar’s gas compressor test facility is powered by a dedicated Titan 130 gas turbine driver on a universal driven-equipment skid that enables full load testing in a hydrocarbon or inert gas closed-loop. Centaur. as well as providing customers with expanded options for shop testing. Its gas compressor test facility (GCTF). They can be matched with electric motor drives as well. The compressors are optimized to match the speed and power ratings of its Saturn. Titan (all registered names of Solar Turbines) gas turbines. Test Facilities Improve Compressor Reliability. MAY 2016 14 COMPRESSORtech2 . Performance Turbines investment in extensive test Predictability > Solar facilities advances compressor development BY NORM SHADE S Solar continues to invest in its product development efforts through its two ISO 9001:2008 certified campuses in San Diego. which began operation in 2009. The three-bay GCTF facility at Solar’s Kearny Mesa continued on page 16 ince the introduction of its first centrifugal compressor in the early 1960s. is part of a substantial investment in new product development. Solar Turbines has steadily developed its compressor product line that now covers a wide range. Mars. Taurus. INNOVATION STANDARD IS THE TRUSTED LEADER IN N AT U R A L G A S C O M P R E S S I O N C O N T R O L S Murphy by Enovation Controls continues to invest in products that help you get the most our of your business and reduce unscheduled downtime. We are creating new ways to help you grow by: Continuing to innovate Developing fit-for-purpose products Bundling end devices that you need to save you more By continuing to add diagnostic capability, performance improvements and unrivaled support, we will work diligently to make the Murphy choice the easy choice. With more than 75 years in the industry, Murphy is the smart choice, too. FIND OUT HOW WE CAN HELP YOU GROW YOUR BUSINESS Contact us for solutions and services. Phone: 918-317-2641 www.fwmurphy.com/newstandard n A significant amount of development and production compressor testing has taken place at Solar’s closed-loop test facilities, which accommodate ASME PTC-10 Type I and II testing. One of the closed-loop facilities is driven by a dedicated 8 MW variable speed electric motor (top). The extensive data gathered during these tests (bottom) is fed into the company’s prediction database to improve analytical models and to improve compressor durability and reliability. MAY 2016 16 complex is used for research, development and production, including new and aftermarket testing of compressors in accordance with ASME PTC10 Type I and II. In the first two bays, a dedicated Titan 130 gas turbine engine and an 8 MW variable speed electric motor drive (VFD) — equipped with universal driven-equipment skids — enable full load testing in a hydrocarbon or inert gas closed-loop up to 3500 psig (241 bar). The third test bay can accommodate full compressor package closedloop string testing up to 30,000 hp (22.3 MW). Testing of Solar compressors at the GCTF facility provides mechanical integrity, accurate measurements and aerodynamic performance. It also ensures rotordynamic stability and low vibration that meet or exceed API requirements. In addition to testing new compressors, the GCTF facility is available to test customers’ gas compressors after overhaul or restage. At its Harbor Drive complex, Solar has an additional closed-loop test facility, which is also used for Type II compressor testing, with a dedicated Centaur 40 gas turbine driver. In the closed-loop facilities, production or aftermarket compressors can be shop tested under load to reproduce the aerodynamic design point. Field gas properties can be simulated through a variety of gas mixtures. Performance verification with shop tests before site commissioning is critical to many customers. Solar is aware of customer requirements for availability and durability of compression equipment, which is why the company emphasizes significant development testing prior to compressor qualification. At development, the compressors are run on natural gas to their speed and pressure limits, pushing beyond their normal operation in the field. A magnetic exciter is used to directly measure damping in the rotor-bearing system. This allows verification of rotordynamic stability under actual operating conditions at high speeds and continued on page 18 COMPRESSORtech2 OPERATE AT THE NEXT LEVEL MODULAR RELIABLE EFFICIENT In an economy where it is important to reduce operational costs, the ZVI unloader does so by reducing down time, reducing maintenance costs and improving efficiency. The ZVI piston-style unloader valve can be used in all brands of compressors, at any speed, for both lubricated and non-lubricated applications 10 YEAR All trademarks.de | www.motortech.motortechamericas.com MAY 2016 18 COMPRESSORtech2 . BIG WORKHORSE – LOW EXPENSE! for more Call today n! Informatio Distribution partner for DENSO spark plugs MOTORTECH Americas. LLC Phone: 1-504-355-4212 | www. logos and symbols are exclusive objects to the right of their owners and are used for reference purpose only. . constants and operating limits. In addition to the closed-loop facilities.operate the unit being tested.com MAY 2016 Sloan_WhenMachinesStop_Mar16_CT. Let our certified lubrication technicians visit your location and conduct a survey of all your lubrication systems.800. 1.com SloanLubrication. then at maximum continuous speed.0250 Sales@SloanLubrication. and generating reports as needed. Product development advances from equipment tested in Solar Turbines’ production test facilities. These applications justify the higher cost of more extensive closed-loop factory validation of compressor aero- COMPRESSOR LUBRICATION SYSTEMS WHEN MACHINES STOP.722. PROBLEMS START.indd 1 dynamic and mechanical performance. Sloan’s Service is the key to flawless compressor operation. initiates automatic performance computations and prints the results for review for a permanent test record. and a well-running compressor. Test data are monitored by video displays as instructed by the test agenda. The system establishes specified test conditions. the unit is operated at break-in speed. Mechanical testing is performed first. while measuring and evaluating its performance. continued on page 22 20 COMPRESSORtech2 2/22/16 3:56 PM . The suction and discharge nozzles are connected to an open-loop configuration that uses atmospheric air. and vibration levels are measured and evaluated against established limits. When acceptable performance levels are achieved. two open-loop test facilities are used to test every Solar Turbines compressor prior to shipment to evaluate mechanical and aerodynamic performance in accordance with test procedures and acceptance criteria as outlined in applicable test specifications. The two open-loop test facilities have dedicated drivers — a Centaur 50 and a Saturn 20 gas turbine. checking values and limits. the test technician initiates a command to a computerized realtime data acquisition system that captures all instrumented points. Key mechanical parameters such as seal gas leakage and separation seal air flow. time-saving evaluation that will give you peace-of-mind. After preliminary checks and static seal testing. oil flow. The dry gas seals are tested statically with nitrogen. It’s a simple. Closed-loop testing is used for development purposes and is often specified by customers of mission-critical compressor applications. selecting various parameters for display. This system can provide backup fuel and startup fuel for operations running on well head gas.girtz. Modularity is also incorporated into the power generation side so that the generator can be replaced with any type of prime mover such as gas compression. liquefied natural gas or liquefied petroleum gas. micro turbines.n Every gas compressor that Solar builds is tested at one of its open-loop test facilities.indd 1 21 2 COMPRESSORtech 1/6/15 1:37 PM . This mobile system allows for interchangeable fuel systems that can be compressed natural gas. A world class solution for your mobile packaging needs Girtz has engineered a modular solution that combines a flexible fuel cell with mobile power generation equipment. The leader in engineering & manufacturing of enclosures for stationary & mobile industrial equipment 1-844-GO GIRTZ | www. The extra fuel storage allows your bi-fuel diesel system to operate in remote locations and extend the operation of gas fired equipment. which have dedicated drivers — a Centaur 50 and a Saturn 20 (right) gas turbine. or pumping stations.com MAY 2016 Girtz_G-Cube. Larger compressors can also be tested open-loop on a (normally) closed-loop test facility driven by a Titan 130 gas turbine (left).com | sales@girtz. “These modern computational tools. scaled model testing at Solar’s ATF. return vanes and volutes. CT2 After the mechanical tests. but also to extend our knowledge of critical parameters. “This extends the prediction capabilities of the design software and improves the ability to design stages with the best compromise between head. Since standardized aero components are used in Solar compressors rather than a completely customized design. For each test article. together with the expanded test capabilities. Surge points are determined at various speed points to validate the surge flow estimate for the entire operating speed range. flange-to-flange performance is determined. In this facility.” said Manoj X. have been used to design compressor stages with high efficiency and a wide operating range. manager. together with the facility data acquisition and reduction system. adding that the ATF tests are used to validate and establish limits of 1-D and 3-D design codes. The primary objective of the test is to confirm the accuracy of the individual stage characteristics used for predicting compressor aerodynamic performance at the air-equivalent design speed. The optimization process makes extensive use of 3-D modeling components. such as diffusion or flow angle. marketing & product strategy. efficiency and flow range. exclusively dedicated to development testing. “The objective of the facility is not only to design and test stages with the best efficiency for direct application to a production stage.n Solar’s aero test facility (ATF) enables testing of scaled single centrifigal compressor stages while making detailed measurements in order to improve prediction capability and help understand component performance. “For example. pre-engineered and pretested components rather than customized stages. etc. far more effort can be spent in careful optimization. and full size testing in its closed-loop test facilities. validates mechanical and aerodynamic performance. evaluate and understand stage component (impeller. using computational fluid dynamics (CFD) tools.” Schor said. Extensive instrumentation. diffusers. The impellers for Solar pipeline compressors have complex 3-D blades with inducer inlet sections. Many different types of compressor stage components can be tested in the ATF. A separate aero test facility (ATF) allows for testing scaled single stages while making detailed measurements in order to improve prediction capability and help understand component performance. return vane. flow speed line from choke to surge and the surge line position against prediction when operating at a speed equivalent to the specified site design speed. are responsible for the adverse effect on component stability. Solar’s engineers can test entire compressor stage impellers. MAY 2016 22 COMPRESSORtech2 . These stages can either be scales of existing production stages or experimental stages. and gather data to help design the next generation of compressors.) losses.” Throughout its compressor line. correlations can be derived as to what critical parameters. establish guidelines for aerodynamic parameters. “This process extends our aerodynamic design knowledge. Solar Turbines makes use of pre-designed. Accuracy is determined by comparing the overall head vs. aerodynamic testing on air occurs. a stage can be designed deliberately with a sub-optimal surge margin and. by analyzing test data and predicted data. Static and total pressures are measured at various locations throughout the stage to determine overall stage performance as well as the performance of each individual component. Dutt.” Schor said. 2016 EDITION XX WWW.NET CTSS .CTSSNET. such as compressors. At NAM/Shell. sometimes months. The rotors for such applications are held suspended in the center of the bearing without any friction or wear. applicable to all rotating machines (specifically high-speed and large-dimension machinery) is active magnetic bearings. The Simotics AMB technology allows the use of standard components from the Siemens portfolio. CT2 n order to limit the wear of moving components. electric motors/ generators. The system is built around standard controller and converter units from the Sinamics family of products from Siemens. such as Sinamics and Simotion control and converter units. To achieve this. The illustration shows a special split bearing as used in a feedpump drive turbine at the Jänschwalde power plant in Germany. configurable human machine interface for system monitoring. The PC-based Simotion P320-4 controller forms a customer-specific. this procedure has been reduced to a few hours and has created new opportunities in the design and implementation of all types of rotating equipment. Siemens has introduced an AMB system for large machines. The analog tuning procedure could take several weeks. With its Simotics Active Magnetic Bearing (AMB) technology. communication with the higher-level plant controller and for auxiliary commissioning functionalities. pollute the environment or the fluid used by the machine. For more than a century. in some cases. two 23 MW high-speed compressor drive trains running at 6300 rpm in the Netherlands’ Groningen gas field utilize Simotics AMBs. The Sinamics standard control components are used both in the IDS in the drive train to control the magnetic bearings as well as in the main converter. Oil consumption can be expensive and. gas and steam turbines. covering their surfaces with an oil film is a conventional practice. With the advent of digital control systems. can be held in a position window that has the diameter of a human hair. sensors record the position of the shaft 16. high-voltage motors or industrial turbines and compressors. spinning at maximum speed. this has been the only way to avoid friction between moving metal components. An alternative system. Simotics AMB technology seamlessly integrates into the Siemens TIA concept. such as high-speed. While not new. In the context of Totally Integrated Automation (TIA) and Integrated Drive Systems (IDS). I precisely in the bearing center.000 times a second and a regulator adjusts the magnetic field to keep the rotor hovering MAY 2016 24 COMPRESSORtech2 . this system’s biggest drawback was its control system. as all components in it are mutually compatible and system tested. Simotics AMB technology is already in use. the company said.Active Magnetic Bearing System For Introduces Simotics Active Magnetic Large Machines > Siemens Bearing technology for wear-free operation in large-machine applications BY ROBERTO CHELLINI n Simotics Active Magnetic Bearing (AMB) technology for wear-free operation in large-machine applications. Even rotors weighing several tons. Simotics AMB technology is a highly efficient and matched solution for large machine applications. as well as at Germany’s Jänschwalde power plant in a 10 MW steam turbine running at 5700 rpm. services and lifecycle support of the leader in online monitoring at your disposal.com www.
[email protected]. Best of all.com . With PROGNOST. Critical assets – from rotating equipment to gear boxes and bearings – achieve true reliability. PROGNOST is your portal to the world’s most comprehensive and effective machinery diagnostics expertise. machinery and people are protected from the unexpected. maintenance decisions become clear and fact-based.Intelligence on Duty From here. you see greater uptime. See for yourself how machinery uptime grows with the systems. including electrical feeders. the HighPROTEC-2 interfaces with Woodward’s engine and turbine controls and generator set controllers to form a complete control and protection solution for generator systems. as well as electrical generators. Modbus. a failure is always possible. parameter configuration. A quick replacement with top quality DCL Metalcor® products is the key to getting you out of trouble. CSA. Catalyst elements work hard under extreme conditions. and communication protocols (DNP3. and fault data. transformers and motors. DCL WILL BE ON THE SPOT. The HighPROTEC-2 has worldwide certifications including CE. Programming and operation menus.dcl-inc. Broad voltage and current inputs (0-800V ac and 1A/5A). 1-877-965-8989 www. Users can configure each product to address the specific aspects of a given application. mains decoupling and line protection. Nine separate HighPROTEC-2 products target different electrical applications. alarms. www.S. This flexibility reduces the number of product variations that occurs when matching a solution to unique application requirements. wide range input power.woodward. available in seven different languages. trends. IEC 61850. So you won’t be on the spot – we will. We stock a wide range of products in our Houston facility. A PC-based service tool simplifies configuration and includes parameter plausibility checks and an ANSI menu structure.0. Using the expanded communications capabilities. UL. reside in each unit. A graphic display shows the HighPROTEC-2 connection architecture along with real-time operating values and messages.com OKLAHOMA CITY • DALLAS • GILLETTE • HOUSTON • LOS ANGELES • TORONTO • DENVER . It includes a display screen editor and event.FEATURED PRODUCTS Protection Relays Woodward’s new HighPROTEC-2 protection relays are designed to protect electrical buses and equipment. and even with regular maintenance. EAC and marine certifications.com/hpt-2 WHEN CATALYST ELEMENT FAILURE PUTS YOU IN A BIND. ready for rush delivery anywhere in the U. Profibus) provide application flexibility. And a plant operation shutdown is never a good thing. These medium-voltage protection relays for generators and power distribution applications monitor the electrical condition of equipment and disconnect the power source quickly when a problem or potential problem is detected. and disturbance recorders and counters to aid operation and troubleshooting. . . . MAY 2016 Russian licensee REP Holding assisted with the engine development. according to the test results. The test confirmed turbine efficiency. Italy. facilities last September. and designing the engine package for the Russian market. GE Oil & Gas completed the full-load engine test of its 16 MW industrial gas turbine for mechanical drive compressors and power generation. GE said. A gas generator full-load test also took place before GE shipped the module to REP Holding’s Nevsky facility in 30 COMPRESSORtech2 . power output and emissions levels. which involved validating the engine requirements and main design parameters. MW gas turbine slated for GE Tested. while emissions came in lower than expected.n GE Oil & Gas completed a full-load engine test of its 16 MW industrial gas turbine last September. Efficiency and power were higher than analytical forecasts. REP Holding also contributed to the preliminary and detail design. as well as the crafting the low-pressure turbine. REP Approved > 16 Russian installation BY ROBERTO CHELLINI A t its Florence. which went through its validation and characterization test campaign.TULCO. We offer quality products with high-tech support and comprehensive service. The engine was heavily instrumented with research and development strain gauges. Tulco’s Lubsoil® Synthetic LPG-WS and LPG-WI Lubricants provide optimal performance and better equipment protection compared to any other lubricant on the market. as well as fully characterize the performance of each machine component and define a baseline thermodynamic cycle. semi-synthetic and full synthetic Lubsoil® brand lubricants. continued on page 32 DESIGNED LUBRICANTS. Petersburg. WWW. No matter the challenge you have with your compressor. the company said. the licensee performed further joint testing on the gas turbine as well as subsequent field installation at a combined heat and power plant. The latter will constitute the starting point to further increase the turbine power output and efficiency. Tulco’s synthetic lubricants offer: Reduced gas solubility leading to extended lubricant life Improved compressor efficiency and wear protection Superior performance in vapor recovery compressors Excellent performance in H2S and CO2 rich or “heavy” gas compression St. temperature probes and pressure probes MAY 2016 Tulco Oils has been a top-rated global marketer for decades. The instrumented unit will remain on its test stand in Florence for research and development purposes throughout 2016. temperatures and secondary flows. DESIGNED TO BE THE BEST. a dedicated test stand was constructed with a gearbox from GE Lufkin and an electric generator from GE Power Conversion. all while increasing your compressor’s productivity. while also improving emissions. GE Oil & Gas finished the assembly of a fully instrumented unit. At the facility. The measurements will be used to finalize the digital engine model. the Tulco team will have a solution. Our field tested and formulated products are proven to save downtime and money.(among other equipment) in order to map performance. Two months later in Florence. In order to test the complete GE train configuration. Russia.COM (800) 375-2347 31 COMPRESSORtech2 . and manufactures petroleum. developed in collaboration with TransCanada Corp. CT2 COMPRESSORtech2 . The three units will be used to drive REP Holding centrifugal compressors as part of the modernization of Russian pipeline infrastructure. which will be used in St.com MAY 2016 32 GE Oil & Gas is working on the production of three gas generators for REP Holding. test.download to PC anytime Contact Testo now for a free trial version
[email protected]. with a dedicated GE Oil & Gas designed package and BOP. GE Oil & Gas announced an all-GE pipeline configuration of its 16 MW unit. GE Oil & Gas said. The job. temperatures and secondary flows. esting T e n i g #1 En re! Softwa TEC soft Testing & Emissions Compliance Software for the testo 350 Emissions Analyzer Now g din Inclu • New automated testing runs • New standard calibration template • Improved calibration screens • New template with gm/bhp calculations Intuitive: Simple navigation and “Site” setup Flexible: Calibrate. Petersburg. and launched as NovaLT16. GE Oil & Gas is working to produce one complete turbo compression train for installation along a Canadian pipeline in Alberta. The modernization is expected to improve transportation efficiency (amount of natural gas consumed vs. temperature probes and pressure probes (among other equipment) to map performance.com • 1-800-227-0729 • www. review. requires more than 4000 GT units. it is called the NovaLT16 for the Russian oil and gas market. REP Holding will complete the manufacturing of the lowpressure turbine modules and engine packages to create the T16 gas turbine engine. transported gas and availability) with longer maintenance intervals and a smaller environmental impact.n GE’s 16 MW industrial gas turbine was heavily instrumented with research and development strain gauges. or print anywhere Efficient: Save testing values into analyzer . In 2014. which will see industrial gas turbines replacing aged turbo-compressors. analog output of 0 to 5 Vdc. a division of Harold G. www.79 in.5. flat washers and lock washers are also included.1 mm) standoff spacers to provide sufficient clearance for shaft shoulders. Schaevitz Industries LLC. chart recorders and controllers. Split rings come in mating halves that simplify field installation around the shafts of in-service/coupled motors. and a response time of 1 ms.com The Sensor Connection The Sensor Connection.com . They are provided with 0. (67.7. this output is ideal for interfacing to instrumentation equipment including data loggers. This Single Channel Type K Thermocouple Amplifier Module converts the low output voltage signal from a Type K thermocouple probe to a single independent linearized 0 to 5 Vdc output voltage. (12. Product features include a Type K thermocouple input.5 in. The Aegis Pro SLR Ring is specially designed with O-ring barriers that prevent the ingress of dust. Mounting bolts. and excessive contamination that could lessen contact of the ring’s conductive microfibers with the motor shaft.4 and 38. The Aegis Pro-MR combines a PRO Bearing Protection Ring with a shaft voltage-monitoring ring in a single unit.0 and 1. 1.64 to 7. temperature measuring range from 32 to 2282°F (0 to 1250°C). Specially designed universal mounting brackets allow installation of Aegis Pro Series Rings on large motors. According to the company.05 to 197. has expanded its line of measurement and control instrumentation with the addition of the model TCAMS-K-1. slingers. http://thesensorconnection. or other end bell protrusions.8 mm) greater than the shaft diameter. temperature indicators.FEATURED PRODUCTS repaired motors prior to their installation. 25.est-aegis. These brackets attach to Pro Series Rings with screws and have slotted legs that allow mounting to the motor with a bolt circle of 2. debris. shafts. I equipment manufacturer).” Types of projects include rerates for improved performance.” said Jerry Hallman. component repairs. RMS performs a wide range of services on turbomachinery. specializing in the support of the former A-C Compressor line of centrifugal compressors. as opposed to OEMs. including reliability improvements. casings. and an assembly shop (right) with a full range of lifting.RMS Expands Machinery Services Inc. fluid catalytic converter (FCC) and nitric acid expanders. inspectors. Its experience includes axial and centrifugal compressors. company president and co-founder. “Our assemblers. The company has experience with repowering turbomachinery packages and has also supplied new custom-designed equipment skids and lube oil systems. and field service that ranges from inspection and turnaround support to providing supervisors to full turnkey responsibility. a group of experienced turbomachinery engineers with a strong aftermarket engineering background founded Rotating Machinery Services Inc. becoming a major force in providing turbomachinery aftermarket engineering and repair services to the refining. engineered overhauls of rotors and complete machines.ft. “We take pride in our ability to refurbish turbomachinery to a condition that ensures long-term trouble-free operation for our customers. giving users a complete alternative to the OEM (original MAY 2016 34 COMPRESSORtech2 . And we provide customers with open access to RMS’ experts. mechanical redesigns and upgrades.000 sq.” Hallman said. machinists and field service supervisors have an average of 25 years of experience in their respective fields and continued on page 36 n 1998. Pennsylvania. Wisconsin. provides full range Its Footprint > Rotating of turbomachinery repair and upgrade services BY NORM SHADE n The RMS service facility consists of three 10. moving and storage equipment. reapplication of surplus equipment trains. aeroderivative power turbines and steam turbines. RMS opened a satellite engineering office in Appleton. We also focus on ‘orphaned’ equipment that is no longer fully supported by an OEM. “We have a total focus on existing compressor equipment. power generation and steel industries. We can provide superior engineered solutions to long-standing problems that the OEM is unwilling or unable to solve. “RMS provides a full range of turbomachinery services. disks. Earlier this year. the company has steadily grown its business. component replacement and the supply of upgraded/overhauled surplus equipment. new parts supply including rotor blading. (RMS) in Bethlehem. (929 m2) bays that include a rotor assembly shop (left). large-capacity machine shop with quality control room. chemical. gas turbines. repair. which have their resources focused on new equipment. performance optimization. bearings and seals. gas transmission. Now in its 18th year. stators. reliable and efficient rotating equipment for nearly every application in the oil and gas market. As you have come to expect.Everywhere. wherever you are. for the applications that matter to you. downstream and in-between. But there’s more. So what can you expect from us? High-quality products and services. The new Dresser-Rand business now has expanded resources and more experience as a member of the global Siemens family.com . dresser-rand. Providing solutions for oil and gas applications upstream. We are where you need us. combined with local support around the clock. Welcome to a new era of innovation and technology. We offer more choices—where you need us—all from a single supplier. Dresser-Rand provides safe. The Dresser-Rand business combines one of the industry’s most extensive portfolios of rotating equipment with a universe of intelligent solutions and one of the world’s largest technical support and service center networks. Engineering makes the difference.” RMS has analytical capabilities in structural analysis...” said Robert J. totaling 559. Reliability. vice president. Integrity.com 36 take great pride in our facility and our ability to handle our customer’s property with the greatest efficiency and attention to detail. Klova.axh. and RMS supplies field supervision for each crew to ensure proper execution of every project. Strong design and analytical engineering form the backbone of everything we do.100 SF on 67 acres. PE. “We leverage our experience with the latest engineering technology.” Hallman said that RMS is affiliated with respected millwright service organizations throughout the country. (918) 283-9200 MAY 2016 Fax (918) 283-9229 www. “Our organization is made up of uniquely experienced engineers and technicians. chief engineer and cofounder. The AXH manufacturing complex consists of six plants. rotor dynamics and metallurgy using the latest analytical tools.Experience. The RMS service facility consists COMPRESSORtech2 . and we focus on continuous development of the next generation of turbomachinery engineers to serve customers’ future needs. aerodynamics. Experience in all types of custom-engineered turbomachinery separates the optimum solution from the run-ofthe mill. The temperature-controlled. The machine shop houses multiple large machine tools including a 5 in. a variety of hydraulic coupling and tie-bolt stretching equipment. a 52 in. MAY 2016 rotary table inspection stations. (8. The assembly shop has six large assembly cells. a Mazak 300M CNC turning-milling center. (127 mm) bar CNC horizontal boring mill. A recent major project was an ammonia/water turbine generator set. machine shop with quality control room. (929 m2) bays that include a rotor assembly shop.. The machine shop is equipped with 25 and 15 ton (22. positive material identification equipment and two precision air bearing LOW. coordinate measuring equipment with scanning capabilities. aerodynamics (e.hoerbiger. ready for immediate dispatch to customer sites.000 sq.. (5994 mm) between centers engine lathe. (6.5 tonnes) overhead cranes. (1524 mm) swing CNC vertical boring mill. (18. quality control room houses a number of granite tables. nondestructive test (NDT) area with magnetic particle and wet magnetic particle booths.RATING n The capabilities of RMS’ experienced engineering staff include expertise in all major types of custom-engineered turbomachinery and a full range of analytical expertise with the latest analytical tools in rotordynamics. and a Bracker hydraulic rotor tenon peening system..5 tonnes) overhead crane. To support the project. steam turbine blade erosion. right). This shop is supported by a 35/15 ton (31.g. a 60 in. knee mills and grinders. turbine disk.2 m) hook height and multiple jib cranes. RMS provided the complete train of equipment..1 m) fully equipped sea container/shop and gang boxes. including the application of dry gas seals for ammonia containment.140 and 7710 kg). RMS’ field service operations maintain a 20 ft. which is serviced by a 25 ton (22. (2286 mm) swing vertical boring mill.ft. left). RMS had to develop continued on page 38 37 low-rating. an electrical runout (glitch) system.000 lb.5 and 13.. Also in this area. houses multiple indicating stands and stacking pits. developed from a surplus steam turbine for a process customer in Pakistan... and an assembly shop. (1321 mm) swing by 236 in. . center) and performance (e. structural analysis (e. with new controls and auxiliaries. centrifugal stage flow path.g. and a 90 in.g. The rotor shop.. RMS’ capabilities are evidenced by its list of successful turbomachinery projects. .com of three 10.. a weld shop. two Schenck balancing machines with respective capacities of 40. as well as a variety of small manual lathes.000 and 17. an abrasive blast room and multiple abrasive blast cleaning cabinets.5/13.5 tonnes) crane with 27 ft.. Starting with a surplus train. an I-R E520 nitric acid tail gas expander experienced a highpressure seal failure. Improved cold alignment. performance analysis capability for ammonia and steam mixtures. the lowest historical level for this expander.n RMS provided this complete ammonia/water turbine gen-set for a process customer in Pakistan. including controls and auxiliaries and the application of dry gas seals for ammonia containment. RMS engineering supervised the change-out of the damaged expander with a spare unit that had been sitting idle following a multiyear run. The spare expander had experienced high of 2 to 3 mils (51 to 76 µm) and unstable shaft vibrations during its prior run. RMS completely designed the axial compressor and rerated the turbine. MAY 2016 38 COMPRESSORtech2 . Nitric acid is the basic material for the production of fertilizers. The company has special expertise in fluid catalytic cracker (FCC) and nitric acid expanders. n RMS provided this complete machinery train for a nitric acid plant in 2008. It also rerated the customer’s existing expander during a turnaround. providing a new lube oil console as well. it provided the complete train of equipment. To support the project. Developed from a surplus steam turbine. In 2014. bearing changes. and careful setup resulted in low and stable vibration of less than 1.06 mils (27 µm). explosives and chemicals. RMS had to develop performance analysis capability for ammonia and steam mixtures. n An axial compressor rotor is ready for return to a customer after an engineered overhaul in RMS’ shop. Utilizing forged material from in-house stock. A failed Elliott hot gas expander was at the heart of the breakdown. RMS provided a complete machinery train for a nitric acid plant. one week ahead of the agreed-upon 14 weeks. RMS completely designed the axial compressor and rerated the turbine.and second-stage stator housings in an expedited 16 weeks from date of order. Starting with a surplus train. Last year. providing a new lube oil console as well. RMS’ field service team travelled to Europe to support the installation of the intake casing and expander assemblies. so that the entire replacement rotor assembly was assembled. and new CAD models were created. continued on page 40 n RMS provides engineering and support to users with older power turbines. RMS was able to complete five-axis machining of the impellers and a finished product. The engineering and manufacture of a new shaft. The impellers were reverse engineered through mechanical and FaroArm inspection methods in four weeks. in less than eight weeks. balanced and shipped in 13 weeks. MAY 2016 39 . It also rerated the customer’s existing expander during a turnaround. casing redesigns. Dresser-Rand DR61 and DresserClark DJ125. including overspeed testing. In 2012. Projects have included remaining life predictions for rotors and stationary components. such as Cooper RT65. In 2008. enabling an early startup. During the inspection process. balance piston and shaft sleeves were completed in 12 weeks. and rotor and complete power turbine overhauls. I-R GT51 and GT61. The company then received another contract for a root cause analysis of the failure and for rebuilding the damaged expander using an existing spare rotor. RMS was able to restore the main axial compressor to service on motor only within a 10-day period. RMS also performed a rotordynamics analysis and developed performance curves for the design. In addition to service and repair. It was able to deliver a new intake casing assembly. RMS engineers analyzed the inspection information. replacement of major stationary and rotating parts including outer casings and rotor disks. RMS was offered a unique challenge to urgently replace a Cooper-Bessemer RC20 compressor rotor that suffered a heavy rub failure caused by impellers contacting the diaphragms. RMS was contracted to support the emergency breakdown of a European refinery’s FCC power recovery train. including first. RMS determined that the entire intake casing assembly was no longer suitable for service. field service. the end user was faced with the need to replace the machines entirely. RMS developed a number of unique features that have significantly improved blade and disk lives. These include low-erosion rotor and stator airfoils. solving turbomachinery problems with engineering analyses and improved designs has always been an RMS focus. The new compressors were installed in the spring of 2014. a 1968 vintage GHH horizontally split centrifugal compressor in a toxic gas service had experienced chronic joint leakage over many years. service and support has earned it a strong and growing place in the FCC expander aftermarket. However new compressors would not match the existing layout MAY 2016 40 and pipe locations. blade platform seals. The end user tried various fixes including purchasing a spare compressor with a thicker casing. “RMS’ significant experience in all aspects of FCC expander design. The low erosion design doubled the life of the rotor disk and blades to six years at one customer site. and a unique overlapping platform design upgrade that shields the rotor disk from the harmful effects of catalyst laden flue gas. and lead time was over 30 months. Finally. Dry gas seals and a new common oil system were also included as part of the upgrade. where numerous refineries rely on us to support their FCC power recovery trains. completely eliminating the chronic leakage problems.n RMS refurbishes and upgrades process (left) and pipeline centrifugal compressors including new custom-engineered aerodynamic assemblies (right). For example. FCC expanders can experience significant erosive wear due to catalyst particles entrained in the flue gas.” Klova said. yet the sealing problem could not be consistently eliminated. bearings and inner seals. The complete units utilized new RMS casings and diaphragms with the customer’s existing rotors. RMS custom designed and manufactured two new 300 series stainless-steel “drop-in” replacement compressors with upgraded barrel type casings to solve the split line leakage problem. CT2 COMPRESSORtech2 . Using computer fluid dynamics (CFD)aided state-of-the-art aerodynamic design. com TrueRock released brochures to highlight the features and benefits of its line replacement/upgrade parts for Gemini compressors. The brochures feature the H Series aluminum piston rod (pictured) and the M/H Series variable volume clearance pockets. www. Fuzzy’s cooling solutions include radiator packages.truerocksupply.fuzzysradiator.com A-76 Technologies supplies the A-76 line of preservation coatings and lubricants.LITERATURE Compressed Technical Services Cooling Solutions Gemini Upgrade Parts Preservation Coatings Stark Industries’ brochure outlines its Compressed Technical Services offering. fin fan packages. www. cooling coils. radiator cores. A green variation contains no volatile organic compounds. www.a76tech. helping customers reduce emissions. soda blasting and repair services.com The Fuzzy’s Radiator brochure lays out the products. heat exchangers. high-salinity environments. oil-removal systems and air-storage solutions are enumerated along side the company’s services offering. www. CTS designs and manufactures compresor system packages for industrial gas. charge air coolers.com Stop by Booth 301/400 at the EGCR for more information . hydro blasting. offering corrosion prevention and lubrication in highhumidity. gaskets. services and technologies used by the Texas panhandle company. Compressors.starkindustries. The motor operates at 4000 hp (2983 kW) at 327 rpm.000 lb. Great attention is paid to all details of the plant in order to achieve maximum operating time. minimize costs BY JIMMY SALMON AND ENZO GIACOMELLI n Booster primary compressor. The compressor has 24 Nuovo Pignone-designed valves manufactured by Cozzani. All the cylinders are equipped with plastic piston and packing rings. The second stages have one suction valve and one discharge valve per cylinder. production and performance aspects of the booster primary compressor follow.Ing. designed and manufactured by GE Oil & Gas. MAY 2016 42 COMPRESSORtech2 . The booster primary compressor brings the pressure from low value up to the suction of the hyper compressor that feeds the reactor. T he production of low-density polyethylene (LDPE) requires special compressors to obtain the pressure necessary for the product. the primary’s first stage is double acting with 2+2 valves. The booster primary compressor requires stringent capacity control. The three cylinders are double acting on the booster. while the two second and third stages are single acting and positioned on the same cylinder with a tandem arrangement. It is the same one that is applied for the booster/primary and hyper compressor.Mario Cozzani Srl./hr (25. a capacity of 16. The discharge of the primary reaches 3600 psi (25 MPa) to feed the hyper compressor. which combines the function of the booster and primary on one frame manufactured by Nuovo Pignone (now GE Oil & Gas). Plant features The booster primary machine is a six-cylinder. The primary compressor operates up to 3771 psi (26 MPa) and has two cylinders with a tandem arrangement (secondstage inboard and third-stage outboard). while the third stages have one combined suction and discharge valve per cylinder.000 kg/hr) for the primary. The valves represent an important component that strongly influences the reliability of compressors and the plant. The machine has Jimmy Salmon is a senior principal engineer with 40 years of continuous service in LDPE maintenance. maintenance strategies help to optimize availability. The cylinder lubrication is made with a mineral oil with lubricity additives.Analysis: Valve Performance On Booster Primary Compressor For LDPE > Production of critical parts. reliability and production.000 lb. An analysis of the design. is an eight-cylinder machine that raises the pressure to full reactor pressure.6 MPa). The hyper compressor. Enzo Giacomelli is a consultant for Dott. further increasing its complexity./hr (7000 kg/hr) for the booster and 56. Additionally. collecting the gas from the plant recovery system. multiservice compressor. The booster’s suction pressure is slightly above the atmospheric one. which reaches a pressure of 3278 psi (22. bearings and valves are replaced on a time-based schedule. Changes in gas temperature and interstage pressure were the signals to indicate failing valves. there were no issues. pressures and vibration). including a surface treatment for longer life. Castle-type locknuts were used to prevent the assembly from loosening in service. such as springs and rings. The capacity control requires the use of finger-type.Valve applications The set of 30 valves is equipped with metal rings in all stages of booster and primary. After this shutdown. and functional checks on compressor alarms and shutdowns MAY 2016 43 COMPRESSORtech2 . (temperatures. we monitor process and oil temperature and pressure. One throw per shutdown is checked for web deflection. In 2006. The critical parts. Other work includes oil and filter change. A detailed inspection showed no problems. All other valves remained in service. Valve performance The valves are critical compressor components. onestep unloading systems as well as continuous bypass control. These inspections (nearly every two years) also include a rider band wear check. are designed to withstand fatigue stress. continued on page 44 Maintenance strategies In the years following the 1983 commissioning. Following the 1996 valve change. The valve bolts for the seat/guard system were provided with a threaded connection. a preventative. which followed the standards elsewhere on site. the next change occurred in 2002 for all of the valves. the primary third-stage valves were changed during re-ringing of the third-stage cylinders. the material of the seat and guards is alloy steel AISI 4140. lubricator box inspection. Their performance has been checked by pressure and temperature analysis. These nuts also include an anti-friction surface layer to reduce damage during maintenance. as the cylinders were already largely dismantled. In the first 13 years. we also check bearing clearances and rider band wear. In operation. Because the gas involved is not corrosive. the decision was made to use predictive maintenance for determining when the valves should be changed. Simulation programs have realized the design on the full operating range. Today. however. as well as machine vibration. We crack detect critical bolts by ultrasonic means. During the scheduled shutdowns. The machines have been manufactured to meet quality control procedures. timebased maintenance program was developed for the valves. A lengthy turnaround in 1996 provided an opportunity to change out all valves on a proactive basis. The attention to any deviation from the design parameters and homogeneity of the valves of the same cylinder is essential to assess performance and keep operations running until a failure can be predicted. Conclusions The original valves installed in a booster primary compressor have performed well from one proactive switch to the next during the 32-year window. The springs were intact. Every reconditioning was made according to the recommended procedure. The last valves placed in service now have nine years and are still operating. CT2 In 2013. with the coordination of the compressor manufacturer and supervision from the valve manufacturer. While slight wear occurred to some seating surfaces. Texas. The final reconditioning efforts took place in Cozzani’s service center in Magnolia. The valves were in good condition during each inspection. as part of the proactive replacement plan.indd 1 44 2 COMPRESSORtech 4/14/16 2:24 PM . The rings were in good condition. The primary third-stage valves were removed with lives of four to 13 years. All replacement parts have been designed to the original more than 30-year-old design. Although potential design improvements could be made. such as plastic rings.Most valves have lives of six to 13 years. n Ring valves after disassembly. There was also slight wear in the bottom of some spring recesses. with no cracks or broken pieces. with none of them broken or misshaped. the booster and first-stage primary valves were reconditioned. MAY 2016 EGCR_May16CT_HalfHorizNonBld. it wasn’t enough to cause performance issues. the original work suited this application. compressortech2.COMPRESSOR ECT Dedicated To Gas Compression Products & Applications E-NEWSLETTER Industry News Delivered Straight To Your Inbox m o C r e t pu ) 1 ( x o b n I d e r r a t S t SUBSCRIBE TODAY! n www.com/subscribe/ Se . The facility is the latest addition to Enerflex’s global branch network and the seventh location in Australia. Burckhardt Compression Burckhardt Compression will acquire a 60% stake in Shenyang Yuanda Compressor Co. established in 1997. manufacturing and service of reciprocating compressors. opened its new service facility in Adelaide.5 bara). flare gas capture and wellhead compression. CNPC will be the operator for this project. Enerflex Ltd. The correct minimum pressure is 50 psig (3. WESS will have product and service offerings that include vapor recovery. The contract is BP’s first shale gas production sharing contract in China and covers an area of approximately 579 sq. engine exhaust gas. In addition to unconventional resources. Correction The minimum suction pressure for MAN Diesel & Turbo barrel compressors was incorrectly stated in “Standardized Refinery Compressor Packages” in the March 2016 issue (page 75). a supplier of products and services to the global energy industry. Australia. upgrades. greenhouse gas monitoring and carbon capture. aftermarket service and support. location. The facility includes a workshop focused on equipment overhauls.K. the framework agreement covers possible future fuel retailing ventures in China. The 21.K. U. This production-sharing contract is the first achievement from BP and CNPC’s framework agreement on strategic cooperation that was signed last October during the visit to the U. trading under the same name and continuing to supply the same range of products.PRIME MOVERS them gain local market reach in new market segments. compression market.528 sq. exploration of oil and LNG trading opportunities globally.. Gasmet Technologies BP Gasmet Technologies has acquired Quantitech Ltd. and carbon emissions trading as well as sharing of knowledge around low carbon energy and management practices. provides advanced environmental and process monitoring instrumentation in the U. Ltd. WESS’ network includes the Middle East. Quantitech will remain at its Milton Keynes. Quantitech Ltd. As a LeROI packager and distributor. process control.mi.. Headquartered in Finland. MAY 2016 46 COMPRESSORtech2 . Following the acquisition.K. project optimization. by Xi Jinping. Burckhardt said the acquisition helps Wasco Engineering Services Singapore Wasco Engineering Services Singapore (WESS) has signed an agreement to serve as LeROI Gas Compressors’ authorized packager and distributor. LeROI controls more than 60% of the U. will provide Enerflex’s complete product and service offerings including compression. and integrated asset management for the Southern Australia region. the company said. located at Gilman. China.S. development and production in the Neijiang-Dazu block in the Sichuan Basin. Gasmet Technologies is a global manufacturer of gas monitoring instruments and systems for industrial and environmental applications including continuous emissions monitoring. BP and China National Petroleum Corp. South East Asia and Australia. a Chinese reciprocating compressor manufacturer. well unloading. Enerflex Ltd.ft. Shenyang Yuanda reportedly had sales of about US$111 million in 2015 with 650 employees. (CNPC) have signed a production sharing contract for shale gas exploration. president of The People’s Republic of China. (1500 km2). is focused on the development. retrofits. as well as a regional training facility and a parts warehouse. fuel gas compression. (2000 m2) facility. and general asset management. and Ireland. process and electric power equipment sales. Shenyang Yuanda. expands its product portfolio to cover market requirements and gives them direct access to a well-established local supply chain.. com www. such as blowers. Rotary Systems and Renewable Energies Exclusive Sealings Exclusive Materials Exclusively OEM We proudly present the SD50 Sealing Ring – a contacting segmented ring for rotating equipment. Suite 100.Now established and manufacturing in the US – German Experts in Sealing Technology for Reciprocating Compressors. 19911 Morton Road Katy. mixers and other rotating applications.stasskol. info@stasskol. The gas tight design reduces the loss of buffer gas and split housings are enabling an easier maintenance of the SD50 Sealing Ring. This ring provides a high sealing efficiency against the rotating shaft through overlapping sealing elements even at high shaft speeds up to 45 m/sec. Texas 77449 USA +1 713 2445050 .com STASSKOL GmbH Maybachstrasse 2 39418 Stassfurt Germany +49 3925 288100 STASSKOL Inc. dryers. 000 Chilled 47°F (8. the demand for larger capacity compressors has increased.000 20. continued on page 50 Chilled Output (HP)Turbine Output (HP) 0 5000 10. due to its clean. MAY 2016 to gain significant incremental gas flow from its existing facilities was very compelling. ease of operations and low emissions. the opportunity Gary Hilberg is president of Everest Sciences.000 25. A s natural gas usage continues to grow.3°C) 48 15. Contact him at: ghilberg@ everestsciences.A. forcing users to accept lower capacity or add Titan 130 19802S incremental equipment to comMars 100 15000S pensate for this loss. Petróleos Mexicanos S.V. Figure 1 shows the performance of sevMars 90 T1300 eral leading gas turbines used to Taurus 70 10300 drive compressors. Many operators use gas turbines to drive their compressors due to their power density.000 Ambient 100°F (37. cost-competitive and efficient nature.Inlet Cooling For Gas Turbines Driving Gas-Gathering indirect evaporative chilling Compressors > Hybrid systems help optimize performance BY GARY HILBERG n Hybrid indirect evaporative chilling systems are efficient due to their use of indirect evaporative cooling operating in series with mechanical chilling.8°C) COMPRESSORtech2 . (Pemex). Oklahoma to evaluate the potential benefits of providing inlet chilling the existing Solar Taurus 60 gas turbines at its Parédon facility. For one integrated oil and gas Taurus 60 7800S firm. Pemex worked with Everest Sciences of Tulsa. Centaur T6200 de C.com. One challenge with modern gas turbines is that they lose signifiChilled Turbine cant output and efficiency as air temperatures rise. . California USA KB Delta Inc.kbdelta. is an aftermarket and OEM supplier of compressor valve parts. however to the best of its knowledge. OEM specifications are adhered to on all of the parts manufactured. KB Delta makes no representation that all of the parts it manufactures are OEM parts.com 800-632-3994 Torrance.r o s s re p m o c r u o y t e g o t Looking for quality parts ? k n a b e h t g in k a re b t u o h it w t s fa g in n n ru d n a up QUALITY Y R E V I L E D T S FA COMPETITIVE PRICES KB Delta Manufacturing COMPRESSOR VALVE PARTS Metallic Plates|Thermoplastics|Springs|Buttons|Poppets|Kits|Center Bolts|Pins|Lift Washers|O-Rings www. indd 1 50 2 COMPRESSORtech 1/13/16 5:23 PM .n Inlet cooling optimizes gas turbine performance by cooling the gas turbine inlet air and providing more mass flow for combustion and increasing the efficiency of the gas turbine compressor.com ● Reduce your rigging weight and health & safety concerns by using the shackle-free Trunnion Spreader Beam system MAY 2016 Modulift_JanFeb16_CT.modulift. Unit 5 Performance & Reliability Test – January 2016 Unit 5 Performance & Reliability Test – Jan 2016 400 70 160 60 120 50 80 40 40 30 0 :0 :0 30 – 00 :0 18 – 29 29 – 12 :0 :0 06 29 – 00 :0 – 29 28 – 18 :0 28 – 12 :0 0 28 – 06 :0 28 – 00 :0 0 27 – 18 :0 0 27 – 12 :0 0 27 27 – – 06 :0 0 00 :0 0 26 – 18 :0 12 – 26 0 200 0 80 0 240 0 90 0 280 0 100 0 320 0 110 0 360 Temperature / °F 120 Power / kW 130 Date & Time TI-01 Ambient Air XI-02 Relative Humidity TI-05 Air Leaving ESID (primary air) T1 ½ TI-06 Final Leaving Air Temperature T2 Plant Power Spreader Beams Experts in the design and manufacture of standard and custom lifting equipment within the oil and gas industry Trunnion Spreader Beams ● Modular Spreader Beams up to 400t in stock and available worldwide for distribution Spreaderr & Lifting Frames ● Experts in custom lifting solutions and projects requiring high QA standards ● All products fully tested and certied with DNV Type approval as standard Lifting Beams ● In house rig design team building the ideal solution for your lifting needs For more information contact Head Ofce: +44 (0) 1202 621511 Email:
[email protected] www. leveraging the existing staff. and Pemex issued an international request for proposals in 2014.534. Call Summit today and reduce your lubricantrelated operating and maintenance costs. providing a consistent inlet temperature and system gas flow This evaluation showed a significant value proposition. For most applications. For the Pemex Parédon plant. Summit offers a variety of synthetic lubricant base stocks to solve these issues. CT2 Gas Compressor Synthetic Lubricants Synthetic Lubricants Save Money and Protect Equipment Come See Us at the EGCR Show Booth #523 Summit synthetic gas compressor lubricants are formulated and field tested to eliminate many of your serious gas compressor problems.klsummit. Summit Synthetic gas compressor lubricants will increase productivity with minimal downtime. with operations starting in early 2015.4 MMcfd (946 m3/d) in the coldest month of the year.0 MMcfd (8.com 903. as shown in Figure 2. Free technical support. Inlet cooling optimizes gas turbine performance by cooling the gas turbine inlet air and providing more mass flow for combustion and increasing the efficiency of the gas turbine compressor. in the summer it is expected that the perunit gas flow will increase by an additional 10%. Future projects with Pemex are expected to complete quickly now that all parties are familiar with the technology. Increased output from existing equipment optimizes the overall facility.com 51 www. this solution provides the efficiency of evaporative cooling without using incremental water. For the Pemex Parédon project.sublimedescaler. Call us we can help! Summit Quality • Service • Expertise 800.749.5 x 105 m3/d) to 33. and reduces the overall operating cost on a US$/hp-hour basis. The MAY 2016 even as the ambient temperature varies.5823 www. The hybrid indirect evaporative chilling systems tsolution is highly efficient due to its use of indirect evaporative cooling operating in series with mechanical chilling.8021 COMPRESSORtech2 . A key benefit of hybrid indirect evaporative chilling is the automated and reliable operations of the chilling solution. Each gas compressor application has its own unique set of operating parameters and issues. while still providing the consistent inlet air temperature of mechanical chilling. The two hybrid indirect evaporative chilling systems were installed in late 2015 and commissioned in early 2016. Gas flow is a key metric for all gas transportation companies.ability to gain 15 to 25% incremental power continuously over a 12-month period is a key advantage of modular inlet chilling solutions. Everest and its local partner Equipos Industriales del Golfo (EIGSA) received the contract to supply three hybrid indirect evaporative chilling systems to Pemex in November of 2014. this reduction in inlet temperature increased the per unit gas flow from 30. the modular equipment was factory packaged and tested and then delivered to the site for installation by EIGSA. PUZZLEMASTER I D O I M N Y T A G B R E R E O M K H M T Atheism Beige Being Blueish Caffeine Codeine Counterfeit Deigned Deionize Deity Dreidl Dyeing Eighty Einstein Either Feisty Foreigner Forfeited Freight Heifer Height Heirloom Heist Kaleidoscope Leisure Neighborly Neither Onomatopoeia Poltergeist Preignition Proteins Reign Reinforce Rottweiler Seismic Seizures Sheik Sleigh Sovereign Stein Surveillance Their Unveil Veins Weightless Weiner Weirdest Zeitgeist .com/scheduled-downtime/ for answers 5 I Before E.compressortech2. Except … D T V D Z C O U N T E R F E D R H E C N A L L I E A S I Y P E G I I I I P S T E N R B E I I N I B C F E N G E N C Y O D E S O E F O R F E G P T E U E S N E E Z W R H D R N R N E E A I I E I I I E D E Z E E U N N S G S G R E G I I I I T S I I I I N O D E I I I I E D L R H T Y T E R L E T F S R R Y P U O R G M H O G T G O S R E R T U D I L I S E E T M P E W H I I Y N C G T E O G S I I T R N V E I W N Y G E E N T O S H M L E H I I P T Z B E C R O F N I E L I I R O L G E R E E D S N W I I I L E T L G E E R T O Y E T T O G B H L F P S E D P M L R A T I E R S F S E E O B E V G H E S L A T G E U I S T Y S N U O L E E R F Y D R E F K E D O C O S E Z N B E H H F C I I T E D B P I I E H E F F A C E N M E H I I E V R U S S H E N L A D V L H T T S W M B E N T MARK THAYER.7 2 Scheduled Downtime 3 4 6 Visit www. USENERGYCORPORATION.COM Online Storefront Order your books. No charge for typesetting.com Phone: (262) 754-4140 MAY 2016 53 Page 1 . 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[email protected] 1 11/20/15 8:56 AM Custom Reprints Available Articles in COMPRESSORtech2 can be reprinted at a very reasonable cost and used for effective direct mail purposes. answering inquiries. trade show distribution and many other sales development activities. ...........................................................net) and/or 2016 Compression Technology Sourcing Supplement (at CTSSnet......................................................13 * Cozzani......................................................................... Mario Cozzani S.....44 SYNTHOSOL ...................................53 Modulift ..........43 PROGNOST Systems GmbH .............. Dott.................................................................................... ..................Dieselandgasturbineguide..51 E Instruments International ....................... ....................................9 Shinkawa Electric Co....................................................... The . 15......................................40 Compressor Products International .....................l.......................................................................................................................................................................................................17 ...........................47 DCL International Inc........................................................................................... Ltd...net).......................................... ............ Fourth Cover Armco Compressor Products Corp........ Inc............................................................................................ Mfg............................................................................................33 Eastern Gas Compression Roundtable ......... ACI Services Inc.................................................................................................Third Cover Neuman & Esser Group .......7 STASSKOL GmbH ....................................36 MOTORTECH GmbH .............. Inc.25 * Burckhardt Compression AG ............Ing........................................................................................... ................. ...............................................28-29.41 * KB Delta Compressor Valve Parts..................Second Cover Exline..................................31 HOERBIGER .................................................... Inc................. ....21 Tulco Oils ................... ..............3 BG Service Co........................18 Altronic......................................................................... ....5 Sloan Lubrication Systems ........ LLC .............1 Murphy by Enovation Controls ..........46 “Sumy NPO” PJSC ................................. 49 ADIPEC 2016 .........................10-11 * ARIEL CORPORATION .Advertisers’ Index *Further information on this company’s products can be found in the 2015 Edition of the Diesel & Gas Turbine Sourcing Guide (at www.......32 Girtz ..............................26 Sullair ................................................35 Summit Industrial Products .........................................................39 * Dresser-Rand .....19 * Testo.................... ...................................................20 Cook Compression .......................50 Air-Cooled Heat Exchangers ......27 * Elliott Group ..37 Zahroof Valves Inc...............................r.............. 9 PDX16 6. with MAY 2016 55 COMPRESSORtech2 . as well as encapsulated compressors and vacuum systems.5 108 to 385 3. commonly called “gas ends. Its line of single-stage air compressors ranges from 5 to 450 hp (3. Sullair provides the widest range of rotary screw compressors available for natural gas applications. An oil-free dry screw compressor line was introduced in 1979.5 400 or 500 27.0 to 4.7 to 47.03 204.04 255.0 PDR32 12.S.5 bar).4 bar) as well as spiral and slide valve options for capacity control.0 400 27. By 1968.4 PCC25 10. Sullair compressors are used in thousands of common applications as well as many unique applications that most wouldn’t expect — like fountains in Las Vegas and parades in New York City. was the first in the U.5 to 36. which became a public corporation in 1972. mm psig bar cfm m3/min PDX10 4. featuring an economizer port and slide valves for capacity control. delivering the first 500 psig (34. The new Sullivan Machinery Co.000 rotary screw compressors since its beginning. Sullair gas compressors have been commonly applied for vapor recovery. which became part of the United Technologies’ Hamilton Sundstrand business unit in 1999. In 1971. in response to customer needs. Sullair has remained a pioneer of air compressor technology.0 300 20. This made Sullair one of the very few companies with full lines of screw compressors optimized for both air and refrigeration applications.5 PDR25 10.2 200 13. thousands in operation and with some units running for well over 20 years. the Sullair line of portable compressors ranges from 185 to 1600 cfm (5.5 bar) two-stage portable compressor in 2003.7 PCC16 6. coal bed methane.Cornerstones Of Compression story continued from page 56 Rotor Diameter Max.03 204. market to completely rely on rotary screw compressor technology.3 PDX20 8. The PC series are direct drive units capable of flows up to 3527 cfm (99. Sullair OEM gas compressor models.6 to 8.04 255.3 200 13. Sullair celebrated its 50th anniversary.5 583 to 857 16.5 or 34. the company introduced stationary rotary screw compressors to the industrial air market. Sullair developed air treatment systems for its compressors and. Sullair was purchased by Sundstrand Corp. and a full line of pneumatic air tools was introduced in 1985 to complement the company’s portable air compressor line.4 to 12. In the early 1970s.6 bar).8 962 to 2329 27.3 200 13. Later that year it changed its name to Sullair. Discharge Pressure Full Load Capacity Range Series in.9 m3/min) and pressures up to 400 psi (27.1 to 10.3 PDX32 12. being designed for years of use in extreme field conditions.0 to 28. Together.8 1732 to 3292 49. Over the next two decades. CT2 in 1966. The PD series offers a range of geared and direct drive options to deliver flows up to 3292 cfm (93.5 PCC20 8. Over the ensuing decades. being offered in a complete turnkey package. gas gathering.8 258 to 555 7. after Sullivan had established itself in markets that use portable compressors.7 to 335 kW) and two-stage compressors range from 100 to 600 hp (75 to 447 kW).01 102. Today.3 to 15.3 m3/min) with output pressures from 100 to 500 psi (6. PDX and C series.0 400 27.43 163.03 204.06 408. rotary screw compressors would almost completely displace reciprocating compressors in portable and industrial air compression applications.2 400 27. landfill gas recovery. making it one of the first manufacturers to enter this new market.0 200 13.7 to 34. Responding to market demand for clean and dry air in specialized applications. Sullair screw compressors were first adapted for natural gas compression.8 554 to 1674 15.5 to 24. In 2012. they represent the broadest range of natural gas screw compressor types and options of any manufacturer in the market.2 PDR20 8.65 321.8 163 to 295 4.0 PDX12 5. In 1984. Operating behind the scenes in many cases.” are the PDR.2 m3/min) and pressures up to 600 psi (41.8 72 to 176 2. sweet and sour process gas and fuel gas boosting..43 163. the Sullair “C” series was developed for refrigeration applications. wellhead compression. developed a line of proprietary compressor fluids and related products that enabled it to become a dominant supplier in the air compression market. noting that it has manufactured well over 300.7 3527 100.8 547 to 1289 15.0 n In addition to being a leader in portable and industrial air compression markets.0 200 13.0 to 92.0 200 13.02 127.2 to 45.5 200 13.5 223 6.65 321.02 127. In 2015.4 PDH12 5.8 423 to 996 12.2 to 66.5 298 to 441 8.2 PCC40 16. it became part of Accudyne Industries Inc.0 200 13. As president. market to completely rely on rotary screw compressor technology. Hoodes and his team moved quickly to produce its first 150 cfm (4. especially marble. In 1946. Starting with Ingersoll Rand in 1958. Sullair has manufactured well over 300. in 1968. Early in the 1900s. mining. oil field exploration and industrial construction. which became Sullair Corp. In 1928. And during World War II.. a Pittsburgh-based manufacturer of mining and reciprocating compressor equipment. Sullivan Machinery Co. Through the years. Sullivan Machinery dates back to 1868 when the New England company was formed to MAY 2016 manufacture a newly invented diamond-channeling machine for quarrying stone. Hoodes departed Joy Manufacturing Co. Sullivan reciprocating compressors supplied high-pressure air for rock drills penetrating the backbone of the Cascades for the Great Northern Railway tunnel. Hoodes brought with him Roger Gustafson. name was previously connected with Joy. was the first in the U. the new company acquired a license from Svenska Rotor Maskiner AB (SRM) of Sweden to market rotary screw compressor technology. taking the name of Sullivan Machinery Co. Sullivan rock drills and channeling machines dug 185 ft. Indiana. Sullivan’s rapidly expanding business completed a new factory in Michigan City. excavated 15 mi. In Michigan City.S. Over the succeeding 50 years. Interestingly. In 1923. which opened the door for Hoodes’ new enterprise. was cited for its contribution in war production equipment and services.25 m3/min) portable rotary screw air compressor continued on page 55 56 COMPRESSORtech2 . Their shared interest was the relatively new rotary screw compressor technology that was emerging for air compressor applications. Borje Vagenius and C.S. In 1901 it purchased another company in Chicago that expanded its products and services in prospecting. Sullair Rotary Screw pioneered screw compressors Compressors > Company to domination of portable and industrial air compression markets BY NORM SHADE I n 1965. New York. he founded a privately held company. Joy in 1960 and Gardner Denver in 1963. interest in screw compressor technology was rapidly growing in the U. (24 km) of rock for the Chicago Drainage Canal and countless Sullivan rock drills helped carve out the Panama Canal. In fact. Joseph as vice presidents.000 rotary screw compressors. Founded in 1965 by former employees of Joy Manufacturing Co. Joy Manufacturing acquired Sullivan. Joy ultimately elected to stick with reciprocating and later centrifugal compressor technology for its air compressors... Sullivan moved quickly to introduce its first portable rotary screw air compressor in 1966. Donald C. The Sullivan Machinery Co.J.4 m) deep wheel pits at Niagara Falls. of those three well-established air compressor companies. many innovations in machinery for the basic industries were attributable to the dedication of Sullivan engineers.C ornerstones Of Compression n The Sullivan Machinery Co. That same year. (56.