Gas Machinery Journalc/o Striker Communications 106 East 6th Street Suite 900 Austin, TX 78701 PRSRT STD US POSTAGE PAID DALLAS, TX PERMIT 2024 ½g 1g 3g 5g 10 g bhp-hr bhp-hr bhp-hr bhp-hr bhp-hr Get your engine on the road to recovery Emission treatment for legacy engines. Your engine’s treatment begins with a turbocharger Problematic, mechanical prechamber check valves upgrade to improve its breathing. Then a high are replaced with care-free, electronic prechamber pressure, electronic fuel injection system check valves (ePCC) which when coupled with (HyperFuel) is installed in the cylinder heads to ion-sense technology perform closed-loop control enhance fuel mixing throughout the large cylinder and deliver feedback for power cylinder balancing bore. An air:fuel ratio controller maintains an (HyperBalance) and engine diagnostics. The final optimum mixture that is ignited by an advanced stage of treatment is mapping emission levels ignition system. against model predictive control (MPC) for transient Fully integrated engine automation and facility upgrades. enhanced mixing cooling systems electronics air compression engine control.
[email protected] • www.hoerbiger.com GMJournal_EngineAd_Jan2012.indd 1 1/27/2012 3:14:20 PM About the Gas Machinery Journal The Gas Machinery Journal is published by STRIKER Enterprises, LP (dba STRIKER Com- We are actively seeking expanding our readership - if your group or organization would munications), an independent, privately owned publishing company based in Austin, Texas. like to receive the Gas Machinery Journal at no cost, please contact us at: STRIKER Enterprises is not affiliated with any other industry organization, but maintains cooperative partnerships with energy industry associations and groups. The Gas Machinery Journal is distributed at no charge to 5000 energy industry professionals and top-level decision makers with responsibility for gas machinery and compressor station design, installation, operations and maintenance. The Gas Machinery Journal welcomes submissions on all aspects of natural gas machinery and compressor station design, installation, operations, and maintenance, articles and case studies relating to topics such as valve performance and wear, pulsation control and mounting issues, and challenges presented by unwanted surge and how to deal with them. Also of interest are contributions on the topics of emissions reduction, engine efficiency, performance and reliability, gas/electric regulations, and gas and electric partnership. We especially welcome case studies that illustrate implementation of new ideas and technologies, and submissions from the users of gas machinery technology. Gas Machinery Journal Marsha Short, Editor 106 East 6th Street, Suite 900 Austin, TX 78701 1.800.524.1620 x 4
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[email protected] Gas machinery Journal p. 3 2013 Gas / Electric partnership conference overview gas liquids such as petrochemicals and gas export will be in Dramatic changes in flow for long-haul pipelines to the Norththe Gulf Coast because of existing infrastructure and political east are forecast and issues for those pipelines were discussed considerations. These forces cause changes and even reversals by Williams Gas Pipeline representatives. Gas Infrastructure for New Supply and Industrial/Export Markets of flow directions for gas pipelines. Offshore Oil and Gas Production The 2013 Gas/Electric Partnership Conference February 5-8 in Houston focused on two major energy issues: the impact of On the supply side, discussions revolved around the outlook for The consultancies of Infield and Endeavor provided an overthe game-changing North American shale oil and gas supply the various shale regions and issues for infrastructure for natural view of offshore oil and gas production both in the Gulf of Mexico and worldwide. They show that shale reserves are even growth and how gas and power industries can coordinate to gas, natural gas liquids (NGLs), and power. greater in Latin America and China than in North America. Moprovide energy smarter and more efficiently. The interest of the group was on the driving forces impacting infrastructure for Reviews of infrastructure issues for the Bakken, Eagle Ford, zambique and Tanzania in East Africa hold 250 tcf gas in the gas and natural gas liquids and focused on compression in the Permian, Utica and Marcellus pointed out obstacles and oppor- offshore and thus could become an exporter. Shale is having an upstream, midstream, and pipelines. New perspectives on tech- tunities. A Shale Infrastructure roundtable compared the issues impact on the offshore driving investment in the Gulf of Mexico pushing activity toward very deep water. nology for solving these problems were presented by leading for the different basins. equipment manufacturers in the technical update sessions. Assessments were presented by various speakers to show how The types of production systems and trends were discussed by the Marcellus and Utica regions will increase production so sig- Endeavor and the options were described. The issues for selecNew Supply and New Markets for Gas It is broadly appreciated that major new supplies of gas are re- nificantly that these Appalachian regions will become major net tion include water depth, whether gas or oil production, geosulting in competitively priced gas in North America and this exporters of gas and NGLs in the near future. Projects to use graphical location, role of oil export, gas usage and export ophas profound global economic implications. With gas prices competitively priced gas were discussed by Mike Juden, McKin- tions, fabrication, and whether surface, subsea or both. in North America as low as one-eighth the price in the large sie & Co., and Marybeth Nored, Apache Corp. Ms. Nored premarkets of Asia, there is a driver for gas exports from locations sented a wide array of industrial possibilities, including metha- There is growing interest in Floating Production, Storage and in the Gulf Coast, British Columbia, and possibly other areas. nol, ammonia, gas to liquids, combined cycle power, CNG/ Offloading Systems (FPSOs) which were originally considered Furthermore, changes in the locus of gas supplies changes po- LNG fuels, compressor gas for transport, and gas export. Mr. an economical solution for the production only for marginal litical power dynamics for international actors like Russia, Iran, Juden looked quantitatively at many of these gas demands and fields. Later, FPSOs became an essential component in develshows that the likely production from Marcellus is large enough oping remote offshore fields as production capacity, numbers and others. to overwhelm both traditional and new gas uses for quite some of risers, and capability to operate at increasing water depths Closer to home, the competitive price of gas is causing new time. This is good news for the economy but not so for those allowed their utilization as full field production facilities. markets for gas to emerge for a wide range of industries, trans- hoping to see higher gas prices. Now, floating LNG is creating a good deal of interest. Develportation, power and export. Also of great importance is the oped for smaller stranded gas fields, there are some interesting location of new supply and new demands, and the impact on Impact of New Gas Supply and Uses for Gas Pipelines gas pipelines. The gas supplies are emerging in places like the An estimated 29 Bcfd (~$27 Billion) of additional interstate advantages which may broaden its appeal. According to one Marcellus in the Northeast which, in the past, was a major mar- transport capacity could be required through 2020, but most speaker, floating LNG can be developed more quickly with ket for gas from other areas like the Gulf Coast. It may be that will be regional pipelines, expansions or laterals. A large part of lower environmental impact than other options. -- see “2013 Gas / Electric” next page the sites of new industrial projects that will use gas and natural gas infrastructure investment will be in gas and NGL gathering. Contributed by W. Richard Schmeal, Coordinator of the Gas Electric Partnership Oil and gas transaction appetite down slightly as confidence in economic outlook grows LONDON - The bi-annual Oil & Gas Global Capital Confidence Barometer released recently highlights that nearly half (44%) of the 152 oil and gas company executives surveyed believe the global economic situation is improving, up from 27% in October 2012. Notably, oil and gas companies are generally more optimistic than the broader global sample of 1,600 respondents in 50 countries. However, only 27% of the respondents expect to undertake any M&A activity in the next six months, a decline from six months ago. Andy Brogan, Ernst & Young’s Global Oil & Gas Transactions Advisory Leader explains this “confidence paradox”: “While general confidence in the state and outlook of the economy is improving, this is accompanied by increasing levels of uncertainty about the direction of travel of commodity prices in general and oil and gas prices in particular. This is leading to a valuation disconnect which is delaying many transactions.’ Appetite for mergers and acquisitions declines slightly The oil and gas sector has been one of the most resilient for M&A over the last five years. However, this survey sees a slight decrease in sentiment with 27% of respondents now expecting to pursue acquisitions over the next 12 months, down from 28% in October 2012 and 31% a year ago. It is not just a lack of confidence in the business environment that is holding companies back — many are also concerned about the gap between their valuation of potential acquisitions and the prices sought by sellers. For many companies, the appetite for M&A has declined. Five years after the financial crisis, many executives are still waiting for more price visibility before taking action. That conservatism aside, oil and gas respondents expect that global M&A deal volumes will increase over the next 12 months, with 72% expecting volumes to at least modestly improve. Expectations of the larger global sample were broadly similar. Growth focus returns Prioritization of growth had broadly declined as companies in general became more focused on the fundamentals, but that decline has seemingly ended. Oil and gas companies’ focus on growth had similarly been declining, but increased sharply in this survey. Notably, our oil and gas respondents continue to be more focused on growth than the global sample of companies. Compared with six months ago, our respondents, both in the broader global sample as well as the oil and gas respondents, report a decreased focus on reducing costs, improving efficiency and optimizing capital. Growth remains the number one objective for a majority of our oil and gas companies, with 61% reporting that growth is their primary focus, as compared to 20% whose primary focus was on cost reduction and operational efficiency, and 17% whose focus was on maintaining stability. This is the highest percentage of respondents citing growth as their top priority since April 2011. Credit conditions improving globally While credit has remained broadly available, particularly to large-cap enterprises, our global respondents report a substantial increase in credit availability. Compared with two years ago, banks are -- see “Oil & Gas Transaction” next page p. 4 Gas Machinery Journal 2013 Gas / Electric partnership conference overview, cont’d. EPA Current Regulatory Issues Jeffrey Adams, BP, gave a comprehensive discussion of the status and impact of numerous pending environmental regulatory developments affecting gas compression. The President’s inaugural address emphasized climate change and the environment. However, the congressional split limits like legislation and thus regulations will drive the agenda. NGOs will continue to press for EPA regulations via court action, public comments, and “sue & settle” agreements. 2020 nationwide, and nuclear challenges remain high cost, waste management and Fukushima psychology, according to Gurcan Gulen, The University of Texas Center for Energy Economics. Yet in ERCOT, current prices are not sufficient to encourage enough generation capacity to meet forecasted demand, according to Mr. Saathoff. New builds will be gas and wind. He also spoke about various price forecasts and the issues of the intermittent supply of power from wind. Since the peaks and valleys of wind generation do not match those of power needs, natural gas capacity is needed to fill in the gaps. Expected high impact air quality rulemaking includes 75ppb ozone standards, final oil and gas New Source Performance Standards A major issue is that smart power is needed and NESHAPs, existing engine NESHAPs and for our nation’s energy efficiency. The Federal Energy Regulatory Agency (FERC) is consource aggregation. cerned with this issue. A panel with Christina Hayes, FERC Legal & Policy Advisor to ChairGas Transmission and Power Power is a huge market for natural gas and gas man Wellinghoff, Bob Truman, CenterPoint is earning a growing share of the power market. Energy, and Joseph Pollard, TransCanada Kent Saathoff, Vice President of Systems Op- discussed the tight gas/power interaction and eration of ERCOT (Electric Reliability Council how it leads to a need for “smart gas transmisof Texas) pointed out that gas is now providing sion.” Issues of concern are pricing structures, 44.6% of power use in ERCOT and represents communication protocols, and enhanced 57% of power generation capacity. The inter- nomination schedules. The interdependence actions between these vital energy commodi- of gas and power is nowhere more vital than ties are complex and both are affected by the during weather events such as hurricanes and growing generation of power by wind. Gas is ice storms. Thomas Wooden, Spectra Energy, the marginal fuel supply and electricity prices presented a case study on Spectra’s experience providing natural gas for power in the Northtend to trend with it. east during Hurricane Sandy. Another imporUp to 80 GW of coal capacity may retire by tant gas/power interface of great concern is the use of power to drive compressors. Rob Krenz, Williams Gas pipeline, gave an update on a huge facility which has been operating for several years. A 15-member consortium has come together with Southwest Research Institute (SwRI) to develop guidelines for electric motor driven centrifugal compressors in pipeline applications and to investigate operational reliability and life cycle costs of various commercially available electric motor drive technologies. The results of this study were presented. The results of this study and all presentations from this conference can be downloaded at www.gaselectricpartnership.com Oil and gas transaction appetite down slightly, cont’d. on a stronger footing and better capitalized. Yet this healthier picture has not always translated into increased lending, as many banks tightened their lending standards, particularly for small to-medium enterprise (SME) borrowers. Banks also face higher capital requirements under impending Basel III regulations, which could restrict their ability to increase the flow of credit into the economy. In our recent survey, more than 74% of the oil and gas respondents reported debt-to-capital ratios below 50%, with 40% reporting ratios of less than 25%. Both of these percentages declined, however, from our October 2012 survey. Clearly, some oil and gas companies, as well as companies in general, are choosing to shed some of their caution. Eighty-five percent of oil and gas respondents now view credit availability as stable or improving. Within this, the percentage of oil and gas companies seeing credit conditions loosening has increased substantially. Debt decreases as a source of deal financing Only 30% of the oil and gas respondents were expecting to refinance loans or other debt obligations in the next 12 months, up from 21% from the October 2012 survey, but still down from 49% in the April 2012 survey. With large-scale changes to their capital structures now completed, oil and gas companies are focused on refinements — reducing interest costs, extending debt maturities and removing restrictive covenants. Declining in importance for refinancing has been the optimization of the corporate structure and retiring of maturing debt. Mixed global deleveraging trends The oil and gas sector has tended towards conservatism with respect to leverage. The improving credit conditions have prompted many of them to review and adjust their capital structure. Some took advantage of better credit conditions to take on debt and reduce their overall cost of capital. However, reflecting the industry’s traditional conservatism in this area (and the buoyant oil price), over the last two years, more oil and gas companies have been looking to deleverage their balance sheets. The proportion of companies expecting to finance to further expand their operations — and increase their debt-to-capital ratios — grew to 28%, up from 21% in October 2012. However the proportion of oil and gas companies looking to take the opportunity to decrease their debt-to-capital ratios increased even more sharply to 45%, up from 31% in October 2012. Brogan concludes: “Throughout the crisis and recovery period the oil and gas sector has proved remarkably resilient. Many companies have already taken advantage of improving credit conditions to restructure their balance sheets but overall the industry remains conservative in this area. Going forward we expect the sector to remain resilient both from an operational and an M&A perspective. However, with expectations on forward price curves for oil and gas subject to increasing uncertainty we can see that pricing is going to be a key issue in the transaction markets over the next six months.” Gas machinery Journal p. 5 A Novel Method to Detect Surge During Surge Test Mantosh Bhattacharya, Petrofac UAE Centrifugal Compressors are most widely used high speed machines in Oil & Gas industry. A failure of compressor leads to major revenue loss and downtime. A good percentage of compressor failure did happen in past due to operational instability which includes Surge. By dint of numerous papers by experts and case studies presented in various symposiums, end users are now very much aware of consequence of such phenomena. Compressor surge prevention and control are now part and parcel of any software installed in unit control panel which operates the compressors. Most of the algorithms for anti surge control work on the data taken from various process parameters. This paper endeavors to propose a new method to identify and mitigate surge related damage, particularly during commissioning / surge test of centrifugal compressors when operators are mostly dependent on groans / squeals of compressor. Mechanism of Compressor Surge - When the pressure ratio across a centrifugal compressor exceeds the maximum pressure ratio that can be produced for that gas and impeller speed, the flow will suddenly reverse through the compressor. The flow reversal allows the discharge pressure to drop and at the same time will cause the suction pressure to rise, resulting in a sudden drop in the pressure ratio. The flow reversal essentially relieves the condition that caused the flow reversal to occur. Within few moments after the flow reversal started, the flow will start moving forward again through the compressor. If the condition that has temporarily created a higher than designed pressure ratio across the compressor is not changed, the flow reversal will repeat. At this point, the compressor shall be in surge. The unit in surge shall emit a load groaning / squealing sound in every few seconds. Before surge to occur an “alarm” rings as incipient surge inside the machine. Incipient surge occurs when the flow through the impeller is not sufficient to fill the impeller flow passage. Boundary layer separation occurs on the trailing side of the vanes. Stall cells are formed in the separation area and when they reach the impeller exit, it moves in a counter-rotation direction to another flow passage. Most of the times rotating stall occur just before the time of surge. This phenomena a radial pulsation is produced that acts orthogonally of the axis of Rotation of compressor rotor. The exciting frequency of the pulsation are transgressed into radial non synchronous vibration which normally happens at 0.3 -0.6 X of RPM. This is mostly combined with a Noisy signal and generally cascaded by lubrication related troubles like whirl ( 0.43-0.47X RPM ). As with surge, the pressure pulsations that occur during incipient surge are also a function of the gas density and impeller tip speed squared. However the magnitude of the pulsations are about 0.05 times those experience during surge. Also, the pulsations that occur during incipient surge act in the radial direction, rather than in the axial direction. there is a net force on the impeller that acts toward to the suction that is shall not be equal to the difference between the impeller suction pressure and the impeller discharge pressure applied over an area equal to the impeller eye. This inequality is compensated by a balance drum and /or balance line. During a surge condition, the gas flows backwards through the impeller from the discharge to the suction. This cause the discharge pressure to drop and the suction pressure to rise. This reversal in the pressures causes the net thrust that is normally acting on the rotor to reverse directions. During this cycle, the pressure change across the impeller is proportional to the density of the gas and the impeller tip speed squared. This means that for a given compressor, the surge event is more loud and clear with a gas of higher density and the speed is higher. The more significant is the effect of speed being squarely proportional. When a compressor is at very low speeds (way out of bottom line of compressor speed line map), the effect of surge shall not be severe. Pressure Fluctuation during surge shall cause axial excursion. This can be well understood by axial loading directional diagram as shown below during normal design range flow conditions for a typical back to back compressor. [1] p. 6 Gas Machinery Journal After inspection of inlet suction strainers, it was decided to open the Anti Surge Valve which was found clogged with foam acting as Heart Pump in recycle line. This means whenever sponge was stuck to cage, flow dropped down and discharge pressure rose to create a event of surge. This occurrence and subsequent vibration data acquisition led to draw an alternative method to detect surge particularly during field testing. The plots and observations on them are shown below (left) in Figure 2. It was observed that time interval of “cat scream” sound and Rotor axial movement trend had some distinct relationship. This excursion was detectable as RPM of rotor was quite low, Compressor was at recycle mode at low suction pressure. During the whole episode, Gear Box Pinion radial vibration fluctuation was also found in line with time interval of screaming sound. Fig-3 Hunting in pinion vibration readings during “Cat Scream” Fig -1 A back-to-back compressor configuration with load direction A case study placed for example - During commissioning of a Centrifugal Compressor before Work range mapping and surge line drawing , Compressor is run a lower speed with a controlled suction flow and recycle valve fully open. Slowly the recycle valve is modulated towards closure to look into a point of surge locus. Again the same procedure is followed with a bit higher speed and flow. During such activity of commissioning of a commissioning of a Gas Turbine driven Centrifugal Compressor a “Cat Scream” sound inside the compressor was observed. At that time recycle valve was fully open. To avoid any untoward consequence, compressor was shutdown. The coast down of the compressor indicated the machine to be all right. The test RPM of compressor was slightly lower than 70% of rated RPM during the incident . Machinery Vibration trends were taken from event log from diagnostic system. This sound was in cyclic interval as detected by Vibration Waveform generated by Machinery analysis Module. The biggest problem with incipient surge is the frequency at which the pulsations occur. The frequency of incipient surge often is close to that of the rotor’s natural frequency. If the compressor operates for very long in incipient surge, the opportunity exists for exciting the rotor, acts as a catalyst to high radial vibration leading to probable damage. Under normal conditions when the flow is moving forward, the area of the shroud is exposed to discharge pressure as is the back of the hub. Since the area of the eye is exposed to suction pressure, Further investigation suggest led to a conclusion in obstruction in Recycle line gas path. A rotor rub will lead to high vibration during coast down at machine critical speed, which did not occur. Change in machine behavior during surge - Usually surge is limited to be identified with excessive rotor excursion / vibration and audible “cat scream” sound yet there are cases when surge was not audible yet occurred and caused damage to the machine. Generally onset of surge causes fluctuation of temperature, differential pressure fluctuation with a high order and change in rotor axial position. Monitoring first three parameters, require smart and special type of transmitters. High pressure compressor onset of surge is accompanied by a low frequency asynchronous vibration which are detected when the surge energy is quite high. If the Compressor train is driven with a speed increasing gear box, the pinion being the lightest part of system can demonstrate some excitation in low frequency regime and a spectrum can easily reveal the symptom. Fig 4 – Gear Box vibration spectrum Fig-2 Hunting in axial probe reading during “Cat Scream” Pressure Fluctuation during Rotating Stall at stage although the last impeller of compressor might go to a condition of incipient surge first shall cause high lateral sub synchronous instability. -- see “A Novel Method” page 8 Gas machinery Journal p. 7 A Novel Method to Detect Surge During Surge Test, cont’d During normal operation pressure differentials between two sides of each impellers are balanced by end balance drum and center wall balance drum. The proposed scheme requires a microprocessor with a good scanning time with a logic box, a counter, a high value gate, signal booster and charge amplifier to amplify gear box casing / compressor casing vibration. Comparative study on various Possible Setting of a early warning system other than Compressor Antisurge control module normally in use. Measurement of flow and discharge pressure oscillation is difficult to achieve at site as they require special type of transmitters.[2] Measurement and monitoring of radial vibration at low frequency calls for a very accurate band pass filter. Calibrating very low frequency accelerometer is difficult task. During compressor operation it is quite difficult to pin point surge with the increase of Non synchronous vibration as a tool. Fig -6 –Schematic of proposed instrument layout Description of Proposed Logic in Microprocessor S1 Fig -8 Axial excursion counter with a set timer. For those single casing centrifugal compressors those are operated by a DOL Induction motor at a constant speed and compress a gas with a firmed up composition ratio within a fixed operating regime this logic can work well. For a variable speed driver, some more algorithms must be developed like speed x axial probe reading as an invariant taking the status of machine as point for deducing the end result. Fig - 5 Compressor shaft vibration spectrum during surge These can be only used as a diagnostic tool if location of rotating stall is already detected before tow out. Test and drawing a stall line can be performed during full load full speed Type -1 test at Compressor Manufacturer’s premises.[3] If this happens and the compressor is operated at a turndown condition, there is risk that compressor could drift into surge without the operator knowing about it, which could lead to a machine failure. Monitoring compressor performance is therefore important to not only ensure efficient compressor operation, but also to protect against operating the machine in surge. If the unit uses a speed increaser gear box, a low frequency accelerometer can pick up the vibration as pinion is the lightest part in transmission. It must use Piezoelectric Transducer, shall be capable of overcoming monitor noise shall be less sensitive to strain. [4] Measurement and monitoring of axial vibration. It has been observed that axial vibration do occur during surge. To measure axial vibration needs shaft end face minimum surface finish must be in compliance with API 670 latest edition where maximum ARH of 1 micron is allowed. Besides this , there are other issues like misalignment and bent shaft which may cause axial vibration at 1 and 2 times operating frequencies and create a confusion in diagnosis. Rotor speed and the coupling type/stiffness have a strong effect on the vibration spectra. The level and type of misalignment had a significant effect on the vibration signature. Due to inadequate data the effects of machine dynamic stiffness can not be quantified ..Filtering the axial vibration value at particular frequency from direct axial vibration reading may need human interface. Monitoring Axial excursion level and rate of Rotor. The rotor excursion during surge is dependant on dynamic pulsation of machine which then is a function of gas density and Square of rotor peripheral speed. The schematic diagram of proposed early warning system of surge is illustrated in Figure 6 (top, right). • Where CV1= Gear Box casing vibration measured particularly at Low Frequency . • CV2 = Casing vibration measured with a band pass filter ( should be used as Diagnostic tool to baseline the other input values to firm up a Logic ) • Z1 & Z2 = axial displacement measured by dual probes preferably with a signal booster. • Z0 = difference between Z1 & Z2. This value shall be counted with a timer. S is the microprocessor. p. 8 Gas Machinery Journal Fig -7 Proposed Logic diagram A parallel operated valve with Cv of approx to that of ASV (Anti Surge Valve) can be used to be operated as ON /OFF based on signal by Microprocessor S1 during surge test. The configuration of the valve shall be same as a Cold Gas By Pass Valve. The Microprocessor S1 shall be armed just after compressor crosses the 1st Critical speed or 60% of deign speed (base speed). Then it will start reading Z1 and Z2 (both in microns) and a calculation block shall calculate difference between Z1 and Z2 (a dimensionless value). It parralelly checks if Z (overall excursion) has crossed a preset limit of A. If the Z remains greater than A for count of more than M during a measuring span of 2 seconds, Microprocessor shall trigger an alarm. Advantages – The proposed scheme avoids human interface to interpret Surge with maximum extent. The other part of logic shall calculate an invariant (RPS x Z x K2) where RPS is rotation per second, K2 is sensitivity constant i.e how much onerous the reading shall be. Parallely, the low frequency accelerometer reading CV1 from gear box pinion location. If the CV1 remains greater than Y, it shall create an another invariant (RPS x Cv x K1) where RPS is rotation per second, K1 is sensitivity constant i.e how much onerous the reading shall be. Due diligence shall be exercised to decide upon A , Y ,K1 & K2 . The author wishes to thank Mr. Abdul Rahman Dandachi, Controls Specialist Petrofac for his valuable suggestions. These two invariants shall pass the high value gate and one of them shall be accompanied with counter output to annuciate an alarm or trip . The logic box shall attenuate an alarm if number of axial position of rotor shift is more than Z0 micron counts exceeds A in 2 seconds. Axial position transducers shall be measuring element. The value of 2 sec is based on numerous vendor experience that compressor can withstand a surge for 2 seconds with surge event counting of 2. All data required can be taken from VMS (Vibration Monitoring Rack) directly with RS232 communication. The proposed system is cheaper and can be used at various sites with a Laptop having the program. References – 1. Compressor Handbook by W.E.Frosthoffer 2. Increased Flexibility of Turbo-Compressors in Natural Gas Transmission Through Direct Surge Control by Robert McKee, Shane Siebenaler & Danny Deffenbaugh-Southwest Research Institute 3. Application Guideline for Centrifugal Compressor Surge Control Systems by Klaus Brun & Marybeth Nored-Southwest Research Institute 4. Papers on Non Synchronous Forced Vibration by D.R. Smith & J.C. Wachel 5. Product Catalog – Wilcoxon 6. Articles by Late Dr. Donald Bently on Rotating Stall It’s not magic… it’s physics. The new Passive Pre-Chamber (PPC) sparkplugs from Altronic are designed specifically for each application. They provide the combustion assurance you need without the cost and complexity of traditional precombustion chambers. PPC models for the Caterpillar G3500 family of engines are available now, and models for other engine families—including slow-speed integrals—are coming soon. Learn about the NOx reduction and fuel efficency gains possible today. Find an Altronic Distributor near you at www.altronic-llc.com Gas machinery Journal p. 9 Business Briefs ESG Solutions Announces Successful Expansion of Surface-based Regional Monitoring System for Induced Seismicity CALGARY, Alberta - ESG Solutions, an industry leader in microseismic technology and services, is pleased to announce the successful expansion of a near-surface seismic monitoring system in Western Canada. Initially installed in 2012 to monitor any potential larger magnitude induced seismicity during hydraulic fracturing operations, the system was recently expanded to provide greater monitoring range spanning multiple well pads. In response to increased concern surrounding subsurface injections and induced seismicity, many operators are taking the initiative to better understand the response of unconventional reservoirs to hydraulic fracture stimulations, especially in the presence of nearby geological structures. ESG’s near-surface regional seismic solution encompasses an array of ESG manufactured surface-based sensors optimized for seismic detection between M0 and M+4. “Operators are looking for a reliable, cost-effective solution to help them understand the triggering mechanisms of seismicity detected near injection operations,” says Dr. Ted Urbancic, EVP of Global Energy Services at ESG. “ESG has been collecting and analyzing induced seismic data for 20 years. This experience gives us the knowledge to integrate site-specific seismic data with existing regional networks and decode the trigger mechanisms associated with that seismicity.” Continuous passive seismic data from the near-surface array is collected using ESG’s 32-bit, high resolution, low noise Paladin™ digital seismic recorder and the data is integrated seamlessly with ESG’s Hyperion Seismic Software Suite for accurate processing and analysis. “ESG manufactures equipment and develops software in-house. Depending on the customer’s needs, we can utilize third party components for less cost to the client, or custom design and build seismic systems for each site so that operators have access to the accurate and timely information required to make operational decisions,” says Urbancic. Prior to its recent expansion, the regional seismic array deployed to monitor operations in a Canadian shale play had detected hundreds of events above magnitude 0. By extending the monitoring range to cover additional regions of the field, operators hope to further understand the way in which the reservoir is responding to stimulation activities, and ultimately maximize production from the field. Surface-based regional seismic arrays can complement downhole microseismic monitoring, integrate with established regional seismic networks or be used independently to establish a baseline for local seismicity, to better characterize nearby faults or provide a means of alerting operators to abnormal induced seismicity. A number of similar ESG near-surface arrays are currently in operation throughout the world for applications as diverse as natural gas storage, waste injection, reservoir impoundment, carbon sequestration, coal-bed methane and mining operations. ESG designs and manufactures its own permanent microseismic instrumentation for longer-term reservoir stimulations and surfacebased regional seismic networks in addition to providing wireline data acquisition, processing and advanced analytics for hydraulic fracturing. Caterpillar Unveils Well Stimulation Pumps and Releases Dynamic Gas Blending Retrofit Kit for Well Stimulation Applications Well Stimulation Pumps Unveiled at OTC The Cat Well Stimulation Pumps feature fluid ends and power ends designed to an industry standard footprint. This will allow customers to easily fit the Cat pump into their existing trailer designs. In addition to the standard fluid end Cat will offer an Extreme Duty (XD) fluid end with superior durability for the harshest operating conditions. The fluid ends on both models have a valve-over-valve design to simplify valve, seat and plunger installation, and each fluid end block is manufactured with a robust material conditioning process. A full assortment of discharge flanges, suction manifolds, and bore sizes will also be offered. Caterpillar Global Petroleum is pleased to announce the launch of Cat® Well Stimulation Pumps for the well service market. Starting in May 2013, Caterpillar will begin accepting orders for the Cat WS223, a 2250 bhp (1678 bkW) triplex well stimulation pump, as well as the Cat WS255, a 2500 bhp (1864 bkW) quintuplex well stimulation pump. In addition to offering the complete pump for well service customers, Caterpillar will offer a variety of 8” and 10” stroke fluid ends individually. A 2700hp triplex pump, available in late 2013, will be on display along with several fluid end models at the Caterpillar booth #3341 at OTC The new Cat well stimulation pumps will be distributed, sold and supported through the 2013, May 6th – 9th in Houston, Texas. worldwide Cat dealer network with trained “At Caterpillar, our goal is to provide the most technicians to ensure service support is never reliable and durable power solutions for the out of reach. Well Service and Pressure Pumping market. By adding the well stimulation pumps to our Dynamic Gas Blending Retrofit Kit for Well portfolio of offerings we are able to provide a Stimulation Applications Released more comprehensive pressure pumping solution for our customers,” Mark Helgren, Cat- Houston, Texas – Caterpillar Global Petroerpillar Global Petroleum-integration man- leum today announced that it has developed ager stated. “Our customers, who have been a Dynamic Gas Blending (DGB) retrofit kit pleased with our engines and transmissions, for use on the Cat® 3512C (HD) engine used will be able to readily implement the Cat well in well stimulation applications. Available stimulation pumps into their operations with to order in June 2013, this system will allow the utmost confidence in their performance for maximum substitution of diesel fuel with natural gas during high pressure pumping opand Cat Dealer support.” p. 10 Gas Machinery Journal the combined muffler and Cat Diesel Oxidation Catalyst (DOC) included in the DGB kit. The system is capable of achieving maximum substitution at various speeds and loads over the full operating range, and will automaticalHeavily leveraging decades of success with ly adjust to changes in gas quality without the Cat natural gas engines and the recent intro- need to perform any recalibration or adjustduction of the Cat DGB system for land drill- ments to the system during or between jobs. ing and production, the Cat well stimulation DGB system makes no compromise with per- The DGB system is fully integrated with the formance, safety, and reliability while burn- engine control system, optimizing engine pering a mixture of diesel and natural gas fuels. formance and ensuring that the engine always “Through our product development work in operates within safe parameters while blendthe field with some of the leading well servic- ing diesel and natural gas. This results in no ing companies, the Cat DGB system has per- compromise with performance, maintenance formed exceptionally well. User feedback has intervals, engine reliability, and most imporbeen very positive with ease of installation, tantly, safety. Installation of the Cat DGB kit engine performance, and the integrated safety on existing engines is streamlined through features of the Cat DGB system,” said Scott efficient design. The combined muffler and Roberts, Caterpillar Global Petroleum Well DOC eliminates the need for the customer to integrate a DOC with their existing mufflers, Service Product Marketing Manager. and a single advanced Engine Control Unit Along with the benefit of realizing significant simplifies the electrical system. fuel cost savings by substituting diesel fuel with natural gas, there are several other key features of the Caterpillar DGB system that make it a winning solution for well stimulation. Operators can run the system with confidence on CNG, LNG, and field gas with a lower heating value between 850 and 1,250 Btu, knowing that the engine is maintaining United States EPA Tier 2 level emissions with erations, and is available in both Air To Air After Cooled (ATAAC) and Separate Circuit After Cooled (SCAC) configurations for 2250 hp and 2500 hp @1900rpm ratings. field services > Rotating equipment repair > Full compressor overhauls > Lubrication system installation > On-site technical support > Parts and equipment upgrades > Installation of quality CPI manufactured parts expert knowledge and field support... CPI Service and CPI Lubrication Group provide global coverage to support the following industries: > Chemical and refining > Natural gas > Off-shore and FPSO > PET bottle blowing evolving solutions around your world tel: Toll free US and Canada 800 664 4033 tel:: +1 281 207 4600 or 800 675 6646 or alternatively: +1 713 462 1061 email:
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[email protected] www.c-p-i.com www.c-p-i.com Business Briefs New Database At Colorado State University Tracks Energy Legislation In All 50 States The database has been developed in collaboration with Advanced Energy Economy (AEE), a national business organization representing the entire advanced energy industry, from wind, hydro, solar, and natural gas to efficiency and electric vehicles. ees. Participating companies were rated by DiversityInc. in four key areas: CEO Commitment to Diversity Management, Workforce Diversity and Human Capital, Corporate/Organizational Communications, and Supplier Diversity. “This online database provides information on critical state legislation that is available nowhere else,” said Graham Richard, CEO of AEE. “AEL Tracker is a nonpartisan tool that allows researchers, journalists, policymakers and concerned citizens to follow and analyze advanced energy legislation, individually and in aggregate. We hope this unique database will increase awareness of advanced energy Today, state legislatures are considering more and the way state action can unleash its ecothan 2,100 bills that could change the way nomic potential for the United States.” Americans produce, buy and use energy. AEL Tracker identifies all those measures and Both Richard and Ritter shared additional monitors the progress of many advanced enviews in videos that can be found on the AEL ergy bills as they move forward. Tracker website: www.aeltracker.org. “It is an honor to be named by DiversityInc one of the top regional utilities in the country for diversity. As a utility that serves some of the most diverse communities in the nation, PG&E views diversity as the very fabric of our corporate culture,” said Laura Butler, Vice President of Talent Management and Chief Diversity Officer at PG&E. “This commitment to diversity and inclusion is a critical part of our values and how we work to provide safe, reliable and affordable gas and electric service to our customers.” FORT COLLINS, Colo. - Colorado State University’s Center for the New Energy Economy (CNEE) today announced the rollout of the Advanced Energy Legislation (AEL) Tracker – a new online database of energy-related state legislation pending in all 50 states, from solar to natural gas and everything in between. This first-of-its-kind database, created in partnership with Advanced Energy Economy (AEE), will also enable CNEE to conduct analysis of trends in state energy legislation. “If we look at where the country is going on advanced energy policy, overwhelmingly that transition is being led by states,” said Bill Ritter, Jr., director of CNEE and former governor of Colorado. “To get the pulse of where the country is going we need to understand what the states are doing. AEL Tracker brings together information on energy-related legislation in all 50 states, in a form that is easily accessible not only to lawmakers at all levels of government, but to academics, analysts, environmentalists, funders, business leaders and the general public. It will allow our Center to conduct critical academic analysis of issues related to energy legislation nationwide.” CNEE operates the database on the Fort Collins campus of Colorado State University, a landgrant university with a long history of cuttingedge research into natural gas emissions and renewable energy, water resources and the environment. The university provides credible, multi-disciplinary solutions to the complexities facing America’s energy industries. PG&E Ranked One Of The Top Utilities In The Nation For Diversity Atlas Pipeline Partners, L.P. Closes on Acquisition of TEAK Midstream Additionally, the Partnership has acquired a 50%-75% interest in various joint venture agreements that currently exist between TEAK and TexStar Midstream Services, L.P. The Partnership will be the operator of the joint venture assets following the transaction, which include: • 235 miles of pipeline, including rich gas gathering, header, and residue pipelines; • 3 miles of NGL pipeline; and • A Co-Gen facility, which will produce power for the Silver Oak complex as well as the ability to sell power to third-parties and back to the grid during peak season The Silver Oak processing complex is expected to expand in early 2014 by installing a new 200 MMcfd facility, the Silver Oak II plant, and potentially expand further thereafter by adding an additional 200 MMcfd facility. Any expansions will be 100% owned and operated by Atlas Pipeline. PHILADELPHIA - Atlas Pipeline Partners, L.P. (NYSE: APL) (“APL”, “Atlas Pipeline”, or the “Partnership”) announced that the Partnership has closed on its previously announced purchase of TEAK Midstream, L.L.C. (“TEAK Midstream” or “TEAK”), a private midstream company. The effective date of the acquisition was April 1, 2013. Final cash consideration for TEAK totaled $1.0 billion, subject to working capital and other adjustments contemplated by the Purchase and Sale Agreement. Fifth Year in a Row Utility Recognized by Di- Eugene Dubay, Chief Executive Officer of the Partnership, commented, “As I mentioned in versityInc as a Leader in Diversity the initial announcement, we are very excited Based on information available only in AEL SAN FRANCISCO - Pacific Gas and Electric about this acquisition of TEAK Midstream. Company (PG&E) has been recognized by Di- This is the right entry point into the Eagle Ford Tracker: • Nearly 25 percent of pending state ener- versityInc as one of the top regional utilities in with the right infrastructure and with tremengy legislation call for new financing tools the country for its strong diversity practices. dous future growth potential. After success– including tax incentives – for the instal- This is the fifth year in a row that the utility fully executing organic growth across all of has been recognized by DiversityInc, a lead- our legacy systems, we look forward to doing lation of energy facilities; the same with our new Eagle Ford assets.” • Roughly 21 percent of pending bills pro- ing publication on diversity and businesses. mote development of clean energy sourc“It is clear that U.S. companies are increasing- Upon the closing of this transaction, the Partneres; and • About 8 percent encourages adoption ly conscious of the importance of diversity,” ship will own 100% of the following TEAK assets: • 200 MMcfd of cryogenic processing caof energy-efficient appliances, building said Luke Visconti, Chief Executive Officer of pacity (“Silver Oak I”); codes and practices – the low-hanging DiversityInc. “We are very encouraged to see • A second 200 MMcfd cryogenic processPG&E applying for this distinction. We also fruit in America’s energy supply chain. ing facility to be in service in the first note a continued positive correlation between quarter of 2014 (“Silver Oak II”); The Center’s first trend analysis is on energy achievement in diversity and overall company • 265 miles of primarily 20” to 24” gatherefficiency, entitled “Rediscovering the First performance.” ing and residue lines with 750 MMcfd of Fuel.” The Center expects to publish 2-3 trend throughput capacity; and analyses per month and will next publish a For the 2013 ranking, DiversityInc surveyed • 275 miles of low pressure gathering lines white paper on financing of advanced energy. 893 companies with at least 1,000 employ- May 20-22 – Houston The 2013 CORE program will be focused primarily on On-Board Diagnostics (OBD) tools for the natural gas transmission industry. A review (with case studies) of current and planned industry research will presented including how OBD can be used as a tool to provide emissions compliance verification, diagnose and identify critical equipment faults. Discussions will also include the integration of sensors, actuators and controllers to move further to an “expert” level of OBD. CORESymposium.com -- continued next page p. 12 Gas Machinery Journal Compression requirements change. ACI Services will guide you to the most cost-effective Compressor Evaluation New and Refurbished Compressor Equipment Mechanical Services compressor solutions. ACI has the expertise to develop and implement the best solutions and to manage Performance Control your compression project to optimize your compression Pulsation Control Systems assets. Compressor Component Engineering Engineering Analysis ACI Services, Inc. • Cambridge, Ohio • www.ACIServicesInc.com • (740) 435-0240 Business Briefs -- continued Robert Earl Holding, Former owner of Sinclair Oil dies at 86 Wyoming billionaire Robert Earl Holding, died on April 19 at age 86, apparently from old age and complications related to a 2002 stroke. He attended school in Salt Lake City and after serving in the Army Air Corps, he earned a Civil Engineering Degree from the University of Utah. He married Carol Orme and in 1952 they moved to southwest Wyoming to manage a money-losing motel/gas station in isolated Little America. He eventually bought out the other owners and started adding gas pumps. He later borrowed to buy the Mobil refinery in Casper, Wyoming in 1968 and went on to purchase Sinclair Oil in 1976. A year later he bought the Sun Valley Ski Resort in Idaho. family and his employees as they were to him. Most of the employees hired by Earl in the early days spent their entire careers with him and even their children work with the company to this day. Earl enjoyed working alongside his people and watching them succeed. Earl deeply loved the land and the beauty of the American West. He looked for every opportunity to spend time at the ranch working the fields, cattle and crops and being surrounded by the natural beauty of God’s creations. Many of his business ventures were centered on creating something from nothing, making improvements, and building from beautiful natural materials. When planning the Grand America Hotel he personally traveled to Bethel, Vermont to select the granite for the project. He was fascinated by the possibilities found in nature, from drilling for oil to preserving a stand of trees on a ski run. Earl’s tireless efforts on behalf of the Olympics helped bring the 2002 Winter Games to Salt Lake City. He was an enthusiastic supporter of the Olympics believing the Games stood for the ideals of athletic excellence and international cooperation. Earl is survived by his wife, Carol, their three children, Anne, Kathleen, and Stephen, their spouses, twelve grandchildren, his brother, Ralph, and many extended family members, busiDespite his business success, Earl never forgot that it was the people he worked with who made ness associates and friends who were just like part of the family. He was predeceased by his the difference. He often remarked that “you do business with your friends.” He inspired those parents, his sister, Helen Jean, and his close business partner and childhood friend, Kenneth around him to give their best efforts, and then, even a little more. He was as fiercely loyal to his Y. Knight. -- continued next page Gas machinery Journal p. 13 Business Briefs -- continued Platts: Asia’s Power Capacity Expansion Saw Upswing in Q1 2013 Platts Project Tracker Shows Early-Year Improvement After Marked Slowdown in 2012 LONDON, May 8 - Asian power generation development activity in the first three months of 2013 totaled 62.74 gigawatts (GW), according to the latest quarterly project tracking report by Platts, a leading global provider of energy, petrochemicals and metals information. “This was 12% lower than in the same period of 2012, but was well up on the prior quarter – in fact, more than a fifth higher than in the last three months of 2012,” said Martin Daniel, editor of Platts Power in Asia, the newsletter in which the quarterly data is published. The earliest stage of the project development process is the announcement of planned new capacity. The amount of new capacity announced in the first quarter of 2013 was much the same as in the same period of 2012. “But at more than 21 GW, the level of Q1 activity was almost double that of the fourth quarter of 2012, which appears to indicate an improvement in developer confidence,” said Daniel. First quarter project approvals were approximately 12.85 GW, which was down versus a year ago but up almost twofold compared to Q4. But the amount of planned new power capacity actually signed to construction and equipment contracts was down 40% from both the prior quarter and Q1 of 2012. “This seems to indicate that the revived confidence visible at the start of the project development pipeline has yet to turn into firm orders,” Daniel said. “This is not surprising, given the long gestation period of most power generation projects.” The Platts power project tracker shows that the pattern of new capacity build in Asia was not uniform. In India, where new power development had been hindered for much of 2012 by fueling and financing issues, there was a significant revival in activity of approximately 8.1 GW during the first three months of this year. New power development in China, of nearly 12.5 GW, also was up compared to a year ago and versus the last quarter of 2012. Southeast Asia and west Asia also saw continued buoyant new capacity activity at 19.1 GW and 12.5 GW, respectively. In terms fuel and technology, a clear winner in the new power capacity build in Q1 was solar power. New programs in India, China and numerous other Asian countries caused Q1 solar sector development to treble versus Q4. Capacity expansions for coal-fired plants accounted for 45% of total activity in the first quarter of 2013, little changed from the prior quarter and first quarter of 2012. Data showed a close split of about 13.8 GW of new plant capacity going to the use of local coal and approximately 14.3 GW dedicated to or potentially using imported coal. By contrast, most of the 15.1 GW of natural gasfired plant capacity that changed status in Q1 will go to use of either imported or indigenous gas. The Platts Power in Asia project tracker was developed by Platts in 2011 to identify trends in the Asian power generation market. It is a bottom-up aggregation of identified individual projects. Platts tracks these projects as they move through the development pipeline from announcement to completion. The Platts tracker only tracks projects registering a significant change in status during the quarter such moving from announcement to approval or to start of construction. It does not capture the much broader amount of capacity under development in Asia. registration now open Gas/Electric Partnership Midcontinent Natural Gas Production Challenges September 12 – Oklahoma City This one-day workshop will explore solutions, best practices, and emerging technologies for addressing the challenges associated with compression and processing of natural gas from wellhead gathering to the point of delivery into long-haul pipelines. Although focusing primarily on issues encountered by Midcontinent gas and oil producers, many of the topics will be relevant to operations in other regions of the U.S. Topics will cover a broad range of issues including the gas and oil industry outlook; strategies for utilizing stranded gas; rich gas treating and processing; gas and electric driven compression; compliance with current and proposed environmental regulations – exhaust emissions, greenhouse gases, HAPs; vapor recovery; fuel conditioning; and more. CECO’s Combustion Characteristics June 4-7 – Colorado Springs - Instructor: Randy Anderson Combustion Characteristics covers all aspects of combustion and emissions, with a primary focus on troubleshooting operating changes on a variety of reciprocating engines—two–stroke cycle (2SC) and four–stroke cycle (4SC) engines, as well as naturally aspirated 4SC engines used as generators. Students of this course will receive instruction covering peak firing pressure (PFP), mean effective pressure (MEP), exhaust temperatures, turbocharger speed, fuel consumption, and emissions. CECO’s Compressor Characteristics August 20-21 - Oklahoma City - Instructor: Randy Anderson This class provides a solid foundation of basic troubleshooting skills. It introduces the student to various troubleshooting techniques and their applications and limitations. Course topics include integrated operational excellence for gas machinery, analytical fundamentals of troubleshooting, twenty-five (25) diagnostic troubleshooting tools, ignition troubleshooting, power cylinder troubleshooting, compressor troubleshooting, auxiliary and rotating equipment troubleshooting and unit startup troubleshooting. CECO’s Fundamentals of Troubleshooting August 22-23 - Oklahoma City - Instructor: Randy Anderson Compressor Characteristics teaches concepts of reciprocating compressor application and operation. It covers naturally aspirated 4-stroke cycle, piston scavenged 2-stroke cycle, pure turbocharged 4-stroke cycle, and turbocharged 2-stroke cycle engines. The course is divided into two sections: Compressor Fundamentals (A lecture describing physical components, mechanical linkages, fundamental operating theory, and operating characteristics) and Compressor Characteristics (a series of problems that describe certain changes on a compressor and their effect on critical compressor performance parameters) Visit www.striker-ent.com or www.GasMachineryJournal.com to register for any of our 2013 Knowledge Transfer events. p. 14 Gas Machinery Journal 73968 DR Services Ad for Gas Machinery Journal — Live 10.25 x 10.5 Non Bleed 24/7/365 SERVICE — BECAUSE EVERY PART COUNTS. Bringing energy and the environment into harmony.® Dresser-Rand Services cover everything from upgrades, revamps, rerates, product training, and field services, right down to the nuts and bolts. 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