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Spotlight:
Turbomachinery
COMPRESSOR
August-September 2013
Quiet
Compression
Dresser-Rand Marks
DATUM Milestone
MAN Expands
Industrial Steam Turbine Line
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Customer:
Challenge:
Result:
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Page
COMPRESSOR
Joe Kane
Compressortech2
Founder
PUBLICATION STAFF
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A New Dictionary Of
Process Machinery Terms
Robert X. Perez has just made a
valuable contribution to the data available for personnel involved in energy
production and transmission and process operations.
Perez, a machinery engineer, has
compiled an illustrated dictionary of essential process machinery terms. The
book is being printed by Diesel & Gas
Turbine Publications, which is the parent company of COMPRESSORtech2.
The 200-plus page dictionary will be
helpful for compression industry professionals who need to communicate
ideas or understanding design, performance and maintenance documents.
According to Perez, process machines come in a wide variety of forms
and perform many critical functions.
They are designed to efficiently and reliably pump liquids, compress gas, move
air, generate mechanical power, transmit mechanical power, convert mechanical power to electrical power, etc.
Without such machinery, our processes would come to a grinding halt,
which is why it is important that anyone working in these industries have
a basic knowledge of the purposes
and construction of machines.
The purpose of the dictionary is to
be a tool for those working around
machinery, but who are not machinery
professionals. It will help them quickly
locate frequently used process machinery terms and definitions in order
to make better decisions.
The dictionarys succinct format
and portable size makes it an ideal
field reference. This resource is perfect for plant decision makers, maintenance personnel, process operators,
MAN Inside
Isothermal and
Gear-type compressors
Centrifugal
compressors
Steam turbines
Expanders
We build rock solid components for a broad range of applications in reneries and petrochemicals. Whether for hydrogen production and recovery, desulfurization, uid catalytic
cracking (FCC), PTA, Fertilizer or IGCC our axial, screw and centrifugal compressors, as
well as our steam turbines and reactors are built to achieve the highest level of availability.
Redening reliability today and tomorrow. Find out more at www.mandieselturbo.com
August-september 2013
COMPRESSOR
Follow Compressortech2
at www.compressortech2.com
PUMPtech
28 Pumping Up The Offshore Market
42 A Case For VS4 Pumps
Departments
4 Page 4 A New Dictionary Of Process Machinery Terms
8 Global Perspective Infrastructure Sharing Could Help Indian Gas Flow
10 Meetings & Events
12 About The Business Pipeline Metamorphosis Begins In Northeast U.S.
14 Monitoring Government Mexico To Embrace Foreign Energy Companies
36 Recent Orders
MEMBER OF
36 Literature
41 Featured Products
47 Prime Movers
106 Snapshot GE Gets Contract For Snhvit Injection
108 Scheduled Downtime
109 Marketplace
110 Advertisers Index
112 Cornerstones Of Compression The Evolution Of Piston Rod Packing
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D a l l a s
H o u s t o n
l o s
a n g e l e s
o k l a H o m a
C i t y
Global Perspective
By Roberto Chellini
Associate Publisher
Infrastructure Sharing
Could Help Indian
Reliance eye cooperation
Gas Flow > ONGC,
in Krishna-Godavari Basin
production by 212 to 318 MMcfd (6 to 9 x 106 m3/d) in mid2017 or about 77.3 to 116.2 Bcfy (2.19 to 3.29 x 109 m3/y).
However, independently developing the necessary infrastructure to tap natural gas resources in the basin could
be difficult. ONGC had planned capital expenditure of
US$12.72 billion in fiscal 2012, but actual spending was
nearly 60% higher.
Its capital expenditure is unlikely to fall anytime soon,
particularly as it continues to expand its reach into offshore
production. In March, ONGC decided to invest more than
US$670 million to upgrade infrastructure along the Indian
West Coast to facilitate offshore field developments. That
was in addition to the US$673 million earmarked for the
Mumbai High, Heera, Bassein and other offshore projects
in the West.
The deal with Reliance would reduce the burden of
ONGCs East Coast capital expenditure and could encourage it to increase upstream field investments to further tap
the resource potential of the Krishna-Godavari Basin. Two
years ago the U.S. Geological Survey estimated that the
basin could still hold 36.7 Tcf (1.04 x 1012 m3) of undiscovered mean gas resources and 950 million barrels of mean
undiscovered liquids resources.
Indias heavily regulated energy environment remains a
threat to the maximization of the hydrocarbon potential in
the promising but technically challenging Krishna-Godavari
Basin. Business Monitor International has reported that
while the governments recent decision to double domestic natural gas prices was a positive development, the new
price at US$8.40/MMBtu could threaten the profit margins
for Indias electric power producers and risk power shortages without a corresponding reform of electricity market
prices. This situation might result in a reversal of the policy,
particularly since an election is expected in 2014.
Yet without supportive natural gas prices, upstream
players in the Krishna-Godavari Basin could find it hard to
develop the regions resources even if the infrastructure is
in place. CT2
Compressortech2
Its all in
the name...
Cooper-Bessemer is a registered trade name of Cameron Corporation, used under license by Rolls-Royce plc
www.rolls-royce.com
September
Sept. 17-19
*Gas Compressor Conference
Norman, Oklahoma
Tel: +1 (405) 325-3891
Web: www.engr.outreach.ou.edu/
gascompressor
Sept. 17-19
Developing Unconventional Gas Eagle
Ford Conference & Exhibition
San Antonio
Tel: +1 (713) 260-6492
Web: www.dugeagleford.com
Sept. 18-20
*Wyoming Natural Gas Fair
Jackson, Wyoming
Tel: +1 (307) 234-7147
Web: www.wyogasfair.org
Sept. 25-26
ChemInnovations Conference & Expo
Galveston, Texas
Tel: +1 (713) 343-1884
Web: www.cpievent.com
Sept. 30-Oct. 3
*International Pump Users
Symposium
Houston
Tel: +1 (979) 845-2924
Web: www.turbolab.tamu.edu
Sept. 30-Oct. 3
*Turbomachinery Symposium
Houston
Tel: +1 (979) 845-7417
Web: www.turbolab.tamu.edu
October
Oct. 2-4
*Power-Gen Asia Bangkok
Tel: +1 (918) 835-3161
Web: www.powergenasia.com
Oct. 6-9
*Gas Machinery Conference
Albuquerque, New Mexico
Tel: +1 (972) 620-4026
Web: www.gmrc.org
Oct. 7-10
*Argentina Oil & Gas Expo
Buenos Aires, Argentina
Tel: +54 11 4322 57
Web: www.aog.com.ar
Oct. 10-12
China (Beijing) International Petroleum
Technology Conference & Exhibtion
Beijing
Tel: + 86 10 6273 0706
Web: www.ciptc-top.com
Oct. 22-24
*Louisiana Gulf Oil & Gas
Exposition Lafayette, Louisiana
Tel: +1 (337) 235-4055
Web: www.lagcoe.com
Oct. 28-30
Shanghai International Petroleum
Petrochemical Natural Gas Technology
Equipment Exhibition
Shanghai
Tel: + 86 21 36411666
Web: www.sippe.org.cn/en
For a complete listing of upcoming events, please visit our website at www.compressortech2.com
+1 717-767-3200
+1 905-670-3122
Oct. 28-31
International Rotor Dynamics
Seminar
Cologne, Germany
Tel: +49 2267 6585-0
Web: www.arla.de
Oct. 30-Nov. 1
EP Shanghai 2013
Shanghai
Tel: +86 10 5129 3366
Web: www.epchinashow.com
November
Nov. 10-13
*Abu Dhabi International Petroleum
Exhibition & Conference
Abu Dhabi, United Arab Emirates
Tel: +971 2 4444 909
Web: www.adipec.com
Nov. 12-14
*Power-Gen International
Orlando, Florida
DECEMBER
Dec. 5-8
Basra Oil & Gas Conference and
Exhibition
Basra, Iraq
Tel: +90 212 356 00 56 (1725)
Web: www.basraoilgas.com
JANUARY 2014
Jan. 21-23
Offshore West Africa
Abuja, Nigeria
Tel: +1 (713) 963 6283
Web: www.offshorewestafrica.com
February
Feb. 4-7
*Gas/Electric Partnership
Conference
Cypress, Texas
Tel: +1 (713) 529-3216
Web: www.gaselectricpartnership.com
Feb. 19-21
Australasian Oil & Gas Conference
Perth, Australia
Tel: +61 3 9261 4500
Web: www.aogexpo.com.au
Feb. 24-27
Nigeria Oil & Gas Conference
Abuja, Nigeria
Tel: +44 20 7978 0000
Web: www.cwcnog.com
MARCH
March 19-21
China International Offshore Oil & Gas
Exhibition Beijing
Tel: +86-10-5823 6555
Web: www.ciooe.com.cn/2014/en
For a complete listing of upcoming events, please visit our website at www.compressortech2.com
918.933.6232 | MIRATECHCORP.COM
NSCR SCR DPF SILENCER AFRC NESHAP CPMS FIELD SERVICE TRAINING TURNKEY
By Norm shade
Pipeline Metamorphosis
Begins In Northeast
bonanza spawns new
U.S. > Gas
construction, compression
Coast or western Canada to feed the energy-hungry Northeast is now coming from Marcellus producers.
This has presented a major dilemma for interstate pipeline operators. While flows through the existing long-haul
pipelines to the Northeast are declining, regional pipelines
must be added and compression systems reconfigured to
support dramatic increases in production close to market
areas especially the Marcellus shale.
Market analyst Bentek Energy predicts that by 2017 production centered around residue gas (from oil and liquids
rich gas) production will lead to natural gas production increases of 8.4 Bcfd (2.0 x 108 m3/d) from the northeastern
shales. It said that Marcellus production should reach 16
Bcfd (4.5 x 108 m3/d) by 2018.
Analysts predict that as much as 29 Bcfd (8.2 x 108 m3/d)
of additional interstate transport capacity could be required
through 2020, but most will be regional in nature. Natural
gas liquids (NGL) and oil represent a large and growing
fraction of total pipeline opportunity. An oversupply of NGL
exists in the Utica and Marcellus shales, which is holding
back production in the region.
Some relief will come with the first quarter 2014 completion of the ATEX Express ethane pipeline that will connect the
Northeast with processing facilities in the Texas Gulf Coast.
And Kinder Morgan plans to convert an existing Tennessee
Gas Pipeline transmission line to liquids by the fourth quarter
of 2015, reversing the flow from northeast to southwest.
With continuing strong demand for shale gas compressors, Ariel Corp. has introduced a 5 in. (127 mm) stroke
compressor to match 1400 rpm engines. The new JGF series shares the same frame, running gear and cylinder selections as the successful JGC and JGD frames, but with a
shorter stroke crankshaft.
The JGFs rod load rating of 57,000 to 60,000 lb. (25,850
to 27,211 kg) puts it at the top of the class for 5 in. (127
mm) stroke, 1400 rpm compressors. Previously, Ariel 1400
rpm compressor offerings were limited to 4.5 in. (114 mm)
stroke with about 33% lower rod load rating than the new
JGF provides. CT2
The U.S. shale plays continue to drive astounding production growth as infrastructure catches up with exploration
and drilling. The Energy Information Administration (EIA)
reported that domestic oil production in July totaled 7.5 million bbl/d, the highest monthly figure since 1991. Full year
output is estimated to average 7.4 million bbl/d.
Despite the 2012 slump in natural gas prices, the Northeast U.S. is forecast to double gas production by 2020. Research firm Wood Mackenzie says all current natural gas
drilling in the U.S. is economic at prices above $4/Mcf.
So far, most of the Northeast gas is coming from the development of the Marcellus Shale. But gas drillers in Pennsylvania are finding that the shallower Upper Devonian
Shale is also lucrative. And, of course, the Utica Shale in
eastern Ohio is just starting to ramp up production.
Oil output from the Utica will be dwarfed by gas, according to recent reports by the Ohio Department of Natural Resources. It said that Utica gas output averaged 0.035 Bcfd
(9.9 x105 m3/d) in 2012, a pittance compared to the figures
coming from the Marcellus. But the Utica was just getting
started in 2012 as producers searched for the sweetest
acreage, and output is still hampered by a lack of processing and pipeline infrastructure.
According to EIA data, Marcellus wells in Pennsylvania
and West Virginia produce 7 Bcfd (2.0 x 108 m3/d). Thats
more than 10% of all natural gas production and 25% of all
shale gas production nationwide and its nearly double the
Marcellus production of the previous year. A recent Standard & Poors report said that the Marcellus could contain
almost half of the current proven natural gas reserves in
the U.S.
This powerful combination of resource, cost and location
is altering natural gas prices and market trends across the
nation. Gas that used to come all the way from the Gulf
Norm Shade is senior consultant and president emeritus of ACI
Services Inc. of Cambridge, Ohio. A 43-year veteran of the gas
compression industry, he has written numerous papers and is
active in the major industry associations.
AUGUST-SEPTEMBER 2013
12
Compressortech2
www.c-p-i.com/lubrication
Monitoring
Government
Mexico To Embrace
Foreign Energy
at Pemex could boost
Companies > Reforms
shale gas efforts
by patrick crow
output has fallen by 835 million bbl/d during the past eight
years to the current 2.5 million bbl/d. He said the government intends to restore that to 3 million bbl/d by 2018.
We need capital, technology and knowledge, Joaquin
Coldwell said. We must associate with those who have them.
Pemex has long been the cornerstone of Mexicos economy. It provides about a third of the governments income.
According to the Pea Nieto administration, its energy liberalization program could add a full percentage point to Mexicos economic growth within four years, and two percentage
points by 2025.
Under the plan, the government would lower Pemexs royalties and license fees. To offset those losses, Pemex would
begin paying income taxes on its production operations.
The national oil company would be reorganized into two
divisions, one focused on exploration and production and
the other on processing crude oil and natural gas into fuels
and petrochemicals.
The detailed Pea Nieto proposal is due to go to Congress in September. In order to permit private participation
in a state-owned Pemex, articles 27 and 28 of the Constitution must be amended. That will require a two-thirds vote in
both chambers of Congress and then approval by a majority of the state legislatures.
Aurelio Nuo Mayer, the presidents chief of staff, predicted the constitutional amendments and secondary legislation
would be approved by the end of the year. No major roadblocks are in sight and both the major parties back the reforms.
Even though the powerful Union of Petroleum Workers,
which represents Pemex employees, may not enthusiastically support the measures, it isnt expected to oppose
them either.
Sec. Joaquin Coldwell said no layoffs are expected at
Pemex as the result of foreign participation. But they must
occur eventually if Pemex is to function more like an international oil company and less like a government entity.
Mexico Citys Research Center for Development reported earlier this year that Pemexs 151,000 workers produce
24.5 bbl/d per capita, less than any other Latin American oil
company, and a third of the 76.4 bbl/d rate for Ecopetrols
workers in Colombia. CT2
AUGUST-SEPTEMBER 2013
14
Compressortech2
Saftey First!
Tome Stanic is head of business development and aftermarket for Voith Turbo
BHS Getriebe GmbH, Germany. He
holds a mechanical engineering degree
and an MBA in Change Management
and International Consulting from the
University of Applied Sciences, Kempten, Germany. He can be reached at
tome.stanic@voith.com.
AUGUST-SEPTEMBER 2013
YouR BeneFit:
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Power up to 31000 kW/42100 HP
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b + c: Compound Gear Planet
d:
Sun Pinion High-Speed Side
n Figure 1. The PDG uses a planetary arrangement that can
transmit more power at higher speeds than is possible with a
conventional parallel shaft or epicyclic gearbox.
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n Figure 3. The PLV in a PDG remains below the 656 fps (200 m/s) safe limit
for power ratings up to 87,000 hp (65 MW) and more. The traditional parallel
shaft gear, on the other hand, tops out at a power rating of 34,900 hp (26 MW).
n Figure 4. Bearing journal velocities tell a similar story: where parallel shaft
gears are limited to 34,900 hp (26 MW) in this application, the PDG maintains
acceptable journal velocities up to 87,000 hp (65 MW) and more.
PDG bearing loads below the maximum of 3.45 N/mm2 set by API 613.
These pins function as fixed profile
sleeve bearings, and are proven in the
more than 8000 epicyclic gear units
supplied by Voith. Bearing loads are
also reduced because the PDG has
six bearings (two for each planet gear
shaft) compared to the four supporting
the gear set of the parallel shaft gear.
Efficiency: Especially in the oil and
gas industry, reliability, safety and
continued on page 22
Compressortech2
n Figure 5. With the right choice of pin diameter for the planet gears, bearing loads in the
PDG remain below the API limit even at high powers.
n Figure 6. Close to its maximum power, the parallel shaft gear shows reduced efficiency.
The efficiency of the PDG remains higher even at power ratings up to 87,000 hp (65 MW).
availability of machinery are rightly
the most important operating characteristics. But as operators also come
to focus on the cost of energy and
cutting CO2 emissions, efficiency also
plays a role.
As with the other criteria, in terms of
efficiency the PDG rivals the parallel
shaft design (Figure 6). As the parallel shaft gear approaches its limit of
34,900 hp (26 MW), losses increase
significantly, and at 34,900 hp (26 MW)
the efficiency of the PDG is 0.7% higher. Even more importantly, the PDG retains its efficiency of nearly 99% even
when transmitting 87,000 hp (65 MW).
AUGUST-SEPTEMBER 2013
n Figure 7. The PDG requires somewhat less oil than the parallel shaft gear, and oil consumption increases linearly with power rating.
Revitalized...
AUGUST-SEPTEMBER 2013
ACI.indd 1
23
Compressortech2
8/13/13 2:08 PM
Spotlight:
South America:
Gas compression packagers set
The Next Frontier sights on market potential
By DJ Slater
AUGUST-SEPTEMBER 2013
Canada
Carbon Dioxide
200% Increase
England
Boil-off Gas
750% Increase
US Gulf Coast
Gas Gathering
100% Increase
Russia
Ammonia Gas
600% Increase
Oman
Gas Gathering
495% Increase
Colombia
Gas Gathering
300% Increase
Congo
Gas Gathering
150% Increase
ThesearejustafewoftheinstallationswhereCookvalvesare
reachingruntimesoncethoughtimpossible. Itsthe resultof
customengineering, patenteddesignsandadvanced
materialsonlyavailablefromCookCompression. Forany
heavy-dutycompressor, inanytypeofservice,anywherein
China
CNG Fueling
300% Increase
Thailand
Polypropylene Gas
200% Increase
Australia
Gas Production
100% Increase
theworldCookmakesextendedvalvelifearea lity.
www.cookcompression.com
See Whats Happening at Cook Now
Spotlight:
Spotlight:
Reciprocating Compressors for Process Gases acc. API 618 up to 17,000 kW and 1,000 bar
Centrifugal Compressors for Process Gases acc. API 617 up to 12,000 kW and 80 bar
Compressor Parts
Services: Installation, Overhauling, Engineering, Maintenance, Spare Parts Management, Training
www.borsig.de/zm
AUGUST-SEPTEMBER 2013
Borsig.indd 1
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Compressortech2
7/8/13 2:20 PM
Pump
Pumping Up The Offshore
supplying more than 100 pumps
Market > Sulzer
through two orders
n The FPSO vessels P-66 and P-69 will receive 42 pumps from Sulzer.
The FPSOs operate in the pre-salt Iracema cluster areas in the Santos
basin, off the coast of Rio de Janeiro, Brazil.
AUGUST-SEPTEMBER 2013
tech
n Sulzer Pumps API 610 OH3, BB2 and BB5 type pumps will be installed on
a 1100 ft. (335 m) FPSO vessel for the Inpex-operated Ichthys LNG Project
in the Browse Basin offshore Western Australia.
28
Compressortech2
Insight onsite.
AUGUST-SEPTEMBER 2013
branded Ojibway Enclosures by Universal. According to Universal, all employees will be retained and will continue to work at their current locations.
The combined companies will have a
workforce of 350.
Universal and Ojibway share common customers including Caterpillar,
Cummins, MTU and other prominent
engine distributors.
Universal AET and Ojibway are now
in a better position to serve their customers: engine distributors who source
silencers, emissions treatment products
or complete power generation packages for data centers, hospitals and other
large-scale facilities that require standby
power generators, Universal AET Executive Vice President Dick Strojinc said.
Engine distributors will seek either
a complete enclosed genset package,
which is Ojibways core competency,
or components of a system, which
are Universals products. Now that
Ojibway will be part of Universal, our
staffs can work together seamlessly,
and our customers projects will be
managed by just one contact. CT2
Compressortech2
n Man Diesel & Turbo makes two different steam turbines, one rated at 161,000 hp (120 MW) and the
other rated 6300 hp (4.7 MW), with the same modular turbine setup.
53,640 hp (40 MW). They are assembled in Changzhou for the Chinese market, one of the fastest developing business areas for the German company.
The increasing size and power requirements of the compressors made
at Oberhausen and Zurich has imposed a parallel development of their
steam turbine drivers.
The steam turbine has to meet the
32
FPSO Project,
Brazil
Our customers dream was
to build one of the largest,
most efficient and reliable
converted FPSOs in the world.
Nidec delivered.
Nidec ASIs explosion proof motors
provide maximum reliability,
performance and safety with
a high level of efficiency.
Nidec ASI
Bearing Bush
Guide Vane
Guide Vane Carrier
Adjusting Lever
Adjusting Ring
Compressortech2
reply@prognost.com www.prognost.com
REEal improvement of
Ever worried about the reliability, energy efficiency
and environmental soundness of your compressors?
The continuous improvement of compressors is fundamental if plants are to meet
modern demands in terms of run cycle, energy effciency and enivronmental compliance.
In order to do this, clear data on the real performance of your compressor is required.
The REE Assessment carried out on-site by HOERBIGER senior compressor experts
ranks your equipment using the REE index. It allows you to see where there is potential
for improvement and savings, helping you to choose the right technology and make the
info-hkth@hoerbiger.com
www.hoerbiger.com
Recent Orders
literature
Hoerbiger.indd 1
Dresser-Rand
Dresser-Rand has received a US$200
million contract from Apex Compressed Air
Energy Storage for equipment for a 425,100
hp (317 MW) compressed-air energy storage (CAES) facility planned near Tennessee Colony, Texas.
The Apex Bethel Energy Center would be the first CAES facility in
the United States since the Power South
facility in McIntosh, Alabama, which was
built in 1991. It also contains DresserRand turbo machinery.
A CAES system provides two different
services either sequentially or concurrently high-pressure air compression
and electric power generation derived from
expanding the compressed air. More than
40 such projects being considered across
the U.S., many of them linked with wind
and solar power farms.
Siemens
Siemens Energy will supply Hangzhou
Zhongtai Cryogenic Technology Corp.
AUGUST-SEPTEMBER 2013
8/15/13 10:05 AM
the compressor trains for three liquefied natural gas (LNG) plants, the fifth
follow-up order for Siemens from the
Chinese company.
The trains, which compress the
mixed refrigerant that cools the natural
gas, each consist of a six-stage, vertically split, barrel-type compressor and
a Siemens constant-speed electric
motor. Siemens said this type of drive
and control using inlet guide vane assemblies provides more efficient and
reliable operation than conventional
compressor solutions with throttle valve
or speed control.
The equipment will be entirely
fabricated, assembled and packaged
with the drives in Huludao, China. Siemens said it has developed and uses
a pre-engineered compression concept
for medium sized LNG plants.
The synthetic LNG plants each
will have a capacity of 500 MMcfd
(14.1 x 106 m3/d). Delivery of the
equipment is due in June 2014. CT2
36
Rotary Lobe
Pumps
at the
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achiner
nd Turbom
42
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Hoerbiger.indd 2
8/15/13 10:05 AM
Ignition
Products
Gas Supply
System
HGM Pump
Protection
Dri-Prime
Pump
AUGUST-SEPTEMBER 2013
37
Compressortech2
Spotlight:
Siemens held a party when it
manufactured its 1000th SST 300
steam turbine in Brazil.
Tropicalization Is Common
Siemens adapts compressors,
For Brazilian Packagers equipment for heat
By Mauro Belo Schneider
AUGUST-SEPTEMBER 2013
Recognized
Leader
Spotlight:
storage and offloading vessels (FPSOs) for the Cesso
Onerosa petroleum exploration area, where the percentage of local content for motor driven compressors varied
from 38% for the first one to 49% for the fourth. For the
turbocompressors, it varied from 22 to 32%. Caldas explained that the percentages are negotiable.
There was a situation once when we needed to buy locally the electric motors, base, tubing and valves because it
was specified in the business, Caldas said. For other projects, its normally not mandatory.
Siemens compressor packages are mostly used in refineries and offshore facilities in Brazil. The compressors are imported from the companys Duisburg, Germany, manufacturing plant and are packaged at its Jundia plant in So Paulo
state. If the company wants to maximize the local content,
just the compressor, coupling and some other minor components must be imported.
Caldas said Siemens makes steam turbines in Brazil and
packages them at the Jundia plant. Used to generate energy, the equipment is also in demand by industries such as
oil and gas, chemicals, mining and metallurgy, cellulose, food
and others.
For powers above 134,100 hp (100 MW), they are made
in Germany. The gas turbine drivers are manufactured in
Lincoln, England, and Finspng, Sweden. Alternative compressors are packaged at Siemens plant at Elblag, Poland.
Siemens also uses Ariel compressors.
The compressors in Siemens packages are centrifugal and
axial, following API 617 and API 672 requirements. Discharges are up to 1450 psi (100 bar), volume and flow up to 46
MMcf/h (1.3 x 106 m3). Lubrication can be forced or none, such
as with model STC-ECO, which has magnetic bearings.
Siemens uses steam turbine, gas turbine, electric motor
and turboexpansion drivers. Depending on the demand, the
company can apply emission controls and sound attenuation.
Siemens will invest US$600 million in Brazil through
2016, said Welter Benicio, oil and gas division director at
Siemens, when the company announced the acquisition of
Expro Holdings UK.
The news impacts directly the companys businesses in
Brazil, which is considered the largest center of subsea oil
and gas applications in the world a market that might
reach 2 billion globally through 2020. One of Siemens
main focuses will be to increase the Brazilian content of the
products it offers.
The company said its Jundia plant has the only Schenck
DH7/DH50 high-speed balancing machine in South America.
The service for balancing turbine rotors and compressors in
high speed was previously only done in Europe and would
take 90 days. Since the machine was brought to Brazil three
years ago, this time was reduced to one month. It is available
to all operators of rotating equipment. CT2
AUGUST-SEPTEMBER 2013
Innovator in State-of-the-Art
Pipe Supports & Clamps
Inventor of Flywheel Lock
Leaders in Field Machine Work
Pioneers in Casting Rapair
PRODUCTS:
n Pipe Supports & Clamps
n Epoxy Grout
n Anchor Bolts
n Flywheel Locks
n Temperature & Vibration
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SERVICES:
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n Machine Shop
n Broken Bolt Removal
n Frame Reinforcement
n Alignment Services
918-252-7545
www.r-f.com
info@r-f.com
Tulsa, OK
39
Compressortech2
Dresser-Rand, Honeywell
Merge Turbo Control
embeds anti-surge, load-sharing
Systems > D-R
programs into Honeywell controller
AUGUST-SEPTEMBER 2013
FEATURED
PRODUCTS
Flexible Switch
Expert Engineering.
Proven Results.
AUGUST-SEPTEMBER 2013
www.waukeshabearings.com/CT
41
WaukeshaBearings.indd 1
Compressortech2
8/19/13 11:16 AM
Pump
tech
AUGUST-SEPTEMBER 2013
Emissions Requirements?
Murphy can help solve the puzzle
Murphy understands that some applications
require complex control of sophisticated
systems. Achieving compliance while
maintaining simplicity is easy with our
air-fuel ratio controls.
Balance your investments by taking
advantage of Murphys full range of
emissions control strategies to meet
emissions needs now and in the future.
8-2013
Visit us at
Booth #718
scrubber?
Let Murphy solve the puzzle
8-2013
Visit us at
Booth #718
Spotlight:
Argentinas Shale
Prospects Continue
Tight gas could be the answer to slide
To Brighten in conventional production
PRIME
Movers
Miratech
Miratech
has
made several staff
appointments. The
company appointed
Tim Martin to the
position of project
manager. Martin,
who will be based
T. Martin
in the companys
Tulsa, Oklahoma headquarters, formerly served as the logistics preconstruction and products liaison for Turner Construction in Brentwood, Tenn.
J. Brown
F. Reder
Miratech also appointed Jeff
Brown as its strategic account manager and Frank Reder as an acoustic engineer. Brown will be based in
the Houston area and be responsible
for handling corporate relationships
with Miratech customers in the power generation and gas compression
fields. Before joining the company,
Brown was the director of North
American sales and marketing for
EMIT Technologies.
As an acoustic engineer, Reder, who
will also be based in the Tulsa headquarters, is responsible for the design,
sizing and production of silencer products and their integration with catalyst
products. He previously was a staff engineer for Lewis B. Goodfriend and Associates, a New Jersey-based acoustical engineering firm.
GE Waukesha
A GE Waukesha gas engine has
entered full commercial operation at
the Chongqing gas field in China. The
engine, a GE Waukesha 16 V 275GL+
with an output of 4835 bhp (3605 kW)
at 1000 rpm, powers a high-speed reciprocating compressor, which is part
of a compression station owned and
AUGUST-SEPTEMBER 2013
testo 350.
Testo.indd 1
Compressortech2
1/22/13 9:06 AM
n These two large radial active magnetic bearings will be used for a
natural gas centrifugal compressor.
AUGUST-SEPTEMBER 2013
turbomachines superseding conventional hydrostatic bearings and allowing compressor, motor and turbine
manufacturers to eliminate lube oil
systems from their turbomachines.
The very simple idea of a floating
shaft within a magnetic field (which
is the principle of AMB) became reality through space research following World War II. AMB was originally
used in rockets and at the time, the
international space race was a major challenge. About 150 members of
Wernher von Brauns ballistic team,
48
with a lot of their research documentation, had joined the newly formed
French space research center on
the north bank of the River Seine,
opposite Vernon and about 44 mi.
(70 km) northwest of Paris.
At this location, a team of experts
was dedicated to magnetic bearings.
Maurice Brunet enhanced and transferred the pioneer knowledge to a
younger generation of engineers, who
founded S2M in 1976 (50% French
space program and 50% SKF). By the
continued on page 50
Compressortech2
UPSTREAM SOLUTIONS
THAT LEAD TO AN IMPRESSIVE DROP
IN FUEL CONSUMPTION AND EMISSIONS.
Weve packaged technology, efficiency and reliability all into one to help lessen your impact
on the environment and lower the total cost of ownership for your upstream applications.
Our products centrifugal and reciprocating compressors, steam and gas turbines for mechanical
drives and gen sets, control systemshelp you reduce fuel consumption and lower emissions.
And they can be applied to all segments of the upstream market, including re-injection, gas lift,
gas processing, gas gathering, CO2/N2 injection, gas treatment, export gas, LNG, liquefaction, and
boil-off gas. For example, our DATUM I integrated compression system (ICS), shown at right, is
capable of serving all oil and gas applications while using half the space and weight of traditional
compression modules.
Find out today how Dresser-Rands solutions can help your cash flow.
CompressorsTurbo & Recip / Steam Turbines / Gas Turbines / Engines / Control Systems / Expanders
www.dresser-rand.com
MAKE A CONNECTION
CENTAMAX HTC
High Thermal Capacity
design - patent pending
,PSURYHG DLU RZ SDWWHUQV
for higher Power Loss
Sizes thru 45 kNm nominal
torque
Torsionally very soft
linear characteristic
51
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Compressortech2
AUGUST-SEPTEMBER 2013
Last March, the MTC ran a performance test for the second of two
geared-type compressors to be installed in the United States.
Each of the three process stages
underwent a Class I test under full
speed, full load and full pressure. The
compressor is driven by a 26,820 hp
(20 MW) class, 60 Hz, fixed-speed
Siemens electric motor.
The two compressors will transport,
via pipeline, the CO2 produced at an
integrated gasification combined cycle (IGCC) plant powered by Siemens
gas turbines, to the Gulf Coast and
will be injected into offshore oil wells
continued on page 54
Compressortech2
Experienced
Machining!
C
Compressor cylinder
relining
Pistons and rods
Piston rings and
rod packing
Compressor valves
Thread rolling
CNC machining
Repair parts
Used and refurbished
compressors
Gas compressor packaging
200hp - 1500hp
3 RVICE
SE
YE A RS HE G AS
TO T SSION
E
COMPR STRY
INDU
1-800-533-3849
Granbury, Texas
Monahans, Texas
n The test bench was challenging because each process stage required
dedicated CO2 loops.
Job interstage coolers were included in the loops with the addition of
an aftercooler from the Siemens test
equipment for supercritical CO2 at the
eighth stage delivery. This ensured
stable suction conditions on the third
process stage during the test.
Flowmeters were added to control
the actual delivery of each process
stage during the test. The high-pressure
loop, designed for a discharge pressure
of 2175 psi (150 bar), was kept as short
as possible upstream the throttle valve.
A further challenge was the different
current frequency used in Europe, 50
Hz, versus the American 60 Hz grid and
the different voltages, 13.2 kV at site
and 11 kV available at the MTC. A shop
frequency converter had to be used to
feed the job motor during the test.
The three loops were filled separately with CO2 at the required pressure from a 16.5 ton (15 tonne) tank
located just outside the MTC and in54
Test program
During the two-day testing program
the compressor was manually controlled by Siemens specialists. The test
bed data acquisition and evaluation
system, featuring 200 channels, collected test data required by the customer and additional information useful
to implement Siemens experience.
The test was carried out with inlet
guide vanes placed in front of the
first impeller of each of the three
process stages in the various positions to explore the full operating
range of the machine.
Also, two cold starts and two hot
starts were performed during the twoday, 16-hour test program.
All collected data responded to the
design data and the test was concluded with full customer satisfaction.
Setup of the compression system inside the MTC was completed over two
months. The compressor itself was laid
on a 2690 sq.ft. (250 m2) area on the
floor. Another 1940 sq.ft. (180 m2) was
occupied by the CO2 loops, the control
equipment and the space required by
the test operators to closely check all
components of the package.
During the actual test the entire
MTC was closed for safety reasons.
Only the test personnel were admitted
inside the building.
During its five-year life, the Duisburg
MTC has performed a number of special tests under specifications requested by its compressor customers. CT2
Compressortech2
FEATURED
PRODUCTS
HEINZMANN Contacts in
North America
Subsidiaries
prevents cross-contamination; an improved position indicator for quick recognition of valve actuation; easier cartridge removal for maintenance; and an
atmospheric reference vent module.
Developed by Parkers Instrumentation Products Division (IPD), the Gen
II R-max is designed to control gases
and liquids in analytical systems ranging from vacuum to 500 psig (34 bar),
while requiring 65 psig (5 bar) actuating
air pressure. The system is designed for
use in the analytical, oil and gas, petrochemical, and chemical industries.
www.parker.com
Data Monitoring
Atlas Copco has introduced a compressed air monitoring program, SmartLink, which is designed for continuous
data monitoring. When paired with the
Elektronikon controller, SmartLink provides a web-based monitoring dashboard that alerts users of potential
problems to prevent equipment failure
and provides information needed for reducing energy costs, Atlas Copco said.
With SmartLink, data is gathered,
compared and analyzed, providing
customers with a snapshot and complete in-depth analysis of their air
supply. SmartLink is also fully customizable to fit a customers data monitoring needs. When necessary, warning
messages are sent to customers via
text message and e-mail.
Atlas Copco plans to integrate
SmartLink into compressed air installations worldwide. The program will
start becoming a standard on most
oil-injected rotary screw compressors
throughout 2013.
www.atlascopco.com
continued on page 94
58
USA
Heinzmann America, Inc.
1305 Duff Drive, Unit 1A
Fort Collins, CO 80524
Phone:
+1-970-484-1863
Email:
info.usa@heinzmann.com
Canada
Heinzmann GmbH & Co. KG
1013-14 Avenue
Wainwright, AB, T9W 1K5
Phone:
+1-780-231-2280
Email:
b.powers@heinzmann.com
Agents
USA
Kraft Power
Corporation
199 Wildwood Ave.
Woburn, MA 01801-2024
Toll free: +1-800-969-6121
Further ofces:
Suwanee, GA
Phone: +1-800-394-0078 (Toll free)
Email: GAinfo@kraftpower.com
Gaylord, MI
Phone: +1-866-713-2152 (Toll free)
Email: MIinfo@kraftpower.com
Charlotte, NC
Phone: +1-704-504-3033
Email: NCinfo@kraftpower.com
Houston, TX
Phone: +1-800-394-0078 (Toll free)
Email: aschaub@kraftpower.com
Massillon, OH
Phone: +1-330-830-4158
Email: rmontgomery@kraftpower.com
Pompton Plains, NJ
Phone: +1-800-221-3284 (Toll free)
Email: NJinfo@kraftpower.com
Syracuse, NY
Phone: +1-877-349-4184 (Toll free)
Email: NYinfo@kraftpower.com
Sturtevant, WI
Phone: +1-262-884-8666
Email: WIinfo@kraftpower.com
Canada
Advantage Governor &
Controls Inc.
1013-14 Avenue
Wainwright, AB, T9W 1K5
Phone:
+1-780-842-4248
Email:
sales@advantagegovernor.com
Wajax Power Systems
2997 rue Watt
Quebec, QC G1X 3W1
Phone:
+1-418-651-5371
Email:
PCusson@wajax.com
Me
e
bo t us
oth
a
92 t
2
an
d
We supply it all
bo
oth
31
9
PHLOX II
New Generation of
Ignition Control
Ignition Control
Wastegate
Knock Control
PHLOX Ignition Control System for all engine sizes and fuel gases
All components from one supplier
On-board diagnostics
Up to 8, 12 and 16 cylinders
www.heinzmann.com
on an Ariel/Caterpillar
package at the Houston
fabrication shop.
AUGUST-SEPTEMBER 2013
SEC provides compression equipment, parts and services to all industry segments. It designs and
makes gas-, electric- and dual drivedriven equipment from 50 to 8000
hp (35 to 6000 kW) to meet specific
operating requirements.
The company now also provides
engineering services, overhaul revamp facilities, truck-based service
technicians, OEM parts and power
generation equipment.
Frank Northup, director of sales and
marketing, said the centerpiece of the
Houston expansion is the 63,000 sq.ft.
(5880 m2) assembly building. The 12
new bays are each deeper and wider
than those in the current shop.
According to Northup, the most exciting addition to the assembly building will be the installation of a dynamometer. Once operational, SEC will
be one of the few compression pro60
AUGUST-SEPTEMBER 2013
286,000 SF Manufacturing
Facilities on 38 Acres
(918) 283-9200
61
AXH.indd 1
www.axh.com
Compressortech2
4/16/12 4:42 PM
August-September 2013
62
Compressortech2
Visit us at
Turbomachinery
Symposium
Booth 620
Dresser-Rand Marks
unit was a Datum I, the latest
DATUM Milestone > 1000
addition to the series
th
By Brent Haight
The compressors for the littoral project are being manufactured at DresserRands factory in Le Havre, France. The
compression trains will be packaged
and shipped to the United States toward
the end of 2013. Upon arrival, they will
then be packaged with the balance of
the compression module equipment in
Texas. It is expected that the compression modules will arrive at the offshore
location in the Bay of Campeche in the
early part of 2014.
Since introducing the DATUM compressor in 1995, we made a commitment to provide a reliable, technologically superior compressor that results
in the lowest total cost of ownership
for our clients, said Jesus Pacheco, executive vice president of New
Equipment Worldwide at DresserRand. The DATUM I compressor is
another example of the adaptability of
the DATUM product line and its ability
to meet the unique application challenges of our clients.
The DATUM line consists of 15
standard frame sizes that are scaled
from the median size frame. Discharge pressures range up to 15,000
psig (1000 bar). Maximum flow rates
are from 5400 cfm (9200 m3/h) to
700,000 cfm (1.2 million m3/h). Power
ratings have exceeded 120,000 bhp
(90 MW). Cases can be axially split
(900 psig max [62.1 bar]) or radially
split (15,000 psig max [1034 bar]).
The full family line of DATUM compressors has evolved to include the
DATUM P, originally developed for
pipeline applications; the DATUM C, a
compact, hermetically sealed design
for emissions-free operations; the DATUM I, which uses Dresser-Rands
proprietary rotary separation technology to remove liquids from the incoming gas stream within the casing, and
the DATUM ICS, a complete package
continued on page 68
Compressortech2
Features and
BeneFits
FEATURE
BENEFIT
_________________________________________________________________________________________________________________________________________________
Carbon or stainless steel construction
Innovative Double Bulb Gasket provides the best seal for removal and bypass prevention
Validates date of manufacture and quality assurance with full tracking capabilities
_________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________
BLOOMER, WI 715-568-2882
GILLETTE, WY 715-933-2641
FORT WORTH, TX 715-933-1559
TULSA, OK 715-933-4154
www.CatalyticCombustion.com
MACHINERY ANALYSIS
AUGUST-SEPTEMBER 2013
Tokyo +81-3-5739-6771
Munich +49-89-242-1842
Houston, Texas
+1-713-655-0015
sales@kobelco-kca.com
www.kobelcocompressors.com
LSE system
Sound Fighter Systems pioneered
the use of high-performance absorptive noise barriers for extended use
in harsh outdoor environments. We
are the oldest manufacturer of such
products in the nation, said President Patrick Harrison.
Although our product was designed
more than 40 years ago, the physics
of acoustics dont change over time.
The product still works effectively today to mitigate offensive frequencies,
he said.
The companys LSE Absorptive Barrier System uses interlocking panels
to erect walls of various heights and
lengths around outdoor equipment.
The high-density polyethylene
Location/Condition
n These were the sound levels inside and outside the Sound Fighter Systems LSE sound
wall installation. The 125 Hz sound is louder
than might be expected at 50 ft. (15 m) due
to the tall exhaust outlet on the mufflers and
125 Hz being the firing rate of the engines.
AUGUST-SEPTEMBER 2013
125
250
500
1000
2000
4000
8000
Overall
dBA
Inside Barrier
Center Yard
94
87
88
90
86
84
82
76
92
92
82
81
80
77
73
70
65
82
Outside Barrier
Center-west at 3 ft.
80
75
66
57
54
47
40
32
63
75
68
62
55
56
49
42
36
60
72
Compressortech2
L.A. Turbine is also the trusted turboexpander provider for any OEM and non-OEM aftermarket
repair, redesign, maintenance and spare part production need. Plus, our global, best-in-class
field service team offers commissioning, maintenance and 24/7 emergency support.
Looking for innovative equipment solutions, performance, reliability and service responsiveness?
Contact L.A. Turbine, the world leader in turboexpanders for the oil and gas industry,
at www.laturbine.com.
LAT 529
Standard Package
L2000 TurboexpanderCompressor for Texas
natural gas processing plant
www.laturbine.com
Altronic.indd 1
2:28 PM
Soon to be available
in other horsepower
ranges.
literature
Altronic.indd 2
8/13/13 2:28 PM
High-Pressure Pumps
Liquid Ring
Compressors
A brochure on high-pressure
pumps is available from
Hammelmann. The brochure provides sections on
the construction and features of the companys highpressure pumps, as well as
horsepower and pressure
ranges. A list of available
accessories and company
services is also provided.
www.hammelmann.com
AUGUST-SEPTEMBER 2013
75
Compressortech2
n This forced draft vertical engine drive cooler has a 168 in. (4267 mm) fan, two water sections and three gas sections.
Rick Ketchum is the vice president and general manager of Hudson Compression Cooling. He holds a BS in electrical engineering from the University of Tulsa, plus a masters
in electrical engineering and an MBA from Oklahoma State University. He has been in
the heat transfer industry for 13 years. Contact him at rgketchum@hudsonproducts.
com. Bob Giammaruti is vice president and general manager of Hudson Products Corp.
- Process Cooling. He holds a BS and MS in mechanical engineering from Drexel University in Philadelphia. He has been in the boiler and heat exchanger industry for 22
years. Contact him at rjgiammaruti@hudsonproducts.com. Robert Khami is the general
manager for Hudson Products Corp. Fans, Americas. He holds a BS in aerospace
engineering from the University of Michigan and an MS in mechanical engineering from
the University of Washington. He has been in engineering, manufacturing, and operations for more 25 years. He can be reached at rkhami@hudsonproducts.com.
AUGUST-SEPTEMBER 2013
76
E50001-E420-F130-V1-4A00
STC-STO meet and even exceed the demanding requirements for quality, such as reliability and energy-sensitive operation. Pre-designed turbocompressors from
Siemens have proven to be more efficient than conventional solutions in the long run. This is how Siemens
is already meeting the future demands of the sulfur
industry.
siemens.com/energy/turbocompressor
Actuators-Throttle Bodies
G
A
C
OVERNORS
MERICA
ORP.
Fan
Parameter
Value or
Description
153,680 (72.53)
129.5 (0.52)
0.0722 (1.157)
13.0 (3.96)
Fan Case
Fan
Type
Fan
RPM
Shaft Power/
Fan HP (kW)
Sound Power
Level per Fan
dB(A)
ACHE Base
STD
296.9
12,124 (61.6)
18.3 (13.7)
102.1
ACHE 1
STD
265.6
10,847 (55.1)
18.7 (14.0)
99.3
ACHE 2
VLN
234.4
9573 (48.6)
21.0 (15.7)
95.7
ACHE 3
VLN
208.8
8527 (43.3)
21.0 (15.7)
92.7
ACHE 4
VLN
168.2
6869 (34.9)
20.7 (15.4)
89.6
ACHE 5
ULN
208.8
8527 (43.3)
18.3 (13.7)
85.6
ACHE 6
ULN
186.9
7633 (38.8)
17.9 (13.3)
82.6
ACHE 7
ULN
151.4
6659 (33.8)
18.1 (13.5)
80.4
ACHE 8
ULN
136.5
6004 (30.5)
18.6 (13.9)
79.3
STD Standard Noise, VLN Very Low Noise, ULN Ultralow Noise
We
move
the
world
Visit us at
Turbomachinery
Symposium
Booth 1119
FLENDER
GRAFFENSTADEN
Through a long history of gear manufacturing,
we have acquired the know-how and the experience
to be a leader in the field of high speed gears.
Our industrial site has developed a tradition
in high performance gear units for over 60 years
and through more than 13000 references
for the Power Generation and the Oil & Gas industries.
FLENDER-GRAFFENSTADEN S.A.S.
1, rue du vieux moulin - BP 10063
F - 67402 Illkirch Cedex - France
Phone : +33 (0)3 88 67 60 00
www.flender-graff.com
HIGH PERFORMANCE TRANSMISSION FOR ENERGY
n Figure 5. Graph shows ACHE bay cost increase vs. near and far field SPL.
n Figure 6. This is the percent cost increase split between fans and mechanicals.
AUGUST-SEPTEMBER 2013
80
ACHE description
The base-design ACHE described in
this paper (Figures 1 and 2) is a grademounted, carbon-steel induced draft
item built to the API-661 Standard2.
The ACHE has a thermal duty of 29.3
MW (100 MMBtu/hr) cooling a hydrocarbon liquid from 141F (60.3C) to
100F (37.8C) at an ambient design
temperature of 90F (32.2C).
The item consists of 11 individual
bays with 40 ft. (12.2 m) long, 1 in.
(25.4 mm) OD carbon steel tubes with
extended surface. The extended surface consists of extruded aluminum
fins 0.625 in. (15.9 mm) high spaced at
10 fins per inch. The tubes are spaced
in an equilateral tube pitch of 2.5 in.
(63.5 mm). The individual bays are
16.34 ft. (4.98 m) wide with an overall
item width of 179.8 ft. (54.8 m). Height
from the bottom of the tube bundle
frame to grade is 9 ft. (2.74 m).
The base mechanical fan drive systems consists of 25 hp (18.6 kW),
60 Hz, single-speed motors, synchronous
belt speed reduction, and 13 ft. (3.96
m) fiberglass reinforced plastic (FRP)
fans with four blades. Each bay has two
mechanical drive systems with the entire item containing 22 such systems.
Case ACHE
Figure 3 lists the common operating
parameters of all the ACHE fans studied. Figure 4 lists the base case fan condition along with the lower noise options
listed in order of decreasing noise.
As one can see from Figure 4, the fan
speed was lowered to approximately
50% of the base design while the fan
shaft power remained fairly constant.
Fan speed was varied in approximately
10% increments by a combination of
drive ratios and motor speeds to achieve
the required noise reductions.
Multiple fan selections were performed for the STD, VLN and ULN
fans types as applicable to achieve
the overall most cost effective solution at that particular speed. Cost increases were estimated for fan cases
one through eight taking into account
changes (if any) in fan, motor, drives,
mechanical structure and fan rings.
continued on page 82
Compressortech2
n Figure 7.
This graph
shows rpm
and sound
power level
by fan type.
n Figure 8.
This graph
shows the
relative fan
comparison
by fan type.
dB(A) of far field noise reduction increased the overall cost per ACHE bay
by about 4% from the base design.
However the next 10 dB(A) increased
the cost 20% from the base design.
The majority of this increase is related to the fan and, depending on the
type of fan, VLN or ULN, (see photo
showing a general size comparison)
will range from 70 to 90% of the total increase. This is shown in Figure 6
where the costs increases are plotted
as a function of fan sound power level.
The variance shown in Figure 6 is
simply a function of the design points
chosen. For example, at the 92.7 dB(A)
SPL point, nearly 30% of the cost increase is due to nonfan components
due to the fact that the fan, in this instance, did not change as the speed
was reduced. However, when considered in total, this combination of fan,
motor, drives and so forth provided the
least amount of overall cost increase.
Another factor is the fan material. Aluminum fans tend to be less costly than
FRP fans and will move the cost split
more towards the nonfan components.
A good rule of thumb is that the fan
will account for approximately 70% (aluminum) to 85% (FRP) of the total cost
increase as noise is reduced. However,
every situation is unique and the owner/
operator is encouraged to investigate all
possibilities with the OEM/supplier.
Levels at constant static pressure
To effectively cool the fluid in the
tubes, an ACHE will need to maintain
a certain static pressure. The graph
in Figure 7 shows a comparison of the
STD, low noise (LN), VLN and ULN
fan types. These fans curves are at
the same static pressure while comparing rpm and near field noise.
This shows that the noise level
can be decreased significantly using
different blade types. There are, of
course other considerations such as
increased blade width and decreased
rpms which may require an increased
fan ring height and larger drive mechanisms (gear box or belt drives), respectively. This may create challenges
for retrofitting an existing ACHE, but
has been achieved in many prior examples and retrofits.
Compressortech2
The graph in Figure 8 shows the relative cost increase by fan type. Typically
the cost increase from a STD to a LN fan
type is fairly small. However the relative
increase between LN, VLN, and ULN is
an increasingly linear relationship. Note
that this is directional data on the fan
type itself and does not include changes
to the structure, fan ring, or drive mechanisms that also may need upgrades.
How quiet can we be?
As we know, there are times when
the noise level is the overriding driving factor and the cost of the cooler/fan
is a secondary consideration. The following graph shows the low end of the
VLN noise spectrum to get some idea
of how quiet the cooler could be with
associated static pressure available.
Figure 9 shows a comparison of PWL
vs. rpm at the same static pressure (0.5
in. of H20) and airflow while varying rpm.
This clearly shows the advantage of the
ULN which is primarily due to the wider
chord length and lower tip speed.
Figure 10 is similar to the previous
figure, but at a much higher static
pressure while varying rpm. The
shapes of the curves vary slightly, but
the delta is fairly similar. Again this advantage is primarily due to the wider
chord length and lower tip speed for a
given airflow and static pressure.
Summary
As presented, the cost of noise, in this
case lower noise, significantly impacts
the cost of an ACHE depending on how
low and where the noise guarantee points
are located. While significant near and
far field noise reductions are achievable
(in these cases without adding ACHE
Bays or CT cells), as the curves show,
the increase in cost is not a linear function but rather a third order polynomial
that accelerates quickly as one reduces
the noise levels.
Maintaining the necessary static
pressure for the ACHE to work properly certainly has design and cost
ramifications with regard to fan ring
depths and sheave sizes.
The ULN capabilities of current
technology will accommodate reasonable static pressures at a nearfield noise level of 70 to 80 dB(A) on
AUGUST-SEPTEMBER 2013
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n These are three of six Caterpillar G3616LE gas engine-driven Ariel KBZ/4 reciprocating compressor
packages that UE Compression designed and built earlier this year for a Texas gas plant.
n UE Compression designs all packages in Solidworks 3-D CAD. The 3-D model (top) shows the design of a 1250 hp (932 kW) five-stage Ariel JGK/6 CO2
package shown in fabrication (bottom). The package was destined for a Weld
County, Colorado, gas processing plant.
ing air and service air compressor skids, large motor-driven rotary
screw compressor packages for
power generation fuel gas boosting,
a large liquefied natural gas boil off
compressor package, several midstream natural gas packages of various sizes and a large five-stage CO2
compressor package.
Two of the fuel gas booster packages in production included 1750 hp
(1305 kW) US Motors/Nidec electric motors driving single-stage Frick
SGC3511 rotary screw compressors.
Each package will boost 57 MMscfd
(1.6 x 106 m3/d) of gas from 385 psig
(26.5 bar) suction to 545 psig (37.6
bar) discharge. The two packages will
support a 785 MW combined cycle
gas turbine power plant in Texas.
Five 3750 hp (2796 kW) General
Electric motor-driven, three-stage
Ariel KBZ/4 reciprocating compressor packages were being fabricated
for a midstream compressor station
in the Wattenberg area of Colorado.
Each package will deliver 22 MMscfd
(6.2 x 105 m3/d) of gas from a suction
pressure of 70 psig (4.8 bar) to a final discharge pressure of 1100 psig
(75.8 bar).
The CO2 package in production
was for a Weld County, Colorado, gasprocessing plant. It included a 1250
hp (932 kW) General Electric motor
driving a five-stage Ariel JGK/6 reciprocating compressor package that will
deliver 4 MMscfd (1.1 x 105 m3/d) of
CO2 from 7 psig (0.48 bar) suction to
1190 psig (82.1 bar) discharge. After
mixing with residue gas, the CO2 will
go into a sales pipeline.
Kern said that earlier this year,
UEC completed six 4850 hp (3617
kW) Caterpillar G3616LE gas enginedriven Ariel KBZ/4 reciprocating compressor packages for a Texas gas
plant. Each compressor was designed
to boost 110 MMscfd (3.1 x 106 m3/d)
of inlet gas in a single-stage from 550
psig (37.9 bar) suction to 1000 psig
(69 bar) discharge and also move 53
MMscfd (1.5 x 106 m3/d) of residue
gas in two stages from 300 psig (20.7
bar) to 1175 psig (81 bar).
Another unusual project that demonstrates UECs diverse design and
manufacturing capability was com-
AUGUST-SEPTEMBER 2013
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Young Company
Has Decades Of Experience
n November 2012, Euro Gas Systems SRL celebrated the completion of its new compressor package assembly plant in the industrial
park adjacent to the airport at Targu
Mures, Romania.
Founded in early 2010, Euro Gas
Systems (EGS) began operations in
a modest facility in the city of Targu
Mures. Less than two years later, it
had delivered 16 compressor packages, ranging from 40 to 420 hp (30
to 315 kW) for customers in Ukraine,
Russia, Kazakhstan and Poland.
The company also sold more than
60 EGS-designed and manufactured
Pressure Equipment Directive (PED)
certified vessels as separate items to
other packagers and end users during
that time.
EGS built the new plant in re-
AUGUST-SEPTEMBER 2013
sponse to strong sales growth, including a demand for larger compressor packages. Its backlog had grown
to 17 packages by the time the plant
was completed.
The facility has 25,835 sq.ft.
(2400 m2) of manufacturing space
plus 10,340 sq.ft. (960 m2) of office and meeting space in a twostory format attached to the side of
the factory. The assembly area is
divided into two 49 x 262 ft. (15 x
80 m) bays that are each equipped
with two 55 ton (50 tonne) cranes
and three 11 ton (10 tonne) cranes.
The facility has a 20 x 50 ft. (6 x
15 m) paint booth and welding machines, CNC pattern torch, metal
shear, saws, etc. for skid and pressure vessel manufacturing.
Production in the plant ramped up
88
See BGs online catalog for complete information on extensions & cable
products, connectors, spark plugs, turbine leads, and service equipment
including coil and primary testers, firing indicators, timing lights and tools.
IGNITION PRODUCTS
The BG Service Co., Inc
1400 Alabama Avenue West Palm Beach, Florida 33401
(561) 659-1471 Fax (561) 659-1728
Email: sales@bgservice.com
www.bgservice.com
KIENE
OUTSTANDING REPUTATION IN
THE TURBOMACHINERY INDUSTRY.
for each assembly bay. All cranes will be able to traverse the
full 525 ft. (160 m) length of the expanded facility.
Were a young company with many years of experience, said General Manager Roger Wachter, who has
spent more than 30 years in the compression industry in
the U.S. and Europe.
Located in Transylvania, where most of the Romanias
gas and oil is produced, EGS has been able to assemble a
management team and work force that was already knowledgeable about the industry it serves.
In addition, EGS uses U.S.-trained consultants to guide
the workforce in building quality equipment. Eric Harrison, a
consultant to the EGS field service and aftermarket department, has more than 23 years of hands-on experience in the
operation, maintenance and repair of gas engine and electric motor-driven compressors of all sizes. Hector Llamas, a
consultant to the production department, has more than 11
years of experience in the packaging of gas compressors.
W W W. L U F K I N . C O M
AUGUST-SEPTEMBER 2013
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Compressortech2
1/27/10
11:51 AM
Page 1
3/7/13 9:49 AM
We Manufacture and
Remanufacture the
Worlds Largest
Crankshafts
Ellwood Crankshaft Group
Irvine, PA, USA 16329
Hermitage, PA, USA 16148
1-800-247-1326
or 724-347-0250
ecgsales@elwd.com
www.ellwoodcrankshaftgroup.com
n EGS made these 420 hp (315 kW), 1000 rpm ABB electricmotor-driven Ariel JGE/2 single- and two-stage compressor packages for Polish EPC contractor PGNiG Technologie. The systems
are inside explosion-proof, noise-supressing enclosures.
AUGUST-SEPTEMBER 2013
91
Compressortech2
and operating philosophy is much different than in the U.S. market. Packages delivered to the European Union
(EU) require CE marking and compliance with four major EU directives:
ATEX, the Pressure Equipment Directive (PED), the Machinery Directive
and the Low Voltage Directive.
Compressor packages for the CIS
(the former Soviet Union states) require compliance with GOST standards and other market and end user
requirements. Wachter explained that
EGSs mission is to provide quality,
cost-effective compressor packages
to the European market based on
U.S.-made compressors and engines.
EGS is an approved packager of
Ariel compressors and offers both
electric and gas engine-driven gas
compressor packages, ranging from
50 to 5000 hp (37 to 3729 kW).
Caterpillar, GM, Tedom and Waukesha gas engine or ABB, Siemens or
UMEB electric motor drivers are offered with EGS compressor packages. ACE-Alfa Laval air-cooled heat
exchangers and Altronic, FW Murphy
and Kilowatts Design Co. control panels are offered.
Company officials indicated that
EGS could make any type of steel
fabrication needed. Pressure vessels
can be certified to European PED or
ASME codes. The company can provide the engineering and drawings for
AUGUST-SEPTEMBER 2013
FEATURED
PRODUCTS
ECDS Systems
Brel & Kjr Vibro, an independent
supplier of vibration condition monitoring products, has launched of a new
generation of ECDS systems, Series
ds821 and Series ds822 ATEX. The
systems are designed for machine
monitoring applications.
supply voltage and optical path integrity. The IR400, which uses 4.8 W of
power and requires no routine calibration, also features heated optics
to eliminate condensation and a dirty
optics indicator to distinguish between
true alarms and maintenance needs.
The device can be configured for analog output, Modbus, and HART.
www.generalmonitors.com
Control Module
Gas Detector
Alliance Sensors
Group released the
MR Series of linear
position sensors for
use in measuring the
ram position of hydraulic and pneumatic cylinders. The MR
Series is designed to
be a drop-in form, fit,
and function replacement for magnetostrictive sensors, targeting port-mounted
applications of indus-
94
Compressortech2
AUGUST-SEPTEMBER 2013
CECO.indd 1
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FEATURED
PRODUCTS
Housings, cylinders,
connecting rods
trial, mobile, or subsea hydraulic cylinders and large pneumatic actuators, the company said.
The MR Series sensors can withstand intense shocks
and vibration, and operating temperatures up to 185F
(85C) for standard products and 257F (125C) for custom units. The sensors are available in full ranges from 2
to 36 in. (50 to 900 mm) with either an analog dc voltage
or current output, a linearity error of less than or equal
to 0.1% of full scale output, and a -3 dB(A) frequency
response of 500 Hz.
www.alliancesensors.com
Pressure Transmitters
Omega has introduced
a new series of pressure
transmitters designed for
use in hazardous locations.
The PX835 series is suited
for use in oilfield equipment, upstream oil and
gas production, natural gas
compression and transfer
control, alternative energy
projects and fuel cell manufacturing. The transmitters have
an all-welded stainless-steel case and are manufactured
to provide accurate, reliable and stable output data, the
company said.
Hahn_AugSept.indd
The PX835 transmitter requires no special mounting
hardware and can be mounted in any plane, Omega said.
For transmitters with 4 to 20 mA output signal, the minimum
voltage at the terminals is 12 Vdc; the maximum supply voltage is 30 Vdc.
www.omega.com
Ignition Systems
10:01 AM
Gill Instruments, a global supplier of ignition and control systems, has introduced three ignition system product
lines: MaxiSpark, ZeroDrift and Ultimate.
MaxiSpark, formally known as the GS range, consolidates several ignition modules into five, with one module
capable of fitting an entire engine fleet.
The ZeroDrift air/fuel ratio control, which replaces the AF
range, is now capable of controlling rich burn, lean burn, 4
to 20 mA or up to 5 Vdc wastegate or high flow valve control from one module. ZeroDrift also offers start-up, warmup
and closed loop control along with an updated optional load
input for simple programming, the company said.
The Ultimate Complete System package is a combination
of MaxiSpark and ZeroDrift, which provides an all-in-one
ignition and air/fuel engine control system.
All versions include self-diagnostics, logging, 2-D and 3-D
timing maps, dual fuel timing and adjustable spark duration.
www.gillusa.com
continued on page 100
AUGUST-SEPTEMBER 2013
EXPECT MORE
Expertise in Gear Design
and Engineering
State-of-the-Art Gear
Grinding Equipment
Technical Innovation
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Field Experts Available
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W W W. L U F K I N . C O M
95
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8/15/13 3:48 PM
n Left to right, Valerus master trainer Mitch LeBlanc shows service technicians John Dylan Hyche and Chase Stevens the proper
methods for lubricating compressor cylinders and packing glands.
AUGUST-SEPTEMBER 2013
AUGUST-SEPTEMBER 2013
Problem Solving
Synthetic Lubricants
Lubricant Dilution?
Summit
Industrial Products
800.749.5823
www.klsummit.com
97
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8/15/13 9:55 AM
literature
Pressure
Sensors
Condition
Monitoring
Hydraulic
Starters
Ignition Control
& Monitoring
AUGUST-SEPTEMBER 2013
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8/7/13 11:10 AM
fs-elliott.com
FEATURED
PRODUCTS
Compressor Lubricants
Ultrachem has developed the Chemlube Plus Series, a line of highperformance synthetic lubricants designed for use in rotary screw, rotary
vane, and centrifugal compressors,
as well as vacuum pumps.
The lubricants, made with a polyol
ester blend, are fully compatible with
most OEM rotary screw compressor
oils and can also top off and replace
existing fluids, the company said.
About OxyChem
Pressure Transmitter
Primary Flow Signal, a designer and
manufacturer of flowmetering products
for oil and gas, water/wastewater, and
industrial applications, announced the
availability of its battery-powered differential pressure transmitter for its entire
differential flow meter product line.
The transmitter provides flow measurement readings for gas, water, chemical and air (with temperature limitations)
applications without the need for an external power source, making it ideal for
remote locations, the company said.
The transmitters can be applied to
PFS meters such as the WedgeType
flowmeter for monitoring oil and gas
applications, and also on Venturis to
provide options for high accuracy in demanding applications, such as irrigation
water, aeration air and fueling systems.
www.primaryflowsignal.com
Carbon Graphite
2 x 4.76
AUGUST-SEPTEMBER 2013
OxyChem.indd 1
Metallized Carbon
CT2 Corp. announced
100
8/15/13 9:43 AM
Radiators
GEA has redesigned its modular
compact radiators and has matched
their efficiency to that of the individually configurable radiator ranges.
The primary application for the
companys Energy Modular Compact
Radiators is the cooling of stationary
diesel power plants. The largest model offers cooling capability of more
than 3350 hp (2.5 MW).
The structural design has been
re-engineered horizontal suction
featuring single- or dual-row configuration and new design software
makes it possible to assemble standard components to efficient systems,
the company said. Sixty available unit
lengths and two predetermined enclosure widths allow several possible
enclosure sizes.
www.gea.com
Compressortech2
Need A
Low Noise
Solution?
Let Moore
Help.
Introducing The Class 10000
MAG Ultra-Low Noise Fan.
Since 1940, Moore Fans has provided customers with high efficiency,
high-quality axial flow fans for industrial applications worldwide.
Operating in air-cooled heat exchangers and cooling towers, Moore
fans keep fluids cool in refineries, power plants, process plants, gas
compressors and limitless other industrial settings.
e
n
i
g
En
vveed
i
r
D pro
Ap
PRIME
Movers
Sasol
Sasol has placed an order with MHI Compressor International Corp. for the main ethylene compressor trains at
the world-scale ethane cracker it plans to build at Lake
Charles, Louisiana.
The US$5 to US$7 billion cracker will be constructed in
conjunction with an US$11 to US$14 billion gas-to-liquids
plant, the first of its kind in the United States.
Sasol said the ethane cracker, which would benefit from
the current low U.S. natural gas prices and the abundance
of ethane, would allow the company to expand its differentiated ethylene derivatives business in the United States.
Everest Sciences
Everest Sciences Corp. said Equipos Industriales del
Golfo, S.A. de C.V. (EIGSA) will distribute its air cooling
products in Mexico, including its indirect evaporative inlet
cooling technology.
The Tulsa, Oklahoma-based company launched its first
product in 2008, and has sold and installed systems for oil
and gas, chemical processing and energy companies in the
United States, Canada and the Caribbean.
With operations in Mexico City, Tabasco, and other regions, EIGSA specializes in air cooling and water management products for industrial clients including Petroleos Mexicanos and Mexicos Federal Electricity Commission.
Johnson Matthey
Johnson Mattheys Stationary Emissions Control said RES
Energy Solutions will be a distributor for its technology for stationary diesel and gas engines, including Modulex catalytic
converters, SCR systems and oxidation catalysts.
RES Energy Solutions, based in Houston, offers a broad
set of products and services for the oil and gas, natural gas
pipeline, power generation and marine markets.
RES provides engine maintenance services, catalyst maintenance and washing services, and emissions/stack testing
services to help customers comply with federal Quad J and
Quad Z regulations.
Chaparral Energy
Chaparral Energy Inc. has started a 23,500 hp (17.5MW)
compressor station at Coffeyville, Kansas, as part of a US$250
million carbon dioxide gathering and injection project.
The station pushes CO2 from a fertilizer plant in Coffeyville through an 8 in. (20 cm), 68 mi. (110 km) pipeline to the North Burbank Unit, an oil field in Osage
County, Oklahoma.
The field has produced more than 319 million barrels
since its discovery in the 1920s. The project will inject up to
60 MMcfd (1.7 x 106 m3/d) to enable the additional recovery
of 10% to 15% of the original oil in place.
Chaparral, which is based in Oklahoma City, operates 10
CO2 injection projects in the U.S. It has a supply of about 90
MMcfd (2.5 x 106 m3/d) of CO2 and operates 386 miles (621
km) of pipelines to deliver it to various oil fields.
Atlas Copco
Atlas Copco CMT USA has named
Dave Pietrzykowski vice president for
parts and service.
Pietrzykowski, who had been vice president for store operations, started with the
company as the business line manager
for the rental fleet and used equipment.
He also served as business line manager
D. Pietrzykowski for rock drilling tools.
His new responsibilities include customer service, inventory control, logistics and procurement, warranty, service administration, training initiatives, store parts and service development, distributor business management, and the technical
management team.
continued on page 104
AUGUST-SEPTEMBER 2013
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8/14/13 1:59 PM
Compressortech2
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Movers
Flowserve
Sulzer Pumps
Dresser-Rand
Dresser-Rand will embed its proprietary anti-surge control and load sharing
programs into the Honeywell Experion
C300-20 controller and will manufacture turbomachinery systems using the
Honeywell device.
With the Experion PKS Turbomachinery Control Solution, clients benefit from
an open, unified control platform that
delivers turbine control, compressor
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AUGUST-SEPTEMBER
2013
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PRIME
Movers
Hydrotex
Hydrotex, a manufacturer and distributor of lubricant and fuel improvement
products, announced a strategic alliance with perma USA, a provider of single and multipoint lubrication systems.
The combination of Hydrotex synthetic greases with premium applicators, including perma Flex and the revamped perma Star Vario 2.0, creates
a lubrication solution for manufacturing
plants across the United States, the
company said.
Some of the new features on the
perma Star Vario 2.0 include a purging function, an increase in operat-
AUGUST-SEPTEMBER 2013
FLP_april.indd 1
Exterran
Exterran has opened an operations
services center in Fort Worth, Texas,
the first of several such sites to support
North American customers.
The center, at 2100 Great Southwest Parkway, will serve as the hub
for Exterrans Barnett Shale business
unit. It has a large shop specializing in
aftermarket services, including swing
engines and repackaging of customerowned compression.
The company said the center will enable it to help customers comply with
the National Emissions Standards for
Hazardous Air Pollutants (NESHAP)
Subpart ZZZZ requirements.
In addition to providing NESHAPcompliant compression services, Exterran performs required maintenance,
105
Enerflex
Enerflex is closing its Casper, Wyoming, manufacturing facility, reflecting a slowdown of coalbed methane
(CBM) compression in the Powder
River Basin.
The company opened the Casper
plant in 2006, primarily to supply CBM
compression. It said the facility served
that market for several years.
The remaining equipment scheduled
to be packaged in Casper will be completed at the companys Calgary facility
or its newly expanded Houston plant.
The Casper facility had employed
89 people, of which seven were transferred to the gas drive and rentals/
retrofit business units in Casper, Wyoming. The rest will be discharged.
Compressortech2
12/20/12 10:03 AM
Compressortech2
106
AUGUST-SEPTEMBER 2013
snapshot
Photo by Statoil
KILO-PAK
Our core name has changed, but our philosophy remains the same and weve been building on this tradition since 1946.
2
3
4
6
Scheduled Downtime
DJ Slater, Puzzlemaster
Southern Spotlight
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Argentina
Basin
Brazil
Capture
Challenges
Chile
Climate
Colombia
Companies
Continent
Economy
Ecuador
Environment
Expansion
Expense
Evolution
Fabrication
Flaring
Flourish
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Formations
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Shift
Shipping
South America
Stake
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ARLA
Engineering Service
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Compressortech2
U.S.
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ARLA Maschinentechnik GmbH,
3/11/03
11:06
GERMANY
Internet: www.arla-online.com
EXPLOSION PROOF
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7/12/13 10:21 AM
AC&DC ENGINE STARTING SYSTEMS
STARTER MOTORS ALTERNATORS
SWITCHES CLASS I, DIV. 1&2, GROUP D
Phone: 262-754-4100
E-mail: mgraesing@dieselpub.com
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Advertisers Index
*Further information on this companys products can be found in the 2013 Edition of the Global Sourcing
Guide (at GSGnet.net) and 2013 Compression Technology Sourcing Supplement (at CTSSnet.net).
ACI Services, Inc. ......................................................... 23
www.aciservicesinc.com
*ARIEL .............................................................................. 1
www.arielcorp.com
MIRATECH .................................................................... 11
www.miratechcorp.com
Cameron ..................................................................56-57
www.c-a-m.com
*Dresser-Rand ................................................................ 49
www.dresser-rand.com
COMPRESSOR
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n RENEw
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63
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41
62
99
manufacturing Compressors
manufacturing or Packaging
Compression Sets and Systems
manufacturing Natural Gas or
Dual-Fuel Engines
manufacturing Gas and Steam Turbine
Engines and Gas Expanders
manufacturing Industrial Power
Transmission Products & Compressor
Components, Accessories & Control
Systems
None of the above.
my companys business is
3. MY JOB
FUNCTION IS:
EN
Engineering
PR
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Purchasing
OP
Operating/
maintenance
AD
Administrative/
marketing
OT
Other (describe)
IMPORTANT
2013
Compressortech2
C ornerstones Of Compression
Clearance Hole
In Radial Ring
A.
Compressortech2
Intelligent Ignition
Control System
Ensure the health of your spark-ignited
natural gas engine with Murphys IntelliSpark
ignition controller and components.
True primary and secondary diagnostics provide
users with an intelligent view of engine operation,
while increased programming capabilities give
you ultimate control. The IntelliSpark systems
feature microprocessor, capacitive discharge
functionality for any application that requires a
cost-effective operation.
Keep the spark going in your engine by
running Murphys Engine Integrated Control
System (EICS). EICS utilizes IntelliSpark technology
to provide integrated spark and diagnostic
capabilities as part of a comprehensive Engine
Management solution.
1311251 5-13