Compressor Tech August September 2013

pumptech
Spotlight:
Turbomachinery
issue South America Technology
COMPRESSOR
August-September 2013
Dedicated To Gas Compression Products & Applications
Quiet
Compression
Dresser-Rand Marks
DATUM Milestone
MAN Expands
Industrial Steam Turbine Line
Universal AET Acquires

Ojibway Enclosure Systems
www.compressortech2.com
This Issue Driven By

Click on company logo to see ad page
HOERBIGER Engine Solutions
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Power & Compression
The Turboexpander Company
Customer:
Challenge:
Result:
Refinery, Louisiana, USA.

Increase reliable, on-site power generation
within the plants existing carbon footprint.
An Elliott 36 MW FCC hot gas expander-generator

converts refinery waste gas to electrical power.
They turned to Elliott
for green, reliable power.
The customer turned to Elliott because of our 50 years of experience and nearly 500 MW
of installed capacity in FCC power recovery. Elliott TH expanders routinely operate 5 years
and more between shutdowns, extending FCC maintenance cycles and reducing
maintenance costs. Who will you turn to?
C O M P R E S S O R S
T U R B I N E S
G L O B A L
S E R V I C E
The world turns to Elliott.

www.elliott-turbo.com
40,000
COMPRESSORS SHIPPED TO OVER 100 COUNTRIES SINCE 1966...
Ariels 40,000th compressor being

assembled in November 2012.
CHANCES ARE, ONE OF THEM IS YOURS.

IF NOT, TALK TO US ABOUT YOUR COMPRESSION NEEDS.
WELL SHOW YOU THE ARIEL DIFFERENCE.
Ariel reciprocating compressors from 100 to 10,000 BHP are utilized in the upstream, midstream, and downstream
sectors. Our compressors are designed and built for long service life and ease of maintenance. Ariel is there every
step of the way, offering you the best customer service in the industry. For all your compression needs, choose
Ariel.
Learn more about unit F40,000 at www.arielcorp.com/unit40k
ARIEL CORPORATION
World Standard Compressors
35 Blackjack Road
Mount Vernon, OH 43050
www.arielcorp.com
Page
President & CEO ..................... Michael J. Osenga

Executive Vice President .... Michael J. Brezonick
COMPRESSOR
A Member of the Diesel & Gas Turbine Publications Group
Joe Kane
Compressortech2
Founder
PUBLICATION STAFF
CT2 Founder ........................... Joseph M. Kane

Publisher .................................Brent D. Haight
Associate Publisher ...............Roberto Chellini
Editor ...........................................Patrick Crow
Executive Editor ............................... DJ Slater
Senior Editor .................. Michael J. Brezonick
Senior Editor .............................. Mike Rhodes
Associate Editor ................................ Jack Burke
Associate Editor .............................Chad Elmore
Copy Editor ................................ Jerry Karpowicz
Digital Content Manager............Catrina Boettner
Circulation Manager ...................Sheila Lizdas
Production Manager ............. Marisa J. Roberts
Graphic Artist ........................Brenda L. Burbach
Graphic Artist .............................Carla D. Lemke
Graphic Artist ........................... Amanda J. Ryan
Graphic Artist ................................ Alyssa Loope
PUBLICATION HEADQUARTERS
20855 Watertown Road, Suite 220
Waukesha, Wisconsin 53186-1873
Telephone: (262) 754-4100 Fax: (262) 754-4175
CONTRIBUTING EDITORS
Ellen Hopkins - Midland, Texas

Norm Shade - Cambridge, Ohio
Mauro Belo Schneider - Rio Grande du Sul, Brazil
HOUSTON OFFICE
Brent D. Haight, Publisher

Patrick Crow, Editor
Mike Rhodes, Senior Editor
12777 Jones Road, Suite 225
Houston, Texas 77070
Telephone: (281) 890-5310 Fax: (281) 890-4805
GERMAN OFFICE
Lisa Hochkofler, Advertising Manager

Gabriele Dinsel, Advertising Manager
Niemllerstr. 9
73760 Ostfildern, Germany
Telephone: +49 711 3416 74 0 Fax: +49 711 3416 74 74
UNITED KINGDOM OFFICE
Ian Cameron, Regional Manager/Editor

Linda Cameron, Advertising Manager
40 Premier Avenue
Ashbourne, Derbyshire,
DE6 1LH, United Kingdom
Telephone: +44 20 31 79 29 79 Fax: +44 20 31 79 29 70
ITALIAN OFFICES
Roberto Chellini, Associate Publisher

44, Via Delle Forbici
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Telephone: +39 055 50 59 861 Fax: +39 055 57 11 55
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JAPANESE OFFICE
Akiyoshi Ojima, Branch Manager

51-16-301 Honmoku Sannotani, Naka-ku
Yokohama, 231-0824 Japan
Telephone: +81 45 624 3502 Fax: +81 45 624 3503
CHINESE OFFICE
S.H. Mok, Branch Manager

Rm 1405, Kowloon Building
555 Nathan Road
Kowloon, Hong Kong
Telephone: +852 3118 7930 Fax : +852 3110 3572
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,
purchasing agents, or anyone needing to understand machinery terms.

The dictionary contains essential
terms for a wide array of process machines including: centrifugal pumps;
rotary pumps; reciprocating pumps;
centrifugal compressors; reciprocating and rotary compressors; fans and
blowers; electric motors; gas turbines;
steam turbines; expanders; internal
combustion engines and ancillary
equipment and components.
In addition to specific equipment
terms, the dictionary contains other
related machinery topics in order to
provide broad coverage of the process
machinery field. Those include: lubrication; condition monitoring; vibration
and rotordynamics; plus reliability and
machine shop methodologies.
The book also has a quick reference section listing frequently used
acronyms. It contains a compilation of
all of the acronyms contained within
the dictionary, as well as commonly
used acronyms within process machinery applications.
Anyone with a recurring need for
machinery information should find this
dictionary to be a useful addition to
their technical library. It already has
demonstrated its value in the communication business that deals regularly
with energy and process industries.
The dictionary will be displayed at
the COMPRESSORtech2 booth during the Turbomachinery Symposium
in Houston in October.
So, while you are paging through
this comprehensive dictionary, in a
similar manner, may the Lord hold
you in the hollow of His hand. CT2
MAN Inside
Reliable solutions for the long run
Isothermal and
Gear-type compressors
Process-gas screw compressors

Axial compressors
Reactors
Centrifugal
compressors
Steam turbines
Expanders
Marine Engines & Systems Power Plants Turbomachinery After Sales
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

Featured Articles
16 The Next Generation Of Turbo Gearboxes
30 Universal AET Acquires Ojibway Enclosure Systems
32 MAN Expands Industrial Steam Turbine Line
40 Dresser-Rand, Honeywell Merge Turbo Control Systems
48 More Turbomachines Turning To Active Magnetic Bearings
52 Full-Load Test Of A CO2 Compressor
60 SEC Triples Capacity At Its Houston Complex
62 Downhole Compressor Technology Advances
66 Dresser-Rand Marks DATUM Milestone
Cover Designed By
Marisa Roberts
Compressortech2 (ISSN 1085-2468)

Volume 18, No. 7 Published 10 issues/year
(January-February, March, April, May, June,
July, August-September, October, November,
December) by Diesel & Gas Turbine Publications,
20855 Watertown Road, Waukesha, WI 531861873, U.S.A. Subscription rates are $85.00 per
year/$10.00 per copy worldwide. Periodicals postage paid at Waukesha, WI 53186 and at additional mailing offices. Copyright 2013 Diesel &
Gas Turbine Publications. All Rights Reserved.
Materials protected by U.S. and international copyright laws and treaties. Unauthorized duplication
and publication is expressly prohibited.
Canadian Publication Mail Agreement # 40035419.
Return Undeliverable Canadian Addresses to: P.O.
Box 456, Niagara Falls, ON L2E 6V2, Canada. E-mail:
slizdas@dieselpub.com. POSTMASTER: Send address
changes to: Circulation Manager, Compressortech2,
20855 Watertown Road, Suite 220, Waukesha, WI
53186-1873 U.S.A.
Follow Compressortech2
at www.compressortech2.com
70 Acoustic Walls Muffle Texas Compressor Station

76 The Cost Of Reducing Fan Noise
84 UE Compression Going Strong At New Location
88 Young Company Has Decades Of Experience
96 Gearing Up For The Big Crew Change
Spotlight: South America

24 South America: The Next Frontier
38 Tropicalization Is Common For Brazilian Packagers
46 Argentinas Shale Prospects Continue To Brighten
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
MEMBER OF BPA WORLDWIDE

PRINTED IN THE U.S.A.
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D a l l a s
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l o s
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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
n a bid to reduce the development costs of offshore plays

off Indias East Coast, Reliance Industries may share its
infrastructure in the Krishna-Godavari Basin with statecontrolled Oil and Natural Gas Corp. (ONGC).
On July 27, the two large Indian oil companies signed
a memorandum of understanding to conduct a nine-month
study on the details of the possible infrastructure sharing
and the commercial terms.
Although ONGC has not publicly estimated its potential
savings in capital expenditures, The Indian Express has reported that an internal company study had calculated the
range at US$4 billion to US$4.5 billion. The cooperation
also would enable Reliance to benefit from better utilization
of its extensive offshore infrastructure investment.
The Krishna-Godavari Basin is home to Indias largest
natural gas discovery, which Reliance made in 2002 on the
deepwater KG-D6 gas block. Although technical challenges
have resulted in disappointing production levels, Reliance
plans to invest US$6.5 billion to restore output at the flagship
offshore project an action that would be greatly helped by
the governments upward revision to natural gas prices.
Reliance, Indias largest private upstream player, estimates that the additional investment could push production
to more than 740 Bcfy (21 x 109 m3/y) nearly four times the
200 Bcfy (5.7 x 109 m3/y) average production rate from KGD6 in April 2013.
ONGC is also expanding its presence in the prolific basin. In March it announced two discoveries an onshore
field with very high quality oil and a shallow-water gas/
condensate find at its Saveri-1 well on block KG-OSN-2004.
In July it spudded a Krishna-Godavari Basin well in 10,411
ft. (3174 m) of water, setting a world record in the process.
The firm planned to bring the offshore G-1 field on flow in
August at an initial rate of 40 MMcfd (1.1 x 109 m3/d) from
two wells. Production will peak at 92 MMcfd (2.6 x 109 m3/d).
ONGC has targeted the Krishna-Godavari Basin as a key
growth area for the company. The G-4, KG-DWN-D and KGDWN-E fields are expected to help boost its total natural gas
AUGUST-SEPTEMBER 2013
Compressortech2
Its all in
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A proud past leads to a new future

They may display a proud old name on the outside,
but the driving force within the worlds best-engineered,
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The heritage name, Cooper-Bessemer, still carried by older
machines, echoes the engineering excellence that has
earned Rolls-Royce an unparalleled reputation for quality.

Today, in a business where productivity and dependability
mean so much, the unsurpassed engineering experience
of the past makes Rolls-Royce the compressor name
of the future.
Trusted to deliver excellence
Cooper-Bessemer is a registered trade name of Cameron Corporation, used under license by Rolls-Royce plc
www.rolls-royce.com
Meetings & Events

*Indicates shows and conferences in which Compressortech2 is participating
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
Meetings & Events

*Indicates shows and conferences in which Compressortech2 is participating
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
Tel: +1 (918) 831-9736

Web: www.power-gen.com
Nov. 13-15
Developing Unconventional Gas (DUG)
East Conference & Exhibition
Pittsburgh
Tel: +1 (713) 260-5209
Web: www.dugeast.com
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
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About The Business
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.
12
Compressortech2
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All is about to be revealed...
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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
n a move that would have been unthinkable only short while

ago, President Enrique Pea Nieto has asked Congress to
open Mexicos energy sector to foreign investment.
That would end the 75-year monopoly that Petrleos
Mexicanos (Pemex) has held on most oil exploration, production and distribution in the nation.
To make the changes politically palatable, Pemex will remain a state-owned company and foreign firms wont be
allowed to own oil and gas reserves outright.
But foreign companies who partner with Pemex on projects would get a share of any profits proportionate to their
investments. In the case of U.S. firms, they could book the
value of their contracts on the basis of the estimated amount
of rights that they own, facilitating private financing.
In a televised address, President Pea Nieto reassured
his nation that Pemex is not for sale and will not be privatized. Pemex will grow stronger and modernize.
If instituted, the reforms could be a major step toward
developing Mexicos vast gas shale resources, opening opportunities for more pipeline construction and more compression orders.
Mexican natural gas demand has been surging in recent
years, forcing the nation to import a third of its gas through
pipelines from the U.S. or via liquefied natural gas tankers from
other nations (see COMPRESSORtech2, June 2013, p. 14).
An obvious solution to that problem has been for Pemex
to exploit its scarcely-drilled shale gas zones. The U.S. Energy Information Administration has estimated Mexico has
681 Tcf (1.9 x 1013 m3) of technically recoverable shale gas
resources, the fourth largest in the world.
The Pea Nieto administration is clear that the energy
policy changes, by encouraging joint ventures with international oil companies, would gain Pemex the technology and
expertise to develop deep-water oil in the Gulf of Mexico
and the complex shale fields.
In a parallel move, Pemex Director General Emilio Lozoya
Austin also announced the state company would establish a
subsidiary for joint ventures within the U.S. Again, the goal
would be both to accumulate reserves and the expertise to
develop shale gas and deep-water oil.
Energy Sec. Pedro Joaquin Coldwell said Mexicos oil
14
Compressortech2
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n A technician works on a Voith power

distribution gear (PDG) assembly.
The Next Generation Of

designs offer potential to
Turbo Gearboxes > New
debottleneck entire drive trains
By Tome Stanic
s the power and power density

of rotating machines continue
to increase, turbo gearboxes
are approaching their limits in terms
of safe and reliable operation. Some
radical rethinking in gearbox design is
needed if future machinery trains are
not to be compromised by the capacity of their gear units.
Gearboxes are widely used to reduce or increase the speed of prime
movers to match these to the driven
machinery. Especially in critical operations where redundant equipment
is not installed, the gearbox is just as
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.
important to reliability and safety as

any other link in the power train.
Yet perhaps not surprisingly, many engineers are more interested in the driver
or the driven equipment compressors, gas turbines, electric motors and
pumps than in the gearbox, which is
often treated as a commodity item.
The fact that this is possible is a
tribute to the reliability of standard
turbo gearboxes, which operate under
punishing conditions of stress, impact
and wear. Even gear experts cannot work miracles, however, and the
turbo gearbox as we know it is rapidly
reaching the limits of performance. It
is time for something new.
Limits of convention
Traditional gear designs for turbomachinery fall into two types: parallel shaft and epicyclic.
Parallel shaft gearboxes have two
shafts, each carrying a single gear.
They are available in power ratings
16
up to 188,000 hp (140 MW) for small

gear ratios of less than six when installed, for instance, between a gas
turbine and a generator. As the name
suggests, the input and output shafts
do not share the same axis.
Epicyclic gearboxes split the power
between several planet gears which
move around a central sun gear while
also meshing with a surrounding ring
gear. Epicyclic gears are compact and
provide coaxial input and output, but
are limited to a power rating of 60,000
hp (45 MW) in the demand for a gear
ratio of more than six.
To understand the limiting factors in
gear design we need to translate external operating characteristics power
ratings and speeds into gear-specific
design parameters. The main factors
controlling power and speed limits are:
Pitchline velocity (PLV) the linear velocity of the gear teeth;
Elastic deflection produced by
continued on page 18
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a:
Sun Pinion Slow-Speed Side
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.
torques and bending moments on

all parts of the gearbox, especially as it applies to the pinion (the
smaller of the two gears in a parallel shaft gearbox);
Desired input and output speeds;
Operating limits of the bearings
(loads and journal velocities);
Factor of safety chosen for the
application.
The job of the gear designer is to
find the best balance between these
limiting factors, which sometimes conflict. For instance, taking advantage
of the increased speed capacity of
a high-performance bearing implies
an increase in the PLV, which in turn
raises both the circumferential forces
within the gears and the tendency for
oil flow to be interrupted. In a parallel shaft gearbox the solution is to increase the center line distance (and
hence the overall gear size) to create
a larger lever effect.
Currently the maximum achievable
PLV is 650 fps (200 m/s) and the maximum journal velocity is 330 fps (100
m/s). The maximum bearing load is
3.45 MPa according to API 613 (paragraph 2.7.2.4), the gear standard applicable to high-speed gearboxes in
the oil and gas industry.
These limits mean that in some
cases the gear unit becomes the
determining link in the drive train.
Turbocompressors, for instance, are
currently restricted to approximately
47,000 hp (35 MW) by their gearboxes, depending to some extent on the
input and output speeds required.
Outside the box

Incremental design improvements,
such as the use of high-grade steels
to withstand high PLVs, or an improved bearing design for higher journal velocities, boost the capabilities of
conventional gear units.
The resulting improvements are
small, however, and the tweaked
gearbox is still operating at its limits.
Also, of course, it is a bad idea to be
using what are essentially prototype
gear units running in unproven areas
of the speed-power chart.
An alternative to waiting for incremental improvements in materials
science is to use an alternative gear
design with a split power path. Such
an approach overcomes the limiting
parameters controlling the teeth and
bearings of conventional gear types.
Most importantly from the point of
view of the plant designer, it removes
the bottleneck imposed by current
gear designs on the power limits of
entire turbomachinery chains.
Splitting the power path to create a
power distribution gearbox (PDG) allows the speed limit for a given transmission power to be increased and considerably eases the bearing problem.
The limiting factor in the design of a
PDG becomes the toothing: the speeds
at which the teeth mesh and the heat
generated there, mainly through compression of a mixture of oil and air.
PDGs can currently be designed for
power ratings up to 228,000 hp (170
MW), output speeds up to 100,000
RPM, and gear ratios up to 10.
18
PDG design and function

The PDG combines the simple and robust construction of parallel shaft gears
with the load-splitting ability of epicyclic
gears (Figure 1). The result is a gear unit
which offers high power ratings, speeds
and speed ratios while remaining well
within critical technical limits and so providing excellent safety margins.
The PDG contains three or more
planet gears arrayed around a central
sun pinion. Each planet gear is actually a compound design whose second
set of teeth meshes with a second sun
pinion on a separate shaft (Figure 2).
The whole arrangement acts like a
two-stage parallel shaft gear, but with
several advantages:
Distributing the power between
several planet gears reduces
tooth loads;
As with epicyclic gears, each sun
pinion is supported by its planets,
so no bearings are required on
either the low-speed or the highspeed side;
The three planet gears are supported by six hydrodynamic bearings instead of the four used in
parallel shaft gear units;
The input and output shafts are
coaxial;
Since there is no outer ring gear,
as an epicyclic gearbox would require, the PDG is compact.
n Figure 2. Because the two sun gears are

supported by the planets, the main input and
output shafts of the PDG need no bearings.
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Integral double diaphragm couplings

on the input and output shafts of the
PDG accommodate axial, radial and
angular offsets to ensure optimal power
transmission and rotordynamic performance. The short axial length of these
couplings reduces the overall distance
between shaft ends (DBSE) between
the driver and the driven machine.
Performance in critical
applications
An example of a typical gas turbinedriven compressor shows how the
PDG outperforms a parallel shaft
gear unit in applications requiring high
power density. The gas turbine speed
is assumed to be 5000 rpm and the
compressor speed 12,500 rpm.
Pitchline velocity: Figure 3 shows
how the maximum PLV of the gear
teeth varies as a function of transmitted power for the given input and output speeds.
A parallel shaft unit reaches in this
case its maximum safe PLV of 620 fps
(190 m/s) at a power rating of 34,900
hp (26 MW). For the PDG, the PLV
curve rises more slowly, and at 34,900
hp (26 MW) its PLV is 30% lower (58
m/s lower in absolute terms) compared to that of the parallel shaft unit.
Even at power ratings up to 87,000 hp
(65 MW) and beyond, the PDG still
has a PLV below 590 fps (180 m/s).
The reason for this improved performance is the smaller diameter of the
planet gears in the PDG compared
to the pinion gear in the parallel shaft
unit. This increases the safety margin
for centrifugal forces that is proportional to the square of the velocity divided by the diameter.
Journal velocity: The curves relating bearing journal velocity to power
transmitted (Figure 4) are quite similar to
those for PLV against power. The parallel shaft gear cannot handle more than
34,900 hp (26 MW) before the journal
velocity reaches its safe limit of around
328 fps (100 m/s). At this power rating,
the PDG bearings are running at only
164 fps (50 m/s) a 100% safety margin and even at 87,000 hp (65 MW)
the journal velocity is no more than 213
fps (65 m/s), still well below the safe limit.
The lower journal velocities arise
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.
because the pins (like stub axles) of

the planet gears in the PDG are smaller in diameter than the radial bearings
which support the pinion in the parallel shaft gear unit.
Bearing load: Along with pitchline
and journal velocities, bearing load is
the third main factor limiting gearbox
performance. Figure 5 shows nearly
identical bearing loads for both gear
designs in our compressor example.
Even at high powers, increasing the
diameter of the planet pins keeps the
20
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
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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).
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).
Oil consumption: Also interesting
to compare is the oil consumption of
both gear units, since this affects the
capital cost of the lubrication system.
At its power limit of 34,900 hp (26
MW) the parallel shaft gear uses more
oil than the PDG (Figure 7) because
of its high PLV and especially because
of the higher bearing journal velocity.
Although the parallel shaft gear has
fewer bearings than the PDG, one
22
reason for its lower efficiency is the

higher temperatures in the high-speed
bearings of the pinion shaft, which in
turn require more oil for cooling.
When to use a PDG
As we have seen, splitting the power path gives the PDG more headroom in all three of the main parameters PLVs, journal velocities and
bearing loads which limit power
transmission in conventional parallel
shaft gears. Lower stresses and temperatures make the PDG more reliable, and its efficiency remains high.
However, the higher complexity of
Compressortech2
n Figure 7. The PDG requires somewhat less oil than the parallel shaft gear, and oil consumption increases linearly with power rating.
a PDG compared to a parallel shaft

gear unit means that some design aspects have to be considered carefully.
To ensure sufficient tooth lubrication, for instance, the planet gears
require internal oilways as well as external flush lubrication. The relatively
high ventilation within the gearbox created by the rotating suns and planets,
which is at least proportional to the
square of the velocity, also can dis-
rupt external lubrication and prevent

the sun gears from getting enough
oil. Special oil baffles are needed to
tackle this problem, and there is room
for further improvement.
As a result, the PDG is best suited
to applications requiring high power
density, where traditional gear designs are approaching the limits of
feasibility. In such cases it offers some
compelling advantages.
In particular, this new gear design

brings opportunities to debottleneck
drive trains in which the gearbox
has previously been the limiting factor. Gas turbine-driven compressor
trains, for instance, can now use
larger compressors, and gas turbine
models that up to now have been
used mainly for power generation
can find new applications as compressor drivers. ct2
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23
Compressortech2
8/13/13 2:08 PM
Spotlight:
Valerus shipped these 6X 7044GSI Waukesha

Cooper MH64 packages, rated at 10,080 hp
(7517 kW) to Congonhas, Brazil, in 2009.
South America:
Gas compression packagers set
The Next Frontier sights on market potential
By DJ Slater
he United States has made

headlines in recent years for
the abundance of shale gas
beneath its soil. As oil and gas companies continue to tap into those resources, some gas compressor packagers also are paying more attention
to Latin America.
My focus this year is to expand our
business opportunities and our name
recognition in South America, said Tom
Sawyer, the director of International
Business Development for SEC Energy Products and Services. I probably
communicate with my South American
contacts several times a week.
Sawyer and SEC are not alone. Several packagers already have a presence in the continent, viewing it as the
next frontier in the shale gas revolution.
But even with the glut of shale gas and

oil resources in South America, those
same packagers are proceeding with
caution as the political and economic
landscapes develop.
Things down there are driven much
more dramatically by politics, Sawyer
said. Argentina, for example, has tremendous oil and gas shale reserves.
The problem is that the economy and
the current political situation make it
very difficult to do business there.
For example, last year Argentina President Cristina Fernndez de
Kirchner announced that Argentina
would nationalize YPF, the nations
major oil company. The government
said YPF, owned by Repsol of Spain,
had not invested enough to develop
Argentinian oil and gas resources.
24
The action created a backlash from

Spain and the European Union, and
left packagers uneasy about doing
business in the area, Sawyer said.
When that (nationalization) happens, it throws up a huge red flag, Sawyer said. Theres no lack of opportunity.
Theres a lack of a favorable business
climate there. Theyve got lots of potential, but also a lot of issues.
Even when business conditions
arent favorable, Sawyer said SEC,
as well as other packagers, shouldnt
cease their operations. You have to
be there, because it will turn around,
he said. The main thing is to have a
presence and keep a finger on the
pulse of the opportunity in Argentina.
The governments YPF strategy
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Spotlight:
has shown some signs of success.

In July, Chevron Corp agreed to invest US$1.24 billion to help YPF develop oil and gas reserves in the Vaca
Muerta shale.
To pave the way for the deal, the
government decreed that companies
could export, tax free, up to 20% of
their oil and gas production.
In addition to Argentina, other areas
in South America have potential for a
shale gas revolution. Patricia Martinez,
the vice president of Latin America for
Valerus Compression Services, said
theres a wave of development in Brazil and Mexico, particularly with natural
gas pipeline and infrastructure projects,
as well as initiatives to reduce flaring.
In the last 10 years, weve seen a
great deal of industry deregulation in
Latin American countries, Martinez
said. The energy space was previously dominated by the national oil
and gas companies, but now were
seeing independent oil and gas companies flourishing.
This shift has been very positive
for our business, creating an environment that we havent seen before. The
market is much more competitive. You
dont have to be a multibillion dollar
company to compete.
Still, this activity is not without its
Brahma Compression uses 20-ft. (6 m)

long shipping containers as the base floor
and enclosure for its vapor recovery units.
The finished packages are shipped inside
the containers.
share of challenges. Martinez said the

economic growth in the region is fragile, making the business environment
unpredictable. Another challenge has
been the concerns about the environmental effects of shale gas recovery.
The common production practice of
hydraulic fracturing has received negative coverage from the media and some
nations, such as France, have banned
it. The fracking procedure uses water,
sand and chemicals at high pressures
to fracture shale and release the gas.
South American governments are
in the early stages of studying the
environmental impact of fracking,
Martinez said.
At the end of the day, each country
makes its own decisions and regulations, she said. Martinez added that
the Latin American shale gas industry
is still at a very early stage and is at
least 10 years behind the U.S.
The concern over environmental impacts has worked out favorably for Foremost Brahma Ltd. (Brahma Compression), a Calgary-based gas compressor
26
packager specializing in the sub-400 hp

(300 kW) segment. The company has
found a niche in South America with its
vapor recovery units (VRUs).
Thats our biggest product in South
America, General Manager Don
Schafer said.
Flaring gas has been huge in South
America forever, he said. Now, more
and more countries are starting to disallow flaring. That gas is going to be captured and brought into the gas lines.
Schafer added that the continents
collective environmental consciousness works out well for packagers because many of the concerns can be
solved with compression technology.
Brahmas South American presence
extends to several nations, including
Colombia, Argentina, Ecuador, Mexico
and Brazil. Its customers are mainly
government-owned and operated oil
companies such as Ecopetrol in Colombia and Pemex in Mexico.
Not everything runs smoothly for
Brahma in South America. The continents technology is behind the
advancements made in the United
States and Canada, Schafer said, and
projects dont progress at a swift pace.
Any and everything that happens is
slow moving, he said.
Geographical challenges also play
Compressortech2
Spotlight:
a role. While Brahma has representatives in each of the countries where it

conducts business, the company cant
avoid the costs of transporting equipment to its customers.
There are not a lot of local compression fabrication companies in South
America, Schafer said. Thats why they
come to us to do it. When our customers have to pay to have our compressor packages shipped from Canada to
South America, its an added cost.
He also noted a lack of diversity
among Brahmas competitors in South
Brahmas containerized vapor recovery

units have gained popularity in the South
American marketplace as environmental
concerns have grown.
America. Schafer said hes seen the

same U.S. and Canadian companies
opeating in South America over the
years without much change.
Positive change, though, is what
many gas compressor packagers predict for the continent in the decade to
come. Martinez, like Sawyer and Schafer, is encouraged by the areas poten-
tial. Valerus Compression Services

already has its resources in multiple
projects in Latin America. The projects
are in their infancy, but Martinez said
theres plenty of room for growth.
There is a huge promise (for business) for the decade to come, she
said. In my view, the industry has yet
to see the promise of the shale resources tied up in Latin America.
Prior to 2013, Sawyer wasnt able to
think about being entrenched in South
America because SEC, an OEM
packager for Caterpillar, GE Waukesha and Ariel Corp., was in the midst
of an expansion to triple the size of its
Houston facilities.
With that expansion near completion,
Sawyer said he can now monitor South
America and tap into the potential hes
seen evolve over the past 20 years.
Were in a position to more readily
produce equipment for areas outside
the U.S., he said. We are going to
start being more active in the South
American marketplace.
Sawyer added that SEC is working
on establishing relationships and projects in Peru, Argentina and Venezuela.
I see tremendous opportunities
for us down there, he said. Its just
not something thats going to happen
overnight. CT2
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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.
will be made at various locations in

the Sulzer Pumps global manufacturing network, with 40% of the pumps
packaged at the companys Busan,
South Korea, facility. Established in
2011, the packaging facility performs
engineering, packaging and testing
for bare shaft pumps and components, Sulzer said.
The second order has Sulzer supplying 42 pumps for two FPSO vessels,
P-66 and P-69, under a contract from

Keppel FELS Brazils affiliate Lindel. The
FPSOs operate in the pre-salt Iracema
cluster areas in the Santos Basin, off the
coast of Rio de Janeiro, Brazil.
Petrobras-led consortium Tupi chose
Keppel FELS Brasil for the fabrication
and integration of the vessels. With the
contract, which includes pump packages for sea water lift, water injection
and auxiliary services, Sulzer will supply pumps to eight FPSOs currently under construction for Petrobras and more
than 1300 pumps in service for the
companys offshore operations in Brazil.
Sulzer said the water injection pump
packages contain API 610 BB5 pump
models driven by 5.5 MW electric
motors, while the sea water lift pump
packages have vertical pumps run by
960 kW submersible electric motors.
Other pumps are used for various
auxiliary services, such as cooling
water circulation, hot water circulation
and water injection pump boosting.
Scheduled for delivery in 2014, the
pump packages will be built at Sulzers
manufacturing and distribution center
in Jundia, So Paulo, Brazil. CT2
Photo courtesy of INPEX
ulzer is putting more of its API

610 pumps into the offshore
seascape. The company received two orders for its pumps that
will be used in floating production storage and offloading (FPSO) vessels on
opposite sides of the world.
The first order calls for Sulzer Pumps
to supply 69 pumps to Daewoo Shipbuilding and Marine Engineering. The
pumps will be installed on a FPSO for
the Inpex-operated Ichthys LNG project in the Browse Basin offshore Western Australia. The order is scheduled
for delivery in several phases, spanning from this year until mid-2014.
Sulzer Pumps South Korea will undertake the full project management
and complete unit testing, while Sulzer Pumps Customer Support Services, based in Western Australia, will
handle offshore commissioning and
eventual servicing of the equipment.
Various API 610 pumps, including
OH3, BB2 and BB5 types, will be supplied for topside and hullside process
and utility applications aboard the
1100 ft. (335 m) vessel. The pumps
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.
Universal AET Acquires Ojibway

complete inlet to
Enclosure Systems > Creates
exhaust capabilities
By Brent Haight
n A Universal Puck Silencer is

shown in an Ojibway enclosure.
niversal Acoustic & Emission

Technologies has purchased
Ojibway Enclosure Systems, a
manufacturer of enclosures and packager of generator sets.
Universal provides engineered
acoustic, emissions and filtration
solutions for the oil and gas, power
generation and other industrial markets. The move brings enclosure
and light-gauge fabrication capabilities to Universal, creating a singlesource provider of air inlet and exhaust systems, ducting, diffusers,
enclosures and other components
used on a turbine system.
In addition to its enclosure expertise,
Ojibway allows Universal deeper penetration into the oil and gas market.
A good portion of our business is
serving customers who utilize turbine
systems that are used on compressor stations, said Ron Jake, marketing
manager at Universal. A turbine system has a number of inlet and exhaust
air-handling components, which we design and manufacture. But we did not
have the enclosure piece of it. A lot of
our turbine customers were asking us to

quote an enclosure with their package.
Enclosures are an Ojibway skill
set. Its a different, lighter-material
gauge than what we are used to working with the thicker, heavier-gauge
metals for silencers.
The acquisition gives Ojibway immediate access to Universals expertise for designing noise control, emissions and air filtration products.
We have been a customer of Universal for many years, said Debbie
Schilling, senior business development manager at Ojibway. As part of
our gen-set enclosure packaging, we
install the engine silencers inside the
enclosure packages.
Jake said, Ojibway allows us the
opportunity to provide a much more
complete package for recip engines
and turbine customers. We can be a
one-stop shop. Customers dont have
to look for multiple suppliers. We can
provide a complete solution from the
turbine inlet to the exhaust, or a complete standby generator set package.
As of July 1, Ojibways products are
30
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
MAN Expands Industrial

are tailored to match increasingly
Steam Turbine Line > Units
large and powerful compressors
By Roberto Chellini
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.
AN Diesel & Turbo (MDT)

offers the industrial marketplace a line of industrial
steam turbines tailored to meet specific applications, with a particular emphasis on compressor drive.
These steam turbines are designed
and manufactured in Oberhausen, Germany, with capability up to 161,000 hp
(120 MW) and in Hamburg, for up to
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
power and speed required by the

compressor, but above all, it has to
make an efficient use of the steam
produced by the exothermic process
in which the compressor is operating.
In many cases the process steam
is not the ideal for a steam turbine,
explained Klaus Behnke, vice president and head of engineering steam
Compressortech2
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.
Explosion proof motors - ET series
Fernanda owns a bar on the beach in Carnarupim.

Her dream is to build a hotel one day.
The use of an FPSO means that her beach
will remain clean and pollution free.
Nidec ASI, turning dreams into results.
Nidec ASI
www.ni dec- asi . com
n This direct-driven, compact,

high-speed steam trurbine is
made for refinery gas compressor applications.
turbines for the process industry at

MDT Oberhausen.
Behnke said in gas-to-liquids and
coal-to-liquids plants, the steam is
available at about 290 psi (20 bar) and
428F (220C). At purified terephthalic
acid (PTA) plants it has lower values:
43.5 psi (3 bar) with side steams just
below 14.5 psi (1 bar). The increase in
power outputs requires the turbine to
handle enormous flows of steam.
MDT steam turbines are available in
modular construction. A line of standard
inlet and exhaust casings are selected
to match the steam inlet and exhaust
conditions and matched with intermediate casings developed for the specific
job, together with the necessary admission and/or extraction nozzles.
The intermediate casing allows the
combination of the high-pressure turbine with the medium-pressure one, in
practice eliminating one turbine body.
A row of variable guide vanes (VGV)
can be placed in the intermediate
pressure admission to increase the
operating range of the machine.
Behnke said the MDT line of industrial steam turbines includes units that
have special characteristics that are
not commonly available.
They can handle high-pressure,
high-temperature steam, 2030 psi
(140 bar) and 1000F (220C) in small
applications. These often are at refineries running compressors at 14,000
rpm to handle heavy gases.
Their wide load management allows the machine to operate when
the process requires the sudden
shut off of steam valves to comply
with process parameters.
MDT said the selection of a steam

turbine to serve as centrifugal compressor driver can be achieved according to two different criteria.
One is to reduce to a minimum the
number of casings of the compressor
train by eliminating the gearbox. In this
case the steam turbine speed has to
match the compressor speed.
The other is to reduce costs by using
smaller compressors as well as steam
turbines that directly coupled and rotating at the same high speeds.
This solution also allows savings in
weight and footprint and is mainly required for offshore platform applications.
In refinery applications, the steam
turbine is often operated with aggressive steam. In these cases the
steam has to be carefully analyzed
and the materials used in the machine, especially rotor blades, have
to be selected accordingly. When
the steam is moderately aggressive,
it may be convenient to use special
materials to prolong the service life

of the machine.
If the steam is strongly aggressive
(containing sulfur components) experience has shown that the use of expensive materials will not avoid corrosion.
In such cases it is economically more
attractive to use standard materials
and plan to replace the entire rotor every two to three years of operation.
MDT said the efficiency of a condensing steam turbine is strictly related to the vacuum achieved by the
condenser. When water is available
on site, a water-cooled condenser is
the choice. In dry areas, an air cooled
condenser can be the option.
When an air-cooled steam condenser is selected, to maximize plant
efficiency year-round and minimize
steam consumption, it is essential to
conduct a detailed analysis of the environment with the customer.
It is necessary to know the average seasonal temperatures, especially in the winter and summer.
Also, information on the hours of
daylight and darkness are important
to build the data needed to select
the best solution.
Applying such knowledge, a small
change in design parameters can
make a great difference in the
plants efficiency.
MDT constantly upgrades and extends its industrial steam turbine line.
A major project is underway to redesign of steam turbines for the direct
drive of-high speed centrifugal compressors rated at 1340 to 13,400 hp
(1 to 10 MW). CT2
Bearing Bush
Guide Vane
Guide Vane Carrier
Adjusting Lever
Adjusting Ring
Guide Rollers For

Adjusting Ring
n Variable guide vanes can increase performance significantly for

extraction steam turbines.
34
Compressortech2
Trust the #1 online monitoring system for mission-critical equipment
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We can advise you on a shutdown, alarm or any machinery problem.
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For on-demand help and periodic analysis, Remote Access is like having our team
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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.
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ranks your equipment using the REE index. It allows you to see where there is potential
For more information:
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info-hkth@hoerbiger.com
right business decisions.
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.
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
A brochure from Netzsch

provides information on its
Tornado rotary lobe pumps
including photos and characteristics. The pumps
have flow rates up to
35,315 cu.ft./hr (1000 m3/h)
and pressures up to 145
psi (10 bar). A section on
pump accessories is also
featured.
www.netzsch.com
Compressortech2
at the
Visit us
y
achiner
nd Turbom
42
ium in
Sympos
501
booth 1
,
n
o
t
s
u
Ho
so
und
R EE
v
En
e Effci
bl
en
10
Relia
your compressors
iro
nmentally
8
7
6
5
4
3
2
1
0
Hoerbiger.indd 2
8/15/13 10:05 AM
Ignition
Products
Gas Supply
System
HGM Pump
Protection
Dri-Prime
Pump
The 2014 edition of BG

Corp.s ignition products
catalog is available. Products covered include adapters, gaskets, spark plugs,
and turbine components.
The company caters to industrial gas reciprocating
and turbine engine users
through a worldwide distribution network.
www.bgservice.com
EagleBurgmann offers literature on its RoTechBooster

gas supply system. The system is designed to provide
clean gas flow. Recommended applications include centrifugal compressors, as well
as equipment in the oil and
gas, refining, petrochemical
and hydrocarbon industries.
www.eagleburgmann.com
KSB has released a brochure on its PumpExpert, a

diagnostic system for HGM
pumps. The system combines three functions: monitoring, diagnostics and recommendations for action.
It features a user display
showing measured variables, offers infrared data
transfer to a PDA.
www.ksb.com
Flygt has published a

specification sheet on its
FCD100M dri-prime pump.
The pump offers flow rates
up to 1013 gpm (3835
L/min) and discharge heads
to 124.7 ft. (38 m), with the
capability of handling solids up to 1.8 in. (45 mm) in
diameter.
www.flygt.com
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
he tropicalization of compressors, modifications to make

them more resistant to extreme
heat, is a common practice for Brazilian packagers.
Much of the nations production is
near the Tropic of Capricorn, where
temperatures average 78F (26C) year
round. Summer temperatures can be as
high as 104F (40C).
Marcelo Pereira Moura is manager
of oil and gas business development
for Atlas Copco, which has a facility in
Barueri, on the western edge of So
Paulo. He said the oil circuit thermostatic valve on compressors is routinely changed to adjust for the high
temperatures. Its necessary to define
different set points and occasionally
modify the suppliers.
The technicians follow the specifications of our headquarters in Belgium,

but we need to change some items,
Moura said. Among the changes is the
fan of the cooler, increasing the airflow
to generate bigger capacity.
The electrical motors are WEG, developed exclusively to be used for Atlas
Copco compressors, and are not sold
in the market, rated at 9 to 845 hp (7 to
630 kW). Moura said they have been
adequate for the operating environment and are used in the oil and gas
chain from upstream to downstream.
Siemens also practices tropicalization when it assembles compressor
packages. The process includes several
steps: installation of all the base components, from the instrumental panel
wiring up to junction box; installation of
38
all piping, painting, testing without load;

supervision of the installation and commissioning; quality control and preparation of the Manufacturing Data Book;
preparation for dispatch and transport;
purchase activities and training.
Almost everything is changed in
Brazil in our packages, except the compressor and coupling, said Jader Caldas, sales manager at Siemens. When
the packages are used with the steam
turbine, they are totally manufactured in
our Jundia plant, in So Paulo.
As with other foreign-based companies, it also has to meet Brazils requirements for indigenous content in
equipment. The amount depends on
the project.
Siemens supplied compression
trains for four floating production,
Compressortech2
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
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39
Compressortech2
Dresser-Rand, Honeywell
Merge Turbo Control
embeds anti-surge, load-sharing
Systems > D-R
programs into Honeywell controller
n Honeywells C300 controller will get Dresser-Rand software.
resser-Rand said it 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.
The companies said the cooperation
combines Dresser-Rands centrifugal
compressor knowledge and experience with Honeywells Experion Process Knowledge System. The single
integrated platform will give plant managers control of not only turbomachinery but also all other plant equipment.
The companies said the unified
platform would deliver turbine control,
compressor automation, compressor
anti-surge protection, and plant and
safety controls. The open platform can

be easily maintained and upgraded if
necessary, improving process visibility and safety.
The Dresser-Rand/Honeywell solution provides common spare parts
and maintenance, eliminates the need
for hardware-specific technician training, improves productivity and allows
for easy expansion.
The firms noted that one of the most
effective ways to improve the performance of turbomachinery, which is essential to refining and petrochemical operations, is through control algorithms.
Dresser-Rand said its anti-surge
control and load-sharing programs
have been shown to improve production, simplify maintenance and reduce
40
energy consumption. It has made and

installed more than 3000 turbomachinery control systems since 1958.
The company said its anti-surge
control inherently compensates for
variable gas conditions and properties, eliminating unnecessary recycle flow and associated losses.
Its compressor load-sharing system
maintains the controlling signal and
functionality even if the compressor
anti-surge control line is crossed.
Since the 1970s, turbomachinery
controls have evolved from mechanical-hydraulic to microprocessor-based
digital controllers. Initially, the digital
controllers were necessarily proprietary (or black box) solutions because
commercially available controllers did
not have the required speed or capability for turbomachinery control.
Although black box solutions provide good machinery control, they
also have significant downside to
owners and operators: the added cost
of dedicated spare parts, specialized
operations and maintenance training,
difficult and problematic integration
into the overall plant control scheme,
and frequent replacement due to unilateral obsolescence declaration by
the manufacturer.
Not only has Dresser-Rand helped
clients minimize the number of control
platforms operating in their plants, but
it also has helped them implement turbomachinery controls using commercially available controllers instead of
black box solutions. Dresser-Rand introduced a commercial programmable
logic control application in 1988 and a
distributed control system in 2011.
In todays competitive environment, the industry is moving toward
increased visibility of all plant equipment, said David Scheef, DresserRands director of marketing, strategic
business units.
Firmly entrenched in many U.S.
refineries, Honeywell is a leading
supplier of distributive control systems and an ideal partner to help
meet the needs of our clients. By
harnessing the strengths of our
businesses, together we now can offer technology replacing operators
obsolete turbomachinery controls
with a totally integrated system. CT2
Compressortech2
FEATURED
PRODUCTS
Flexible Switch
said Rick Harris, director of Marketing, Natural Gas Compression (NGC).

With EICS, all the components have
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The EICS was designed and tested
to work with specific engine models,
Fluid Components International has

introduced the FLT93 series FlexSwitch,
designed for monitoring relief valves,
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and gas production, refining, storage
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A dual-function instrument, the
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Expert Engineering.
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We are never satisfied.

Technology leadership is at the forefront of every
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Engine Control System

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governing, interface and diagnostics,
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Sealed radial magnetic

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Learn about the launch of Automated Commissioning

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41
WaukeshaBearings.indd 1
VISIT Booth 1231 at the Turbo Symposia.
Compressortech2
8/19/13 11:16 AM
Pump
tech
A Case For VS4

specialist Amarinth says they often can
Pumps > Pump
handle VS1 duties
n A pump like this Amarinth VS4 was
slated for use within the dosing system
for the storage and removal of sodium
nitrate on an offshore vessel.
he two API 610 vertical pumps

most commonly specified for oil
and gas projects are VS1 and
VS4. While VS1 pumps are best suited
for duties that require high flow or head,
there are several applications where a
VS4 pump (with or without a booster
pump) will perform just as well.
Oliver Brigginshaw, managing director of Amarinth, a company specializing in the design, application
and manufacture of pumps and associated equipment, explained why
companies that have always specified
a VS1 pump should consider using a
cost-effective VS4 pump (Figure 1).
Multistage VS1s
VS1 pumps can be single or multistage and, theoretically, can work to
a limitless depth. VS1 pumps achieve
this by using multiple stages stacked

on top of the other (Figure 2). The fluid
is pumped from the sump through the
support column and out into a discharge bend. The sharp bend on the
discharge, however, produces a loss
in performance and a VS1 pump generally requires a double mechanical
seal and Plan 53 seal support system
to prevent leakage.
The bearings of the shaft in each
stage of a VS1 pump are mounted
inside the support column by spiders.
This works well for relatively clean fluids, but if the pumping location contains sand or grit, which is typical in oil
and gas applications, the spiders will
start wearing out.
Also, in places where sand or grit
is present, VS1 pumps require an expensive seal support system to enable
42
a clean flush to be fed to the bearings.

The grease lubrication of the bearings in VS1 pumps can be expensive
to manufacture. And since all vertical
pumps require removal over time, and
disassembly and reassembly of VS1
pumps is time consuming.
VS4 advantages
VS4 pumps overcome most of these
issues. In a VS4 pump, the central
column contains the drive shaft to the
pump that is supported by a number of
bearings depending on the length, but
the pumped fluid exits via a separate
discharge pipe running parallel to the
column from the sump to the top plate.
That means it can pump the gritty fluid
independently of the shaft bearings using various filtering techniques.
Compressortech2
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n Figure 1. This chart shows the

head and flow comparison between VS1 and VS4 pumps.
There is no need for a complex

mechanical seal at the top plate.
Usually, a simple vapor seal is needed, which costs less than a double
mechanical seal system. The discharge pipework design can also be
improved to reduce loss. The shaft
bearings, also referred to as line
bearings, in the VS4 pump can be
easily lubricated and flushed, either
by recirculating some of the pumped
fluid (which can be filtered through
strainers if sand or grit content is
high) or using a separate clean fluid
flush system.
VS4 pumps can also be built in
stages, allowing for removal for maintenance in areas of limited headroom.
Where a higher flow is required, a
VS4 can act as a booster pump with
the main pump operating in series
and feeding a horizontal centrifugal
pump above ground.
The VS4, in turn, achieves similar
head and flows compared to a VS1.
The advantage lies in horizontal centrifugal pump maintenance being
quicker as it does not require lifting
out the sump beforehand.
There are definitely occasions where
a VS1 pump must be specified, such
as when there is not enough net positive suction head available to feed the
pump. Customers, however, are finding that a VS4 pump is cost-effective
and easy to maintain compared to a

VS1 pump, even when an additional
horizontal pump is present.
If a company has a requirement
for a vertical sump pump and has
only specified VS1 pumps, it should
n Figure 2. A schematic of a VS4 (left)

and VS1 (right) shows the disadvantage
of the discharge bend in the latter.
44
consider whether a VS4 pump would

meet its needs. If the VS4 pump can
perform the duty, it can be a better
choice than a VS1 pump, particularly
if the fluid being pumped contains
abrasive solids.
VS4 pumps catching on
In May, Amarinth secured its first
order in Korea from Hyundai Heavy
Industries for API 610 VS4 vertical
sump pumps to be installed on BPs
Quad 204 floating production, storage
and offloading (FPSO) vessel destined for operations in the North Sea.
Amarinth worked with Firscomp
Co. Ltd. in Korea to obtain the order.
The project calls for two 23 ft. (7 m)
stainless steel API 610 VS4 vertical
pumps to be used within the dosing
system for the storage and removal
of sodium nitrate. The pumps will operate the produced water treatment
and reservoir pressure maintenance
reinjection package on BPs Quad
204 FPSO vessel.
BP recommended Amarinth to
Hyundai Heavy Industries for the
supply of these API 610 VS4 vertical sump pumps. BP has demanding
foundry and supplier approval audit
standards that Amarinth had successfully met on previous projects, which
was a key factor in BPs recommendation, the company said. CT2
Compressortech2
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Spotlight:
Argentinas Shale
Prospects Continue
Tight gas could be the answer to slide
To Brighten in conventional production
rgentinas shale gas production is only about 5% of the

supply mix now, but its potential is growing by leaps and bounds.
The nation clearly has the best
South American hunting grounds for
substantial gas production from shale,
according to the U.S. Energy Information Administration (EIA).
In a recent update of global shale
resources, EIA ranked Argentinas
potential at second in the world with
802 Tcf (22.7 x 1012 m3) of technically
recoverable gas.
Argentines rate their shale prospects even higher. For the giant Vaca
Muerta shale region alone, the potential is 1181 Tcf (33.4 x 1012 m3), according to state-run YPF. It estimated
in July that Vaca Muerta, which is in
the Neuqun Basin of western Argentina, also holds a possible 661 Bbbl of
shale oil.
YPF and Chevron recently announced a US$1.24 billion deal, sanctioned by the government, to develop
part of Vaca Muerta. YPF holds 3 million acres (1.2 million ha) in the 7.4
million acre (3 million ha) Vaca Muerta
area. Apache, ExxonMobil and Americas Petrogas also have exploration
rights in the basin.
Also, YPF has found a large formation of commercially promising tight
gas and shale gas thought to total
4.5 Tcf (127 x 106 m3) near Neuquns Loma La Lata field, which for
Argentina has five primary

shale basins.
decades has been a leading source of

conventional production.
As Argentina continues developing
its shale potential, its pipeline infrastructure will necessarily have to be
reconfigured and additional compression will be required.
EIA said Argentine gas output has
declined more than 10% from peak
levels in 2006. Although once a net
exporter of natural gas to neighboring countries, Argentina became a
net importer in 2008 and has since
begun importing liquefied natural
46
gas to narrow the supply/demand

imbalance.
EIA said Argentina has experienced wintertime shortages of natural gas in recent years, hurting industrial users whose supplies were
interrupted or diverted to satisfy basic residential needs.
Argentina imposed price controls in
2001 to combat inflation and help consumers through an economic crisis.
Industry analysts said those controls
caused natural gas to be relatively inexpensive by regional standards and
deterred investments in production,
stimulated consumption, and forced
the nation to rely on more imports.
The government responded with
the Gas Plus program that allowed
companies to sell gas from new or
unconventional fields at prices roughly double the national average price.
After that measure proved inadequate, President Cristina Fernandez
Kirchner announced a 300% hike in
gas prices last year that would effectively end price controls. She said energy companies, including YPF, will
be expected to reinvest their profits
in gas production.
EIA said Argentina has more than
18,200 mi. (29,290 km) of natural gas
pipelines. Transportadora de Gas del
Sur operates the most extensive pipeline system in Latin America. The second largest in Argentina is Transportadora de Gas del Norte. CT2
Compressortech2
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.
operated by South West Oil & Gas

Co. of the China National Petroleum
Corp. The station, located in southwestern China, produces 98.8 MMcfd
(2.8 x 106 m3/d) of natural gas.
The engine also provides a 3% increase in gas compression compared
to other machines in its class, GE
said. Over a five- to 10-year period,
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
testo 350.
Compliance testing and tuning

the easy way.
Superior performance for state and
federal testing
Menu-guided HD display
Powerful on-board & PC data management
Wireless operation simple data collection
Rugged construction
O2 CO NOx SO2 CO2

800-227-0729 www.testo350.com
47
Testo.indd 1
the 3% increase in gas compression

represents a significant increase in
the amount of gas that is compressed
for pipeline transportation, the company said.
Additionally, the Waukesha 275GL+
natural gas engine produces lower
greenhouse gas emissions relative to
Compressortech2
1/22/13 9:06 AM
More Turbomachines Turning To Active

sees shift from experimental
Magnetic Bearings > S2M
to standard solution
By Roberto Chellini
n These two large radial active magnetic bearings will be used for a
natural gas centrifugal compressor.
n oil and gas, it took us 37 years

to reach the milestone of 1000 turbomachines equipped with S2M
active magnetic bearings (AMB), but
we will double this figure in only seven
years from now, predicts Vincent Megret, managing director of S2M (SKF
Magnetic Mechatronics).
COMPRESSORtech2 interviewed
Megret at the companys Vernon,
France, headquarters. Megret said
the experimental phase of AMB has
ended and that the technology can
be now considered for high-speed
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
Compressortech2
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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.
Visit us at the 42nd Turbomachinery Symposium, Booth 737, Houston, Texas,

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www.dresser-rand.com
n SKF made this axial thrust magnetic

bearing for a centrifugal compressor.
middle of the 1970s, the space race

had just given birth to new industrial
requirements including civil telecommunication satellites and sophisticated electronics devices.
One of the first civil applications of
AMB was in 1976, when the magnetic
bearings were applied to turbomolecular vacuum pumps used in the
manufacturing of silicon wafers. S2M
has made more than 130,000 of these
and still manufactures them today.
After various hand-overs, and a move
to Vernon-Saint Marcel in 1986, SKF
acquired the entire company in 2007.
Megret manages a S2M/SKF Magnetic Systems unit that consists of
the Vernon headquarters, an excellence center in Calgary, and sales
and service organizations in Moscow
and Yokohama. A third of the 300
employees work in R&D. Megret said

15 nationalities are represented in
the Vernon workforce.
The units 2012 turnover was 62
million. Investments in R&D exceeded
15% of annual revenues, with 58%
of the R&D budget dedicated to research and the rest to development.
Magnetic bearings are an ideal
method to minimize footprint, weight
and cost when compressor, expander
and turbine manufacturers increase
the speed of their machines.
These bearings are a necessity for
subsea machines when the time between overhaul (TBO) is at five-year
intervals and lube oil cannot be used
for hydrostatic bearings.
AMB allow the turbomachine
(compressor plus motor) rotor to be
levitated and turned at high speed
50
without friction, enhancing the reliability of the system.

Applications for AMB are practically
endless but, due to S2Ms small size, it
is concentrating its research in just four
main fields: oil and gas; air and Freon;
vacuum; and high-speed spindles.
Each of them has several sub-segments. Oil and gas for instance, includes many segments ranging from
power generation to upstream, midstream, subsea, cryogenics, high
temperature solutions, etc.
Megret said S2M is involved in the
development of AMB for the first two
subsea projects now being implemented in the North Sea: Ormen
Lange field with GE Oil & Gas and
sgard field with MAN Diesel and Turbo. The sgard compressor train on
MANs Zurich test bench has reached
full-load, full-speed conditions.
At Vernon, S2M is working on a
100% mockup of this compressor train
mounted in a container just outside their
research lab. The mockup is turned
at high speed by an auxiliary electric
motor and its rotor, supported by four
AMB, reproduces the weight (nearly
3.3 tons [3 tonnes]), stiffness and mass
distribution as the original rotor.
The test program performed on the
mockup has given rotordynamic results comparable to the ones obtained
by the actual turbocompressor on the
Zurich test bench.
Development of AMB for subsea applications started in Vernon in 2007 and
is still a major item in the R&D program.
While for this application the magnetic
bearings themselves are of special
robust design (now under implementation for onshore machines), all the
electronic controls are redundant and
provided with monitoring, tuning and
diagnostic systems. To increase the reliability of emergency landing bearings,
SKF has developed special ball bearings featuring ceramic balls.
SKFs ownership of S2M provides the
opportunity to transfer knowlege on both
sides, an advantage that Megret said is
not found elsewhere in the marketplace.
It is common practice to replace landing bearings after a certain number of
landings independently from their conditions. In this case, the monitoring system
indicates the landing bearing conditions,
Compressortech2
in less harsh environments. Each solution fit a specific gas composition,

and together cover a large part of the
industrys needs.
The use of advanced AMB is the
technological answer for the environmentally friendly (without lube oil
system) turbomachinery of the future,
demonstrated by the projects presently being implemented.
AMB peripheral
is PM
much
Centa.qxp
6/1/10speed
12:02
Page
higher than that allowed by hydrostatic bearings. The load capability
is large: gas turbine generator rotors

of 11 tons (10 tonnes) are supported
by only four radial AMB. Their stiffness and damping capabilities have
been demonstrated by using AMB to
replace the hydrostatic bearings in
conventional turbomachines that are
experiencing high vibration problems.
Although 95% of current turbomachines use oil lubricated hydrostatic
1bearings, Megret said a shift to AMB
as a standard and proven solution
is accelerating. CT2
MAKE A CONNECTION
n The company developed this

digital control unit for its active
magnetic bearings.
thus avoiding a useless and costly maintenance operation.

During the test program, one set of
system controls was installed at the Zurich testing department of MAN while
the second set was in Vernon so that
S2M personnel could follow the tests.
Inspired by the subsea controllers,
S2M is developing a next generation
of digital control cabinets integrating
new design, hardware and functions
to better fit the customers needs.
These new cabinets will be offered on
the market in 2014.
The increasing interest of oil and
gas companies to produce sour gas,
which has been neglected due to the
technical problems that hydrogen sulfide poses, has pushed S2M to design
AMB specially for such gas applications. The canned bearings feature an
enclosure which protects the stators
magnetic components from direct
contact with the sour gas, although
this solution entails a small loss in
overall efficiency. In the non-canned
robust design, magnetic components
are resistant to corrosion and erosion
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Since 1970
CENTAMAX HTC
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2570 Beverly Dr. #128, Aurora, IL 60502 T 630.236.3500
Compressortech2
Full-Load Test Of A CO2

conducts complex trials at its
Compressor > Siemens
Mega Test Center
By Roberto Chellini
n Siemens built a complex facility to test CO2 compressors at Duisburg, Germany.
ince 2008, Siemens has been

using its Duisburg, Germany,
Mega Test Center (MTC) to
perform compressor tests at full load,
full pressure with different gases and
with different drivers (motors, steam
or gas turbines).
The planning for a test starts in the
bidding phase and, once the order is
in house, continues with the preparation and execution according to customer specifications.
During the bidding phase, customer
requests are carefully examined to determine the feasibility. A pre-engineering
study is performed to define the testing
effort, the availability of required equip-
ment and if this equipment belongs to

the order, to the MTC or has to be purchased to perform the test.
The various interfaces such as the
testing area required to install the
compressor and all the auxiliary equipment, power, cooling water, lube oil,
seal gas, test gas, etc. are checked.
All this work is aimed to supply
the sales organization with the cost
of the request and the lead time
feeding back into the overall delivery schedule. Depending on the
complexity of the test required, the
investment in the testing of a compression system can be 5 to 10% of
the entire order.
52
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
Compressortech2
Experienced
Machining!
C
ompressor Elements is your quality source

for fast gas compressor machining and repair
services. Our large inventory of standard
replacement parts allows same day service
in most cases.
We also manufacture compressor parts to
your exact specifications.
Our Quality Control department carefully
checks precise tolerances. To save valuable time
we maintain an archive of all your past repairs,
ring and valve specifications, groove dimensions
and weights, etc.
And, as with all Compressor Elements parts
or repairs, your job is guaranteed.
Call us today for
Compressor cylinder
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Pistons and rods
Piston rings and
rod packing
Compressor valves
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CNC machining
Repair parts
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Compressor Elements has extended its service

area into the Barnett shale gas play with a
machine shop service center and parts warehouse in Granbury. To further our commitment to
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(432) 943-6701
sswarb@compressorelements.com
dividually tested. The CO2 tank was

refilled by truck each day of the test.
All CO2 leakages were vented
through an MTC stack, all the area
around the stack was monitored by
sensors capable of detecting any abnormal CO2 concentration.
Compressor lubrication was supplied by a shop lube oil system.
In advance of the test, extensive dynamic simulations were performed to
verify the transient conditions of startup and shutdown by using Siemens
proprietary simulation tools. In addition, backward rotation was checked
under trip conditions by analyzing
job-specific performance maps for reverse flow condition in a forward rotating compressor.
n The test bench was challenging because each process stage required
dedicated CO2 loops.
operating in the Gulf of Mexico. The

system is aimed to enhance oil recovery and at the same time, sequester
the CO2 underground.
These eight-stage integrally geared
compressors consist of three different
process stages: the first process is
performed by the first two stages; the
second by stages three and four; and
the third process is performed by the
last four stages.
A mechanical test of the first machine was performed before the fullload test of the complete system to
ensure that no mechanical complications arose during the full-load test.
Bench constructed
The setup of the test bench was
complex and challenging because
of the three different process stages, each requiring dedicated CO2
loops with different volumes and
specific conditions.
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
FLOW EQUIPMENT LEADERSHIP
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engineering to field support, for any make or model all from one convenient and attentive
source. We are a dedicated aftermarket team that exists to help customers keep their equipment
running efficiently, reliably and, above all, profitably. Camerons network of aftermarket facilities
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under one name. Learn more by calling 1.866.754.3562 or at www.c-a-m.com/cs.
FEATURED
PRODUCTS
Heinzmann GmbH & Co. KG

Am Haselbach 1
D-79677 Schnau/Germany
Phone: +49 7673 8208 - 0
Fax:
+49 7673 8208 - 188
Email: info@heinzmann.de
Oil Purification Systems

Oil Filtration Systems has introduced a new series of equipment to
remove water, particulate, entrained
gases and varnish from hydraulic and
lubrication oils.
HEINZMANN Contacts in
North America
Subsidiaries
The vacuum dehydration oil purification system (VDOPS) helps extend

the life of rotating equipment by maintaining optimal fluid cleanliness and
original oil viscosity, the company said.
The VDOPS employs a vacuum
distillation tower design and high cfm
vacuum pump to extract all water contamination from oil, including free,
emulsified and dissolved water. Very
low overall water content as low as
20 ppm can be achieved in hours,
the company said. Entrained gases
such as benzene, propane and methane are also effectively removed by
the vacuum distillation process.
Additionally, the VDOPS vacuum dehydrators use pleated microglass filter
elements to remove particulates from
oil. VDOPS units are available in a wide
range of configurations and flow rates.
www.oilfiltrationsystems.com
Steam Switching System

Parker Hannifin Corp. offers its new
Parker Gen II R-max stream switching
system, a multi-functional system capable of integrating stream switching
and filtering into a compact, modular
assembly. The Gen II system features
enhancements to the R-max stream
switching system.
Those enhancements include backward compatibility; a captured vent that
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
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:
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Me
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SEC Triples Capacity At Its

buildings provide space for more
Houston Complex > New
packaging, vessel manufacturing
By Patrick Crow
n SEC employees work
Photo by Patrick Crow, CT2
on an Ariel/Caterpillar
package at the Houston
fabrication shop.
EC Energy Products & Services

is completing an expansion that
will transform it from a traditional
packager to a one stop shop for the
entire chain of compression needs, from
design and fabrication to engineering,
spare parts and ongoing maintenance.
The expansion includes 212,000
sq.ft. (19,700 m2) of building space and
triples the manufacturing capability
at the companys Northwest Houston
compression packaging facility. That investment, along with its 10 warehouse
locations across the nation, will give
SEC a presence in the key oil and gas
producing plays.
Construction at SECs 46 acre
(18.6 ha) Houston complex began in
January and will be fully finished in
October. The five-building construction project includes skid assembly,
vessel fabrication, engine overhaul,
warehouse and office buildings.
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
viders with the capability to test the

power of each compressor on site.
The new facilities also will allow
SEC to build its compressor skids inhouse rather than outsourcing them or
purchasing kits for assembly.
Northup said the packaging shop
has operated at capacity for 2.5 years
and currently has a six-month backlog. Weve had to turn away some
business, due to our delivery schedules. Now we will be able to take on all
that work, he said.
Another key addition is a 53,000 sq.ft.
(4900 m2) vessel fabrication shop. Until
now, SEC has lacked the space to build
all the vessels and tanks that it needed,
especially the larger ones, and has had
to purchase some from third parties.
Northup observed that U.S. oil and
gas producers, in response to strong
prices for hydrocarbon liquids and
relatively low prices for dry natural gas
Compressortech2
Photo by Patrick Crow, CT2
n Another skid at SECs Houston shop also is based on an Ariel compressor.
prices, have shifted their focus to drilling

wells that produce oil and/or wet gas.
That, in turn, has required more liquids-handling capability on compressor
skids such as vessels for separators
and dehydrators. It also has created
demand for skid-mounted equipment
to strip the lease gas enough for use
in an engine.
The vessel shop brings all of that capability in-house and helps us capture
more of the value stream, Northup said.
It also responds to customer demand
and helps us broaden our business.
The companys new 40,000 sq.ft.
(3700 m2) engine rebuild facility will
help it meet strong demand to revamp
units that have been operating in the
field for several years.
Also nearing completion are the final
elements of the expansion: a 32,000
sq.ft. (3000 m2) warehouse and a
22,000 sq.ft. (2300 m2) office building.
SEC has packaged more than 2.5
million hp (1860 MW) since its startup
in 2003, which includes Energy Transfer Technologys dual drive compressor that offers both an electric motor
and a natural gas engine on one skid.
Northup said a noticeable trend in
SECs overall packaging business has
been the growing use of electric motor
drives, although they still total less than
half of its new packaging orders.
One reason is federal regulations that limit air emissions in ozone

non-attainment areas, Northup said.
Thats what makes the dual drive so
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attractive. Another reason is that vapor

recovery units seem to match better
with electric motors.
While SEC serves all geographic
markets, Northup said most of its packages have gone to the Mid-Continent
area and the eastern U.S.
We got started with the Barnett in
North Texas and followed the shale
plays to Arkansas and Louisiana,
Northup said. Weve put a lot of
equipment in the Eagle Ford shale in
South Texas. Were also in Ohio, West
Virginia and Pennsylvania now.
SEC has 300 employees nationwide and is expecting that number
to increase in the next year. Like
other companies in the compression
industry, it is enduring a competitive
market for experienced engineers
and fabricators.
Its a good time to be a veteran
employee looking for work in this
business, Northup said. We try to
keep our workers happy. We lose
some of them periodically, but we
steal good mechanics from other
companies too. CT2
Fax (918) 283-9229
www.axh.com
Compressortech2
4/16/12 4:42 PM
Downhole Compressor Technology

Advances > Corac cites successful field trials in Texas
By Ian Cameron
any gas wells

cease production
due to liquid loading,
but a technology development program is successfully making progress to combat the problem and extend their working lives.
The extraction of gas from wells often declines as the
pressure within the reservoir falls. As the pressure drops,
the wells begin to load with liquid and methods to remove
water are required to maintain gas flow.
U.K.-based Corac Energy Technologies (CET) is developing applications that it says enhance performance in oil
and gas production. It is working with several partners to
develop innovative, compact turbocompressors.
Demonstrating that the technology has captured the interest of oil and gas majors, CET recently signed agreements with Tullow Oil and BP to develop the applications.
CETs compressors have proven themselves in industrial applications in Europe and the Far East, logging more
than 20,000 hours of maintenance-free operation. The
companys intellectual property portfolio includes more
than 40 patents plus several pending and eight European
design registrations.
According to the company, the goal of the downhole
compressor development program sector was to apply the
unique technical characteristics of the CET
compressors to the oil and gas sector. It said
the compact, lightweight and frictionless
qualities of its equipment can provide long
n Corac is developing its downhole compressor to function much like an electric

submersible pump.
n Field trials of the downhole compressor

were conducted in Texas.
62
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n Corac said its power electronics systems were developed to

be compact and withstand high temperatures.
maintenance-free operating cycles in
an application with high value product.
It added that the intent was to produce an equivalent of the ubiquitous
electric submersible pump (ESP), so
common in oil production, as an artificial lift solution.
The companys downhole gas compressor (DGC) development program is
exploring technology to position a compact compressor underground in a declining gas well to extend production life.
Other development projects are in
progress to define compact compression applications at the wellhead,
both on land and on offshore on production platforms.
Various responses are available for
declining fields, yet liquid loaded wells
are difficult for conventional compression systems, said Melanie Rigby,
CETs managing director. Existing
technologies also require significant
ongoing maintenance and do not necessarily give the benefits expected.
The DGC is a compact highspeed turbocompressor running on
contactless gas bearings, using production gas as both a bearing fluid
and a coolant. The development program aims to demonstrate a system
with only one moving part per compression stage that is highly efficient
and requires no routine maintenance over a production life greater
than two years.
Downhole gas compression can extend the life cycle of declining wells and
improve gas well production. Use of
our patented core technologies allows
us to design a compact and intelligent

compression solution that sits within a
seven-inch pipe several thousands of
meters below the earths surface.
The DGC system comprises a number of compressor modules including a
surface control system that takes a local power supply and changes it to produce a direct current supply of greater
than 2000 volts. A custom ESP-type
cable several thousand feet long transfers power and communications cables
downhole to the installed DGC.
Downhole power electronics systems invert the supply to variable
frequency alternating current that
drives permanent magnet motors at
the heart of each compressor module. A compressor module is driven
by each inverter in the downhole
power electronics module. These are
mounted in series to provide the required pressure ratio over the inlet
gas conditions.
CET said the DGC can be deployed at a depth with suitable temperature and flow characteristics to
deliver the intended pressure ratio
and flow rate. This is typically between 5000 and 10,000 ft. (1524 and
3028 m). The DGC can produce into
production tubing or into the well casing and current projects are exploring
both approaches. Completions are
specific to the wellsite and any specific regulations in force.
The company added that the early
development DGCs are thought to be
most effective in gas wells with liquid
loading liquid at the wellhead but
64
dry lower down (where the DGC can

be positioned) and with 7 in. (17.8
cm) casing or greater.
They are also estimated to be
most effective at deployment depth
(greater than 5000 ft. [1524 m]), flowing bottom hole pressure between 40
and 300 psi (2.7 and 20.6 bar) producing between 2 and 10 MMcfd (56
and 283 x 103 m3/d) with a remaining lifetime of between one and three
years without intervention. There
should also be no solids or brine in
the gas stream and low levels of condensate at the base.
The DGC has the ability to compress gas with a limited liquid content. Initial well tests will be lightly
liquid-loaded wells to establish dry
performance before moving on to
explore the operating envelope,
Rigby said.
However, CET said it is working to
tackle various technical challenges,
notably the miniaturization of compressors prompted by the need to fit
the entire compressor and motor drive
system inside a well casing, or in the
surface variants within a slightly larger
but still limited pipe dimension.
Another test is coping with aggressive environments. A gas stream can
contain fluids of various compositions,
including hydrogen sulfide in some
cases, and solids that can damage or
corrode parts of the system.
CETs work also focuses on power
electronics in high temperature operation. Cooling is a key challenge as
the switching of high-voltage power
supplies introduces heat that must
be managed within a confined space
where cooling media are limited. Furthermore, while the system is intended to have a long service life, it must
be reliable and low cost to attract users, the company added.
Corac said it is addressing these
challenges in a number of ways.
They include using frictionless, dry
start/stop hydrodynamic oil free gas
bearings that work by frictional gas
entrainment to draw a film of gas between the faces and lift the shaft so
it floats in three dimensions. A high
shaft speed is necessary to maintain
a stable gas film. Low friction in the
Compressortech2
low-gas density environment leads to

high efficiencies and the specific load
does not increase with gas density.
CETs system also uses an advanced permanent magnet motor with
a temperature capability up to 428F
(220C) to withstand downhole conditions and a high power density stator
that is compact to fit within the constrained space in the pipe, although
difficult to insulate. The DGC also uses
a modular design that reduces build
time, has high integrity joints between
modules and also plug-and-play IGBT
modules with integrated cooling fins in
the production gas stream.
This year, a DGC was deployed for
the first time in a producing gas well in
Texas. The successful early stage running was completed with more than
140 operating hours logged.
According to CET, the trial has
shown that the DGC system is capable of operating at well depths greater than 6000 ft. (1830 m), where it
encountered conditions as harsh as
it is likely to meet in the intended application wells.
The compressor modules ran at

high speeds in the production gas
stream, the electronics module performed controlled start, stop and
speed control functions and the
communications system relayed
data to the surface control systems
as expected.
Through this trial, the DGC has
shown it can function at inlet temperatures approaching 212F (100C) and
with condensate and other fluids in
the gas stream, Rigby said. Through
the multiple start and stop procedures
within the well plus retrieval and redeployment events the system has
shown itself to be resilient in day to
day operation.
After the tests were completed, Phil
Cartmell, Corac Group CEO, said,
We feel this is a significant event in
the development of high-speed compression for the energy industry.
Our engineers have worked closely with our partners in the field and
have taken our technologies to work
successfully in a place where no
compressor has ever been. There is
Visit us at
Turbomachinery
Symposium
Booth 620
still a lot of work to do, but this first

proof of operation is a positive step
towards the technical readiness of
the system and its future commercial potential.
In July, CET signed a master services agreement with BP Trinidad
and Tobago (BPTT). This five-year
agreement provides commercial
terms to enable BPs procurement
of development, production, testing and installation of compact gas
compression systems.
The agreement builds upon feasibility work carried out for a system to
be deployed on an offshore gas production platform operated by BPTT.
The compression systems will use
CETs core technology with the addition of some established subsystems
provided by supply-side partners.
CET has started a funded feasibility study for Tullow Oil to focus on wellhead compression on
a gas production platform in the
southern North Sea. It also is in
discussions with a number of other
potential partners. CT2
Dresser-Rand Marks
unit was a Datum I, the latest
DATUM Milestone > 1000
addition to the series
th
By Brent Haight
n The latest compressor in the series, DATUM I, is a variation of

the DATUM ICS, shown above.
resser-Rand has sold its 1,000th

DATUM centrifugal compressor
the new DATUM I centrifugal
compressor to Petrleos Mexicanos
(Pemex) to supplement the gas handling capacity on its existing Abkatun-D
Platform located in the Tabasco Field in
the Bay of Campeche. The DATUM I is
one of the latest additions to the companys DATUM (Dresser-Rand Advanced
Turbo Machine) centrifugal compression product line.
Recent changes in Mexican environmental regulations have required Pemex to reduce, and eventually eliminate, natural gas flaring on its offshore platforms. In order to comply
with this requirement, additional compression capacity was needed on its
Abkatun-D platform to move the gas

to a downstream collection point.
Dresser-Rand will supply two singlelift compression trains, each containing two DATUM compressors driven
by VECTRA power turbines. The
DATUM unit in low-pressure service
on each module is configured as a
double-flow machine and handles the
inlet flow capacity of a compressor
much larger in size. In high pressure
service on each module, the DATUM
I compressors incorporate DresserRands proprietary rotary separation
technology within the compressor
body to remove liquids from the incoming gas stream, which eliminates
the need for conventional external
separation equipment.
66
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
Compressortech2
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n Dresser-Rand developed the DATUM C

as a compact, sealed design for emissionsfree operation.
with compressor, driver, separation

system, process piping, valves and
gas coolers, all contained within a
single, compact compression module.
The development of the DATUM
product included the introduction of
many technological advances to improve the mechanical and aerodynamic performance, reliability and
maintainability of what at that time
was considered to be the state-of-theart in centrifugal compression technology, said Jos L. Gilarranz, Manager,
Technology Development DATUM ICS
& Subsea, at Dresser-Rand.
The DATUM product is being
constantly improved and updated
as new technology is developed at
Dresser-Rand. This allows the DATUM product to continue to be the
most technologically advanced centrifugal compressor available today.
As part of the advances in technology, and the emergence of new markets, we started spinning off derivatives of the DATUM. The first was the
DATUM P for pipeline service. It had
a simple modification to the casing
to allow the inlet and discharge nozzles to be located horizontally and it
had special provisions integrated under the compressor casing to anchor

it to the foundation.
The next DATUM variant was the DATUM C. According to Dresser-Rand, the
need to go green led to the creation
of the DATUM C, where the C stands
for compact. Targeting equipment operators in natural gas pipeline applications, the DATUM C compressor is an
integrated, high-speed, electric motordriven, hermetically sealed compressor
that releases no volatile organic compounds (VOCs) into the atmosphere,
and offers a more compact footprint
than any other conventional centrifugal
compressor with similar capabilities, according to Dresser-Rand.
With no shaft seals exposed to the
atmosphere, clients who need to compress highly toxic and lethal gases
are looking at this hermetically sealed
design with great interest, Pacheco
said. The compact, green design of
the DATUM C compressor makes it
ideally suited for urban areas where
electric power is readily available.
The DATUM ICS (Integrated Compression System) followed, taking
the DATUM C a step further. The first
68
DATUM ICS was designed for a client

who did not have the space for conventional compression equipment, but
needed to increase the capacity of an
existing offshore production platform.
The DATUM ICS included a hermetically sealed DATUM I train (with the
integrated separator), and all of the
process equipment required for a
compression module (piping, valves,
heat exchangers, instrumentation,
etc.). This equipment was packaged
into a compact, single lift unit that fit
within the available footprint on the
brownfield installation.
The DATUM I is a variation of the
DATUM ICS, Gilarranz said. It is a
compression train that has the rotating separator integrated into the centrifugal compressor but it does not
include the balance of the process
system that typically would compose
a compression module. The integrated separator can be used in a conventional DATUM compressor, such
as the DATUM I supplied to Pemex
for the Abkatun-D platform, or can
be used in a hermetically sealed unit,
such as the case of the DATUM ICS
module described above. CT2
Compressortech2
MACHINERY ANALYSIS
See us at the Turbomachinery and Pump Symposia, booth 939
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BETAMACHINERY.COM
Acoustic Walls Muffle Texas

Sound Fighter noise solution
Compressor Station > Modified
enables truck access and airflow
By Murray Stacy
n Sound Fighter added 45 wings (one is visible in background) to

improve the effectiveness of the compressor stations barrier wall.
hen the Barnett Shale drilling boom swept across Fort

Worth, Texas, producing
natural gas in a metropolitan area presented myriad problems.
One issue in particular noise
abatement caught nearly everyone
off guard, both operators and residents.
After Mitchell Energys Slay No. 1
well in Wise County piqued the industrys interest in the potential of
Murray Stacy is vice president of Sound
Fighter Systems. A graduate of Centenary College, he has eight years of
experience in assessing and resolving acoustic issues in many industries,
including electrical and water utilities,
commercial big box development
and the transportation segment.
the Barnett Shale in 1981, it took two

more decades before natural gas
prices and the development of horizontal drilling and hydraulic fracturing
technology would combine to make
the shale commercially producible on
a large scale. With the shales recoverable resources estimated at more
than 40 Tcf (1.1 x 1012 m3), the resulting boom was historic.
Although oil fields had been developed in densely populated areas
before, particularly in Los Angeles,
the intense and rapid growth of the
Barnett Shale play presented many
unanticipated hurdles, ranging from
drilling and production problems to
the lack of infrastructure.
The Barnetts sweet spot was
squarely beneath the Fort Worth
70
metropolitan area, which has a population of more than a million. When

the usual exploration operations
began in earnest, many residents
were dismayed by the unanticipated
noise from the temporary clamor
of drilling and fracking operations to
the longer-term drone of natural gas
compressor stations.
Locked in a fierce competition for
mineral leases, the exploration and
production companies proactively
addressed the communities noise
concerns. They orchestrated town
hall-style meetings to hear the apprehensions of residents and they
promised swift and effective action
on those concerns.
As a result of such public input, the
Compressortech2
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the operating cost savings of a screw compressor, the
large volume of a centrifugal compressor or the high
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www.kobelcocompressors.com
n The modified plan for the acoustic

walls included two wings.
city of Fort Worth developed a comprehensive noise ordinance targeting
Barnett Shale drilling and production
operations. The ordinance, one of the
most stringent in the nation, mandated
the adjusted dB(A) levels allowable for
all permanent lift or line compressors.
The maximum permitted sound
levels were 75 dB(A) day or 65 dB(A)
night in industrial areas, 65 dB(A) day
or 55 dB(A) night in commercial areas
and 55 dB(A) day or 50 dB(A) night
in residential areas. The ordinance
further restricted compressor noise by
frequency and duration.
Suddenly, the need for industrialstrength noise reduction solutions
became a front-burner issue for many
Barnett Shale E&P operators.
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.
(HDPE) panels encased a dense,

steel fiber wool material. The number and shape of the perforations
in the HDPE panels are engineered
for optimal access to the acoustic fill
material inside the barrier.
LSE is ideal for absorbing compressor noise due to its very high, nonreflective acoustic performance and
its well-documented durability. It can
reduce compressor dB(A) levels from
the low 90s to the mid-to-low 70s.
When designed as a peripheral barrier, the system eliminates the need to fully enclose compressor stations with insulated metal buildings. Such buildings
Location/Sound Level, dB, At Octave Band Center Freq., Hz

63
125
250
500
1000
2000
4000
8000
Overall
dBA
Inside Barrier
Center Yard
94
87
88
90
86
84
82
76
92
Center West Wall
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
Center West at 50 ft.
75
68
62
55
56
49
42
36
60
72
Compressortech2
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require mechanical ventilation systems

which are expensive to operate and
maintain. Failure of the ventilation system could shut down or even destroy
expensive equipment.
The absorbent attenuation performance of LSE also is superior to
acoustic reflective materials like brick,
block, concrete and metal.
A study presented at the Transportation Research Board annual meeting
earlier this year (Reflective and NonReflective Barriers by Rich Peppin
and Ken Polcak) concluded that it was
almost always better to use an absorptive barrier rather than a reflective one,
and reflective barriers may even worsen the situation in some cases.
Altronic.indd 1
Barnett Shale installation

A few years ago one of the leading Barnett E&P companies asked
Sound Fighter Systems to help reduce the decibels from a compressor
station in Parker County, just west of
Fort Worth.
Given the lack of hard acoustic
data for such applications at that time,
Sound Fighter retained an independent

firm to conduct an acoustical review of
the customers compressor station.
The purpose of the study was to
determine the typical sound levels
from the equipment at the station site
and the anticipated sound levels at
nearby residential sites. Typical overall A-weighted or averaged dB(A) and
one-third octave band (dB) sound
levels were obtained at the station
yard and at the homes.
Sound Fighters site visit to the station determined the optimum layout for a
high-performance noise barrier around
two installed, but not yet operational,
Caterpillar 3516/Ariel compressor/
single fan cooler packages.
It appeared that a 23 ft. (7 m) tall
sound wall would be needed on all
four sides. The operator was concerned about having adequate access for both service vehicles and
airflow to the large, south-facing coolers. As a result, large openings were
designed on the south ends of the
east and west barrier walls.
Sound Fighter was confident that
74
even with these gaps, its system would

8/13/13
achieve significant sound reduction.
But the company was concerned that
unacceptable sound still might escape
through the two openings.
After the LSE barrier walls were
installed and the compressors were
started up, it was confirmed that
unacceptable sound levels were escaping through the two openings in
the barrier. As a result, overlapping
wing walls were added to the detached wall, providing greater sound
reduction while allowing sufficient
room for cooler airflow and maintenance access.
Sound Fighter confirmed that the
modified, overlapping enclosure design performed comparably to a fully
enclosed barrier wall around all sides.
In the summary acoustical findings, the four-sided LSE noise barrier provided reductions of 17 to 20
dB(A) at grade level. Thus the noise
barrier wall provided about 19 dBA
of sound reduction, which is considered an excellent decrease based
on a 23 ft. (7 m) barrier height. CT2
Compressortech2
2:28 PM
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exclusive, patented, directed-energy technology, has been
fully field-tested by large gas engine operators across North
America, and has been found to outperform all expectations,
delivering assured combustion on both low-emissions
applications and on units operating at light loads.
www.altronic-llc.com
literature
Altronic.indd 2
8/13/13 2:28 PM
High-Pressure Pumps
Electric Glycol Pump
Oil & Gas Capabilities
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
Kimray Inc. has produced a

brochure on its electric glycol pump, designed for gas
dehydration. This positive
displacement pump operates in conjunction with an
electric motor, with gas not
required for operating the
pump. Its maximum pressure capacity is 1500 psi
(103 bar) at 1200 rpm and
8.3 gpm (31.4 L/min).
www.kimray.com
Galileo has published a brochure on its capabilities in

the oil and gas industry. The
company has more than 30
years of experience in natural gas technologies, providing compression, transportation, treatment and regulation
hardware. The brochure focuses on field compression,
pipeline compression stations and transportation.
www.galileoar.com
Nash, a division of Gardner

Denver, has produced literature on its liquid ring compressors. The literature contains a
compressor range graph, basic specifications and dimensions. Featured compressors include the Nash HP-9,
the NAM/NAB, the 2BQ, the
2BE4, the Vectra XL/GL, and
the Vectra SX.
www.GDNash.com
75
Compressortech2
The Cost Of Reducing

Fan Noise > The tradeoffs for induced draft air-cooled heat exchangers
Hudson Compression Cooling photo
By Rick Ketchum, Robert Giammaruti

and Robert Khami
n This forced draft vertical engine drive cooler has a 168 in. (4267 mm) fan, two water sections and three gas sections.
wner/operators, OEMs and

suppliers are facing increasingly lower near and far field noise
limits with respect to their equipment.
However, the impact of cost can be
lost in the race to see who can out-quiet

whom specifically, the cost of noise with
respect not only to fans, but also to the
fan mechanical/structural parts as well.
This paper will look at a bank of in-
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.
76
duced draft air-cooled heat exchangers

to evaluate the cost of lower field noise
with respect to the fan and mechanical
and structural components. It will also
compare the effects of standard, lowand ultralow noise fans on noise levels
and static pressures.
Introduction
Noise is referred to as unwanted
sound; it is a common byproduct of
our mechanized civilization and is an
insidious danger in industrial environments. Noise pollution is usually a local problem and is not viewed on the
same scale of importance as the more
high-profile industrial emissions like
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n Figure 1. This drawing shows the front (inlet)

view of an induced air-cooled heat exchanger.
n Figure 2. This is a side view of an induced

air-cooled heat exchanger.
NOx, CO, and particulates. Nonetheless, it is an environmental pollutant of

significant impact.
Serious concern is merited when a
pollutant can result in either environmental damage or human discomfort.
Considering the impact on people,
noise is most often a source of an-
noyance, but it can also have more

detrimental effects, such as causing
physical injury. Noise-related injuries
range from short-term discomfort to
permanent hearing loss.
According to recent statistics, more
than 20 million Americans are exposed to hazardous sound levels on a
regular basis. There are approximately 28 million Americans who have

some degree of hearing loss: about a
third of these more than 9 million
have been affected, at least in part, by
exposure to excessive noise.1
We will consider an 11-bay bank of
air-cooled heat exchangers (ACHE).
Before getting into the descriptions of
the equipment, we will review the assumptions that went into this analysis.
The following assumptions apply unless otherwise noted:
The total airflow and static pressure delivered by the fans is maintained as noise is reduced.
Noise reduction is achieved solely by speed reduction of the fans
and modification of the fans to
different blade counts and blade
types. No other noise abatement
devices were considered and
standard motors, gears or drives
were employed.
Near and far field noise predictions
are for fans only. No attempt was
made to assess noise generated by
the drive/gear systems or motors.
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Fan
Parameter
Value or
Description
Air Flow; CFM (m3/sec)
153,680 (72.53)
Static Pressure; Pa (in H20)
129.5 (0.52)
Air Density; lb.ft3 (kg/m3)
0.0722 (1.157)
Inlet Bell Type
Rounded (R/D = 0.05)
Fan Diameter; ft. (m)
13.0 (3.96)
n Figure 3. This table shows ACHE fan-operating parameters.
Fan Case
Fan
Type
Fan
RPM
Tip Speed ft./

min (m/sec)
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
n Figure 4. This table shows ACHE fan-operating

conditions in order of decreasing noise.
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Inlet conditions and tip clearances of the fans remained

constant.
ACHE near field noise levels were
predicted 3.28 ft. (1 m) below the
ACHE bank center with all the
fans running.
Far-field noise was predicted at
32.8 ft. (100 m) perpendicular to
the long side of the units, 6.56 ft.
(2 m) above the ground.
No additional bays or cells have
been added the plot area remains constant.
Heat transfer surface remained
constant.
Tolerance on near and far field
sound pressure level (SPL) and
sound power level (PWL) noise
predictions are 2 dB(A).
Tolerance on cost estimates is 10
to 15%.
Additionally, the authors wish to
acknowledge that other design options are available for noise reduction such as ACHE redesign or other low noise technologies.
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n This photo shows the relative size of

standard, low noise and ultra low noise
fan blades. Cofimco U.S.A photo.
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.
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.
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.
n Figure 9. This is a comparison of ULN versus LN

at 0.5 in. H2O constant static pressure and air flow.
n Figure 10. This is a comparison of ULN versus LN at

1 in. H2O constant static pressure and air flow.
The cost increase estimates were
then plotted against the near-and-far
field SPL noise predictions as shown
in Figure 5.
The overall ACHE cost per bay significantly increases as noise is decreased
with the lowest noise option increasing
the per-bay cost by approximately 35%.

Given the nonlinearity of the data (a
general third order polynomial was used
to trendline the data) it is apparent that
the cost increase accelerates faster for a
relative steady decrease in noise.
Stated another way, the first 10
82
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.
a sound power level, but the choice

in fan blade types must balance
static pressure, noise and cost considerations for the final solution.
While this analysis is far from exhaustive, the authors hope this paper provides the reader with some
perspective in the realm of ACHE
fan noise. As the adage says, There
are no free lunches. The same is
true here. However, in this instance,
the cost of lunch will probably in-
crease rapidly compared to what

you receive in return.
References
1. Combustion, Charles Baukal, Gen.
Ed. Second Edition, Volume 1, Chapter
16, CRC Press, 2012.
2. American Petroleum Institute,
Air-Cooled Heat Exchangers for
General Refinery Service, API
Standard 661, Sixth Edition, February 2006. CT2
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
83
CST.indd 1
Compressortech2
8/20/13 9:41 AM
UE Compression Going Strong

packager serves diverse array
At New Location > High-spec
of applications
By Norm Shade
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 the year after moving into its

new Henderson, Colorado, facility, UE Compression has produced a wide range of packaged
compressor systems.
The facility, on the northeast side
of Denver, allowed the company to
combine corporate offices, sales,
parts, service and fabrication/packaging facilities at a single location. It
also provided increased production

capacity for the compression needs
of the oil and gas, industrial and
power generation markets.
UE Compression (UEC) is a division
of United Holdings, which Kirby Corp.
acquired in April 2011. In addition to UE
Compression, Oklahoma City, Oklahoma-based United Holdings distributes
and provides services for engine and
84
transmission related products for the oil

and gas, power generation and transportation industries. United also makes
oil field service machinery, including hydraulic fracturing equipment.
UEC was formed in 2002, bringing together a staff with more than 170 years
of compression design experience from
the former Pamco division of Stewart &
Compressortech2
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.
Stevenson. In 2006, UEC acquired Gas

Packagers Inc., Colorado Compressor
Inc. and Iron Horse Compressor, all
well-established gas and air compression packagers and distributors.
These acquisitions broadened market coverage and combined UECs extensive natural gas industry expertise
in engine-driven compressors with
Gas Packagers proven experience in
high-spec electric motor-driven process gas compression and fuel gas
boosting for the power generation
industry. Today, UEC provides a full
spectrum of engine- and motor-driven
custom gas compressor packages

from 50 to 7500 hp (37 to 5593 kW).
UEC also packages custom instrument and service air compression packages for industrial facilities and power
plants using Gardner Denver oil-flooded
rotary screw or reciprocating compressors, as well as Kobelco oil-free rotary
screws, Ro-Flo rotary vane packages
for vapor recovery applications, and
Gardner Denver blower packages for industrial, power and municipal projects.
The company is the authorized distributor for Gardner Denver air compressors, rotary blowers, and acces86
sories for Colorado, Wyoming, Montana

and portions of Nebraska, South Dakota, and North Dakota. In addition to its
Henderson plant, UEC has sales and
service offices in Casper, Wyoming,
and Billings, Montana.
Our experienced staff has been
one of our strengths for many years,
but like the challenge faced by the
entire oil and gas industry, which
has an aging experienced work
force, its important that we continually strive to bring in new talent and
provide them with the right tools for
success, said G. Keith Kern, vice
president of operations.
UECs Henderson facility, completed in August 2012, totals 98,000
sq.ft. (9100 m2) on an 18 acre (7.3 ha)
site that has space for future growth.
The air conditioned fabrication area
includes two long parallel spans, each
with six bays that are 35 x 75 ft. (10.7
x 22.9 m) with either 24 or 28 ft. (7.3 or
8.5 m) wide overhead doors.
The plant has lifting capacity for handling packages and equipment weighing as much as 120 tons (109 tonnes).
Multiple 20 and 30 ton (18 and 27
tonne) cranes service each span with
30 ft. (9.1 m) hook height. The arrangement allows multiskid packages nearly
150 ft. (45.7 m) long to be set up across
the width of the building.
The plant has a 50 psig (3.4 bar)
natural gas supply and a 3000 Amp
electrical service that enable the testing of the largest gas engine-driven
and electric motor-driven packages
that the company builds.
A large weld shop occupies one
end of the plant for the fabrication of
ASME-coded pressure vessels, pipe
and skids. Some welding fabrications
are subcontracted during periods of
peak activity.
An 18 x 45 ft. (5.5 x 13.7 m) sand
blast room and a 26 x 65 ft. (7.9 x
19.8 m) paint booth are in a separate
building adjacent to the fabrication
building. In another part of the facility
are three service bays with 5 ton (4.5
tonne) crane capacity.
A recent tour demonstrated UECs
diverse compressor package design and manufacturing capabilities.
Equipment in production included
multiple small Gardner Denver startCompressortech2
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-
pleted earlier this year. It included

seven Caterpillar C-27 diesel enginedriven, three-stage Ariel JGA/6 reciprocating compressor packages for
high-pressure air boosting in an Australian subsea pipe purge application.
Each package was designed to
compress 5.76 MMscfd (1.6 x 105
m3/d) of air from 450 psig (31 bar)
suction to 2500 psig (172.4 bar) discharge. The high-spec packages
required an export design with CE
marking, DNV and ABS certifications.
87
ECOM.indd 1
Our strength lies in our ability to handle a wide variety of very

high spec work as well as conventional gas patch compression, as
evidenced by the many (turbine) fuel
gas boosting applications for power
plants were building, along with
specialty systems like CO2 compression, in addition to our regular
work in gas gathering, compressor
station and vapor recovery packages, said Steve Tyler, senior account
manager. CT2
Compressortech2
6/5/12 1:11 PM
Young Company
Has Decades Of Experience
Rapidly growing Euro Gas Systems serves European

compression market
By Norm Shade
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-
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
n This is one of three Waukeha 12VAT275GL+ gas engine and Ariel

JGC/4 compressor packages
that EGS built for a 12%
rapidly
H2S Lukoil gas
and by the
compression
end of last May
project.
EGS had delivered 13
more compressor packages
ranging from 74 to 3750 hp (55 to
2700 kW). The three largest packages
included Waukesha 12V275GL+ gas
engine-driven Ariel JGC/4 compressors for a 12% H2S gas compression
application in Russia.
The market has continued to
respond to EGS presence in the
Eastern European market, and
the rapidly growing company is
planning to double the new plants
assembly space to 51,670 sq.ft.
(4800 m 2). The expansion includes
another large paint booth and
another 11 ton (10 tonne) crane
Compressortech2
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The Energy Flows Through Us
OUTSTANDING REPUTATION IN
THE TURBOMACHINERY INDUSTRY.
QUALITY EXPERIENCE PRECISION

World-leading authority in rotordynamics
analysis, design and manufacture of tilting
pad journal and thrust bearings for turbines,
compressors, expanders and gearboxes
Sales and Service team offers maximum
customer support
Value-added engineering capabilities and
aftermarket solutions
Dismounting, balancing and mounting of
IGC impellers
Servicing, repair and refurbishing of gears
and turbo-expanders
Field service 24/7
Discover the powerful advantages of our industry

expertise, service capabilities and personalized
solutions today.
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.
Lufkin RMT is an industr y

leading manufacturer
of precision tilting pad
bearings. Our advanced
designs allow higher
loads and higher speeds
than any other in the
business. RMTs bearings
run cooler, last longer and
perform better than the
competition. We design
and manufacture all types
of journal bearings; such
as tilting pad, fixed pad,
pressure dam, multilobed, and plain journal
bearings.
Tilting pad journal
bearings
Reduced
temperature tilting
pad journal bearings
Sleeve bearings
Reduced
temperature sleeve
bearings
Thrust bearings
W W W. L U F K I N . C O M
Lufkin.indd 1
90
8/15/13 4:26 PM
Compressortech2
n These six Tedom TG 100 DV

NX 86 gas-engine-driven reciprocating compressor packages
were made for a MOL Hungarian
Oil & Gas Plc wellhead compression application. Developed in
cooperation with Ganzair Compressortechnics LLC, each package rating is 120 hp (89 kW) at
1800 rpm.
Claudiu Orban, production control manager, came to EGS

from a management position in a locally based international
energy company. Andras Popp, engineering manager, has
Ellwood.qxp
a masters degree in mechanical engineering and more
than 15 years of experience at a local machine design company. Sorin Apostu, quality control manager, holds a masters degree in quality control management and worked in
the welding industry for 18 years prior to joining EGS. Ioana
Einstruments.indd 1
Tinca, office manager and the first EGS employee, came
from another start-up company, where she gained experience that helped EGS get underway.
The European approach to compressor package design
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.
91
Compressortech2
n One of four 215 hp (160 kW),

1800 rpm Caterpillar G3406NA
and Ariel JGQ/2 single-stage
compressor packages is shown
ready for lifting. The units were
built for Chemomomeftegaz
and include Murphy TTD control panels and ACE coolers.
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
these vessels or work to customerprovided drawings.

Aftermarket parts and service support is another focus of Euro Gas Systems, to ensure customer satisfaction
of delivered products, Wachter said.
We offer a wide range of services including start-up and commissioning,
operation/maintenance programs and
training for the end users. EGS service technicians receive factory training
and certification from the equipment
manufacturers.
The company also offers re-cylindering of existing compressor frames and
can provide new scrubbers, pulsation
vessels, process piping, related controls and new coolers or cooler sections for existing systems as required.
The largest units that EGS has
completed to date are three Waukesha 12V275GL+ gas engine and Ariel JGC/4 reciprocating compressor
packages for a Lukoil gas processing facility in Russia. Rated 3625 hp
(2703 kW) at 1000 rpm, each twostage compressor can deliver up to
19.1 MMscfd (22,500 Nm3/hr) from
87 psig (6 bar) suction to 585 psig (41
bar) discharge pressure. The entire
process gas system, including all vessels, piping and valves, is made from
316 stainless steel due to the high
(12%) H2S content in the gas.
Some of the more complex packages completed to date include two ABB
92
electric motor driven Ariel JGE/2 single/

two-stage compressors produced as
part of a gas gathering application for
Polish EPC contractor, PGNiG Technologie. Each unit has a rating of 420
hp (315 kW) at 1000 rpm to deliver gas
from a suction pressure of 72 to 175
psig (5 to 12 bar) to a discharge pressure of 363 psig (25 bar) in single-stage
mode or a maximum discharge of 914
psig (63 bar) in two-stage mode.
Each package is housed in two
separate enclosures. The compressor
package is inside a noise supressing
enclosure rated for ambient temperatures of -22 to 95F (-30 to 35C). The
enclosure is equipped with normal
and emergency lighting, ventilation
system, fire and anti-explosive environment protection, fire-fighting system, heating system, and alarm devices and protection systems.
All systems are explosion-proof,
meeting Group 2 (Zone 2) G (subgroup 2 A), temperature class T1.
Controls and automation equipment,
including the unit control panel, variable frequency drive, and fire suppression control panel, are housed in
an annex enclosure.
To date, about one-third of EGSs
compressor packages have gone to
applications in the EU and two-thirds
to the CIS. The company said that the
Middle Eastern market is a target for
future expansion. CT2
Compressortech2
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
Both systems are available in

16.4 and 32.8 ft. (5 and 10 m) cable
lengths. In previous systems, the
selection of the driver unit (oscillators/ demodulators) was contingent
on the cable length being used. The
new driver automatically determines
the length of the connected cable and
adapts the measurement accordingly,
the company said.
www.bkvibro.com
Gas Detector
Flowserve Corp. has launched the

Flowserve Limitorque UEX electronic control package for L120 series
actuators. The UEX replaces existing UEC-3 electronic controllers with
a field-retrofitable, MX technologybased package. The UEX can also
be installed into L120 electric actuators that are equipped with integral
control packages.
The UEX is designed to deliver
actuation and network connectivity
through five network protocols for process control. The UEX also incorporates all of the UEC-3 functionality and
features. Additional features include
an LCD display for actuator setup,
status indication in 11 languages, and
position feedback via a battery-free,
absolute encoder. The LCD screen
also provides actuator status and diagnostics, displaying continuous position indication and fault conditions.
www.flowserve.com
Linear Position Sensors

A new gas detector from General
Monitors features a three-second
T90 response time to the presence of
combustible hydrocarbon-based gases, which allows plant operators to respond quickly to gas leaks and avoid
potential accidents, the company said.
The Model IR400 point IR combustible gas detector monitors hydrocarbon-based gases including methane,
propane, ethane, ethylene, butane,
hexane, pentane and benzene. It has
a self-diagnostic design to prevent
false alarms and process shutdowns,
and also monitors conditions such as
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
CECO.indd 1
8/19/13 10:34 AM
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
Visit our website at www.HahnMfg.com

precision boring, milling, drilling, tapping
and grinding on ferrous and non ferrous
material up to 30,000 lbs.
Certified Quality
Management System
ISO 9001:2008
The Energy Flows Through 8/19/13

Us
10:01 AM
THE POWER BEHIND

THE PERFORMANCE
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
Let our skilled craftsmen

get to work for you!
ou need a precision-engineered product that

delivers power, performance and reliability.
With Lufkin as your partner, our highly experienced
and trained teams will provide you solutions
manufactured with the quality, durability, and
precision that is essential for your critical gearing
application.
With a legacy of innovation, Lufkin continues to
bring our energy and power to your demands for
products that provide custom solutions for diverse
industrial applications.
Locations strategically located around the globe to
provide strong aftermarket support.
QUALITY MANAGEMENT SYSTEM
CERTIFIED BY DNV
EXPECT MORE
Expertise in Gear Design
and Engineering
State-of-the-Art Gear
Grinding Equipment
Technical Innovation
Excellence
Industry Leading
Manufacturer of Precision
Tilting Pad Bearings
Field Experts Available
24/7
ISO 9001:2008
W W W. L U F K I N . C O M
95
Lufkin.indd 1
Compressortech2
8/15/13 3:48 PM
Gearing Up For The Big

Valerus center trains recruits
Crew Change > New
for the digitally oriented oilfield
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.
he demand for skilled workers

brought on by the U.S. gas shale
boom comes at a time when millions of baby-boom generation workers
are retiring, giving rise to whats being
called the big crew change.
According to research by the Booz
Allen Hamilton consultancy, nearly
50% of the oil industrys professional
exploration and production staff are
between 40 and 50 years old, while

only around 15% are in their early
20s to mid-30s.
With up to half of the workforce
expected to retire within a decade
and the incoming workforce comprised of tech-savvy Gen X and Gen
Y-ers effective recruitment and
training is essential for companies
like Valerus, which currently has
96
about 100 job openings globally. lt

expects that number to increase as
growth continues with current market demand.
Daniel Cannon, senior vice president of global operations for Valerus,
explained that more is changing
than the crew.
Were moving into the digital oilfield, and our training has to reflect
Compressortech2
that, Cannon said. The incoming

workforce has a different mindset;
they like buttons. They like technology. Theyre savvy.
As a result, he said, training at Valerus is about much more than mechanical fixes. We start with safety
first, then move into the mechanics,
followed by regulatory compliance,
and bring it full circle to the digital
oilfield, the side that hasnt previously been addressed, Cannon said.
In the face of the impending manpower shortage throughout the
industry, the company has implemented a long-term recruiting and
retention strategy that includes the
recent opening of a training center
at Bossier City, Louisiana, that is
specially equipped to train the new
generation of technical workers.
The year-round facility will instruct
Valerus employees from around the
nation, both at the school and at field
locations in northwestern Louisiana.
The facility has a fully functional
shop area that includes simulators
and other tools where service technicians are trained on Valerus product lines, including advanced telemetry systems that monitor equipment
performance and facilitate analysis
in the field.
As an industry, we have yet to
apply digital technology to its maximum effect, Cannon said. At Valerus, with our technology, with the
way we are moving, we need to train
our people to understand what the
digital world brings to us.
Jeff Gill, director of talent management for Valerus, said, Part of
the manpower solution is to build your
own talent pool through focused training programs, and partner with established technical training schools, such
as Universal Technical Institute, to
pre-train candidates.
Gill said Valerus also has partnered closely with equipment vendors and other industry professionals to equip employees with the best
available training aids, in order to offer relevant field-related experience.
Among other training assets at the
facility is a fully operational threestage compressor and a specially
force training programs. The Valerus

installed high-pressure gas line for
Accelerated Development Program
realistic compression training, inenables recruits to become familiar
cluding emissions training and other
with every phase of business at Varelated activities.
lerus through immediate immersion
The goal is to provide recruits
in project management and engiwith the kind of solid, useful informaneering projects, an opportunity that
tion that helps them hit the ground
Valerus said is not always available
running, Gill said.
at larger companies.
He said that the company also is
The change is coming, Gill said.
investing in attraction-and-retention
Were doing what we can to ensure
practices for job candidates, such
Valerus
is the best place to work. CT2
asDilution
mentorship
and
internal 4:45
workAd_Layout
1 8/13/2013
PM Page
1
Problem Solving
Synthetic Lubricants
Lubricant Dilution?
Lubricants used in oil flooded compressors will

tend to absorb the gas being compressed.
This is especially true for hydrocarbon gases with

high BTU content. This absorption results in a
thinning of the oils viscosity and compromises

its ability to properly lubricate bearings. The
effect is known as dilution. To combat this
problem, Summit has developed specialized
equipment that measures a lubricant s change

in viscosity under gas stream and compressor
conditions. Were able to use that information
to predict the dilution effect a gas stream will

have on different lubricant base stocks and
choose a lubricant that will meet your specific

OEM compressor specifications.
Prevent dilution and protect your compressor
Summit
Industrial Products
800.749.5823
www.klsummit.com
97
Summit.indd 1
Compressortech2
8/15/13 9:55 AM
literature
Pressure
Sensors
Condition
Monitoring
Hydraulic
Starters
Ignition Control
& Monitoring
American Sensor Technologies Inc. has released

a new industrial OEM
pressure sensor catalog
featuring various sensor,
transducer and transmitter products. The catalog
offers information regarding product performance
and tools for selecting the
best options.
www.astsensors.com
Windrock provides online

monitoring systems and portable analyzers to diagnostic
services and emissions testing. The companys products are used to analyze,
monitor, trend, alarm and
automatically diagnose the
mechanical condition and
performance of reciprocating engines, compressors
and rotating machinery.
www.windrock.com
Pow-R-Quik has published

a brochure on its hydraulic
starters and its Smart-RValve, which are designed
for the hydraulic fracturing
market. The HS-22 and
HS-36 starters are featured.
The Smart-R-Valve has a
flow rating range of 50 to 80
gpm (189 to 303 L/min).
www.powrquik.com
Motortechs product guide

highlights its range of accessories and spare parts
for ignition control and
monitoring of stationary
gas engines. It has information on more than 1000
products covering ignition,
industrial spark plugs, gas
engine management, wiring
systems, gas regulation and
engine accessories.
www.motortech.de
We Love What We Make.

Compressor Valves. Since 1946.
Cozzani.indd 1
98
Compressortech2
8/7/13 11:10 AM
Introducing the Next Generation of

Oil-Free Centrifugal Compressors
PAP Plus EH Delivers Value, Quality & Performance
Incorporating all the benets of the PAP Plus line of compressors, the EH
model features higher ow ranges, greater horsepower and maximum design
exibility. The unique, horizontally split casing allows for convenient and easy
maintenance. Learn more at fs-elliott.com.
Aerodynamic design of the backward-leaning
impellers optimizes airow and provides highly
efcient air compression.
724.387.3200
fs-elliott.com
FEATURED
PRODUCTS
Compressor Lubricants
Under normal operating conditions,

users can expect up to 11,000 hours
of lubricant service life in rotary screw
compressors. Other features include
thermal and oxidative stability, wide
operating temperature range, antiwear protection, compressor oil compatibility and a high flash point.
www.ultracheminc.com
Turbo Design Software
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
Occidental Chemical Corporation (OxyChem) manufactures

and markets basic chemicals, vinyls and other chemicals
used in water treatment, paper production, pharmaceuticals,
construction, automobile manufacturing, soaps and
disinfection products, among others. For every product it
makes, OxyChems market position is No. 1 or No. 2 in the
United States. OxyChem is committed to safeguarding the
environment and the health and safety of its employees and
surrounding communities.
Maintain protection of the environment and the health and
safety of our employees, customers, and the communities in
which we operate.
Executing approved projects including providing technical
direction and assistance, coordinating with project and
program managers, supervising the work of engineering
consultants and contractors, and participating in inspections
and start-up of equipment.
Completing studies and various requests for engineering
assistance such as providing the mechanical scope of work,
equipment specifications, inspection and testing plans, and
reviewing cost estimates.
Assuring Corporate policies, procedures, and standards and
applicable codes are followed by the incumbent and by
contractors working for them.
Maintaining technical expertise in codes, procedures, selection
and application of equipment, and equipment technology
through individual effort and ongoing training.
Mentoring mechanical engineers to improve core competency
expertise.
Direct involvement in design, testing, operation and
maintenance of major rotating equipment.
Field Fixed Equipment experience required
Knowledge of diagnostics and analysis of equipment
vibration.
Qualifications:
Graduate engineer with 8-15 years of mechanical engineering
experience across a wide range of process equipment,
process vessels, and piping.
Capable of handling multiple assignments up to $10,000,000
value.
Please apply on-line at www.oxy.com/careers

Apply to Job Number 00001128
OxyChem is an Equal Opportunity Employer
Advanced Design Technology announced that TURBOdesign Suite

(version 5.2.1) is available.
This version of the 3-D inverse design software system for turbomachinery products introduces an elliptically
smoothed mesh generation routine in
TURBOdesign CFD for computational
fluid dynamics (CFD) analysis as well
as a new ability to predict stage performance, including volute performance,
which was previously only available
for pumps, the company said. Additional features include volute stage
performance prediction and load distribution section exporting.
www.adtechnology.co.uk
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
OxyChem.indd 1
Metallized Carbon
CT2 Corp. announced
100
8/15/13 9:43 AM
the availability of carbon graphite for

use in piston rings needed to seal
high-pressure gas in applications requiring compressed gases that do not
contain oil or grease.
The piston rings are used in conjunction with carbon-graphite guide
rings or carrier rings, which hold the
piston centered on a cylinder bore, the
company said.
Metcars self-lubricating, carbongraphite piston rings and guide rings
are used extensively in reciprocating
compressors, where oil-free gases,
such as air, steam, refrigerants, hydrogen, hydrocarbons, chlorine, nitrogen
and oxygen can be compressed to
pressures greater than 800 psi (55.2
bar). Wear life up to 10,000 hours is
possible, the company said.
www.metcar.com
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.
foam to further reduce noise levels.

Performance and sound power levels
(PWL) are comparable to the lowest
noise axial fans currently on the market, but at a significantly
reduced cost.
The MAG (Minimum Acoustic Geometry) is an Ultra-Low Noise Fan

designed for new installations as well as retrofit applications. The
MAG is available in diameters 5 through 14 feet in clockwise (RH)
and counterclockwise (LH) rotation. Blade construction is of 5052
high grade marine alloy aluminum and has the same features as the
other Class 10000 Heavy Duty fans including adjustable blade angle
and diameter. Blades are designed with a smooth surface using
robotic spot welds and flush rivets resulting in low boundary layer
separation.
Moore Fans has more than 250,000 fans in operation around

the world. With sales offices in North America and Europe, Moore
factory engineers and customer service
14' Left Hand Fan
representatives stand ready to help you
analyze your air moving requirements,
choose the right product, and provide
reliable service and support before
and after the sale.
As in other proven Moore Fan designs, the blades are resiliently

mounted allowing light weight construction, low inertia, low vibration
and no resonant frequencies. Blades are filled with a high density
For additional information, contact

Moore Fans at 660-376-3575 or visit
us online at moorefans.com.
Moore Fans LLC, oFFiCe & FaCtory

800 South Missouri Avenue | Marceline, Missouri 64658 USA
Phone: 660-376-3575 | Fax: 660-376-2909 | E-mail: info@moorefans.com
Moore Fans LtD, european oFFiCe

44 Cooden Sea Road | Bexhill-on-Sea | East Sussex | TN39 4SL | UK
Tel: +44 1424 845725 | Fax: +44 1424 848780 | E-mail: mail@moorefans.eu.com
IndustrIal aIr MovIng EquIpMEnt
e
n
i
g
En
vveed
i
r
D pro
Ap
PRIME
Movers
continued from page 47

comparable natural gas engines. The Chongqing project is
being supported by a service center set up in Chengdu in
2008 by China Diesel Support Services Ltd., GEs Waukesha gas engines distributor in China.
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.
Dictionary_qurtAd.indd 1
102
8/14/13 1:59 PM
Compressortech2
Compression...
Without Exception
Burton Corblin Process Compressors from Gas and Air Systems

When you specify a compressor to
API 618, you expect the high reliability
achieved by compliance with the Standard.
Gas and Air Systems Burton Corblin
Compressor packages include the
following important features required by
API 618...without exception.
Water-cooled, horizontal cylinders.
Replaceable dry cylinder liners.
Two-compartment, full-stroke
distance pieces.
Buffer-purged packing cases.
Conservative design and ratings.
API 618 demands it... you expect it, and
we provide it...without exception.
Contact Gas and Air Systems for the
process compressor built to your standard.
If you require low-volume and/or high-pressure compression of hazardous gas

with zero leakage and zero contamination, Gas and Air Systems Burton Corblin
Diaphragm Compressors will meet your specification...without exception.
QSR-956
Certified: ISO 9001:2008
Gas and Air Systems, Inc. 1304 Whitaker St. Hellertown, PA 18055
Toll free: 1 (888) 8 GASAIR Ph: (610) 838 9625 Fax: (610) 838 9650 info@gasair.net www.gasair.net
Visit us at Booth #1101 at the 42nd Annual Turbomachinery Symposium

George R. Brown Convention Center, Houston, TX - Sept. 30-Oct. 3, 2013
PRIME
Movers
Rolls Wood Group

Rolls Wood Group, a joint venture
between Rolls-Royce plc and Wood
Group, has completed its 100th upgrade of a Rolls-Royce Avon 200 industrial gas turbine. It will be sent to an
offshore production platform in Asia.
The Avon industrial gas turbine delivers up to 22,000 hp (15 MW) of power operating in a wide range of power
generation and oil and gas applications. More than 1200 units have been
sold and operating experience exceeds
64 million hours.
With a redesigned turbine introduced in 2007, the upgraded Avon
200 delivers up to 22,800 hp (17
MW), improved thermal efficiency
and emissions improvements.
become the exclusive developer and

supplier of diamond-coated hard faces
for its mechanical seals.
When applied to Flowserve base
materials, the ultrananocrystallinestructured diamond coating developed
by ADT produces an exceptionally hard
surface with improved friction and wear
characteristics, the company said. This
is particularly beneficial in services
requiring protection from slurry, dry
running conditions and resistance to
chemical corrosion.
ADT specializes in developing and
applying diamond films for electronic,
mechanical, industrial and biomedical
applications and offers several families
of high-performance products that exploit the characteristics of diamonds.
Flowserve
Sulzer Pumps
Flowserve Corp. has signed a collaborative agreement with Advanced

Diamond Technologies Inc. (ADT) to
Sulzer Pumps and Sinopec Corp.

have established a partnership to serve
the hydrocarbon processing industry.
Sinopec Corp. is one of the largest

integrated energy and chemical companies in China with upstream, midstream and downstream oil and gas
operations. Through this partnership,
Sulzer Pumps will support Sinopecs
international operations and export
business through supply and technical excellence. For service support
and spare parts, Sinopec will be supported by Sulzer Pumps global service network.
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
because grouting aint easy!
SM
WHY CHOCKFAST RED
MIXES EASILY
HIGH LEVEL OF
PLACEMENT CONTROL
EXCELLENT FLOWABILITY
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More options are a precursor

to better solutions.
We provide a wide selection of machinery

grouting products engineered to provide
the optimal performance and reliability for
use under critically aligned equipment.
www.chockfastgrout.com
W
NE
Chockfast Red HF hi-flow, pumpable epoxy can reduce your overall installation
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2013
PR-3118 CF_Red_CT2_SepHalfPg.indd
AUGUST-SEPTEMBER
2013
Chockfast.indd 1
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8/19/13 12:59 PM2

Compressortech
8/20/13 8:54 AM
PRIME
Movers
automation, compressor anti-surge protection, and plant and safety controls,

according to the company.
Dresser-Rand said the open control
platform can be easily maintained and
upgraded if necessary and improves
process visibility and safety.
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-
FLP_april.indd 1
ing temperature and pressure build

up, and a monthly option for the discharge period.
maintains mandated records, provides

emissions-testing services and helps
customers obtain and update air quality permits.
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
snapshot
GE Gets Contract For Snhvit Injection

Dawn breaks at Statoils Melkya Snhvit facility in northern Norway.
Statoil has awarded GE Oil & Gas a US$147 million contract to supply
subsea equipment for Snhvit field. An onshore facility will remove CO2
from Snhvit natural gas and a pipeline will return it to the offshore field for
reinjection. GE will deliver the equipment in mid-2015.
Photo by Statoil
The leaders in compression and power generation have come together to

better serve the industry and bring a new standard in quality and stability.
Introducing the new
Power & Compression
REAGAN EQUIPMENT CO., INC.
AMERICAN WARRIOR, INC.
KILO-PAK
A leading provider for parts, service,

mechanical drivers and leased
compression to include parts and
repair of integral and separable
compression, engines, pumps
and turbines in the oil and gas,
petrochemical, refining and gas
transmission industries reaching
across the U.S. and abroad from
several locations.
One of the leaders in gas compression

and the leader in CO2 compression,
American Warrior has built a reputation
as one of the leading packagers in the
United States. Using conservatively
rated industry recognized components;
the design of each unit is engineered
for durability and ease of service. The
American Warrior brand is well known
for either repackaging your existing unit
or building new to
your specifications
to include creating
the specifications
for you if desired.
While originally designed

specific to the marine industry,
Kilo-Pak has grown throughout the
years to become the Reagan brand
of engineered custom generator
packages. Whether a standard
package or a high spec custom
is required the Kilo-Pak name
means quality.
Power & Compression
Our core name has changed, but our philosophy remains the same and weve been building on this tradition since 1946.
Reagan Power & Compression
11 locations across Louisiana, Mississippi, Colorado, Texas, Kentucky and Florida.
www.reaganpower.com Parts, Service & Leased Compression 800.264.7767 Manufacturing 800.235.9142
2
3
4
6
Scheduled Downtime
DJ Slater, Puzzlemaster
Visit www.compressortech2.com for answers
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
Focus
Formations
Freight
Frontier
Global
Glut
Government
Impact
Landscape
Location
Market
Mexico
Packagers
Paraguay
Peru
Politics
Presence
Prices
Production
Recovery
Regulations
Resources
Shale Gas
Shift
Shipping
South America
Stake
Unpredictable
Uruguay
Venezuela
Venture
Marketplace
ARLA
Engineering Service
Custom
Reprints
From
to Simulate Vibrations in Drive Systems

torsional and lateral vibration analysis
rotordynamics & bearing analysis (fluid-film)
considering complete drivelines with motors,
engines, compressors, gears, couplings
steady-state and time-transient simulation
simulation software (ARMD 5.8)
Compressortech2
Intl Seminar ROTOR DYNAMICS & BEARINGS

Cologne, Germany: October 28-31, 2013
U.S.
Energy Corp 1k x 1"
ARLA Maschinentechnik GmbH,
3/11/03
11:06
GERMANY
Internet: www.arla-online.com
Perfect For Brochures,

Web Attachments
EXPLOSION PROOF
Arla_2013.indd 1
7/12/13 10:21 AM
AC&DC ENGINE STARTING SYSTEMS
STARTER MOTORS ALTERNATORS
SWITCHES CLASS I, DIV. 1&2, GROUP D
& Bragging Rights
( just in case they missed it)
UNITED STATES ENERGY CORPORATION

1600 MISSILE WAY, ANAHEIM, CA 92801
(714) 871-8185 (714) 871-9229 FAX

WWW.USENERGYCORPORATION.COM
Contact Mary Graesing for

pricing and details
Phone: 262-754-4100
E-mail: mgraesing@dieselpub.com
CT_ReprintAd_BWQuarterPg.indd
HHP_DGT code.indd 1
11/20/12
109
Contact
syildiz@dieselpub.com
for
Marketplace Rates
1:07 PM
Compressortech2
8/14/13 4:06 PM
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
E Instruments International ........................................ 91

www.E-Inst.com
Lufkin Industries, Inc. ............................................ 90, 95

www.lufkin.com
Altronic, LLC .....................................................63, 74-75

www.altronic-llc.com
*Elliott Group .............................................Second Cover

www.elliott-turbo.com
*MAN Diesel & Turbo ....................................................... 5

www.mandieselturbo.com
*ARIEL .............................................................................. 1
www.arielcorp.com
Ellwood Crankshaft Group ......................................... 91

www.ellwoodcrankshaftgroup.com
MIRATECH .................................................................... 11
www.miratechcorp.com
AXH air-coolers ............................................................ 61

www.axh.com
*Flender-Graffenstaden S.A.S. ..................................... 79

www.flender-graff.com
Moore Fans LLC ......................................................... 101

www.moorefans.com
BETA Machinery Analysis .......................................... 69

www.BetaMachinery.com
FLP, Fluid Line Products .......................................... 105

www.fluidline.com
BG Service Co. Inc, The .............................................. 89

www.bgservice.com
FS Elliott Co., LLC .................................................... 99

www.fs-elliott.com
*BORSIG ZM Compression GmbH ............................... 27

www.borsig.de/zm
Gas & Air Systems Inc. ............................................. 103

www.gasair.net
*Burckhardt Compression AG ...................................... 17

www.burckhardtcompression.com
*GE Oil & Gas .................................................Third Cover

www.geoilandgas.com
Cameron ..................................................................56-57
www.c-a-m.com
Governors America Corp. ........................................... 78

www.governors-america.com
Catalytic Combustion Corporation ............................ 67

www.catalyticcombustion.com
GUARDIAN Engine + Compressor Control ............... 81

www.guardiancontrol.com
CECO, Compressor Engineering Corp. ..................... 94

www.tryceco.com
Hahn Manufacturing Company ................................... 95

www.Hahnmfg.com
CENTA Corporation ..................................................... 51

www.centa.info
Harsco Industrial Air-X-Changers .............................. 29

www.harscoaxc.com
Compressor Elements ................................................. 53

www.compressorelements.com
*Heinzmann GmbH & Co. KG ..................................58-59

www.heinzmann.com
*Compressor Products International ........................... 13

www.c-p-i.com
High Horsepower Summit 2013 ................................ 109

www.hhpsummit.com
Continuous Control Solutions .................................... 19

www.ccsia.com
The Hilliard Corporation .............................................. 65

www.hilliardcorp.com
Cook Compression ...................................................... 25

www.cookcompression.com
*HOERBIGER Kompressortechnik Holding GmbH ....36-37

www.hoerbiger.com
*Cozzani, Dott.Ing.Mario Cozzani S.r.l. ........................ 98

www.cozzani.com
ITW Chockfast ............................................................ 104

www.chockfastgrout.com
C.S.T. Compression Service Technology srl ......... 83

www.cstfirenze.com
*KB Delta Compressor Valve Parts Mfg. ..................... 31

www.kbdelta.com
*Testo, Inc. ..................................................................... 47

www.testo350.com
DCL International Inc. .................................................... 7

www.dcl-inc.com
Kiene Diesel Accessories, Inc. ................................... 90

www.kienediesel.com
*Voith Turbo BHS Getriebe GmbH ............................... 55

www.voith.com
*Dresser-Rand ................................................................ 49
www.dresser-rand.com
Kobelco/Kobe Steel Ltd. ............................................. 71

www.kobelcocompressors.com
*Voith Turbo Inc. ............................................................ 10

www.usa.voithturbo.com
ECOM America ............................................................. 87

www.ecomusa.com
L.A. Turbine .................................................................. 73

www.laturbine.com
Waukesha Bearings ..................................................... 41

www.waukeshabearings.com/CT
COMPRESSOR
MOTORTECH GmbH .................................................... 15

www.motortechamericas.com
Murphy, FW .................................43, 45 & Fourth Cover
www.fwmurphy.com
Nidec ASI S.p.A ............................................................ 33
www.nidec-asi.com
Neuman & Esser Group .............................................. 21
www.neuman-esser.com
Occidental Chemical Corporation ............................ 100
www.oxychem.com
PROGNOST Systems GmbH ....................................... 35
www.prognost.com
PROTO Industrial Tools .............................................. 93
www.protoindustrial.com
Reagan Power & Compression ................................ 107
www.reaganpower.com
Reynolds French .......................................................... 39
www.r-f.com
*Rolls-Royce .................................................................... 9
www.rolls-royce.com
*Samsung Techwin Co., Ltd. ........................................ 85
www.samsungcorp.com
*Siemens AG Oil & Gas ................................................. 77
www.siemens.com/oilandgas
Summit Industrial Products ........................................ 97
www.klsummit.com
*Tech Transfer, Inc. ......................................................2-3
www.techtran-hou.com
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2013
Cornerstones Of Compression story continued from page 112
n Adam W. Frances 1899 patent document for

the design of his tangent-cut packing ring.
When he took his experimental, home-made, cast-iron

packing to work and installed it on one of the engines he
operated, Frances fellow engineers were so impressed that
they immediately requested him to make packing for the
other engines in the plant.
What started as moonlighting to fill orders for more packing soon became a full-time job, so France opened a shop
in Philadelphia. He targeted orders from large metropolitan
electric power plants as well as the U.S. Navy. Thriving beyond expectations, A.W. France Metallic Packing became
the supplier of choice, not only to the Navy but also to the
U.S. Merchant Marine.
To protect his invention, France patented his tangent-cut
packing ring design in 1899. This full-floating, metallic-type
packing allowed the sealing elements to move freely within
the assembly as opposed to non-floating packings in which
the sealing elements were held rigidly in the stuffing box
and required outside adjustment to compensate for wear
or misalignment.
The full-floating metallic packing eliminated friction-producing materials such as hemp, duck, rubber, metal foil,
metal shreds and innumerable combinations of these substances previously used as packing materials.
Further, the antifriction metal sealing rings withstood high
temperatures and pressures. And they provided an effective seal on piston rods that moved laterally as they stroked
through the packing due to wear of the cross head or cylAUGUST-SEPTEMBER 2013
inder, unequal expansion of the parts, misalignment or innumerable other causes.

Similar packing developments are thought to have been
made by O.J. Garlock. Charles Lee Cook also introduced
several patents that improved piston rod packing. Both went
on to develop their own successful packing and sealing
companies.
Although business was booming and profitable, Warren
France felt that the growing use of marine turbines threatened his company enough that he looked to other applications for his packing. Renting an ice and cold storage plant
in Atlantic City, New Jersey, he experimented with a metallic
packing on the plants ammonia compressor.
His success with the ammonia compressor packing effectively quelled his fear of the turbine, and proved that packing
for air, ammonia and gas compressors would compensate
for any lost ground from his steam turbine business.
Warrens son, Edwin, grew up in the business. He joined
the company full-time in 1922 after completing his education in mechanical engineering. Unfortunately there was a
falling out between father and son.
Edwin established his own business General Packing
Co. and his first original equipment customer was Pennsylvania Pump and Compressor Co. In 1930, Edwins company
incorporated as Adelphia Bronze and Aluminum Foundry.
Warren France died in 1933, and ownership of his company devolved to his second wife. Edwin, trying to survive
during the throes of the Great Depression, decided to reclaim the family name for his packing business, reincorporating as France Manufacturing Co. in 1933.
In 1934, France developed the first non-lubricated packing made of carbon, soon to be followed by a packing of
Bakelite, which could withstand corrosion, and ultimately of
carbon Bakelite. This material paved the way for the development of the other non-metallic packings that are prevalent today.
Before the Second World War, high-pressure gas compressors were being developed in the U.S. and a packing was needed for the demanding new applications. This
led to alloy steel packing cases and lead-bronze for the
packing rings.
In 1949 Edwin purchased the original France Packing Co.
from his stepmother and merged the companies. Before
his death in 1965, Edwin sold his successful company to
Garlock Packing Co., which later became part of Enpro Industries. The France company name continued until 2008,
when Enpro acquired Compressor Products International
(CPI) and chose the CPI name for the combined packing
businesses. CPI continues to serve the worldwide reciprocating compressor market with compressor piston rod
packing and other compressor components.
The France tangent-cut packing ring design eliminated a
variety of piston rod sealing problems and paved the way
for the development of higher-pressure compressors. Modern compressor packing rings are offered in a range of advanced materials but the original France design remains an
industry standard. CT2
111
Compressortech2
C ornerstones Of Compression
Clearance Hole
In Radial Ring
The tangent ring will make a

complete seal, except at the gaps,
which permit compensation for
wear. These are covered by the
segments of the radial ring.
A dowel pin in the tangent ring prevents points

of radial and tangents
from aligning.
A seal is made between
the tangent ring and
packing case.
Gas Tight Joint

Three radial cuts in the radial ring
permit compensation for wear.
n The tangent-cut packing ring (left), paired with a radial-cut ring,

comprises the basic sealing element of most piston rod packing used
in reciprocating compressors.
The Evolution Of Piston Rod

Frances tangent-cut seals enabled
Packing > A.W.
higher-pressure compression
By Norm Shade
A.
W. Frances tangent-cut packing inventions in the

1880s and 1890s made the development of highpressure compressors possible.
The sealing of the piston rod on the first steam engines
was accomplished by cutting washers from ham rind to fit
the piston rod and placing them around the rod where it
entered the cylinder in the recess known as the stuffing box.
Pressure was then applied to the ham rind washers through
a bolted flange and follower, the follower having a tapered
face that caused the washers to press on the rod and make
the seal. The natural grease in the pigskin provided lubrication and the packing did a fair job but required a maximum
amount of maintenance and constant adjustment.
As steam temperatures and pressures increased to keep
up with the requirements for more power, greater demands
were put on the packing. Seeking a more satisfactory material, operators tried all manner of fabric packing, lubricated for the most part with flake graphite and oil. These
operated with varying degrees of success but were rapidly

losing ground because of the demands put on them by the
sealing requirements.
Following the ham hock and fabric era, early forms
of metallic packing appeared. In general, these were
wedge-shaped pieces of some type of soft metal arranged so that pressure from the bolted flange caused
them to press on the piston rod. There were many variations of this design investigated during this period but,
like their predecessors, they required continual maintenance, consumed engine power and rapidly scored the
piston rods.
Adam Warren France worked at an electric power plant
in suburban Philadelphia, Pennsylvania, where he was an
operating steam engineer. Frustration with the soft packing
of an electric generator engines piston rods drove France
to his basement in the early 1880s to seek an improvement.
112
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