2014 Mechanical Drive

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CT2 June Cover.indd 1 5/20/14 4:20 PM

 This Issue Driven By
Click on company logo to see ad page

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n Challenge:
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Untitled-2 1 3/24/14 12:42 PM

TechTransfer_CT2.indd 1 2/22/12 9:11 AM
TechTransfer_CT2.indd 2 2/22/12 9:11 AM
 Page
President & CEO ..................... Michael J. Osenga
Executive Vice President .... Michael J. Brezonick

COMPRESSOR
A Member of the Diesel & Gas Turbine Publications Group
4
PUBLICATION STAFF
CT2 Founder ........................... Joseph M. Kane
Publisher ..................................... Brent 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 Joe Kane
Associate Editor .............................Chad Elmore
Copy Editor ................................ Jerry Karpowicz
Compressortech2
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Founder
Advertising Manager .................... Sarah Yildiz

This Coin Has Two Sides!

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CONTRIBUTING EDITORS
Norm Shade - Cambridge, Ohio from Pat Sucher, Area Manager, En- there by any breeze of doctrine, looks
Mauro Belo Schneider - Rio Grande du Sul, Brazil
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We can rely on it. It gives a certain
Gabriele Dinsel, Advertising Manager sense of freedom. A lie, on the other sis of someone elses truths. This is a
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Telephone: +49 711 3416 74 0 Fax: +49 711 3416 74 74 accommodate any question, light or entails. Freedom is not the absence of
UNITED KINGDOM OFFICE probing. It eventually unravels. The pro- restraint on our behavior, but the capac-
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Linda Cameron, Advertising Manager pensity that we struggle under presently ity to become a true authentic person
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DE6 1LH, United Kingdom the point where we can get away with it. mean doing whatever we want, but do-
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Roberta Prandi challenge to living the good life of free- as wanted. But, we know the person will
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I-38062 Arco, Italy
Telephone: +39 0464 014421 Fax: +39 0464 244529 torship of relativism. One definition of tion are broken. We all come under this
SCANDINAVIAN OFFICE this term is the way in which we deny rule. True freedom does not mean free-
Bo Svensson, Field Editor/Business Manager objective truth truth independent of dom to exploit the poor, to hate ones
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Telephone: +46 70 2405369 Fax: +46 122 14787 and for everyone to the extent that it Truth and Freedom are not opposed,
JAPANESE OFFICE has become conventional wisdom. but independent. Truth is the doorway
Akiyoshi Ojima, Branch Manager
51-16-301 Honmoku Sannotani, Naka-ku Note the many winds of doctrine, ide- through which we must walk in order to
Yokohama, 231-0824 Japan ological currents, modes of thought that be free in the fullest sense of the word.
Telephone: +81 45 624 3502 Fax: +81 45 624 3503
we have observed over the past de- We know it is not ourselves possessing
CHINESE OFFICE
S.H. Mok, Branch Manager cades. They have tossed us from one truth but, as it should be, it is truth that
Rm 1903A, 19/F, Sunbeam Commercial Building extreme to another; to list a few, from embraces and possesses us.
469-471 Nathan Road
Kowloon, Hong Kong Marxism to liberalism, from collectivism May the Lord hold you in the hollow
Telephone: +852 31187930 Fax : +852 23321565
to radical individualism, from atheism of His hand. CT2

CT405.indd 1 5/20/14 9:53 AM

 caring for your reciprocating compressors
critical components lubrication systems

field services reconditioning services

visit us at the
Global Petroleum
Show
evolving solutions around your world
booth # 1004
www.c-p-i.com

CPI.indd 1 5/13/14 10:54 AM

CPi-CT2 ad-june'14.indd 1 12/05/2014 14:56
 June 2014

COMPRESSOR
Dedicated To Gas Compression Products & Applications

Cover Designed By
Alyssa Loope
Compressortech2 (ISSN 1085-2468)
Volume 19, No. 5 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 53186-
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Follow Us @ Compressortech2
MEMBER OF
Featured Articles
16 New Owner Adds Silencer Assets to Miratech
26 Siemens Buying Rolls-Royce Energy Business
30 Ro-Flo Compressors Brings Testing In-House
34 2014 Mechanical Drive Order Survey Shale Sets The Tone
48 Natural Gas Contaminants In Compressor Feeds
58 13 Million HP Of Compression Needed By 2035
64 The Electric LNG Option For The U.S.
66 U.S. NatGas Inventories At 11-Year Low
72 PAN Technology Ready For Field Test
TECHcorner
18 Reciprocating Compressor Suction And Discharge-Valve Monitoring
68 Avoiding Common Torsional Failures Of Rotating Induction Motor Components
PUMPtech
24 Pushing The Boundaries Of Centrifugal Pumps
44 Sundyne Expands GSP Pump Range
Departments
4 Page 4 This Coin Has Two Sides!
8 Global Perspective LNG Used As Fuel On Inland Waterways
10 Meetings & Events
12 About The Business Watch For Bumps In The Road
14 Monitoring Government New England Has Old Idea For New Pipelines
67 Recent Orders
75 Featured Products
76 Prime Movers
78 Snapshot Eastern Gas Compression Roundtable Convenes
80 Scheduled Downtime
81 Marketplace
82 Advertisers Index
84 Cornerstones of Compression Ingersoll Rand Supplements Integral Engine
Compressor Series

MEMBER OF BPA WORLDWIDE

PRINTED IN THE U.S.A.

CT_JuneTOC.indd 1 5/22/14 8:32 AM

 WHEN CATALYST ELEMENT
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 Global Perspective
LNG Used As Fuel On Inland
By Roberto Chellini
Associate Publisher Waterways > May lead to new bunkering
infrastructure
P
ollution reduction from vessels navigating internal
waterways such as rivers, canals or even seas inside
highly populated areas such as the North Sea or the
Baltic Sea would give a push towards a cleaner environment.
Five European ports signed an agreement on April 25
that could boost the use of liquefied natural gas (LNG) as a
shipping fuel. Signees include the ports of Rotterdam, Neth-
erlands; Antwerp, Belgium; Mannheim, Germany; Stras-
bourg, France; and Basel, Switzerland. According to the
agreement, the ports will cooperate in research, promo-
tion, knowledge transfer, legislation and bunker infrastruc-
ture for LNG. It is an extension of a LNG master plan put
forward by the Rhine-Main-Danube corridor that targets the
use of LNG as marine fuel along this inland shipping route.
The agreement is also significant in view of the Emissions
Control Area (ECA) that will take effect Jan. 1, 2015 in the
Baltic Sea, the North Sea and the English Channel. The ECA
obliges ships entering the area to have no more than 0.1% of
sulfur content in the marine fuel used. Meanwhile, the sulfur
content limit in the marine fuel used by other ships in Euro-
pean Union (EU) waters is to be no more than 0.5% by 2020.
This regulation will force shippers to switch shipping fuel,
or retrofit ships with scrubber technology, to continue the use
intermediate bunker fuel oil (IFO). Certain European-based
shippers such as DFDS have invested in scrubbers, estimated
to cost about 4 to 7 million (US$5.5 to 9.7 million) per vessel.
Moreover, there are other costs associated with scrub-
bing technology:
H  igher fuel consumption A ship could require 1 to 2%
more fuel due to energy losses from the process.
N  eed for chemicals Additional costs will be spent for
chemicals required in the scrubbing process.
Uncertainty There are considerable doubts about reli-
ability given that scrubbers are relatively new to the market.
As such, many firms have said that they will switch to
marine gasoil (MGO) from IFO grades to meet the require-
ments of the ECA in the short-term without having to make
expensive investments.
According to Business Monitor International (BMI) LNG
JUNE 2014 8 Compressortech2
Ct390.indd 1
could provide the long-term solution to the high costs shippers
are poised to face with stricter emission standards. In terms of
cost per million British Thermal Units at current prices, LNG
is a much cheaper option to both IFO and MGO. BMI expects
LNG prices to broadly remain at the US$10/MMBtu level
through much of their forecast period, while IFO and gasoil
prices will remain higher despite trending downwards.
Furthermore, the faster-than-expected outflows of LNG
supplies from the United States could pose considerable
downside risk to this forecast. Many firms have expressed
that they will switch to marine gasoil (MGO) from IFO
grades to meet the requirements of the ECA in the short-
term without having to make expensive investments.
There are still considerable technical and market barriers
before LNG can properly become a viable alternative at cur-
rent technology levels.
The energy density of LNG lacks that of oil-based fuel.
Therefore, a larger cryogenic LNG tank is required to
ship the same distance.
LNG bunkering could be more cost-effective for newer
ships, than to retrofit existing ships to enable the use of
LNG as a fuel.
Certain ports in Europe have just started developing in-
frastructure to facilitate LNG bunkering and it will take
some time to complete them.
Unlike oil, LNG lacks a wide marketing and retail base.
These are issues that will most likely only be addressed
by the end of the decade. However, the cooperation of the
five European ports in developing LNG bunker infrastruc-
ture is a positive start. Having the support of these five ma-
jor European ports provides the market incentive for LNG
retailers to widen their operations to consider more types of
end-users in their retail models.
On the buyer side, key collaborations between shippers,
LNG producers and commodity traders have been estab-
lished. For instance, DNV, Royal Dutch Shell, Cargill and
Xynteo are jointly looking into the prospects of LNG as a
marine fuel, while Maersk had been in talks with Gazprom
for possible supplies. CT2
5/22/14 8:33 AM
 rolls-royce.com

Its all in the name.

Cooper-Bessemer is a registered trade name of Cameron Corporation, used under license by Rolls-Royce plc

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has earned Rolls-Royce an unparalleled reputation for quality.
Today, in a business where productivity and dependability
mean so much, the unsurpassed engineering experience
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RollsRoyce.indd 1 10/11/13 1:55 PM

 Meetings & Events
Altronic.indd 1 4/18/13 1:00 PM

*Indicates shows and c

onferences in which Compressortech2 is participating

JUNE Tel: +1 (307) 234-1868 Tel: +1 (405) 325-3891

June 10-12 Web: www.energyexposition.com Web: www.ou.edu/content/outreach/
*Global Petroleum Show engr/gascompressor_home.html
Calgary, Alberta, Canada JULY
July 28-30 Sept. 15-18
Tel: +1 (403) 209-3555
Southern Gas Association Operating *Rio Oil & Gas Rio de Janeiro
Web: globalpetroleumshow.com
Conference New Orleans Tel: +55 21 2112 9078
Tel: +1 (972) 620-8505 Web: www.ibp.org.br
June 16-20 Web: www.southerngas.org
*ASME Turbo Expo
Sept. 17-19
Dusseldorf, Germany SEPTEMBER
Wyoming Natural Gas Fair
Tel: +1 (404) 847-0072 Sept. 10-12
Jackson, Wyoming
Web: *Power-Gen Asia
Tel: +1 (307) 234-7147
www.asmeconferences.org/TE2014 Kuala Lumpur, Malaysia
Web: www.wyogasfair.org
Tel: +44 1992 656 634
June 24-26 Web: www.powergenasia.com
Sept. 22-25
Sensors Expo & Conference *Turbomachinery Symposium
Sept. 11-12
Rosemont, Illinois Houston
*European Forum for Reciprocating
Tel: +1 (617) 219-8375 Tel: +1 (979) 845-7417
Compressors Vienna
Web: Web: www.recip.org/369.0.html Web: http://turbolab.tamu.edu
www.sensorsmag.com/sensors-expo
Sept. 16-18 Sept. 22-25
June 25-26 *Gas Compressor Conference *International Pump Users
Energy Exposition Billings, Montana Norman, Oklahoma Symposium Houston
For a complete listing of upcoming events, please visit our website at www.compressortech2.com

JUNE 2014 10 Compressortech2

CT_meetingsevents.indd 1 5/21/14 8:25 Am

 Its not magicits physics.
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application. They provide the combustion assurance you need without the cost and
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Altronic.indd 2 4/18/13 1:00 PM

*Indicates shows and conferences in which Compressortech2 is participating

Tel: +1 (979) 845-2924 Tel: +1 (888) 993-0302 Abu Dhabi, United Arab Emirates
Web: http://pumpturbo.tamu.edu Website: www.hhpsummit.com Tel: +44 207 384 7983
Web: www.wraconferences.com
Sept. 23-26 Oct. 22-24
*InnoTrans Berlin EP China Beijing DECEMBER
Tel: + 852 2811 8897
Tel: +49 30 30 38 2376 Dec. 4-6
Web: www.epchinashow.com
Web: www.innotrans.de Shanghai International Petroleum
NOVEMBER Petrochemical Natural Gas Technology
OCTOBER Nov. 9-11 Equipment Exhibition Shanghai
Oct. 5-8 China (Beijing) International Petroleum Tel: +86 21 6592 9965
*Gas Machinery Conference Technology Conference & Exhibition Web: www.sippe.org.cn/en
Nashville, Tennessee Beijing
Tel: +1 (972) 620-4026 Tel: +86 10 6273 0706 Dec. 4-7
Web: www.gmrc.org Web: www.ciptc-top.com Basra Oil & Gas Conference and
Exhibition Basra, Iraq
Nov. 10-13
Oct. 6-10 Tel: + 90 21 23 56 0056
*Abu Dhabi International Petroleum
International Rotor Dynamics Seminar Web: www.basraoilgas.com
Exhibition and Conference
Cologne, Germany
Abu Dhabi
Tel: +49 2267 6585 0 Tel: +971 2 4444 909 Dec. 9-11
Website: www.arla-online.com Web: www.adipec.com *PowerGen International
Orlando, Florida
Oct. 7-9 Nov. 24-25 Tel: +1 (918) 831-9160
*HHP Summit New Orleans Plant Maintenance in the Middle East Web: www.power-gen.com
For a complete listing of upcoming events, please visit our website at www.compressortech2.com

JUNE 2014 11 Compressortech2

CT_meetingsevents.indd 2 5/20/14 10:09 Am

 About The Business
Watch For Bumps In
By Norm shade The Road > Compression sector still riding
the crest of a boom
B
y almost any measure, the compression industry
is roaring along, driven by the U.S. shale bonanza.
Proven oil reserves are at a 36-year high and gas
reserves are the highest ever. The U.S. is forecast to be a
net exporter of natural gas within two years.
Mergers and acquisitions are ramping up as some of
the largest international compression machinery compa-
nies pursue larger market shares. GE Oil & Gas purchased
Camerons reciprocating compressor business and now
Siemens is acquiring Rolls-Royces compression and pow-
er generation business.
Rental fleet and packaging capacity are growing steadily,
too. Lead times for small engines and compressors for gas
lift applications are stretching out past nine months. Pack-
agers, fleets and even end users are placing stock orders to
ensure that they have equipment for their production needs.
Its beginning to feel like early 2008 all over again, when
many thought the boom would never end.
Even the White House admitted last month that natural
gas is helping the economy, conceding that it is a neces-
sary bridge until clean energy takes over. It had better be
a long bridge, as the Energy Information Administration re-
ported that wind and solar accounted for only 1.5% of the
nations energy needs in 2012.
When business races along like this, some of us sea-
soned veterans who have experienced the industrys cycles
get a bit nervous. We begin to look around at what could
derail the current oil and gas renaissance and we find many
things that bear watching. First, the Obama administration
recently announced that it is targeting methane emissions
from oil and gas (and landfills and cows), promising new
regulations by the end of this year. Along with expected low-
er EPA National Ambient Air Quality Standards for ozone,
this could seriously limit oil and gas development.
Besides the potential for tighter emissions regulations, envi-
ronmental activists are playing on residents fears to seek local
bans on oil and gas development. For example, in May, voters
Norm Shade is senior consultant and president emeritus of ACI
Services Inc. of Cambridge, Ohio. A 44-year veteran of the gas
compression industry, he has written numerous papers and is
active in the major industry associations.
June 2014 12 Compressortech2
CT396.indd 1
rejected a fracking ban in Youngstown, Ohio for the third
time in a year. The last margin of defeat was only 8%, coming
just a month after Ohio geologists found a probable connec-
tion between hydraulic fracturing and a series of minor earth-
quakes in the state, prompting the state Department of Natural
Resources to restrict fracking near the center of the tremors.
In March, residents in Johnson County, Illinois, voted
against a measure to prohibit hydraulic fracturing. In Colo-
rado, a state with a long history of energy development, en-
vironmentalists success is more alarming. Last November,
voters in four Colorado municipalities, including Boulder
and Fort Collins, passed moratoriums or bans on hydrau-
lic fracturing. Now, in-state and out-of-state environmental
groups are pushing to get a state-wide fracking ban on the
November ballot.
Environmentalists have been persistent in their efforts,
working with a group of congressmen, to urge the Environ-
mental Protection Agency to reopen investigations as to
whether there was a connection between hydraulic fractur-
ing and incidents of water contamination in Pennsylvania,
Wyoming and Texas.
Even if environmental and regulatory threats are mini-
mized, shortages of experienced engineers and skilled
workers are slowing projects and driving up labor costs.
And a recent New York Times story warned that the cel-
ebration of North Americas rising energy production might
be premature. It said that oil and gas that can be cheaply
extracted are gone and the U.S. reserves that remain are
much more expensive to develop. Lower-priced oil from Iraq
and Iran could depress prices enough to undercut the eco-
nomic underpinning for U.S. oil.
Oil and gas companies are facing pressure from their
shareholders for better returns on investments. Some
companies, including ExxonMobil, Chevron and Shell, are
scaling back spending and abandoning plans to explore po-
tentially lucrative shale formations. Others, such as Chesa-
peake, had to sell many assets in order to continue funding
drilling when gas prices faded early last year.
Whatever the causes, this industry will continue to
experience cycles. Driving down this winding highway
requires our full attention, watching for the inevitable
bumps in the road. CT2
5/22/14 8:37 AM
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Man.indd 1 5/5/14 9:36 AM

 New England Has
Old Idea For New
Monitoring Pipelines > Tax could finance Marcellus
gas debottlenecking
Government
H
eres the problem: New England is a huge market
for natural gas in the winter but pipeline capacity
coming from the booming Marcellus Shale region is
constrained and misconfigured. Compounding the problem
is that electric power companies want increasing volumes
of gas, stretching pipelines to capacity.
Although more pipelines obviously are needed in the
ground, and more compressor stations are needed to push
the gas, theres no simple way to pay for them. Power-plant
operators operate under regulated rate structures that re-
strict how much they can pass through to consumers. No
one wants to incur expenses for peak-shaving investments
that may not be needed. Similarly, pipelines arent built on
speculation either.
Heres the solution, according to the New England States
Committee on Electricity (NESCO): Let the states levy a
special tariff on electricity, which would be passed on to
consumers, to raise up to US$2 billion for about 1 Bcfd
(28.3 x 106 m3/d) of additional pipeline capacity.
The governors of the New England states (Connecticut,
Rhode Island, Massachusetts, Vermont, New Hampshire
and Maine) created NESCO to find solutions for regional
energy problems. Its unclear how the Federal Energy Reg-
ulatory Commission (FERC), which oversees all interstate
gas and electricity transmission, would view the tax.
It is clear that New Englands winter gas crunch appears
to be worsening. In 2000, only 15% of the electricity used in
the region came from natural gas. That has grown to nearly
50% as coal and fuel-oil burning plants have been retired
for environmental reasons.
Probably the only thing that avoided rolling blackouts last
winter was that ISO-New England, which coordinates the
bulk electricity generation and transmission system, creat-
ed a Winter Reliability Program that paid oil and dual-fuel
power generators US$80 million to stockpile more fuel oil
than they otherwise would have. The program created a 3
MMbbl reserve, 90% of which was ultimately used.
While those oil-burning plants were going full blast, the
natural gas-fueled plants averaged about a third of their
nameplate capacities because supplies were unavailable
or prohibitively expensive.
IntercontinentalExchange Group Inc. reported that New
England gas prices spiked above US$90/MMBtu in Janu-
JUNE 2014 14 Compressortech2
cT397.indd 1
By patrick crow
ary and Bostons wholesale gas price averaged US$24.09/
MMBtu for January and February, compared with US$3.37
in Pennsylvania.
FERC Commissioner Philip Moeller has observed that an-
other saving grace was that New England experienced ex-
treme cold snaps last winter, but not extended cold weather.
Moeller told a FERC technical conference that tempera-
tures dipped well below the 20-year historical average in
New England in January, but only a few times and for only
one or two days at a time.
We have to assume that we will have another winter, if
not like this one perhaps even worse, where an extended
cold snap could further expose our vulnerabilities, he said.
The New England Power Generators Association argues
that theres a simple alternative to NESCOs tax proposal:
let the free market work.
The electric power group said that over time, pipeline
companies and consumers will agree on the financing of
projects to expand the pipeline capacity into New England
from the west.
For example, Spectra Energy has asked FERC for per-
mission to boost capacity on its Algonquin pipeline to 340
MMcfd (9.6 x 106 m3/d) by late 2016.
However, the U.S. Energy Information Administration
(EIA), in a report last winter on New Englands natural gas
dilemma, observed that Spectra originally had proposed a
1 Bfcd project.
The size of the pipeline capacity expansion was re-
duced 65% from the original proposal because of lack of
interest in signing up for long-term firm transport capacity
contracts. So far, only regulated utilities have shown a
willingness to absorb the financial cost embedded in the
long-term firm contracts.
In general, public utility commissions require utilities to
seek approval for signing long-term contracts and the rate
hikes required to pay for them. The reduction in the pro-
posed expansion capacity of the Algonquin project may in-
dicate hesitation by the utilities and their regulators.
EIA said New England pipeline expansions might be-
come more viable in the future, as base-load consumption
of natural gas to generate electricity continues to grow. But
it warned that market participants could expect more peak
supply crises next winter. CT2
5/20/14 1:59 pM
Cameron.indd 1 5/16/14 1:23 PM
 New Owner Adds Silencer Assets
To Miratech > Low-temp particulate filter gets key approval
A
udax Private Equity has ac-
quired Miratech Corp. and
augmented it with the silencing
business of another company it owns,
Phillips & Temro Industries (PTI).
Audax, which holds more than
US$5 billion in assets in lower-middle
market companies, renamed the Tul-
sa, Oklahoma-based firm as Miratech
Group LLC.
With the addition of PTI Silencing,
Miratech will operate three facilities. It
has a 29,000 sq.ft. (2700 m2) facility
in Tulsa which includes an innovation
center focused on new product devel-
opment. PTI Silencing has a 54,000
sq.ft. (5000 m2) manufacturing plant
at Prior Lake, Minnesota, for its EM
products, and a 17,000 sq.ft. (1600
m2) plant at Winnipeg, Alberta, Cana-
da, for its Cowl products.
Combining these teams gives Mi-
ratech strong expertise in both tech-
nology and manufacturing, President
and CEO Kevin OSullivan said. Our
goal is to be a leading manufacturer
and provider of emission and noise-
attenuation solutions within the North
American large format industrial en-
gine market.
Geoffrey Rehnert, Co-CEO of Au-
dax, said, The combination of Mirat-
ech and PTIs silencing division allows
the combined business to offer a full
spectrum of emissions and noise con-
trol solutions. We are looking forward
to backing Kevin OSullivan and his
team as they grow the business or-
ganically and through strategic add-
on acquisitions.
Miratech offers customers cata-
lysts, housings, silencers, monitoring
systems and related services that re-
duce engine exhaust pollutants such
as NOx, CO, VOC, diesel particu-
lates, HAPs and noise. Its engineer-
ing team provides customers tech-
nical customized solutions to their
emission control requirements and
installation configurations.
JUNe 2014 16 Compressortech2
CT404.indd 1
The PTI Silencing Division designs
and makes silencers and exhaust
system components for an array of
industrial engine applications through
its EM and Cowl brands. It serves
manufacturers and distributors in
various markets including power gen-
eration, off-highway, industrial mobile
equipment, commercial marine and
gas compression.
CARB approval
Separately, Miratech said the Cali-
fornia Air Resources Board (CARB)
has given it level 3+ conditional veri-
fication for its low-temperature regen-
eration (LTR) diesel particulate filter
system technology.
The LTR line, which was launched
May 1, is used by stationary diesel
engine owners/operators. It consists
of a single housing assembly contain-
ing a diesel oxidation catalyst (DOC)
and diesel particulate filter (DPF)
modules. The LTR product line also in-
cludes options for integrated silencing
and an electronic monitor/data logger/
alarm system.
Miratech said the LTR system effec-
tively oxidizes particulate matter (PM,
or soot) at a lower exhaust tempera-
ture than other market options and
has high PM trapping efficiencies of
greater than 85%.
The LTR system does not require
additional energy inputs, complicated
control systems or custom integration
with the engine. The DPF can regen-
n This is a rendering of the
fully assembled LTR, which
is available in multiple sizes.
erate using only the oxygen and tem-
perature in the exhaust gas stream.
The DOC is built into the front of the
filter housing that treats the exhaust
before it enters the particulate filter.
The system is designed for maximum
reduction of engine exhaust emissions
such as carbon monoxide, hydrocar-
bons, volatile organic compounds and
PM, with minimal formation of NO2.
The new LTR filter system succeeds
Miratechs CombiKat DPF line.
Mirartech said the LTR can regener-
ate at a temperature as low as 500F
(260C). It is designed to remove over
85% and can achieve up to 97% re-
moval of PMs from stationary diesel en-
gine exhaust. The captured particulate
matter is oxidized passively (no addi-
tional heat) through catalytic oxidation
energized by the exhaust temperature.
For most engines, it will be possible to
regenerate the Miratech LTR DPF ele-
ments at engine load above 30% with
properly insulated exhaust ducts.
The LTR system is designed for
134 to 5360 hp (100 kW to 4 MW) en-
gines. It can be fitted on Tier 1 or later
engines from all manufacturers and
remain in compliance with their back-
pressure limits. Other engines with
certified PM emissions of less than
0.3 g/bkW-hr are also verified.
In addition, it is engineered for easy
installation and service. Its compact
profile allows for installation flexibility,
especially since it can replace a sepa-
rate silencer. CT2
5/20/14 1:44 PM
 Harsco Air-X-Changers: Since 1954, weve set the industry standards in natural
gas cooling not merely by meeting the customers needs, but by exceeding customer
expectations with better-built, better-performing coolers, year after year. Call
918-619- 8000 (USA) today. Or visit harscoaxc.com

Insight onsite.

Harsco_June14_CT.indd 1 5/19/14 1:04 PM


Reciprocating Compressor
Suction And Discharge-Valve
Monitoring > Evaluating the strengths and weaknesses of the
most common online monitoring technologies
P
rognost Systems failure mode survey of most com-
mon reciprocating compressor failure modes shows
valve failures among the most frequent root cause
for unplanned compressor shutdowns. New valve designs
and improved materials have been introduced in the past
10 years and have reduced the percentage significantly.
However, for many compressor operators valve monitor-
ing is a main concern when evaluating condition monitoring
systems to reduce unplanned downtime.
n Figure 1. Prognost Systems failure mode survey 2009; an
evaluation of 524 compressor damage records detected at 192
machines, located in 72 different plants.
While the high percentage against other machine failures
calls for further improvement, valve leakages in an early
stage are usually not safety relevant. Undetected suction
valve failures might lead into a complete loss of compres-
sion causing more dangerous failures, e.g., seizing cross-
head wrist pins resulting from missing rod load reversal.
In the early days of reciprocating machine monitoring,
maintenance strategies were mainly based on tempera-
ture measurement. Today, different methods of online con-
dition monitoring can be applied to create precise diag-
nostic information of the valves and other components.
By comparing strengths and weaknesses of tempera-
Daniel Goebel is PSG Area Manager responsible for Sales and
Business Development in Russia, Asia and the Pacific region.
JUNE 2014 18 Compressortech2
CT385.indd 1
TECH
corner
By Daniel Goebel
ture monitoring with cylinder acceleration vibration mea-
surement and PV diagram analyses, this article provides a
decision making guideline to identify the best suitable per-
manent monitoring technology for a specific compressor.
Description of the methods
Highlighting these completely different methods, it be-
comes obvious that valve monitoring can be improved
regardless whether it is delivered with a new machine or
retrofitted to an existing machine. In any case, it is the
main objective to detect a leakage of a valve that is caus-
ing a loss in efficiency of the compressor. Other damages
such as broken valve springs or cracks in the valve plate
or rings are considered as early stages of a leaking valve.
Valve temperature monitoring
In compressor thermodynamics, it is considered that a
gas leakage in either a suction or discharge valve is caus-
ing an increase of the gas temperature in the valve pocket.
Two installation options are common to monitor the valve
temperature:
a) Temperature sensor mounted into the valve cover.
b) Temperature sensor mounted in a sleeve installed in
the valve pocket through a drilled valve cover.
In both cases, typically one temperature sensor is in-
stalled on each valve cover. The valve pocket temperature
provides a higher quality of the measurement in terms of
early detection of the leakage. Valve cover temperatures
are subject to bigger influences from environmental con-
ditions such as sunlight or wind. Temperature sensors
installed through the valve cover into the valve pocket
provide an earlier indication of changing temperatures.
The signal coming from, e.g., RTD or thermocouple sen-
sors can be transferred to the distributed control system
(DCS), to a PLC or machine monitoring system (MMS).
In the DCS or MMS, temperatures can be trended to gen-
erate long-term information about the valve condition.
Condition-monitoring systems provide additional analy-
ses for the signals such as the group deviation analysis
to maximize the value of valve temperature monitoring,
no matter at which position (cover or pocket) the sensor
is mounted.
S
5/20/14 2:05 PM
 n Figure 2. Online acceleration signal and
segmented analysis with two thresholds.

PV diagram monitoring PV diagram analyses are based on dynamic pressure

PV diagram analyses require the installation of one pres-
sure sensor for each compression chamber to monitor the
condition of suction and discharge valves. The sensors
can be installed on indicator taps prepared by the machine
manufacturer and may not be mixed up with the suction
and discharge cylinder pressure sensor installed in the pul-
sation dampers or piping. Such taps are required for API
618 machines and typically indicator valves are installed
between the sensor and the cylinder to allow easy replace-
ment of sensors without machine shutdown. If indicator
taps are not available, e.g., old machines, suction or dis-
charge valves can be modified with a special centre bolt.
measurement and require sensors that allow sampling
rates in the kHz range to allow detect small leakages and
high frequency pressure pulsations caused by valve dy-
namics or stepless unloaders. The PV diagram can be vi-
sualized with suitable software. Intelligent diagnostic sys-
tems automatically monitor the PV diagrams. In addition
to the suction/discharge valves, the PV diagram analysis
indicates leakage of various other sealing elements such
as piston sealing rings, piston rod packing etc.
Furthermore, the dynamic cylinder pressures in conjunc-
tion with other parameters, e.g., speed of the compressor,
continued on page 20

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JUNE 2014 19 Compressortech2

SKF.indd 1 11/20/13 9:42 AM

CT385.indd 2 5/20/14 2:06 PM

 Low Cost For Instrumentation PV, Vibration
Early Detection Of Component Condition
PV, Vibration
Changes
Definite Assignment Of Failing Component
Temperature
Vibration
Versatile Usage Of Signal For Monitoring
Additional Components PV Vibration
No CMS Required Temperature
n Figure 3. Strengths and weaknesses of valve monitoring methods.
connecting rod ratio and weight of the piston, allows the cal-
culation and monitoring of the dynamic piston rod load and
its reversal periods. Piston rod load is amongst the most
critical when monitoring the condition and integrity of a com-
pressor and help to identify critical overload conditions.
Cylinder acceleration monitoring
The third method of interest involves acceleration sensors
typically mounted on the cylinder. For permanent installation,
cylinder vibration sensors can either be installed by screwing
them to a drilled thread hole in the cylinder or using a drilled
mounting pad that is glued to the surface of the cylinder.
Combining this piezoelectric sensor with suitable soft-
ware enables users to identify failures of suction and dis-
charge valves based on segmented vibration monitoring,
making use of individual threshold monitoring for each seg-
ment. The segmented monitoring requires only one vibra-
tion sensor per cylinder to monitor four groups of valves
(suction and discharge valves on head end and crank end
side) on a double-acting cylinder.
Strengths and weaknesses
What are the criteria to be evaluated when deciding about
the best suitable method for valve monitoring? Starting point,
typically, is a cost-benefit analysis. Examining solely the in-
vestment for sensors and the monitoring system is insufficient.
Additional effects have to be taken into account such as MTTR
optimization, increase in machine uptime or the systems abil-
ity to detect critical failures other than valve problems.
JUNE 2014 20 Compressortech2
CT385.indd 3
Temperature High Cost For Instrumentation
Temperature Slow Detection Of Component Condition Changes
PV,
Vague Assignment Of Failing Component
Temperature No Usage Of Signal For Monitoring Additional Components
PV, Vibration CMS Required
Figure 3 shows a simplified view to the different
strengths and weaknesses of the methods that are affect-
ing the initial investment, maintenance cost of the valves
and associated efforts to operate the measurement loops
during operation for the lifetime of the equipment.
Valve temperature measurements are only reasonable
in case each valve is equipped with a temperature sen-
sor. This results in a large temperature channel count of
at least 16, in most cases 32 channels for a standard four-
cylinder compressor. Temperature as a measurement pa-
rameter is considered an easy to understand information
that reflects the condition of the dedicated valve it is moni-
toring. The cost for installation and maintenance of the loops
stress the budget throughout the lifecycle of the system.
Valve cover temperature measurements with fixed tem-
perature sensors require all valve covers to be drilled for
the installation of probes. For this measurement, the valve
covers have to be drilled through either by the OEM or
retrofitted to the existing covers. This creates a poten-
tial source for gas leakage that needs to be maintained
throughout the life cycle of the machine.
The advantage of having one dedicated sensor per
monitored valve is often neglected in maintenance rou-
tines. In most cases if one discharge valve has been iden-
tified as damaged; typically all discharge valves on the af-
fected cylinder are replaced and not only the one identified
as leaking. Hence the benefit of having one temperature
value for each valve is lost.
In the same way the cylinder acceleration vibration mea-
n Figure 4. Comparison of trended
suction/discharge valve tempera-
ture, cylinder vibration and two
monitoring parameters derived from
pressure measurement three weeks.
5/21/14 8:44 AM
 surement identifies functional groups of valves on the same
cylinder side (head end or crank end). However, this is
achieved by installing only one sensor on a double-acting cyl-
inder and applying segmented vibration monitoring of the ac-
celeration signal. This method allows to locally and function-
ally determine impending valve failures at a very early stage.
Vibration impacts are measurable before, e.g., a broken valve
plate causes a significant increase in gas or valve cover tem-
perature. Unlike valve temperature sensors, the acceleration
sensors mounted on the cylinder do not have to be removed
during valve replacements and no gas sealing needs to be
checked and maintained after servicing the valves.
Figure 4 shows the temperatures of a suction and a
discharge valve (blue/red) along with two monitoring pa-
rameters derived from the PV diagram (purple) and one
segment of the maximum cylinder acceleration vibration
(black) for one cylinder. The change to bad condition be-
came noticeable with the pressure and the cylinder vibra-
tion signals. The temperature did not change significantly
before the machine was stopped by the operator.
Taking into account the downtime of the machine which
is related to the MTTR, the cylinder vibration is most conve-
nient, as the valves can be exchanged without disassembling
the sensors. Using temperature measurement, all tempera-
ture sensors have to be carefully dismounted before valve
maintenance can take place with further time spent to install
them back and checking the installation for proper sealing.
JUNE 2014 21 Compressortech2
CT385.indd
ACI.indd 1 4
While PV diagram analyses and cylinder vibration
monitoring call for a suitable monitoring software, the tem-
perature measurement is a simple parameter that can be
trended even in less sophisticated systems such as PLC
or DCS. However, a temperature increase can be caused
by other reasons than leaking valves, e.g., an increase
in differential pressure. Such changes in operating condi-
tions can cause false warnings. Furthermore, temperature
crosstalk between neighboring valves mounted in angles
of 90 degrees or smaller can cause uncertainty on the
leaking valve. Only with a more sophisticated monitoring
method that compares valve temperatures of the same
function, a reliable failure assignment can be produced.
While valve temperature monitoring focuses on the valve
condition information, PV diagram and cylinder vibration
monitoring provide condition information of additional
components as well. Vibration monitoring provides infor-
mation about the piston rings, the piston and the cylinder
liner due to specific changes in the vibrational behaviour.
With PV diagram analyses, piston rings and packing leak-
ages are monitored in addition to the valves. Furthermore, it
is the only method that can quantify the amount of leakage
of components and therefore provide critical information for
maintenance decisions. Based on the dynamic pressure, the
combined gas and inertia piston rod load can be calculated
the only way to detect the loss of piston rod reversal conditions
continued on page 22
www.aciservicesinc.com
740-435-0240
5/22/14
5/22/14 1:39
1:35 PM
PM
 which are a main cause for severe motion work damages and
complete machine loss. A reliable dynamic piston rod load
monitoring is a most effective method to reduce the risk of
machine failure especially on capacity controlled machines.
If indicator taps are available on the cylinders, as re-
quired for new API 618 machines, the advantages of hav-
ing only two indicated pressure transducers per cylinder
along with minimum lifetime maintenance efforts for the
indicator valves and the loops itself are inherent of the PV
diagram monitoring. State of the art software informs the
users of any change in the PV diagram.
The lowest install cost and effort are involved for the
installation for the cylinder vibration sensors. The vibration
sensors at the cylinder can be retrofitted by gluing special
sensor mounting pads to the cylinder casing without vio-
lating the mechanical machine integrity.
Guideline for evaluating valve monitoring strategies
Three different options for valve monitoring have been dis-
cussed. Each method provides its own strengths and weak-
nesses. Decision makers have to consider, whether moni-
toring shall exclusively focus on suction/discharge valves
or shall be part of a monitoring solution, covering various
machine components. Valve temperature measurements tra-
ditionally seem to be the best choice, because they are ex-
pected to deliver reliable information one-to-one sensor to
valve. However, for larger cylinders with multiple valves and
multicylinder compressors, one acceleration sensor per cyl-
inder with a segmented vibration monitoring provides a bet-
ter cost benefit ratio as it requires less mechanical work for
installation and causes less efforts during valve replacement.
This is especially true when suction and discharge valves of
one cylinder side are always replaced at the same time.
If advanced monitoring information is required, e.g., on the
piston sealing rings or in case a quantitative assessment of
the leakage is requested to determine the best time of re-
placement the PV diagram provides the best results. This is
especially true when the compressor is load controlled by
(stepless) unloader systems or clearance pockets as those
control functions result in changes of the valve temperatures.
the leakage volume. This can only be achieved by PV dia-
General questions to be asked
Is the process or the machine critical?
Yes No
More versatile and sophisticated
Simple monitoring such as cylinder
monitoring, e.g., PV diagram as
vibration could be sufficient.
should be considered.
Have failures, other than valve failures, been experienced
in the past at the machine?
Yes No
Valve temperature monitoring
might be too limited. Cylinder Valve temperature or/and cylinder
vibration and PV diagram provide vibration could be sufficient.
more information.
JUNE 2014 22 Compressortech2
CT385.indd 5
Instrumentation
How many suction and discharge valves are installed
on the head end and crank end side of the compressor?
If more than two suction and two discharge valves are
installed per cylinder side, cylinder vibration or PV dia-
gram might be commercially attractive. If fewer valves than
mentioned above are installed valve temperature should
be the choice.
Are free channel inputs available on the local compres-
sor control PLC?
If a sufficient number of channels exists to integrate
temperature signals, valve temperature installation could
be an alternative to cylinder vibration. If inputs to exist-
ing PLC or DCS have to be installed, valve temperature
investment cost have to be evaluated carefully.
Is the compressor controlled by a capacity control, e.g.,
(stepless) valve unloaders?
If so, PV diagram monitoring is the best option to moni-
tor, because it allows monitoring the valves depending
on the load condition of the capacity control. Valve tem-
perature and cylinder vibration are more likely to create
false warnings.
Installation and maintenance
Are the cylinders fitted with indicator taps?
Yes No
Valve temperature and cylinder
vibration provide the smallest
PV diagram monitoring can be
installation cost. If required PV
done cost effective and should be
diagram monitoring can be
seriously considered.
installed by modifying the one
valve center bolt per cylinder side.
Monitoring tasks
The earliest indication of a valve leakage/damage shall
be provided?
Typically the earliest information is received by cylinder
vibration followed by valve temperature measurements.
Both methods do not allow a quantitative assessment of
gram monitoring.
Shall the monitoring solution be scalable and extend-
able for future expansions?
Best options for upgrades are provided with dedicated
monitoring platforms (CMS).
Should other sealing elements e.g. piston rings or stuff-
ing box be monitored?
Other sealing elements especially piston rings can best
be monitored with PV diagram monitoring.
Shall the monitoring provide more than valve monitoring?
Cylinder vibration and PV diagram analysis are the most
versatile methods that provide further information on me-
chanical changes, e.g., loose valve cages etc.
Shall the quantity of the leakage be monitored?
PV diagram analysis is the only quantitative monitoring
5/22/14 9:07 AM
 Temperature PV diagram Vibration

General
- ++ -
Machine Criticality

Failure History Besides -- ++ -

Valves Exists

Instrumentation

Sensors Required* 32 8 4

Indicator Caps Exist No Relevance ++ No Relevance GAS ENGINES

Integration In Existing
PLC/DCS
Fault Tolerance With
Changing Loads, e.g.,
Capacity Control
Maintenance
Installation Efforts
Maintenance
Friendliness
Reliable heart for your unit
+ -- --
Power range: 80 - 210 kW
-- ++ - Fuels: NG, Biogas, LPG,
Wellhead gas, CBM gas
and others
Ellwood.qxp 1/27/10 11:51 AM Page 1
info@tedomengines.com, +420 483 363 642
www.tedomengines.com
-- + ++
-- + ++
Tedom STACIO INZ EN 79x121 _25496.indd 1 3.2.14 10:56

Tedom.indd 1 2/3/14 8:53 AM

Monitoring Tasks
-- - ++
Early Failure Detection

Diagnostic Information - ++ -
Of Other Components
Than Valves
-- ++ ++
Monitoring Other
Sealing Elements
-- ++ --
Leakage Quantity We Manufacture and
* 4-Throw Compressor Remanufacture the
n Legend: The better a monitoring strategy meets the specified re-
Worlds Largest
quirement (left), the better the mark; from low (--) to high (++). Crankshafts
methods that allows to determine the best time for a valve
Ellwood Crankshaft Group
change by assessing the quantity of leakage. CT2
Irvine, PA, USA 16329
Hermitage, PA, USA 16148
References 1-800-247-1326
[1] 
1995 API STD 618 (Fourth Edition 1995): Recip- or 724-347-0250
rocating Compressors for petroleum Chemical and ecgsales@elwd.com
Gas Industry Service www.ellwoodcrankshaftgroup.com
[2] www.prognost.com

JUNE 2014 23 Compressortech2

CT385.indd 6 5/21/14 9:00 AM


Pushing The Boundaries
Of Centrifugal
Pumps > Sulzer develops 14,500 psi (1000 bar) design
By Thomas Welschinger and Martin re Villoria
I
n offshore oil production, high-
pressure pumps are used to inject
water into the reservoir to increase
oil recovery. Sulzer has developed a
new centrifugal pump for ultrahigh-
pressure applications up to 14,500 psi
(1000 bar).
Because oil reservoirs are often
found in deepwater, the pressure re-
quirements for pumps have increased
significantly during the last several
years. Such pressures can be provided
by pumps located at the bottom of the
sea (subsea) or by equipment installed
on a production platform (topside).
Sulzer provides equipment for both
applications. This article describes the
topside pump developments.
1000 bar pump development
Sulzer started concept studies in
2009 to develop an injection pump
that delivered 11,600 psi (800 bar) of
operating duty pressure. The outcome
Thomas Welschinger is a head of product
development with Sulzer Pumps Equip-
ment in Winterthur, Switzerland. He has
more than 17 years of experience with
mechanical design of pumps and has a
degree in mechanical engineering from
the University of Applied Sciences in
Konstanz, Germany. Martin re Villoria
is head of engineering at Sulzer Pumps
Equipment in Leeds, United Kingdom.
For the past six years he has worked in
the Sulzer product development centers
in Winterthur, Switzerland, and Jundiai,
Brazil. He has a degree in mechanical
engineering and studied in Hamburg
and Bielefeld, both in Germany.
JUNE 2014 24 Compressortech2
cT391.indd 1
of these studies was presented to ma-
jor oil and gas companies.
In a second development step and
based on client feedback, Sulzer pur-
sued the same concept to develop a
pump that provided 14,500 psi (1000
bar) of operating pressure in 2011.
The main design approach follows
the Sulzer HPcp pump line in back-
to-back or opposed impeller arrange-
ment to achieve an internal load bal-
ance (Figure 1).
Pressure of 14,500 psi (1000 bar)
can be expressed as a weight of
about 2205 lbs. (1000 kg) acting on
each square centimeter of a pressur-
ized area. This means that exception-
ally high loads stress the materials
and components involved. Because
the pumped medium is typically sea-
water, the materials need to be highly
resistant to corrosion as well.
It is possible to use duplex stain-
less steels or low-alloy
steels with applied weld
overlays on all wetted sur-
faces. The high-pressure
classes require certain
barrel case thicknesses
to provide the needed
mechanical strength. The
Pump
tech
design and the thickness of the barrel
cases, however, are limited by the ap-
plicable manufacturing methods.
Dealing with constraints
A pump that has a rated operating
point of 14,500 psi (1000 bar) must
withstand higher pressures (e.g., during
shutoff). This raises the maximum al-
lowable working pressure to 19,140 psi
(1320 bar). In order to qualify the integ-
rity of the case, factory pressure testing
is even up to 27,400 psi (1890 bar).
Since it is not possible to manufac-
ture duplex material cases for such
high pressures with the technologies
currently available, Sulzer adapted
the pump case design. The adapted
case geometry was optimized for the
local internal pressure, which increas-
es through the pump.
For that reason, the pump design
and the pressure test arrangement
followed a three-pressure-chamber
concept. The selected design accom-
modated not only the mechanical in-
tegrity during operation but also the
available manufacturing methods for
the components.
In addition, Sulzer applied the latest
design methods to ensure mechanical
n High-pressure water injec-
tion pumps improve the recov-
ery ratio of deepwater oil wells.
5/22/14 9:06 Am
 n Figure 1. The new 14,500 psi (1000 bar) pump is
based on the established Sulzer HPcp pump line.
integrity. Pump case designs usually
follow commonly available pressure
vessel standards. In this project, Sul-
zer applied the latest editions of the
two preferred standards to guarantee
a validated design approach:
ASME Boiler & Pressure Vessel
Code (Section XIII) Division 2
EN13445-3 Design-by-Analysis
Method
These codes provide procedures
to design and simulate such pressure
cases with finite elements. The simu-
lations can predict the mechanical be-
havior of a pump during pressure test,
design, and operating conditions.
The pump case structure, which is
designed with modern 3-D computer
assisted design tools, was divided into
a finite number of small elements. Each
element was assigned the properties
of the steels used. When the pressures
and external loads are applied to these
elements, they deform the elements
and create internal stresses.
Generally, these stresses need to
be within the elastic regions of the
material throughout the entire pump.
n Figure 2. Finite element analysis validates
the mechanical behavior of the pump case.
JUNE 2014 25 Compressortech2
CT391.indd 2
CELEBRATING
50 YEARS
OF ENGINEERED
EXCELLENCE
Certain material limits, which are also
given by the referenced codes, are
applied to validate the design against
the simulated loads.
Figure 2 illustrates a typical full-size
simulation of a pressurized pressure
case of a multistage centrifugal pump.
These simulations verify all pressure-
retaining components involved (such
as bolting, nozzles and cases). Highly
loaded areas are identified and opti-
mized to reduce local stress regions
of the parts. In 1964 CECOs founder, Ernest G.
In addition to ensuring the me- Hotze, identified a critical industry
chanical integrity of the pump, Sulzer problem, the need for compressor
confirmed that the deformation of the replacement parts. CECO strives
parts remained within a certain limit. It to continue its founders mission
was especially important to check the
by filling the gap with high-quality
clearance between rotor and stator,
which is reduced due to the high pres- compressor parts and services that
sure at operation, to avoid a contact will increase the efficiency and
between the rotor and stator. runtime of your equipment.
Furthermore, the static seals had to
be tight. Sulzer investigated the alter- CECOs Services:
native static sealing solutions that are Parts & Repair
available and qualified in the oil and
gas industry for such extreme condi- Training & Technical Services
tions. Sulzer tested these seals on in-
ternal design test rigs to the highest Pipeline Services
pressures, simulating similar mate- Emissions Testing
rial deformations and confirming tight-
ness. These tests established internal Mechanical Field Services
evaluation criteria for future designs.
Additionally, all standard design pro- LEARN MORE ABOUT
cedures of these engineered pumps
CECOS HISTORY!
were followed and checked against val-
idated external and internal standards:
Shaft stress analyses
Impeller fatigue analysis
Rotor-dynamic analyses
General risk assessment and
mitigation measures.
From Sulzer Technical Review,
1/2014. CT2 TRYCECO.COM 713.663.1668 tryceco@ceconet.com
5/22/14 9:06 AM
CECO.indd 1 5/13/14 10:50 AM
 Siemens Buying Rolls-Royce Energy
Business > US$1.33 billion deal includes share of Rolls Wood Group JV
n This Rolls-Royce equipment was installed
on the West-East Pipeline Project in China.
T
he global profile of the energy
gas turbine and compressor
systems sectors will undergo a
major change through a deal involving
Rolls-Royce and Siemens.
On May 6, the two companies an-
nounced an agreement for Siemens to
purchase the arm of the United King-
dom company that supplies aeroderiv-
ative gas turbines, compressor sys-
tems and related services to customers
in the oil and gas and power generation
sectors in a deal worth US$1.33 billion.
June 2014 26 Compressortech2
CT392_island.indd 1
Upon completion of the sale, which
is expected before the end of Decem-
ber, Rolls-Royce will receive a further
US$339 million for a 25-year licensing
agreement giving Siemens access
to relevant Rolls-Royce aeroderiva-
tive technology for use in the 5300 to
114,000 hp (4 to 85 MW) power out-
put gas turbine range.
The deal does not include some as-
sets in the Rolls-Royce energy busi-
ness, such as Fuel Cell Systems. On
completion of the deal, Rolls-Royces
By Ian Cameron
interest in the Aberdeen, Scotland-
headquartered Rolls Wood Group
joint venture, which provides mainte-
nance, repair and overhaul services
on Rolls-Royce industrial aeroderiva-
tive gas generators in the oil and gas,
power generation, and marine propul-
sion industries, transfers to Siemens.
Rolls-Royces Energy gas turbine
and compressor business has around
2400 employees and in 2013 contrib-
uted approximately US$1.47 billion
of revenue and US$121.6 million of
5/20/14 8:32 AM
 underlying profit. Siemens Energy cations. Pressure capabilities range up up to nine compression stages. Stan-
sector has around 83,500 employees to 3220 psig (222 barg) with power rat- dard configurations are available up to
and in 2013 contributed revenue of ings up to 75,000 hp (56 MW) at design 4500 psig (310 barg) maximum work-
US$36.6 billion and underlying profit speeds from 3600 to 13,800 rpm. ing pressures and up to 35,000 acfm
of US$2.62 billion. Six standard frames have flange (60,300 Nm3/hr) flows. Power ratings
Siemens said the deal would sizes from 20 to 42 in. (508 to 1067 are up to 75,000 hp (56 MW) at design
strengthen its position in the growing oil mm) and design inlet flows range speeds from 3500 to 13,800 rpm.
and gas industry as well as in the field from 1000 to 62,800 acfm (1700 to Rolls barrel compressor installations
of decentralized power generation. 106,500 Nm3/hr). range from single units to multiple-
The company added, By acquir- The companys barrel compressors unit trains driven by gas turbines or
ing Rolls-Royces small and medium are available in four frame sizes with electric motors. CT2
aeroderivative gas turbines with a
power output of up to 88,500 hp (66
MW) (ISO/wet-rating), Siemens will
close a technology gap in its exten-
sive gas turbine portfolio.
Originally developed for use in the
aviation industry, Rolls-Royces ener-
gy aeroderivative gas turbines have a
compact, weight-optimized construc-
tion and are highly efficient. These
characteristics make aeroderivative
gas turbines an attractive power sup-
ply option in the oil and gas industry, in
particular for the operators of offshore
oil platforms where space is limited.
More than 1700 Rolls-Royce com-
pressors have been installed world-
wide, capable of up to 49,600 hp (37
MW) of power, sized to meet a wide
range of flow and pressure needs.
Over 4800 Rolls-Royce aeroderiva-
tive gas turbine units have been sold
to date addressing the 4000 to 88,500
hp (3 to 66 MW) power output range
and reaching more than 180 million
operating hours.
One of the most popular turbines
is the 36,200 to 59,000 hp (27 to 44
MW) RB211 machine mainly used in
oil and gas offshore power generation testo 350.
and onshore pipeline applications. Compliance testing and tuning
Focusing on the Rolls-Royce com-
pressor portfolio, the company has a Speed, power & precision.
long supply history for both its pipeline
Superior performance for state and
and barrel centrifugal compressors.
Over the past 65 years more than 980 federal testing
pipeline compressors have been in- Menu-guided HD display
stalled worldwide and more than 740 Powerful on-board & PC data management
barrel compressors built with 500-plus
Wireless operation simple data collection
installed in natural gas handling ap-
plications, including more than 60 de- Rugged construction
signed for sour gas service. O2 CO NOx SO2 CO2
The companys conventional pipe-
line compressors comprise six models 800-227-0729 www.testo350.com
and can accommodate up to five com-
pression stages for higher head appli-

JUNE 2014 27 Compressortech2

Testo.indd 1 4/15/14 11:29 AM

CT392_island.indd 2 5/22/14 9:12 AM
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 Ro-Flo Compressors Brings
Testing In-House > Rotary test center services company
and external machinery
By DJ Slater

n Ro-Flo Compressors Rotary Test Center includes a test stand that features a GE variable-
speed motor rated for 350 hp (261 kW) with a speed range up to 2400 rpm.

R
o-Flo Compressors no longer
has to find a place to test its
products to ASME, PTC, ISO,
API, customer-specific or proprietary
standards. The rotary vane compres-
sor supplier can just take its equip-
ment 2 mi. (3.2 km) east of its Apple-
ton, Wisconsin, offices to its recently
built Rotary Test Center.
The 7500 sq.ft. (697 m2) facility tests
all rotating equipment, such as positive
displacement compressors, centrifugal
compressors, pumps, turboexpanders,
gearboxes, and all support compo-
nents and systems. With specialized
software, the center provides immedi-
ate assessment of equipment perfor-
mance through data analysis.
Its a great service that we have at
our fingertips, said Matt Duel, direc-
tor of testing for Ro-Flo Compressors.
Customer concerns or issues with
equipment can be examined in detail
under controlled conditions and ulti-
mately resolved.
Its a far contrast from what Ro-Flo
Compressors had to do in order to test
its equipment nearly seven years ago.
Ro-Flo Compressors was formed as
a private company in December 2007
following its divestiture from GEs Oil
& Gas division.
Without GEs in-house testing ca-
pabilities, the company relied on River
Flats Testing. In 2012, River Flats
Testing closed its doors, leaving Ro-
Flo Compressors with a decision
find another testing resource or build
its own. The company chose the latter
since the closest independent testing
center was not in the Midwest.
Duel entered the picture in No-
vember 2012, and developed a bud-
get for the test center the following
continued on page 32

JUNE 2014 30 Compressortech2

CT359.indd 1 5/22/14 9:24 AM

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Prognost.indd 1 6/7/13 11:42 AM


month. He had the next few months
to procure the equipment and build
the facility, which started conducting
testing last June.
The two main components of the
test center are the test stand and the
control room. The test stand consists
of a 10 x 25 ft. (3 x 7.6 m) iron T-slot
floor plate anchored and grouted to a
concrete foundation for a total mass
of 60 tons (54.4 tonnes). This design
allows for modular setups, a variety
of equipment installations and infinite
test arrangements.
The in-house driver is a GE A$D
constant torque variable-speed mo-
tor rated for 350 hp (261 kW) with a
speed range up to 2400 rpm. A Vacon
NXS drive is used to control the GE
motor. Other equipment includes a
Sloan Brothers Watchman lubrication
system, an XChanger heat exchang-
er, an air/oil filter with Keltec elements
and a selection of test piping.
A variety of instrumentation, which
is calibrated on a regular basis, is
also a part of the test stand. Interface
rotary torque transducers are located
between the motor and test article to
provide a direct power measurement.
Rosemount pressure transducers are
used with calibration curve fits to fur-
ther capitalize on their accuracy. Oth-
er instrumentation includes ASME
JUNE 2014 32 Compressortech2
CT359.indd 2
n The two main pieces of equipment in the con-
trol room are an Agilent Model 34980a digital
multimeter and a National Instruments IOtech
Model 652u dynamic signal analyzer.
flow nozzles and orifice plates, Bently
Nevada proximity probes, PCB accel-
erometers and type T thermocouples.
To measure the ambient conditions
within the facility, Ro-Flo uses a Men-
sor barometer and Rotronic relative
humidity transmitter.
The control room consists of an ar-
ray of computer monitors and a rack
tower of equipment. Among various
types of controllers, the two main piec-
es of equipment are an Agilent Model
34980a digital multimeter and a Na-
tional Instruments IOtech Model 652u
dynamic signal analyzer. The Agilent
34980a serves as the main data acqui-
sition unit. The IOtech 652us general
purpose is for vibration data collection
and analysis, but is also used in other
dynamic signal applications.
Its becoming more common for
customers to witness performance
testing of equipment before it is in-
stalled, Duel said. There is increased
interest in data-based decisions. The
Test Center provides a level of cer-
tainty and predictability that meets
that demand.
The perks of having a test center go
beyond evaluating equipment for in-
ternal purposes, said Dennis Wacker,
Ro-Flo Compressors business devel-
opment manager. The company has
been receiving more orders for high
spec applications, which have strin-
gent requirements including perfor-
mance testing. For example, Ro-Flo
Compressors recently secured an or-
der from a Singapore packager for four
compressors on a floating, production,
storage and offloading (FPSO) proj-
ect under construction in Singapore,
a project the company may not have
obtained without the test center.
If we had not had these testing ca-
pabilities, we simply would not have
met the customers requirements,
Wacker said.
Ro-Flo Compressors analyzes its
own equipment weekly, Duel said. The
rest of the centers schedule is filled
with tests of outside equipment. The
tests range from analyzing specific
measurement to examining multiple
parameters at once. The company
has quoted tests of widely differing
complexity and cost and will add pow-
er or other equipment to customize a
test regimen to customer specifica-
tion, he said.
Meeting contractual requirements
is just one benefit of having the test
center nearby. The company can
also develop and improve its prod-
ucts, using the facility to validate
these enhancements.
Were already hashing out ideas as
to how we can take the product line
we already have and expand its ca-
pabilities to other applications, other
markets, Duel said. Obviously, with-
out a test stand, theres no way you
could do that.
Added Wacker: It adds product
improvement capability and a new
dimension of objective equipment
evaluation to the market. There are
large informational gaps in many
capital projects that could be filled
to good effect with objective base-
line data and improved communica-
tion of that information. CT2
5/20/14 2:06 PM
 Bringing energy and the environment into harmony.

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DresserRand_June14_CT2.indd 1 5/19/14 12:14 PM

 2014 Mechanical Drive
Order Survey > Shale sets the tone By Brent Haight

Editors Note: Each year, sister
publication Diesel & Gas Turbine
Worldwide magazine publishes three
surveys designed to provide details
on the markets of larger reciprocating
engines, steam turbines and gas tur-
bines used in power generation, me-
chanical drive and marine propulsion
applications. The Mechanical Drive
Order Survey is devoted to engine
orders for mechanical drive applica-
tions including pumps, compressors,
oil exploration machinery, rail and
other industrial applications. What
follows is an amended version of that
survey, tailored specifically toward
the gas compression marketplace.
uid fuel, as reported in this survey, can ticipating OEMs along with the survey
be any form of diesel oil. forms is included in this report.
An accompanying table identifies
those companies that participated Overview
in the 2014 survey. Every effort is The 2014 Mechanical Drive Order
made to ensure that this survey is Survey (2013 order data) reported
as complete and comprehensive 4453 total orders (all reported drive
as possible and would not have the types), a 27% decline in total orders
level of detail it contains without the compared to last years survey.
generous contributions of the partici- It is important to note that fluctua-
pating companies. tions in OEM participation beyond our
It is important to note that the data control do influence year-over-year com-
in this survey does not represent units parison. As revealed in past Mechanical
shipped, but only the total orders re- Drive Order surveys, as shale goes,
ceived during calendar year 2013. so goes prime mover orders within the
For reference, the geographic break- mechanical drive segment. Capacity
down that was presented to the par- continued on page 36

Diesel & Gas Turbine Worldwides

Reciproca)ng Engine Orders
annual orders surveys can be found at 8000
www.dieselgasturbine.com. 7000
6000
Procedures 5000
Units

The Mechanical Drive Order Survey 4000

includes drivers beginning at 500 kW 3000
(0.5 MW). New orders are broken into 2000

reciprocating engine, gas turbine and 1000

steam turbine orders. 0

2009 2010 2011 2012 2013
Fuel types are simplified to reflect Years
only liquid versus gaseous fuels. Liq-

Mechanical Drive Reciprocating Engine Orders, January December 2013

Engine Operating
Southeast Asia

South America
North America
Central, West,

Total Engine Fuel

East & South
North Africa

Speed Ranges
Russia & CIS

Central Asia
Middle East

& Australia

Output Range Number Output For

America &
Caribbean
Western

300 to 720 to above

Far East
Europe,

(MW) Of Units Each Output

Eastern

Central
Europe

Diesel Heavy Natural

Africa

Range (MW) 600 1000 1000

Fuel Fuel Gas
r/min r/min r/min
0.50 to 1.00 2410 1525 0 0 2410 2328 8 74 568 42 23 248 121 13 0 23 1364 2 6
1.01 to 2.00 1384 2003 0 0 1384 796 0 588 167 134 0 218 55 5 0 10 759 3 33
2.01 to 3.50 253 606 0 27 226 198 0 55 16 6 0 140 8 3 0 11 63 0 6
3.51 to 5.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5.01 to 7.50 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7.51 and 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
above
Totals 4047 4134 0 27 4020 3322 8 717 751 182 23 606 184 21 0 44 2186 5 45

June 2014 34 Compressortech2

CT398.indd 1 5/21/14 9:53 AM

 MACHINERY ANALYSIS

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 Mechanical Drive Gas Turbine Orders, January December 2013

Central, West,
Total Engine

East & South

Fuel

North Africa
Russia & CIS

Central Asia
Middle East

Asia & Aus-

America &
Caribbean
Southeast
Number Of Output For Each
Output Range (MW)

Western

America

America
Far East
Europe,
Eastern

Central
Europe
Units Output Range Diesel Heavy Natural

Africa

South
North
tralia
(MW) Fuel Fuel Gas
1.00 to 2.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2.01 to 3.50 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3.51 to 5.00 2 7 0 0 2 0 0 0 2 0 0 0 0 0 0 0
5.01 to 7.50 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7.51 to 10.00 3 23 0 0 3 1 0 0 0 0 2 0 0 0 0 0
10.01 to 15.00 12 161 0 0 12 0 0 4 3 0 0 0 0 0 5 0
15.01 to 20.00 4 74 0 0 4 0 0 0 0 0 0 0 0 0 0 4
20.01 to 30.00 117 3368 3 0 114 3 42 5 5 4 3 15 2 17 0 21
30.01 to 60.00 47 1560 0 0 47 1 7 5 3 6 0 2 2 15 0 6
60.01 to 120.00 16 1385 0 0 16 0 10 0 0 0 0 0 0 6 0 0
120.01 to 180.00 4 512 0 0 4 0 4 0 0 0 0 0 0 0 0 0
180.01 and above 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Totals 205 7090 3 0 202 5 63 14 13 10 5 17 4 38 5 31

Steam Turbine Orders Gas Turbine Orders

600 250

500 200
400
150

Units
Units

300
100
200
50
100

0 0
2009 2010 2011 2012 2013 2009 2010 2011 2012 2013

Years Years

issues, natural gas pricing concerns Elsewhere, China is making ag- Reciprocating engines
and myriad regulatory hurdles have gressive moves to capitalize on its The number of reciprocating en-
slowed shale activity around the world. own shale fields, announcing mul- gines ordered in 2013 total 4047
The result: order books in 2013 marked tiple partnerships between western units, a 28% decrease compared
the second straight year of decline. OEMs and Chinese shale players. to last years survey. The major-
Despite a slowdown in shale activ- Hope does glimmer in the distance ity of orders were divided between
ity, it is easy to find guarded optimism but not without concern from all players the output ranges of 0.50 to 1 MW
for order growth within the oil and gas involved as, ultimately, oil and gas is an (2410 units) and 1.01 to 2.00 MW
segment. The U.S. is racing to be- industry forced to move at the speed of (1384 units).
come an LNG export leader, a game government. This being the case, look Engine operating speeds above
changer across many aspects of the for continued decline in prime mover 1000 rpm accounted for 99% of the
energy landscape should the U.S. orders within the mechanical drive recip orders reported in the survey.
reach its goals. market segment in 2014. continued on page 38

Mechanical Drive Steam Turbine Orders, January December 2013

Steam Turbine Types
Western Europe

Central America
Southeast Asia

South America
North America
Central, West,

Output
East & South
North Africa

& Caribbean
Russia & CIS

Central Asia

Number Total Engine

Condensing

Condensing

Middle East

& Australia

Range
Extraction

Induction

Of Units Output (MW)

Far East
Europe,
Eastern

(MW)
Reheat

Africa
Non-

0.0 to 1.00 100 29 9 91 0 0 0 8 14 18 15 11 0 0 0 28 0 6

1.01 to 5.00 33 78 7 26 0 0 0 1 6 5 4 7 0 1 0 9 0 0
5.01 to 10.00 16 137 12 2 0 2 0 0 1 1 3 5 0 0 0 2 1 3
10.01 to 30.00 27 526 13 3 0 11 3 1 2 5 7 7 1 0 0 1 1 2
30.01 to 60.00 24 1068 19 0 0 5 1 0 0 0 17 3 0 0 0 3 1 0
60.01 to 120.00 1 64 0 0 0 1 0 0 0 0 0 0 0 0 0 1 0 0
120.01 and 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Above
Totals 201 1902 60 122 0 19 4 10 23 29 46 33 1 1 0 44 3 11

June 2014 36 Compressortech2

CT398.indd 2 5/20/14 2:24 PM

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4/10/14 11:55 AM
2014-03-31-CT2_Juni.indd 1 01.04.14 09:02
 varying classifications by OEMs, there
Combined Geographic Totals (All Driver Types) January December 2013
is a slight difference between the to-
Western Europe 766
tals reflected within the accompanying
Eastern Europe,
Russia & CIS
268 steam turbine orders chart. In some
Middle East 66
cases, extraction admission condens-
ing turbines were counted as extrac-
Far East 665 tion and induction, respectively.
Southeast Asia & 227 The Far East claimed the top geo-
Australia
graphic location with 23% of the total
Central Asia 27
units ordered. North America account-
North Africa 18 ed for 22%, followed by Southeast
Central, West, Asia & Australia, which totaled 16%.
48
East & South Africa

North America
Annual surveys
2268

Central America
13 On behalf of Diesel & Gas Tur-
& Caribbean
bine Worldwide, thank you to all
South America 87
contributors for your continued
participation in this annual survey
Diesel fuel once again dominated the fuel type, ac- process. It is our hope that the three surveys combined
counting for 82% of the reported orders. will provide an accurate snapshot of the entire large en-
North America claimed the top geographic destination for gine landscape, with fine-tuned detail provided for three
reciprocating engines in 2013 (54%), though recip orders in continued on page 40
North America fell 42% between 2012 and 2013. Prolonged
storage constraints will contribute to continued decline in
Combined Totals (All Driver Types)
recip orders within the mechanical drive landscape in North
America, but until another country matches North Americas North America
shale development and infrastructure, it will remain the top 6000
geographic destination for mechanical drive recip engines. 5000
Western Europe, the second top geographic destination 4000
for recip engines within the mechanical drive segment, re-
Units

3000
ceived 18% of 2013 order, followed by the Far East, which
2000
received 15%.
The Far East remains a region to watch and could some- 1000

day challenge North America for top geographic location. 0

2009 2010 2011 2012 2013
Recip engine orders destined for the Far East rose 96%
Years
from 2012 to 2013.
Western Europe
Gas turbines 1200
Gas turbine orders increased by 18% compared to the
1000
2013 Mechanical Drive Order Survey. Total orders reported
800
in this survey equaled 205.
Units

600
Units with the output range of 20.01 to 30.00 MW re-
ceived the most orders (57%), followed by units rated 30.01 400

to 60.00 MW (23%). 200

Eastern Europe, Russia and CIS was once again the 0
2009 2010 2011 2012 2013
top geographic location for gas turbines in mechanical
Years
drive applications, receiving 31% of the orders. North
America claimed the number two geographic location, Far East
accounting for 19% of the orders reported, followed by 700
South America (15%). 600
500

Steam turbines 400

Units

Steam turbine orders fell 39% compared to last years 300

surveys. Total steam turbine units ordered in 2013 200

was 201, falling mostly within the 0.0 to 1.0 MW output 100

range (50%). 0
2009 2010 2011 2012 2013
Noncondensing steam turbines saw the most demand, ac- Years
counting for 61% of the total steam turbines ordered. Due to

June 2014 38 Compressortech2

CT398.indd 3 5/22/14 9:44 AM


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www.recip.com/laby
5/5/14 9:00 AM
 Reciprocating Engine Manufacturers Participating And Reporting In This Mechanical Drive Order Survey

Caterpillar Energy & Transportation GE Distributed Power Niigata Power Systems Co. Ltd.

Caterpillar Inc. GE Oil & Gas Rolls-Royce Power Systems

Fairbanks Morse GE Power & Water

Steam Turbine Manufacturers Participating And Reporting Orders In This Mechanical Drive Order Survey

Dresser-Rand MAN Diesel & Turbo SE

Fincantieri S.p.A. Mitsubishi Heavy Industries Compressor Corp.

GE Oil & Gas Mitsubishi Hitachi Power Systems Ltd.

Gas Turbine Manufacturers Participating And Reporting In This Mechanical Drive Order Survey

Dress-Rand GE Power & Water Siemens AG

GE Distributed Power MAN Diesel & Turbo Siemens Industrial Turbomachinery Ltd.

GE Oil & Gas Rolls-Royce Power Systems Vericor Power Systems

market segments through each in- pulsion. Electronic versions of past tions, comments and suggestions
dividual report power generation, surveys are available at our website: should be directed to bhaight@die-
mechanical drive and marine pro- www.dieselgasturbine.com. Ques- selpub.com. CT2

Country Information For Regions/Regional Codes D&GTW Annual Market Surveys

Western Europe Bosnia and Herzegovina Israel Malaysia Central, West, Mauritania Costa Rica
Andorra Bulgaria Jordan Marshall Islands East & South Africa Mauritius Cuba
Austria Croatia Kuwait Micronesia Angola Mozambique Dominica
Belgium Czech Republic Lebanon Palau Benin Namibia Domin. Republic
Denmark Estonia Oman Papua New Guinea Botswana Niger El Salvador
Finland Georgia Qatar Philippines Burkina Faso Nigeria Guatemala
France Hungary Saudi Arabia Samoa Burundi Rwanda Haiti
Germany Syria Singapore Cameroon Senegal
Kazakhstan Honduras
Greece Turkey Solomon Islands Cape Verde Seychelles
Kyrgyzstan Jamaica
Iceland United Arab Emirates Tahiti Cen. African Rep. Sierra Leone
Liechtenstein Latvia Yemen Mexico
Lithuania Tonga Chad Somalia Nicaragua
Luxembourg Thailand Comoros South Africa
Italy Moldova Far East Panama
Tuvalu Congo Sudan
Ireland Poland China Puerto Rico
Vanuatu Cote dIvoire Swaziland
Malta Republic of Macedonia Hong Kong Virgin Islands
Vietnam Djibouti Tanzania
Netherlands Romania Japan West Indies
Equatorial Guinea Togo
Norway Russia Mongolia
Central Asia Eritrea Uganda
Portugal Serbia North Korea South America
Afghanistan Ethiopia Zaire
San Marino Slovac Republic South Korea Argentina
Bangladesh Gabon Zambia
Slovenia Tajikistan Taiwan Bolivia
Spain India Gambia Zimbabwe
Turkmenistan Maldives Islands Ghana Brazil
Sweden Ukraine Southeast Asia Chile
Switzerland & Australia Nepal Guinea North America
Uzbekistan Pakistan Guinea Bissau Canada Colombia
United Kingdom Australia
Sri Lanka Ivory Coast U.S.A. Ecuador
Brunei
Middle East Kenya Guyana
Eastern Europe, Burma
Russia & CIS Bahrain Cambodia North Africa Lesotho Central America & Paraguay
Albania Cyprus Fiji Islands Algeria Liberia Caribbean Peru
Armenia Egypt Indonesia Libya Madagascar Bahamas Surinam
Azerbaijan Iran Kiribati Morocco Malawi Bermuda Uruguay
Belarus Iraq Laos Tunisia Mali Belize Venezuela

JUNE 2014 40 Compressortech2

CT398.indd 4 5/20/14 2:25 PM

 The compressor improvements you need productivity, Our Best
reliability and environmental compliance are the direct

result of what we do in Cook manufacturing and service Practices,

Your Best
centers around the world. Thats why our World of Quality

initiative is constantly striving to make sure our people,

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results for you.

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See Whats Happening at Cook Now

Cook.indd 1 3/18/14 1:46 PM

KB_Delta.indd 1 5/20/14 4:11 PM
KB_Delta.indd 2 5/20/14 3:51 PM
 Pump
Sundyne Expands GSP tech
Pump Range > Sealless, magnetic-drive centrifugal
pumps meet API specs
By Norm Shade

n Sundyne GSPV magnetic-drive, sealless, centrifugal pumps (left) are available at 1450 to
3500 rpm with nine hydraulic configurations and two frame sizes ranging (above) in head
capability to 400 ft. (122 m) and flow rates up to 1000 gpm (227 m3/hr).

S
undyne LLC is well along on
a five-year plan to expand its
product portfolio and capture
new business.
The company is known for its en-
gineered centrifugal pumps and
compressors for the oil and gas pro-
cessing, chemical and petrochemical
industries, power generation, general
industry and engineered water.
Sundyne products include a broad
range of centrifugal pumps engineered
to meet industry standards including
API 610 (ISO 13709), API 685 and
ASME B73.3. The pump line includes
separately mounted, close-coupled
and gear-driven; single- and multi-
stage; sealless magnetic drive; metallic
or nonmetallic; high-pressure; and in-
line, vertical, and vertically suspended
models. The companys legacy pump
brands include Sundyne, Ansimag,
Sunflo, HMD Kontro and Marelli.
Last year, Sundyne launched the
vertically mounted General Service
Pump Vertical (GSPV) inline cen-
trifugal range that combined its API
685 expertise with the benefits of a
magnetic-drive sealless pump in a
compact package. And this year, it in-
troduced new high-pressure and low-
flow variants of the GSP design.
Mechanical seals are widely regard-
ed as the weakest point in any pump-
ing system. It is generally acknowl-
edged that about 80% of pump failures
involve mechanical seal failure, leak-
age through static seals, and/or bear-
ing failure. By completely eliminating
the seal and associated seal support
system, the Sundyne GSPV range of
pumps is suitable for handling liquids
that are toxic, lethal, carcinogenic,
flammable, expensive, or sour (H2S),
as well as caustic fluids containing
dissolved solids, high-vapor pressure
liquids, heat-transfer fluids, etc.
Sundyne has been building seal-
less magnetic-drive pump units for the
oil and gas industry since 1983. With
the increasing demands for the safety
and protection of personnel and the
environment, Sundyne said sealless
pumps are playing an ever-greater
part in maintaining these goals. Im-
proved magnetic-drive technology
has enabled more efficient and pow-
erful pumps to be built, including high-
pressure units, thus increasing the
application scope for this technology.
When Sundyne provided the first
sealless pumps to the oil and gas
continued on page 46

june 2014 44 Compressortech2

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Mayakawa_Jun14_CT.indd 1 5/19/14 4:30 PM

industry, the American Petroleum
Institute (API) did not have an appli-
cable standard for sealless technol-
ogy, so they were designed to follow
the then-current API 610 standard. It
started with Sundyne legacy brand
HMD Kontro supplying API 610 cen-
trifugal pumps for petroleum, petro-
chemical and natural gas applications.
Since much of the API 610 standard
concerns seals and seal support sys-
tems, a considerable portion of the
specification was not applicable to
Sundyne sealless API pumps.
In 2000, API introduced its Stan-
dard for Sealless Centrifugal Pumps
for Petroleum, Heavy Duty Chemical
and Gas Industry Services (API 685).
By that time, sealless technology had
become accepted in the chemical pro-
cessing industry, but it had not been
as widely accepted in the refinery and
petroleum industries. Sundyne said its
GSPV range of pumps is designed to
comply with all of the requirements set
out by API 610 and API 685, including
the second edition published in 2011.
With a magnetic-drive pump, there
is no opportunity for leaks or emis-
sions. Because there are no seals
and thus no resultant leak path to lu-
bricate, the risk to personnel is greatly
reduced. Additionally, there is no need
june 2014 46 Compressortech2
CT393.indd 2
n The Sundyne HPGSP separate horizontally mounted magnetic-drive, sealless, centrifugal
pump design (left) is available in eleven hydraulic configurations and two frame sizes. The per-
formance parameters (above) include heads to 700 ft. (213 m), flows to 1500 gpm (341 m3/hr),
temperatures from -150 to 500F (-100 to 260C), and pressures to 2700 psig (185 bar).
for environmental monitoring of the
seal system and no requirement for
complex seal support systems. Sun-
dyne officials said that GSPV pumps
reduce the likelihood of accidents, vir-
tually eliminate emissions, and save
time and money in system design, in-
stallation and maintenance.
The vertically mounted inline GSPV
range requires a small footprint, which
is ideal for use in applications, includ-
ing offshore, where space is at a pre-
mium. The GSPV single-stage, seal-
less, magnetic-drive pump range is
available in two basic frame sizes to
suit power requirements and nine hy-
draulic sizes. Silicon carbide internal
bearings support the rotating assem-
bly and are lubricated by the process
fluid. Various standard flange options,
secondary containment systems and
a wide range of instrumentation sys-
tems are available, as well as an op-
tional high-efficiency ZeroLoss com-
posite shell on large hydraulic sizes.
GSPV pumps are available at 1450
to 3500 rpm with nine hydraulic con-
figurations ranging in head capabil-
ity to 400 ft. (122 m), flow rates up to
1000 gpm (227 m3/hr), temperatures
of -40 to 400F (-40 to 205C), and
design pressure ratings up to 580 psig
(40 bar). Higher-pressure ratings up
to 1450 psig (100 bar) are available
upon request.
The company said that GSPV
pumps are particularly applicable to
industries such as refining, petro-
chemical, gas and similar industrial
sectors where volatile, toxic, hazard-
ous, corrosive or aggressive liquids
are handled. The sealless pump is
particularly suited to environments
that are hot or caustic, such as those
in petrochemical refineries.
Sundynes new High Pressure
General Service Pump (HPGSP) is
also based on the HMD Kontro GSP
sealless magnetic drive and built to
API 685 specifications for heavy-duty
pump applications. The separate hori-
zontally mounted design is available
in eleven hydraulic configurations and
two basic frame sizes.
The performance parameters for
the HPGSP include heads to 700 ft.
(213 m), flows to 1500 gpm (341 m3/
hr), temperatures from -150 to 500F
(-100 to 260C), and pressures to
2700 psig (185 bar).
Sundyne said that the pumps are
especially suited to sampling systems
(both onshore and offshore), volatile
liquids in the refining and petrochemi-
cal industries and chemical process
applications that feature increased
suction pressures.
Sundynes new General Service
Pump Low Flow (GSPLF) fills a gap
in the market for a low-flow sealless
5/22/14 9:53 AM
 n Sundynes new General Service Pump Low
Flow (GSPLF) pump (left) fills the need for a low-
flow sealless pump with a relatively high
head capability. It combines
the proven technologies of
Sundyne Barske wheel
hydraulics with the HMD
Kontro sealless magnetic
drive. The GSPLF perfor-
mance (below) ranges to
heads of 720 ft. (219 m) and
flows to 380 gpm (86 m3/hr).
applications with optimized hardware
to fit precise design requirements. The
semi-open impeller design reduces ra-
dial and axial bearing loads on the prod-
uct lubricated internal bearing system.
Optional inducers are available for low
head performance without cavitation.
Build options for the GSPLF include
a high efficiency ZeroLoss contain-
ment shell, secondary control system,
secondary containment system, ex-
ternal filtration, inducers, NACE-com-
pliant materials, vertical mounting,
and various instrumentation options.
GSPV, HPGSP and GSPLF pumps
are manufactured at Sundynes HMD
Kontro facility in Eastbourne, United
Kingdom. Sundyne serves customers
in more than 117 nations with its net-
work of representatives and distribu-
tors. It has 1000 employees, about
half of which are in the United States.
The company has manufacturing and
service facilities in Arvada, Colorado;
Warminster, Pennsylvania; Dijon,
France; Illescas, Spain; Shanghai
and Tokyo. CT2

pump with a relatively high head ca-

pability. The GSPLF pump combines
the proven technologies of Sundyne
Experience, Reliability, Integrity...
Barske wheel hydraulics with the
HMD Kontro sealless magnetic drive.
Like the rest of the GSP range, the
GSPLF meets all requirements of API
685 and is fully ATEX compliant, mak-
ing it suitable for use in oil and gas
installations and petrochemical and
chemical process applications.
The performance parameters for the
GSPLF include heads to 720 ft. (219
m), flows to 380 gpm (86 m3/hr), tem-
peratures from -40 to 500F (-40 to
260C), and pressures to 580 psig (40
bar). Upon special request, higher and
lower application temperature limits of
600F (315C) and -148F (-100C),
respectively, and pressure ratings up to
1450 psig (100 bar), are available.
The GSPLFs removable diffuser
allows for re-rating and easy on-site Now with three plants totaling
conversion for different process con- over 400,000 SF on 53 acres
ditions. The pump has generous clear-
ances and no wear rings that would
degrade performance over time.
The Barske hydraulics provide opti- (918) 283-9200 Fax (918) 283-9229 www.axh.com
mized efficiency in low specific speed

june 2014 47 Compressortech2

CT393.indd 3 AXH.indd 1 5/22/14

2/17/14 9:53
9:06 AM
AM
 Natural Gas Contaminants In
Compressor Feeds > Effective strategies must be based on
careful evaluations
By David Engel and Michael Sheilan

and some liquid-like solids, most con-

taminants often enter the gas process-
ing units untouched. Only a minority
number of plants have the necessary
means to adequately condition sour
gas for processing because of the di-
verse nature of its contaminants.
The most difficult and challenging
contaminants in any gas stream are
small aerosols. These are finely di-
vided liquid particles with diameters
ranging from a few hundred microns
to less than 0.1 .
Basically, the reason for this ineffi-
ciency is directly related to the aerosol
droplet size distribution and the flow
pattern geometry inside the separator
vessel. In other words, the separation
media is not capable of separating small
liquid droplets. Most aerosols just travel
n Figure 1. This graph shows typical liquid aerosol size distribution at the intact across the vessel without being
outlet of a compressed gas stream. separated from the main gas stream.
The vessel design is also fundamen-
tal. In some instances, the separation

I
nlet gas separation upstream of separators with a vane, or cyclonic el- media could be appropriate; however,
processing units and compres- ements or stages. if the liquids removal from the vessel
sors is far more common for gas All these systems are not entirely or the internal flow pattern is deficient,
streams as opposed to liquid streams adequate for an effective inlet con- the vessel will experience consider-
because of its prevalent and diversi- taminant removal from sour gas feeds. able decrease in efficiency. Additional-
fied contamination profiles. Similarly, These systems are typically designed ly, some defective vessel designs may
inlet separation is far more common for bulk liquids removal and large aero- actually shatter and disperse liquids in
in gas processing operations as op- sol droplet sizes. In addition, none of the gas stream manifested as much
posed to refinery activities. these devices is really designed for sol- smaller droplet sizes, adding difficulty
Inlet gas separation is usually con- ids separation (usually done effectively to the separation process.
ducted through the use of a knock- by a wet scrubber or a particle filter). The aerosol contaminant distribution
out drum equipped with a demister With the exception of cyclonic sys- in a gas stream is primarily in the sub-
section, using a mesh pad or a vane tems and some filter separators that micron range. Larger droplets tend to
pack. Some plants use horizontal filter could remove certain solid particles not be as persistent in the gas stream
since the larger droplets are more likely
David Engel has more than 20 years of industrial experience and is the inventor in 15 to gravitationally separate. Larger drop-
U.S. patents. He recently has focused on new technologies for efficiency, reliability and lets are also more likely to shatter as
throughput increase. Engel is president of the American Filtration & Separations Society a result of the shear forces applied to
(Southwest Region) and is managing director of Nexo Solutions. Contact him at: david. the droplet surface. When large drop-
engel@nexosolutions.com. Michael Sheilan is a chemical engineer with 32 years of ex- lets shatter, they create progressively
perience in the gas processing industry, primarily in processes and chemicals used in smaller droplets until the distribution
gas treating. The author of several papers, he is a senior consultant at Amine Experts, is stabilized by the balance between
a division of Sulfur Experts. continued on page 50

June 2014 48 Compressortech2

cT401.indd 1 5/22/14 2:08 PM

Diese Version ist die Druckversion.

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NEUMAN & ESSER USA, Inc.

Located in Katy, Texas (HQs) and
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www.neuman-esser.com
Contact me for Canada and Alaska:
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Sales Manager
melnykk@neuman-esser.com
Direct Phone: +1 403-831-1936

NEA GROUP Headquarters in Germany

NeumanEsser.indd 1 5/15/14 2:43 PM

 n Figure 2. These are examples of a knitted mesh mist pad (left) and vane pack mist elimination device (right).

surface energy, gravitational settling streams in gas processing operations Sour gas conditioning
and shear forces. The distribution of a is coalescing devices using microfiber A typical inlet separation setup is
persistent aerosol in a gas stream can media materials (a microfiber submi- usually comprised of a large capacity
be as much as 50% by weight smaller cron coalescer). These can effectively vessel for bulk liquids removal. This
than 1 and nearly 80% by weight interact with small aerosol liquid drop- will also act as a slug catcher. These
smaller than 10 (Figure 1). lets. If the coalescer element is built vessels can sometimes be equipped
Devices such as demisters equipped correctly, the intercepted liquid will with a mesh pad or vane pack for liq-
with vane packs, mesh pads, low per- be effectively coalesced and drained uids coalescing. These devices are al-
formance coalescers and cyclones from the element (fast) avoiding flood- most always required and should not
are relatively ineffective at capturing ing and further liquids re-entrainment. be avoided; however, these should be
the most penetrating aerosols (0.1 It is important to note that many fab- used only for bulk liquids removal.
to 1.0 ). In instances, these are also ricators advertise systems capable of Downstream of these systems,
unable to properly separate the aero- removing submicron liquid aerosols. there has to be another microfiber
sols that they capture because of the Most do not correlate these claims submicron coalescer separator. This
lack of coalescing power or flooding of and expectations with actual perfor- system is equipped with specially for-
the element. mance. Only a small number of com- mulated microfiber coalescing media
Mesh pads do not have a fiber size or panies possess the proper technol- that has the ability to intercept and
fiber density to interact with small aero- ogy to supply microfiber submicron coalesce submicron aerosols, and to
sols. Vane packs are ineffective as they coalescer systems. drain liquids effectively.
form an interface layer at certain points,
and small aerosols cannot effectively
contact the metal surface. In addition,
the small momentum of the aerosols
also contributes to the inefficiency. Both
mesh pads and vane packs have rather
small operating windows and are prone
to fouling and loading.
These inefficiencies are also seen
in many other systems that use poor
coalescing elements, incorrect media
and materials selection and deficient
vessels from the standpoints of de-
sign, instrumentation, operation and
maintenance. Figure 2 shows exam-
ples of a vane pack and a mesh pad.
Today, the technology of choice for n Figure 3. This shows liquid coalescence: droplet interception, droplet coalescence
high-efficiency removal of submicron and liquid drainage.
aerosols that negatively plague gas

June 2014 50 Compressortech2

CT401.indd 2 5/21/14 10:21 AM

 aerosols between 0.1 and 1.0 in
diameter. This is virtually most of the
liquid aerosol contamination in a gas
stream. These systems can be pro-
tected with an upstream particle gas
filter (equipped with the proper sepa-
ration media) in order to extend the
online life of the coalescer elements
and minimize operational costs as the
replacement separation elements for
particle filtration are substantially less
expensive than coalescing elements.
Microfiber submicron coalescer
vessels have two stages. The best
system designs have the inlet on the
bottom section, which is designed
to remove larger liquid aerosols and
some limited bulk liquids. The upper
section is where the efficient submi-
cron separation takes place. The bot-
tom section is sometimes fitted with
a mesh pad, vane pack or cyclonic
elements. None of these has been
continued on page 52

n Figure 4. Drawings show a liquid/gas

demister (top) and a high-efficiency sub-
micron coalescer (bottom).

Submicron liquid particles compose

more than 50% of the total liquid con-
taminant species in a gas stream. For
effective liquid coalescence in a gas
stream, the system must perform effi-
ciently in all of the following three events
taking place in these systems: liquids
interception, liquids coalescence and
liquids discharge. Figure 3 graphically
illustrates this sequence of events that
occur inside a liquid coalescer vessel.
Microfiber submicron coalescer de-
vices (Figure 4) are carefully designed
based on the flow, pressure and tem- Replacement OEM Filter Elements
perature (both operation and design) Not Just Look-Alike Perform Alike
and must be installed as close as pos-
sible to the equipment or process that Made in America
requires protection. Typical design
Stocked for Shipment
of a microfiber submicron coalescer
will have the capability of removing,
281-951-0202 www.switchfiltration.com Houston, TX
on average, a minimum of 99.9% of

June 2014 51 Compressortech2

CT401.indd 3 Switch.indd 1 5/15/14

5/22/14 10:08 AM
9:56 AM
 cause of absorber foaming. This led to Gas exploration and production
high H2S concentrations in the treated operations and equipment types
gas (making it unable to meet the re- Chemical additive use (type and
quired 4 ppm H2S specification), and dosage)
causing the plant to flare a consider- Contaminant types and concen-
able volume of the gas. As can be trations
observed in Figure 5, the plant had to Aside from heavy hydrocarbons
flare gas, causing emissions and loss and acid gases (H2S and CO2), feed
of revenues. streams can contain other sulfur-
bearing species (COS, CS2, RSH, etc.)
Inlet gas contamination and also many other contaminants.
Proper gas inlet contamination con- The most common contaminants are
trol prior to any gas processing is es- outlined in the following list, indicating
sential for plant stability, performance their likely origins and process impacts:
and low operational costs. This is of- Asphaltenes. These are macromol-
ten achieved when there is thorough ecules (molecules with high molecular
understanding of virtually all inlet feed mass: 400 to 1500 kg/kmol) that are
contaminants in the gas stream and the native to the crude oil (Figure 6). They
information is taken into consideration can be crystalline or an amorphous
n Figure 5. This was a plant flare before when determining what separation (gel) depending on the exact structure
installation of a coalescer. process and system is used. Inlet con- and process conditions. They can con-
tamination in gas processing can vary tain a number of different metals such
drastically and depends on a number as vanadium, nickel and iron. They can
properly proven to enhance efficiency. of factors, including the following: also contain many organic components
In fact, some of these are detrimental Geographical location and geo- such as thiophene, benzothiophene
for the vessel operation. Both sections logical formation and other cyclic sulfur-containing spe-
must be fitted with a liquids level vi-
sualization, controls and drain valves.
The gas then leaves the bottom
chamber flowing immediately above
into the second stage via the co-
alescing elements (inside-to-outside
flow). This is where the gas is passed
through the formulated microfiber co-
alescing media. The fine aerosol liq-
uids are intercepted, coalesced and
finally drained from the elements by
gravity. The purified dry gas then exits
from the top of the vessel.
It is important to mention that key
considerations are required when
designing the drain and level control
systems to ensure that the elements
remain clear of liquid, whereby satu-
ration of the elements would render
them ineffective for properly remov-
ing liquids from the element and ves-
sel interior. Even the best coalescing
devices are rendered ineffective if the
instrumentation and control schemes
are not functioning well.
Figure 5 illustrates the fundamen-
tal importance of proper inlet contami-
nant separation in feed gas steams.
The picture shows a gas plant in the
Middle East that was unable to pro- n Figure 6. Some general structures of asphaltenes are shown.
cess the majority of the sour gas be-

June 2014 52 Compressortech2

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 n Figure 8. The schematic
structure of typical waxes
is shown.

Corrorision ad_Layout 1 5/14/2014 5:15 PM Page 1

RELIABLE
n Figure 7. These paraffin waxes were
removed from an inlet separator.

Synthetic Lubricants
cies, aromatic rings, long aliphatic
chains and any functional groups.
Because of rather poor solubil-

Corrosion Protection
ity properties in some hydrocarbons,
asphaltenes can be present as solid

Hydrogen sulfide (H2S) and carbon dioxide (CO2)

particles and can assist in foam and

are known as acid gases. If free water is present, it

emulsion formation in amine units or
glycol units and have been known to
retrograde condense in downstream will react with these acid gases to form ver y corrosive
compounds. These compounds can quickly corrode
process units such as desiccant dehy-

coolers and separators, result in bearing failures,

dration towers. They are also respon-
sible for valve plugging in absorbers.
The presence of these components change the performance ratings of valves and
reduce pressure ratings for vessels and piping.
can be eliminated by filtration, solvent
treatment (solubilizing asphaltenes) or
chemical additives (modifiers known as Summit lubricants are formulated with high quality
dispersants). These additives change additives to prevent corrosion from acid gases and
saltwater. They are specialized gas compressor
the surface of the asphaltene molecule
in such a way that agglomeration of
the particles doesnt occur and solids lubricants for gas compressor applications. They
are minimized. are not gas engine oil, air compressor, transmission
or gear oils that are placed into gas compressor
Waxes. These are usually solid crys-
talline deposits, soluble in crude oil and
other hydrocarbon streams (Figure 7). service.
They can have carbon linear alkane

Call us for Free Technical Support...we can help!

chains or cyclic component chains
varying from C18 to C65 (Figure 8).
Waxes are native components in
some gas streams and can have a
more pronounced impact as result of

Summit
temperature and pressure variations
in the gas stream.
As with asphaltenes, waxes are
prone to depositing in many locations
within a process unit, disrupting prop- Industrial Products
800.749.5823
er flow hydraulics in absorbers and re-
generators, heat exchangers, valving
and flash drums. Separation of these

www.klsummit.com
components is fairly difficult. Filtration
using specialized media is used for
continued on page 54

June 2014 53 Compressortech2

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5/20/14 9:53 PM
AM

n Figure 9. This is an example of salt deposition on a compression system.
wax separation. Care has to be taken
for certain gelatinous waxes. Other
options are the use of upstream cold
sections to condense and sometimes
solidify the waxes.
Water. Sour gas streams containing
water are far more corrosive compared
to their dry versions. This is caused by
the hydrolysis or dissociation of the
acid gases in water. Gas streams are
normally saturated with water vapor
at the hotter wellhead conditions, so
water is a constant contaminant in
the production and processing of sour
gas streams as the gas stream cools
during pipeline transportation.
Some water and produced water
streams can contain very high salts
concentration (i.e., brine, hardness,
etc.) causing not only gas processing
unit contamination but also compres-
sor failures by solids accumulation
and gasket degradation. Hence, in-
let separation has to minimize liquid
water breakthrough because it is im-
portant to keep fouling and corrosive
components out of gas processing
units systems. This is achieved by us-
ing a horizontal two- or three-stage
phase separation vessel with a proper
design and fabrication.
Oxygen. The presence of oxygen
causes the oxidation and corrosion in
June 2014 54 Compressortech2
CT401.indd 6
several equipment locations. It also pro-
duces heat-stable salts and oxidation
products in gas processing solvents
usually found downstream of compres-
sors. Heat-stable salts are contami-
nants that do not regenerate under nor-
mal process conditions in amine units
causing a decrease in the units effi-
ciency and enhancing corrosion rates.
Many contaminants can also cause
foaming solvent. It is always better to
remove oxygen at the source. Oxygen
is a very reactive species so it has usu-
ally reacted with a number of compo-
nents prior to entering an amine or gly-
col system, but even the presence of 1
or 2 ppmv of oxygen is enough to form
a considerable amount of heat-stable
salts and oxidation products gas pro-
cessing solvents. Many operators ask,
How much oxygen is too much oxy-
gen? and the correct answer would be
Anything more than zero ppmv.
Oxygen must not be allowed to en-
ter an amine or glycol process. A num-
ber of upstream systems can cause
oxygen ingression (primarily associ-
ated with vapor recovery systems in
oil production facilities). Possible al-
ternatives are oxygen scavenger beds
or oxygen scavenging chemical addi-
tives. Oxygen will not be removed in a
typical inlet separation device.
Mercury. This is a highly toxic, bio-
accumulative heavy metal. It interacts
with certain metals causing amalga-
mation and leading to catastrophic
equipment failures. The deleterious
effects of elemental metallic mercury
(liquid) are most prevalent in liquefac-
tion plants utilizing braised aluminum
heat exchangers; however, many gas
feeds can have mercury contaminants.
Due to the extreme cold tempera-
tures in liquefaction processes, alumi-
num is the preferred exchanger met-
allurgy because it is not as brittle as
steel. Separation in gas streams is ac-
complished by solid scrubber beds and
impregnated solid-state beds. These
can be activated carbon or zeolites
impregnated with sulfur components.
These impregnated materials react
with certain mercury forms resulting in
the formation of mercury salts within
the bed. One caution prior to installing
any mercury-removal technology is to
consider mercury disposal once it is
separated. Also, it is recommended to
thoroughly and rigorously character-
ize the mercury contaminants to be
separated, as not all mercury contami-
nation is elemental mercury. Mercury
contamination, in general, falls into the
following categories:
Elemental liquids mercury
Mercury ions (water-based)
Solid mercury salts and/or oxides
Organo-mercury (gas phase)
species.
All of these mercury contamination
forms require different removal strate-
gies and methods.
Sulfur (elemental). This acts as
an oxidizer and also degrades gas-
processing solvents, similar to the ef-
fect of oxygen contamination. Elemen-
tal sulfur is highly corrosive and is diffi-
cult to remove it with filtration because
of the large mass that can accumulate
in the filters (demanding specialized
filters to accommodate large mass
quantities). In principle, cyclone devic-
es can also be instrumental in remov-
ing elemental sulfur. Elemental sulfur
can lead to significant corrosion in hot
areas of process equipment such as
reboilers and compressor system.
A big problem with elemental sulfur
ingress is that it is difficult to detect
5/20/14 2:43 PM
 because it tends to enter in discrete could result in regenerator instability. in the glycol or amine solution at the
batches rather than as a steady com- The best method for methanol remov- colder temperatures of the absorber,
ponent of the feed stream. Millipore fil- al is to minimize its use upstream in but precipitate at hotter temperatures
tration (using a 0.45 inert membrane) combination with a washwater injec- or when water is evaporated (Figure 9).
is the prime source of detection of ele- tion point upstream of a microfiber This leads to severe scaling problems
mental sulfur. These filter membranes submicron coalescer device. in high-temperature heat exchanger
can be clean and clear in one test and Salts. These can be primarily calci- surfaces and compressor internals.
then completely full of elemental sul- um and sodium chlorides, and are sol- Chloride salts can also lead to chlo-
fur only one-half hour later. This shows uble in the water phases of both amine ride-induced stress corrosion crack-
the variability in sulfur ingress. and glycol systems. Many salts are ing of stainless steels and they also
Ammonia. Ammonia is very solu- inversely soluble in the process fluid, aggravate crevice or under-deposit
ble in gas processing solvents, so the meaning that significant salt dissolves continued on page 56
presence of any ammonia in the feed
streams will result in significant quan-
tities of ammonium salts and ammo-
nia contamination, which concentrate
in certain locations causing enhanced
corrosion and solids deposition prob-
lems. Ammonia is an inorganic nitro-
gen base and will react with both H2S
and CO2 to form ammonium salts that
will precipitate at relatively cool tem-
peratures in compressors, reflux con-
densers, pressure and flow control
valves and even in the downstream
sulfur recovery unit (waste heat boiler
tubes, for instance).
Ammonia ingress is very prevalent
in refinery operations, but rare in natu-
ral gas treating. Refiners usually purge
the reflux loop continually to mitigate
the effects of ammonia build-up in the
reflux loop. Natural gas plants do not
generally have to perform any system
remediation for ammonia removal.
Methanol. This component is used
all over the world as a hydrate inhibitor
and a co-solvent for chemical additives
for low temperature use. Methanol is CAMGT 3V-600

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often over-injected because opera-
tors would rather be safe than sorry.
Hence, significant methanol quantities
can enter with feed gases and liquids.
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on the performance of inlet separation devastating pit stops - Camfil filters will provide maximum engine uptime to
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into the separation devices, possibly
designed Inlet Air System or contact your local Camfil representative.
destroying their efficiency. Methanol
also dissolves in amine and is usu-
ally flashed in the regenerator caus-
ing regenerator foam-like conditions
or liquid carryover due to the violent
flashing at the conditions at the top of CLEAN AIR SOLUTIONS

the regenerator. Methanol may also

concentrate in the reflux loop, which

June 2014 55 Compressortech2

CT401.indd 7 Camfil.indd 1 5/22/14 10:33

5/13/14 9:55 AM
AM
 causing corrosion and/or heat-stable
salts formation.
The second type of additives are
corrosion inhibitors, which can have a
wide array of formulations. However,
most of the problems are caused by
quaternary ammonium salts and oth-
er similar surfactant-like molecules.
These are foam stabilizers and can
cause most coalescence media to be
ineffective due to the change in surface
tension of the media material. Remov-
ing the injected chemical additive is
often unlikely; hence, the proper solu-
tion is to change the chemical additive
formulation for nonfoaming versions.
However, certain companies claim to
have coalescing medias that can en-
dure additive presence. To date, these
claims have not been corroborated.
Iron sulfides and iron oxides.
n Figure 10. Lube oil and water are separated downstream of a compressor. Iron sulfides and some oxides can
originate from the formation itself.
More commonly, these are from cor-
corrosion in process equipment. Salts tamination at the outlet of compressor rosion and oxidation in exploration
must be effectively removed at the system (and its infrared analysis). and/or from production activities and
available separation devices upstream Chemical additives. There are equipment such as tubing and pipe-
of the processing units, so it is impor- essentially two types of chemical line transport. The iron sulfide causes
tant that any separation process is as additives that cause problems in plugging of absorbers, pump strain-
efficient as possible. In gas streams, gas-processing units. The first are ers, heat exchangers, valves and
salts can be found as a solid suspend- acids (fracture, organic), which can regenerators. These solids are also
ed in the gas phase, hence, filtration is enter any downstream processing unit excellent foam stabilizers resulting in
a good option for removal as is a water
injection upstream of the separating
vessels provided that they can handle
multiphase settling and separation.
However, salts can also be dissolved in
water droplets carried over in the gas
phase. Separation of the latter is con-
sistent with the water-removal section
discussed previously.
Compressor lubrication oils. Com-
pressor lubrication (lube) oils contain
multiple components for various func-
tions (detergents, lubricity, friction re-
ducers, etc.). Many of the formulation
components would be considered sur-
factant in nature. These surfactants,
if not separated properly by the inlet
separation devices, will definitely act as
foam promoters and foam stabilizers in
amine and glycol systems.
Microfiber submicron coalesce de-
vices are the best technology for cap-
turing lubrication oil carryover that oc-
curs in every upstream compressor. n Figure 11. Iron sulfides are plugging an inlet gas separator.
Figure 10 shows the lubrication oil con-

June 2014 56 Compressortech2

CT401.indd 8 5/20/14 2:44 PM

 solutions that do not react as quickly ously outlined. It is also important to tion systems be closely monitored for
or effectively to antifoam addition. Sol- have correct vessel designs and in- online performance by measuring the
ids, such as iron sulfides, can be re- ternals as these are the heart of any contamination levels in the inlet and
moved by the particle filters installed separation system. outlet. This is necessary for adjusting
in upstream gas separation devices, Also, it is often a serious mistake to the system for optimizing the sepa-
but if these devices are not present design undersized vessels or vessels ration and sometimes to account for
the solids can easily enter any pro- with deficient internal gas flow ge- adjustments in feed conditions. This
cessing unit, disrupting normal op- ometries. These will invariably cause is the proper way to ensure that con-
erations. These can potentially cause contamination breakthrough and will taminants are not crossing the sepa-
fouling and foaming. Figure 11 shows cause instabilities in almost all down- ration devices, so each device can
solids (iron sulfides) plugging an inlet stream processing units. provide the best protection for its in-
gas separator. Finally, it is critical that all separa- dividual purpose. CT2
Silica and sand. Silica and sand
usually originate from reservoir for-
mations. These are quite prevalent
with oil sands and other produc-
tion operations where sand is pres-
ent. These contaminants can cause
equipment plugging, foam stabiliza-
tion and corrosion. For these rea-
sons, it is highly recommended that
these contaminants be removed prior
to processing. To eliminate these at
the source, proper de-sanding pro-
cedures (de-sanding is a process for
removing sand from vessels in up-
stream and refinery operations) must
be implemented. Most sand is associ-
ated with crude oil and its emulsions
(i.e., steam-assisted gravity drainage,
or SAGD). Sand and silica separation
in gas streams can be performed with
filters and in some instances with cy-
clonic devices or its combinations.

Conclusions
For proper gas conditioning for fur-
ther processing in compression sys-
tems, it is critical to understand the
contamination profile in the feed (inlet)
gas stream. Not only current contami-
nation, but also future contaminants
should be considered.
One example is shale gas, as many
plants prepare to incorporate this into
their feedstock. This gas stream has a
number of different and specific con-
taminants, and proper design for their
separation and removal has to be
evaluated prior to processing.
Understanding the contamination
profile will assist in determining the
proper separation system to be uti-
lized. Depending on the nature of
the contaminant (liquid phase, solid
phase or gas phase), the correct
strategy can be developed as previ-

June 2014 57 Compressortech2

CT401.indd 9 BG Services Island.indd 1 5/22/14

1/31/14 10:02
8:25 AM
AM
 13 Million HP Of Compression
Needed By 2035 > Strong growth seen for North American
gas transportation
T
he INGAA Foundation has re-
ported the United States and
Canada will need nearly 13
million hp (9700 MW) of compression
costing US$23.5 billion to accommo-
date new gathering and transmis-
sion pipelines over the span of 2014
to 2035.
That requirement is part of mid-
stream gas pipeline investments esti-
mated at US$14.2 billion per year, or
US$313.1 billion, in 2012 dollars. To-
tal midstream oil, gas, and gas liquids
pipeline investments would be US$30
billion per year, or US$641 billion total.
ICF International prepared the
study for Americas Natural Gas Al-
liance and the INGAA Foundation,
which is allied with the Interstate Nat-
ural Gas Association of America.
Most of the midstream natural gas
JUNE 2014 58 Compressortech2
CT400.indd 1
investments would accommodate new
production, particularly from the pro-
lific shale plays, and growing demand
for gas in power generation, industrial
applications and exports. Natural gas
midstream infrastructure includes
mainlines, laterals, processing, stor-
age, compression and gathering lines.
This report shows a vibrant natural
gas market in the future, and it also
demonstrates the need for additional
midstream infrastructure to support
natural gas fulfilling its potential as a
foundation fuel for our energy econo-
my, INGAA Foundation President Don
Santa said. The good news is that the
natural gas industry has a proven track
record of financing and constructing
this level of infrastructure.
The study said that supplemental
pipeline systems would be required to
n This stylized flow map reflects gas
supply/demand shifts in North America.
move gas, gas liquids and crude oil
from regions where with growing pro-
duction to areas with increasing de-
mand. Not all areas will require signif-
icant new pipeline infrastructure, but
most areas will require new invest-
ment to connect additional supplies
to markets.
In recent years, natural gas produc-
ers and marketers have been the prin-
cipal shippers on these new supply
push pipelines. These anchor ship-
pers have been willing to commit to
the long-term, firm contracts for natural
gas transportation service that provide
the financial basis for moving forward
with these projects. Going forward,
producers should continue to be mo-
tivated to ensure outlets for their gas
supplies via pipeline, the study said.
continued on page 60
5/20/14 9:09 AM
 Only the most efficient technology
ensures maximum availability.
Challenging customer requirements call for excellent compression solutions.

siemens.com/energy/compression

Answers for energy.

Siemens_CTSS.indd 1 1/23/14 8:27 AM


n Shale gas production is expected to dominate U.S. and Canadian natural gas
production in the foreseeable future.
Projections
The reports base case projects
real natural gas prices that average
US$6/MMBtu (in 2012 dollars) in the
long term. It said pipeline construc-
tion costs have risen to US$155,000
per inch-mile from US$94,000 per
inch-mile in its last study, published
in 2011. The report estimated aver-
age compression costs at US$2600
per horsepower. It assumed that
those costs would remain con-
stant in real terms over the entire
study period.
Natural gas consumption in the
United States and Canada was pro-
jected to increase by an average of
1.2% per year through 2035. Total
gas use across all sectors is pro-
jected to rise to an average of rough-
ly 106 Bcfd (3 x 109 m3/d) in 2035
from around 80 Bcfd (2.2 x 109 m3/d)
in 2013.
The ICF reference case projects
about 9 Bcfd (254 x 106 m3/d) of liq-
uefied natural gas (LNG) exports
from the United States and Canada,
and roughly 5 Bcfd (141 x 106 m3/d)
of pipeline exports to Mexico from
the United States in 2035. So, total
consumption for natural gas, includ-
ing gas leaving the United States and
JUNE 2014 60 Compressortech2
CT400.indd 2
Canada, rises to an average of about
120 Bcfd (3.4 x 109 m3/d) in 2035, a
1.8% annual increase.
About 75% of the incremental de-
mand growth within the United States
Natural Gas Capital Expenditures For The Base Case
2014-2035 (2012 $) Average Annual (2012 $)
Gas Transmission
Mainline Pipe
Laterals To/From Power
Plants, Gas Storage,
And Processing Plants
Gathering Line (Pipe Only)
Gas Gathering Line
Compression
Gas Lease Equipment
Gas Pipeline & Storage
Compression
Gas Storage Fields
Gas Processing Capacity
LNG Export Facilities
Total Capital Expenditures
n In the base case scenario, natural gas infrastructure investments
would total US$14 billion/yr.
and Canada occurs in the power sec-
tor, which is projected to account for
more than a third of total gas demand
by 2035. Today, the power sector ac-
counts for about 30% of gas use. Most
of the rest of the demand growth oc-
curs in the industrial sector, where
gas is used incrementally in petro-
chemical and refining operations.
U.S. and Canadian natural gas pro-
duction is projected to grow from an
average of 83 Bcfd (2.3 x 109 m3/d) in
2014 to an average of more than 120
Bcfd (3.4 x 109 m3/d) in 2035, adequate
to meet projected gas market needs.
Unconventional natural gas supplies
account for all of the incremental sup-
ply as production from conventional
areas declines. Unconventional sup-
plies (mostly shale plays) will account
for approximately two-thirds of the total
gas supply mix in 2035. Shale gas pro-
duction is expected to exceed half of the
total production over the next few years.
Of the various shale plays, the re-
port said the Marcellus is projected to
display the greatest growth, more than
doubling its current production of 13
Bcfd (368 x 106 m3/d) by 2035.
continued on page 62
Billions Of Real Dollars
$87.2 $4.0
$45.2 $2.1
$35.6 $1.6
$23.5 $1.1
$26.9 $1.2
$11.6 $0.5
$12.0 $0.5
$27.4 $1.2
$43.7 $2.0
$313.1 $14.2
5/20/14 9:10 AM
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Untitled-9 3 5/19/14 4:25 PM


n The ICF study predicts that gas prices will slowly climb to US$6/MMBtu by 2035.
Supply/demand changes
ICF drafted a stylized flow map re-
flecting changes that it predicts for
the North American gas market. They
included:
Over time, production increases
are greatest in the Marcellus pro-
duction area, the shale plays in the
southwestern production area, and
shale plays in Western Canada.
Increasing production from the
Marcellus shale play displaces
gas transport to the northeastern
United States and provides in-
cremental gas supplies to East-
ern Seaboard, midwestern, and
southeastern gas markets.
Flows through the Tennessee Val-
ley that originate from the Gulf
Coast decline over time as a result
of Marcellus production increases
displacing transport into the area.
Growing production from the Gulf
Coast mostly remains in that area
to meet local demand growth.
Incremental production from the
Southwest also flows to the south-
eastern states to satisfy increased
power-generation demand in
the region.
The Gulf Coast region of Texas and
Louisiana becomes home to most of
the LNG exports from North Ameri-
JUNE 2014 62 Compressortech2
CT400.indd 3
ca, with additional exports from the
East Coast and Western Canada.
Despite significantly growing pro-
duction from Western Canadas
shale plays, flows out of that area
decline significantly as much of
the incremental production re-
mains in the area to fuel its oil
sands development.
Incremental production flows to
British Columbias coastline to be
exported as LNG.
Growing Rocky Mountain produc-
tion mostly flows to the West Coast
to offset declines in transport from
Western Canada and the Permian
Basin of West Texas.
Ontarios increasing gas needs are
met via transport from the United
States as flows into the province
from Western Canada decline.
New Englands increasing gas
needs are met by Marcellus gas.
This gas will displace both flows
from Eastern Canada and gas
from the Gulf Coast region.
Capacity needs
ICF said about 43 Bcfd (1.2 x 109
m /d) of incremental natural gas main-
3
line capacity will be needed from 2014
to 2035 to accommodate new inter-
state gas supplies.
This is a modest increase of 0.2
Bcfd (5.6 x 106 m3/d) per year over
capacity additions in the 2011 study,
which projected 1.7 Bcfd (48 x 106
m3/d) of capacity added per year
through 2035, it said.
Regionally, the most noticeable ca-
pacity additions are out of the north-
eastern and southwestern states. The
northeastern capacity additions are
mostly driven by Marcellus and Utica
gas development. The southwest-
ern additions are driven by growth in
production from the Eagle Ford and
Haynesville shale plays, as well as a
number of other unconventional plays.
The Southwest also is home to sig-
nificant load growth, especially in the
form of gas exports to Mexico and at
LNG terminals, and growing petro-
chemical gas use. The southeastern
and central states will experience
significant capacity additions, mostly
to deliver gas to power plants. These
regions will see significant coal plant
retirements, with gas-fired capacity
serving as the primary replacement.
The majority of the capacity addi-
tions occur over the next decade. This
coincides with the robust production
and market growth expected during
the next five to 10 years. After that,
both production and market growth
slow, with natural gas pipeline expan-
sion slowing accordingly.
In addition to the new capacity addi-
tions, pipeline laterals will be required
to connect directly to new facilities
and new consumption points, and
new gas processing will be needed to
remove liquids and make gas suitable
for pipeline transportation and down-
stream consumption.
ICF said the largest share of re-
gional investment in midstream infra-
structure would occur in the South-
west (New Mexico, Texas, Oklahoma,
Louisiana, and Arkansas), which
historically has been an area of sig-
nificant hydrocarbon development.
Midstream infrastructure investment
in this area is expected to total more
than US$220 billion throughout the
projection period.
The Northeast also is poised for
midstream infrastructure growth,
with investments totaling more than
5/20/14 9:11 AM
 US$80 billion throughout the projec-
tion. The area is home to gas-prone Innovative Bolting Solutions
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infrastructure.

Conclusions
Some of the main findings from the
report are:
Significant infrastructure will be
needed to support growing gas use.
The base case, which assumes
US$100 per barrel of oil and shows
gas prices rising from US$4/MMBtu
to an average of US$6/MMBtu in
the longer term, and is considered
a middle-of-the-road scenario.
The base case projects signifi-
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Approximately 43 Bcfd (1.2 x 109
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That would amount to about 850
mi. (1365 km) per year in new gas
transmission mainline. Superbolt.indd 1 5/15/14 1:37 PM

O  ver 800 mi. (1290 km) per year in

new laterals to/from power plants,
processing facilities, and storage
fields should be constructed.
Almost 14,000 mi. (22,500 km) per
year in new gas gathering lines
would be required.
Approximately 35 Bcfd (991 x 106
m3/d) of new gas processing capa-
bility is projected.
About 37 Bcfy (1 x 109 m3/yr) in
new working gas storage capac-
ity would be built.
M  ore than 580,000 hp (432 MW)
per year for pipeline and gathering
compression would be required.
A  bout 9 Bcfd (1 x 109 m3/d) of new
LNG export capacity should be
developed.
Even under a low-growth scenario,
substantial new midstream infra-
structure will be needed totaling
US$465 billion, only 27% lower
than under the reference case. CT2

JUNE 2014 63 Compressortech2

CT400.indd 4 5/22/14 10:03 AM

Shinkawa_June14_WW.indd 1 5/12/14 10:43 AM
 The Electric LNG Option For
The U.S. > GE explains electric motor-driven compression technology By Roberto Chellini

T
he U.S. has seen a startling
reversal of its energy fortunes
over the last five years: the com- n This 81,800 hp (61 MW) motor
bination of a shale gas boom, good for the Prelude field LNG trains was
electrical infrastructure as well as on- shipped to GE Oil & Gass Massa,
going concerns about CO2 emissions Italy, facility for a full load test.
have been driving the development of
eLNG (electric liquefied natural gas).
COMPRESSORtech2 interviewed
Francesco Falco, general manager of
the oil and gas vertical for GEs Power
Conversion Business to learn more
about eLNG development.
By eLNG I mean the liquefied natural
gas supply chain enabled through full
electric motor-driven compression tech-
nology in the processing, transport and
distribution network for LNG as alterna-
tive to the traditional turbines driven de-
vices, Falco said. It is a fast-emerging
and efficient means of extending the
reach of natural gas resources and one
we are seeing huge interest in.
The U.S. turnaround has been so power output of the drivers, essential- The flexibility of eLNG, which is
spectacular that, from expecting to ly GEs Frame 5, 7 and 9, dictating the able to basically run at the nomi-
become a major natural gas importer, size (output) of the LNG plant. Electric nal torque through the whole speed
the U.S. is now on the verge of becom- motors can be built in any size so that range, is a valuable aid for having the
ing one of the largest LNG exporters. the LNG plant can match the gas flow compressors operating in the best
At the moment, the U.S. LNG industry available with practically no penalty process running desired point.
only delivers its product locally, and if in efficiency. The new trend is to a wider dis-
consumption levels stay the same, the COMPRESSORtech2 asked Falco if tribution of small- and medium-size
U.S. will have sufficient gas resources there is an expected standard size for LNG plants due to the new source
for nearly 100 years. future U.S. eLNG plants. of gas which are more distributed in
However, U.S. lawmakers are dis- The LNG world is very conserva- comparison to the huge concentra-
cussing changes to its energy policy tive and slow in digesting innovations, tion of gas of the first LNG age (i.e.,
that would allow natural gas exports the EPCs, the owner of the gas pro- Qatar, Australia ).
to countries within the World Trade Or- cess definition, are still anchored to From eLNG standpoint we can
ganization. This has led to a number of the typical process gas configurations easily address any process arrange-
plans to turn facilities originally built for which are mainly driven by the avail- ment covering with different technol-
LNG imports to be transformed into liq- able compressors driving machine ogy (i.e., LCI, VSI, synchronous or in-
uefaction export facilities instead. While models, Falco said. duction motor high speed) the gas
the first wave of U.S. LNG exports is still The new shale gas frontier as well processes and compressors require-
a few years away, it could amount to as as the floating LNG installations is cre- ments. As GE we provide always in-
much as 9 Bcfd (254 x 106 m3/d) by ating a wider distribution of gas sourc- tegrated and optimized solutions for
2020, contributing to a rise of between es and relevant liquefaction plants and the complete shaft line, owning the
8 to 25% of global LNG trade by 2035. the range of the refrigerating com- full train electromechanical system
Gas turbine-driven refrigerating pression has to address a much broad integration as well as a full support
compressors have to respect the process needs. to the EPC or end users in term of

June 2014 64 Compressortech2

CT403.indd 1 5/20/14 2:50 PM

 machine operability in complex elec-
trical network.
We are engaged since the feasibil-
ity phase by selecting, together with the
client, the best configuration and elec-
trical system technology, supporting the
whole risk mitigation process and offer-
ing the possibility to extend our OEM
ownership to the whole plant arrange-
ment. We also provide the opportunity
to test the machines in a full string train
configuration exactly in the same con-
dition of the site (gas loop, molecular
weight, power and speed size) with a
huge start up time and risk reduction.
As Power Conversion variable
speed driving systems we are able to
cover the range of 1341 to 134,100 hp
(1 to 100 MW) up to 4000 to 5000 rpm
of speed, thus we have no limitations
in addressing any process arrange-
ment. However the benefit of the pow-
er density and the high efficiency of
our devices can be enhanced mainly
in medium to large size applications.
Inside the GE universe we are merg-
ing our decades of experience and
technology of electrical machines and
power electronic devices manufactur-
er to the excellence of GE in term of
electrical grid control and stabilization.
Our top class product of electrical
variable-speed drive systems (VSDS),
which is the MV7000 VSI driver line, is
easily able to match the most severe
international rules requirements with
no additional harmonics filter installa-
tion need. In addition our active front-
a subsidiary of
Emission Control Silencers from the names you know and trust
For Information Contact:
Burgess-Manning
50 Cobham Way
Orchard Park, NY
Phone 877-TRY-PMFG
Mechanical Equipment Inc.
2525 E. Interstate Hwy 20
Midland, TX 79701
Phone 432-687-0601
Producers of Peerless, Burgess-Manning, Bos-Hatten, and ALCO Products
MAKING ENERGY SAFE, EFFICIENT, AND CLEAN
www.peerlessmfg.com
June 2014 65 Compressortech2
Peerless.indd 1
CT403.indd 2
end drive arrangement is operating as
a power factor manager and can be
operated to provide an additional aid
to the overall electrical grid stabiliza-
tion. In other words, the VSDS is not
a load to be managed but becomes a
contributor for stabilizing and control-
ling the grid.
As already proven by Power Con-
version in the marine engine world, we
are pushing the oil and gas market to
move from the most traditional LCI +
synchronous motor VSDS to the VSI +
induction motor VSDS. The intrinsically
simple arrangement of the induction
motor and the modular design of the
VSI drivers can provide the double ben-
efit of availability of the operations and
the reduced design/manufacturing time.
The VSDS manufacturing and de-
livery time is typically in the shadow
of the compressors production sched-
ule, Falco said, so no time-to-market
change is foreseen for the shift from
conventional drivers to electric motors.
LNG stations are hugely complex
and costly facilities that require major
financial backing. However, introduc-
ing electrification to power LNG offers
three core advantages:
Efficiency. VSDS systems are
more economical to run in com-
parison to gas turbines as they
offer high efficiency at a constant
level, across the entire operating
speed range. Gas turbines, on the
other hand, can only operate at
their maximum efficiency at a high
Attenuation:
15dB to 40dB+
Catalytic Reduction:
Up to 99% NOx & CO
* 3 year catalyst warranty available
Patented Cam-Lock
catalyst locking bar
* Additional Catalyst can be added to
meet changing regulations.
fixed speed, reaching an average
efficiency level of less than 40%.
Compared to that, a typical electri-
cal driving system can reach over
90%. Used through the compres-
sion, liquefaction and transport
processes these are a core ingre-
dient of the eLNG promise.
Reliability. Electrical system ar-
chitectures enhance reliability, es-
pecially in terms of system man-
agement and maintenance. This
is because multiple redundancy
levels can be arranged at variable-
frequency drive (VFD) elements
to ensure full operation even in the
event of a single failure, in addi-
tion to very fast repair time as a
result of the modular structure of
the system. This results in electri-
cal system uptime of up to 99.9%.
Typical architectures are able to
run for up to five years without the
need to stop for maintenance.
Grid stability. Electrifying the sys-
tems architecture also significantly
improves the interaction between
LNG plants and national electri-
cal grids as it solves some of the
most critical problems related to
grid stability. These include issues
such as the evaluation and mitiga-
tion of harmonics pollution, sub-
synchronous torsional interaction
risk, electromechanical system
integration and full torsional lat-
eral analysis for project dedicated
shaft line verification. CT2
3/13/14 4:12 PM
5/22/14 10:09 AM

Source: Energy Information Administration
n U.S. natural gas inventories are off to a slow start in the summer refill season.
U.S. NatGas Inventories At
11-Year Low > But
adequate refill expected
before next fall
I
njection compressors at natural
gas storage sites will be kept hum-
ming this summer to overcome a
larger-than-usual draw on inventories
during the unusually cold winter.
The privately owned inventories,
which are mostly in former under-
ground salt domes and depleted gas
fields, are used to supplement normal
pipeline supplies during the winter
heating season.
The U.S. Energy Information Admin-
istration (EIA) has reported that work-
ing natural gas inventories in the Lower
48 States started the injection season
on April 1 at 824 Bcf (23.3 x 109 m3),
their lowest level since April 1, 2003,
following a record winter withdrawal of
2970 Bcf (84.1 x 109 m3).
EIAs latest tally found that gas in
storage rose to 1055 Bcf (29.8 x 109 m3)
as of May 2. The net storage injection of
74 Bcf (2.0 x 109 m3) for the week result-
ed in storage levels that still were 43%
below year-ago levels and 48% below
the five-year average.
The agency said from the week end-
ing April 4 to the week ending May 2,
net storage injections totaled 233 Bcf
(6.6 x 109 m3). The average value of in-
jected gas was US$4.70/MMBtu, 11%
JUNE 2014 66 Compressortech2
CT395.indd 1
higher than the average value for the
same five weeks last year, of US$4.22/
MMBtu, when injections totaled 178
Bcf (5.0 x 109 m3).
The injection season historically ends
Oct. 31. In order to reach EIAs project-
ed beginning-of-winter inventory level of
3405 Bcf (96.4 x 109 m3), an average in-
jection of 90 Bcf (2.5 x 109 m3) per week
must occur through the end of October.
EIAs forecast for the end of October
inventory levels is below the five-year
(2009-13) minimum value of 3792 Bcf
(107.3 x 109 m3). To reach the five-year
minimum, average weekly injections
through the end of October would need
to be 105 Bcf (2.9 x 109 m3).
The agency said high spot prices
were working against the inventory build.
Despite a steady increase in nat-
ural gas supply, current high spot
prices coupled with comparatively low
price expectations for the upcoming
winter season, when stored volumes
are likely to be withdrawn, have put a
damper on natural gas storage injec-
tions in April, the EIA said.
The agency explained Aprils spot
prices, the highest since 2008, gave
producers little incentive to store their
output in April, because they had al-
most no expected payoff from with-
drawing and selling it when demand
peaks during the upcoming winter
season, compared to what they could
make from selling it to consumers in
the current market.
EIA said the lower expected return
from storing natural gas reflects a
trend that has occurred generally in
recent years, as increased natural gas
production, particularly in consuming
states such as Pennsylvania, has con-
tributed to decreasing seasonality in
natural gas prices.
It said in April 2013 and April 2014,
the average difference in the maximum
winter futures contract and April spot
prices was US$0.31/MMBtu compared
to an average of US$2.14/MMBtu in
April 2011 and 2012. Because the
expected return from storing natural
gas fell significantly, not accounting
for costs directly associated with stor-
ing gas, average net storage injections
were lower than in April 2011 and 2012.
There are other factors beyond
direct economic considerations that
drive storage builds. These include
competition for available supplies from
current consumers, and the need for
local distribution companies (LDCs) to
ensure there are adequate supplies in
storage for the upcoming winter with-
drawal season.
EIA added that net injections in April
do not necessarily indicate what will
occur through the end of the injection
season on Oct. 31. For example, the
high net injections that occurred dur-
ing April 2012 were followed by low net
injections through October 2012, as
high levels of existing inventories con-
tributed to lower prices and increased
consumption from the electric power
sector, it said.
Similarly, the low current stor-
age levels could lead to high injec-
tions through October in areas where
LDCs are legally required to meet pre-
winter storage level requirements, and
where there is a greater incentive to
store in anticipation of regional winter
price spikes. This is particularly true
in the Eastern storage region, where
working inventories consistently reach
90 to 95% of available storage capac-
ity by the end of October. CT2
5/22/14 10:10 AM
 Recent Orders
MarkWest
MarkWest Energy Partners LP has
ordered more than 70 Caterpillar G3600
engines, the companys flagship series
for gas compression applications.
A combination of G3608 engines
rated at 2370 hp (1.7 MW) and G3612
engines rated at 3550 hp (2.6 MW) will
be used to support gas gathering op-
erations across the Utica and Marcel-
lus shale producing regions.
Deliveries are scheduled through-
out the year. AG Equipment of Bro-
ken Arrow, Oklahoma, will perform
initial packaging of the equipment.
AG Equipment, along with Cat dealer
Warren Cat, led Caterpillars efforts on
the sale. Cat dealers Cleveland Broth-
ers and Ohio Cat are coordinating af-
ter sale support services.
GEA
GEA Batignolles Technologies Ther-
miques (GEA BTT), a subsidiary of
GEA Heat Exchangers, has received
a US$54 million order for more than
CT399.indd 1
Voith USA.indd 1
400 air-cooled heat exchangers from
Technip and JGC. The equipment is
for the three-line liquefied natural gas
plant under construction on the Yamal
Peninsula in Siberia.
GEA BTT will design, manufacture
and deliver the heat exchangers. The
heat exchangers will be installed in the
three LNG lines, each of which will pro-
cess 6.1 million tons of LNG annually.
Technip and JGC are developing
and building the arctic LNG plant
in Russia. Commissioning will take
place in three phases from 2016
to 2018.
Siemens Energy
Chinas Shenhua Ningmei Coal
Group has placed a follow-up order
with Siemens Energy for four identi-
cal CO2 compressor trains. Each train
consists of one STC-GV integrally
geared compressor driven by an SST-
600 condensing steam turbine via an
intermediate gear.
The SST-600 is a single-casing
+1 717-767-3200
+1 905-670-3122
+1 717-767-3200 York, Pennsylvania
steam turbine designed for opera-
tion with speed ranging from 3000 to
18,000 rpm for generator or mechani-
cal drives up to 201,153 hp (150 MW).
The turbine is used for both condens-
ing and backpressure applications,
either geared or directly coupled, the
company said.
The scope of supply also includes
the associated auxiliary systems.
The compressor trains are des-
tined for a coal liquefaction plant in
Ningxia Province, in the northwest
part of the country, and are sched-
uled for delivery in the summer of
2015. The end customer is Shenhua
Ningxia Coal Industry Group Co. Ltd.
(SNCG), a subsidiary of the Shen-
hua Group, the largest coal producer
in China.
The compressor trains will be pro-
duced in Europe, while the Siemens
joint venture in Huludao, China, will
deliver the auxiliary systems and
handle local project management
and engineering. CT2
5/20/14 9:13 AM
5/22/13 9:48 AM
 Avoiding Common Torsional TECH

corner
Failures Of Rotating Induction
Motor Components > Improving induction motor
damage tolerance
By Justin Hollingsworth

T
orsional problems can be insidious in that they often
go undetected with standard package instrumenta-
tion until a catastrophic failure occurs.
Fundamentally, these failures are a result of interaction
between the torsional critical speeds (natural frequencies)
of the system and excitation energy produced by the drive
system and/or load. In most cases, these issues are best
resolved by shifting the critical speeds such that the of-
fending excitation can no longer excite them. This is the pri-
mary goal of a torsional analysis during the design stage.
However, once a machine is built and put into service,
the changes necessary to affect a significant shift in the
critical speeds sometimes are difficult and costly to imple-
ment. In addition, for some designs the required duty cycle
will necessitate occasional excitation of torsional critical
speeds, even when their placement has been optimized.
The rotating structural components of typical induction n Figure 1. This shows torsional telemetry system components.
motors have the potential to aggravate torsional critical
speeds and shaft stress behavior. The purpose of this ar- up or shutdown events, as depicted in Figure 2. In this
ticle is to briefly review a few design aspects of induction illustration, a torsional critical speed is evident as it is tra-
motors that have a history of playing a role in common versed by relatively low level energy generated at several
torsional stress-related failures, to recommend practical orders of running speed. Figure 2 illustrates the concept
methods of improving the damage tolerance of the com- that the train may need to tolerate some level of critical
ponents involved, and to discuss techniques to improve speed excitation during operations involving a speed
torsional analysis predictions related to this issue. change, even if the subject mode is not excited at nomi-
nal speed. In addition to common mechanical excitation
Torsional critical speed verification techniques sources (including the driven equipment), motors and vari-
In systems without a gearbox, the typically installed lat- able frequency drives also produce excitation energy that
eral shaft or casing vibration probes are not sensitive to tor- can interact with the critical speeds.
sional vibration. In most cases, specialized instrumentation
must be used to capture this type of data. One common Critical Speed
method involves the use of a strain gage telemetry system,
as shown in Figure 1. Several other methods of obtaining
this data exist, including the use of a torsiograph or encod-
er on the outboard end of the motor or driven equipment.
However the data is obtained, the calculated torsional
critical speeds can potentially be confirmed during start-

Justin Hollingsworth is a principal engineer in the rotating ma-

chinery dynamics section of Southwest Research Institutes
(SwRI) Mechanical Engineering Division. He has been in-
volved in lateral and torsional rotordynamic analyses for 22
years, and is a member of the American Society of Mechanical
Engineers (ASME). Contact him at: jhollingsworth@swri.org. n Figure 2. Excitation of a torsional critical speed.

JUNE 2014 68 Compressortech2

CT394.indd 1 5/20/14 9:29 AM

 The type of data shown in Figure 2 can be utilized to as- Recognized
Leader
sess the damping present in the system (by observing the
amplification factor of the response peaks). Additionally,
dynamic torque or stress levels obtained from the test data
can be compared to rotordynamic predictions.

Motor webs
Induction motor shaft webs serve several important
functions, one of which is to provide a space for cooling
air to flow between the rotor core and shafting. Although
necessary, these features have the potential to contribute
to common torsional stress related failures.

n Figure 3. Typical webbed shaft failure.

Figure 3 illustrates a typical torsional failure, in which a

series of 45 cracks are evident in the shafting and webs. Innovator in State-of-the-Art
In many cases, the cracks form at the base of the webs, Pipe Supports & Clamps
and progress into the shafting itself. Inventor of Flywheel Lock
Figure 4 illustrates how the stress can intensify near Leaders in Field Machine Work
the ends of the web bases, which is consistent with the Pioneers in Casting Rapair
failures shown in Figure 3. The initiation and propagation
of these types of cracks can be significantly influenced
PRODUCTS: SERVICES:
by torsional resonances, excessive web flexibility, and/or
n Pipe Supports & Clamps n Field Machining
stress concentration factors. Special attention should be
n Epoxy Grout n Casting Repair
paid to the web-shaft interfaces to ensure that any neces-
n Anchor Bolts n Crankshaft Machining
sary welds are properly dressed, and that the geometry
n Flywheel Locks n Machine Shop
is optimized in this area to diminish stress concentration
n Temperature & Vibration n Broken Bolt Removal
effects, especially at each end of the webs.
Sensors n Frame Reinforcement
continued on page 70
n Spark Plugs n Alignment Services

918-252-7545
www.r-f.com
info@r-f.com
Tulsa, OK
n Figure 4. Webbed shaft stress distribution.

JUNE 2014 69 Compressortech2

ReynoldsFrench.indd 1 7/8/13 2:07 PM

CT394.indd 2 5/20/14 9:34 AM

 n Figure 5. Representative methods of accounting for base shaft stiffening due to web geometry.
If the webs in a motor design are sufficiently flexible, a
resonance condition can occur as a result of the spring
mass system comprised of the rotor core inertia, the web
stiffness, and the base shafting. In some cases, this subsys-
tem can exhibit a localized resonance that has the potential
to interact with the torsional critical speeds of the system
the motor is attached to. This condition can further aggra-
vate the stress levels developed at the web-shaft interface.
In cases involving significant web flexibility, a finite ele-
ment analysis (FEA) should be conducted in order to de-
termine the effective stiffness of the webs, and it may be
necessary to include additional elements in the torsional
model to represent the webs (connecting the base shaft
to the rotor core inertia) in order to properly account for
this behavior. A similar treatment may be needed for cool-
ing fans or other attached components that are flexible
enough to interact with the torsional system.
Note also that the web geometry attached to the base
shafting can have a torsional stiffening effect. This phe-
nomenon must be accounted for in order to properly cal-
culate the torsional critical speeds. As an example of the
possible magnitude of this effect, base shaft stiffening fac-
tors generally ran in a range of about 5 to 50% in repre-
sentative four- and six-web geometries that were recently
studied by the authors firm [1] Figure 5 illustrates one an-
alytical method [1] for determining the stiffening effect of
the webs, or an FEA can be performed as an alternative.
The importance of generous fillet radii
At any significant diameter change (step) in the shaft-
ing, the potential exists for a large increase in localized
stress concentration.
For some designs, this can result in approximately twice
the dynamic stress developed in the neighboring shafting.
A generous fillet radius applied to these areas has the po-
tential to greatly reduce the stress concentration factor.
Petersons Stress Concentration Factors [2] provides a
good source of practical fillet radii for common ratios of
shaft major and minor diameters, and the resulting stress
concentration factors.
Stepped shafts at bearings
Figure 4 also illustrates another common feature found
in some induction motor designs that can complicate the
stress behavior.
JUNE 2014 70 Compressortech2
CT394.indd 3
In cases where the shaft diameter is decreased signifi-
cantly near the axial location of the drive end bearing, and
then increased again to meet or exceed the shaft diameter
inboard of the bearing, the shaft stress levels developed
can increase dramatically.
The reason for this diameter change is usually attrib-
uted to optimizing the shaft surface speed within a given
bearing design to accommodate the anticipated operating
speeds. As a means of illustrating the potential torsional
stress implications of such a change, a 0.5 in. (12.7 mm)
reduction in a nominal 5 in. (127 mm) diameter shaft can
result in a 37% increase in torsional stress. A stepped
shaft at a bearing can also result in two additional loca-
tions, which require appropriate fillet radii in order to avoid
significant stress concentration.
From a torsional stress perspective, it is prudent to avoid
a reduction of shaft diameter to accommodate a smaller
drive end bearing whenever practical. It is also generally
beneficial to maintain a minimum output shaft diameter of
at least the coupling hub penetration diameter.
Keyways
Interference fits are preferred from a torsional perspec-
tive at couplings and any other features requiring a hub. Al-
though keyways may facilitate maintenance procedures in
some applications, they have the potential to greatly mag-
nify the dynamic stress experienced by the shafting, reach-
ing a level of about three times the unintensified stress in
typical geometries, according to [2].
In some applications, the torque carrying capacities of
the interference fits are insufficient to carry the desired
load. In cases where keyways are an absolute necessity,
a generous fillet radius should be applied to the bottom
of the keyseat to reduce the stress concentration factor
to tolerable levels. ASME/ANSI Standard B17.1, Keys and
Keyseats [3], provides one source of practical guidelines
for recommended keyseat fillet radii.
Ultimate tensile strength
Occasionally, the best efforts to optimize the torsional
critical speeds and stress concentration factors of a given
machine still result in excessive calculated shaft stress
levels. In these cases, the possibility of applying additional
heat treatments to the base shaft material to increase the
ultimate tensile strength (UTS) should be investigated. An
5/20/14 9:31 AM
 CV AND KN SERIES
alternate base shaft material may also be used to increase INDICATOR VALVES
the UTS if appropriate.
For the steels routinely used to produce modern motor CV-72
shafts, UTS values over a range of about 90 to 130 ksi are
KN-22-90
common, depending on the specific material involved and
the heat treatments applied. This range represents a maxi-
mum potential increase of about 44% in allowable shaft
stress, which can greatly improve the damage tolerance
of the machine.
Many manufacturers can offer the option of additional heat
FOR MAXIMUM ACCURACY, BOTH OFFER . . .
treatments or an alternate base shaft material during the de-
Short, straight-through flow path minimizes channel
sign process, if deemed necessary for a particular application. resonance, maximizes accuracy.
Compact design. Fits tight locations.
Summary 90-degree and 316 stainless steel versions available.
Induction motor rotating structures can be optimized to Designed specifically for compressors.
improve long term reliability by avoiding common failure
scenarios. These structural optimizations complement the CV-Series valves have a quarter-turn handle for
fast operation. Safety locking handle option
benefits of a torsional analysis, (which seeks to optimize the available.
frequency of the predicted critical speeds), by improving the
ability of the components to tolerate anticipated stress levels. KN-Series valves offer pressures to 4,000 PSI,
temperatures to 400 F.
Special attention should be paid to the motor web-shaft
interface areas of induction motors to ensure that the CONTACT US NOW FOR INFORMATION
welds are dressed properly, and that the remainder of the
geometry avoids significant stress concentration.
The stiffening effect of the web geometry on the base
Website: www.kienediesel.com Telephone: 1-800-264-5950
shafting should also be appropriately accounted for in the e-mail: info@kienediesel.com Fax: 630-543-5953
torsional model to ensure accurate critical speed predictions.
In cases involving significant web and/or cooling fan
flexibility, the potential for localized resonances should be
Kiene.indd 1 10/21/13 12:50 PM
assessed with FEA, and the torsional model should be
expanded to include the spring mass systems associated Housings, cylinders,
with these components if necessary.
Significant decreases in the diameter of the motor out- connecting rods
put shaft (in order to accommodate a smaller bearing)
should be avoided if possible. Generous fillet radii should
be applied to all diameter changes. Keyways should only
be used as a last resort, and if a keyway is absolutely
necessary a generous fillet radius is recommended at the
bottom of the key seat to reduce stress concentration to
tolerable levels.
If these methods fail to produce acceptable calculated
stress behavior, an increase in base shaft material UTS
should be considered, through the application of additional
heat treatments or utilization of an alternate material. CT2

References
[1] Kulhanek, Chris D., James, Stephen M., Holling- Let our skilled craftsmen
sworth, Justin R., Stiffening Effect of Motor Core Webs for
Torsional Rotordynamics, presented at ASME Turbo Expo
get to work for you!
Visit our website at www.HahnMfg.com
2012, Copenhagen, Denmark, June 11-15, 2012, paper
GT2012-69967. precision boring, milling, drilling, tapping
and grinding on ferrous and non ferrous
[2] Pilkey, Walter D., Petersons Stress Concentration
material up to 30,000 lbs.
Factors, Second Edition, 1997, John Wiley and Sons Inc.,
New York. Certified Quality
Management System
[3] Keys and Keyseats, ASME/ANSI Standard B17.1, ISO 9001:2008
1989.

JUNE 2014 71 Compressortech2

Hahn_AugSept.indd 1 8/19/13 10:01 AM

CT394.indd 4 5/20/14 9:31 AM

 PAN Technology Ready For
Field Test > Technique to recover pulsation energy could
be breakthrough
By DJ Slater

n Packaging of the PAN

system, especially the sup-
port structure for the over-
head suction, is a work
in progress. The human
figures in these models
show that the compressor
cylinders can be accessed
for maintenance.

A
n advance in compression
technology, which has the po-
tential to reshape the industry,
has been developed through a col-
laborative effort that involves several
companies and the Gas Machinery
Research Council.
ACI Services, Optimum Pumping
Technology and the former El Paso
Corp. have spent more than half a
decade developing performance aug-
mentation networks (PAN), a system
designed to improve the efficiency of
reciprocating compressors.
Now an end user is ready to test
the technology. The PAN system will
be applied to an Ariel JGT/4 single-
stage compressor driven by a Cater-
pillar G3516 gas engine rated 1380
hp (1029 kW) at 1400 rpm. The pack-
age is in its final stages of fabrication consultant and president emeritus of the potential to have the same impact
in Enerflexs shop in Houston, Texas, ACI Services. It is the biggest break- on compressors that early super-
before being installed in the Wil- through in improving the performance, charging had on engines.
liams Zick compressor station near reducing the energy consumption and The idea for this technology ironical-
Tunkhannock, Pennsylvania. increasing compressor capacity that ly stemmed from engines, specifically
This has the opportunity to sig- has come along for decades. the high-performance variety used in
nificantly change the way pulsations In fact, I dont know of another re- NASCAR. In 2006, Optimum Pumping
are controlled in reciprocating com- ciprocating compressor improvement Technology was working with Randy
pressors, said Norm Shade, senior that has the capabilities of this. It has Raymer, an El Paso employee, on a

JUNE 2014 72 Compressortech2

CT388.indd 1 5/22/14 1:46 PM

 project to improve engine emissions. During their collabora- The MIRATECH team has been solving emissions
tion, he wondered if engine technology intake and ex- challenges for more than 20 years. As a result,
haust manifold systems could be used on reciprocating our customers are all over the world. The one
compressors to make them more efficient. Furthermore, he
thing they share in common is that they rely on
wanted to know how to eliminate pulsations without signifi-
us to provide their emissions solutions.
cant pressure loss.
Raymer and Optimum contacted Shade, who had wres-
tled with the same idea while working for Ajax Superior. His
knowledge of compressors would prove helpful in the pro-
cess of developing the PAN system, said Glen Chatfield,
president of Optimum.
Its the
We had no credibility in the gas compression industry, MIRATECH
way.
so we needed someone to bridge the gap for us, Chat-
field said.
Multiple simulations and calculations came first, which
then lead to verifying those numbers via test rigs and a
field test at an El Paso station in 2008. Shade and Chatfield
presented that research at several Gas Machinery Confer-
ences, most recently in Nashville, Tennessee, in 2011.
When a compressor is operational, it moves gas from
one pipeline to another, creating waves of pressure, flow
and energy, which in turn create shaking forces on the
frame and system piping. To combat this, operators dissi- ENGINEERED TO PERFORM
pate those pulsations by using conventional bottle systems. 800-640-3141 | MIRATECHCORP.COM
The PAN system takes a different approach. Rather than
dampening pulsations, the system uses that energy to make SOLUTIONS CATALYSTS HOUSINGS & SILENCERS
CONTROLS FABRICATED METAL SERVICE
the compressor operate more efficiently, while simultane-
ously cancelling pulsation in the pipeline to very low levels.
By canceling the detrimental gas pulsations, it prevents them
from traveling upstream and downstream from the pumping
station and minimizes the dangerous shaking forces that
they impose on piping and equipment in the system.
Miratech_June14_CT.indd 1 5/19/14 4:49 PM
Additionally, the system reflects pressure waves back
to individual cylinder suction and discharge flanges at
precise times during the compression cycle when the
valves are open. Proper pressure wave timing increases
the flow rate and reduces the amount of input work and
power required by the compressor to boost pressure from
the plants suction header to its discharge header. This is
similar to how tuned manifolds act on high-performance
reciprocating engines.
The whole PAN concept is one of energy recovery,
Chatfield said. Whereas bottle systems are designed to
dissipate the pulsation energy, we have a strategy of ef-
fectively recovering the energy and using it to improve the
performance.
The system also reduces the magnitude of the vibra-
tory forces compared to pulsation bottles, especially at the
first manifold junction. This means that the high-amplitude
pressure pulsations act on short, smaller diameter header
pipes rather than larger diameter bottles. It also means
that pulsation induced shaking forces can be reduced 25
to 90%, which in turn alleviates vibration-related failures,
Chatfield said.
Due to the absence of baffles, choke tubes or orifice
plates, the PAN system minimizes pressure losses on both
continued on page 74

JUNE 2014 73 Compressortech2

Einstruments.indd 1 3/7/13 9:49 AM

CT388.indd 2 5/20/14 2:58 PM

 n An existing compressor with traditional pulsation bottles will be tested in parallel
as a baseline for comparison with the new PAN unit.
suction and discharge. Instead of tra-
ditional apparatuses, the system uses
smooth bore pipes and ACIs tuning
selection transition (TST) collectors
that minimize flow velocity and tur-
bulence. The TST collectors split or
join flow streams to cancel pulsations
while avoiding flow area changes that
would cause wave reflections.
Each standard size and shape of
the collector is designed for specific
pipe sizes and pressure ratings,
using the same technology, such
as 3-D finite element stress analy-
sis that ACI uses in the design of
custom reciprocating compressor
cylinders. Each TST is serialized,
nameplated and undergoes hydro-
static testing at 150% of its maxi-
mum pressure rating.
Another benefit from the system is
its ability to reduce the compression
horsepower requirement. Optimized
PAN configurations can boost the
pressure at the cylinder suction flange
during the suction event and reduce
the pressure at the discharge flange
June 2014 74 Compressortech2
CT388.indd 3
during the discharge event. This, in
combination with the reduction of
system pressure losses, can lower
pipeline compression energy costs as
much as 20 to 30%, ACI said.
The first customers PAN system is
designed to operate at suction pres-
sures from 450 to 900 psig (31 to 62
barg), discharge pressures from 1000
to 1200 psig (69 to 83 barg) and a
speed range of 1300 to 1400 rpm.
After package installation, vibration
testing and on site commissioning,
thermodynamic performance tests will
be conducted on the PAN unit as well
as on an existing JGT/4 with pulsation
bottles, which will serve as a baseline.
Both the PAN and bottle systems
will be fitted with special instrumenta-
tion, such as individual flow meters to
simultaneously measure the perfor-
mance of both units over a range of
operating conditions. In addition to re-
ducing bhp per scfd, the PAN system
is predicted to increase the flow rate
of the compressor, especially at low-
pressure ratios.
We think we can design many sys-
tems that are significantly more effi-
cient than whats being offered today,
Chatfield said.
Even with the positive simulations
and early test results, ACI said field
tests are needed to validate or dis-
prove the systems capabilities. Not
only does the PAN package look very
different, but it also has presented
packaging challenges that the spon-
sors have been working to overcome.
Engineers at Beta Machinery Anal-
ysis have helped us a great deal in
designing mechanical nature frequen-
cies away from the primary harmonics
of the running speed range, said John
Bazaar, manager of development at
ACI. Weve worked hard to fit every-
thing on the compressor skid and to
make sure that there is reasonable
access to the compressor for mainte-
nance tasks.
We have a number of end users
who are watching this development
and are excited about its potential.
Theres a whole lot of interest. CT2
5/20/14 2:58 PM
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JUNE 2014 75 Compressortech2

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 PRIME
Movers
Zahroof Valves
David Miseldine
has joined Zahroof
Valves Inc., Hous-
ton, as executive
vice president in
charge of sales and
marketing. He also
is responsible for
developing busi-
D. Miseldine ness activities and
implementing strategic growth.
Miseldine has more than 40 years
of experience in the industry. In previ-
ous positions, he was vice president
of worldwide sales and marketing
for Compressor Products Interna-
tional, vice president of marketing at
Hoerbiger Corp. of America, general
manager of worldwide aftermarket for
Atlas Copco Compressor Technique
and a co-founder of Southwest Com-
pressor Services.
Exterran Holdings
Exterran Holdings has signed a 12-
year compression services contract
with the consortium BCAM-40 for its
compressor station in Bahia, Brazil.
Petroleo Brasileiro S.A. (Petrobras)
will serve as the field operator for
the project, which will use 28,000 hp
(20,880 kW) of compression equip-
ment, as well as associated natural
gas production equipment.
The land-based compressor sta-
tion will compress gas from the
Manati field offshore Brazil for trans-
portation via pipeline to a customer-
owned gas treatment facility in So
Francisco do Conde, Brazil. The
compressor station is expected to
have capacity of 230 MMscfd (6.5 x
106 m3/d) of natural gas starting in
mid-2015.
CDM Resource Management
CDM Resource Management has
completed a 16,000 sq.ft. (1486 m2)
training facility on Consulate Plaza
Drive near Bush International Airport
in Houston as part of its enhanced-
training program initiative.
JUNE 2014 76 Compressortech2
PrimeMovers.indd 1
The facility has three classrooms
to accommodate 12 to 15 students
each, a conference room and 10,000
sq.ft. (930 m2) of space for hands-
on instruction with compression and
treating equipment, including a func-
tioning gas compressor package.
CDM said its constantly growing
workforce has created the need for
more basic training. Also, it is pro-
viding continuing instruction on En-
vironmental Protection Agency and
Occupational Safety and Health Ad-
ministration rules, including the lat-
ters more stringent Process Safety
Management Standard (see COM-
PRESSORtech2, May 2014, p. 16).
Basic training will include CDMs
new-employee orientation, instruc-
tion on governmental safety rules,
professional development, and CDMs
full training curriculum including trou-
bleshooting and preventive mainte-
nance classes.
Advanced classes will be offered
on electronics, Adem 3 troubleshoot-
ing and coupling alignment. Training
for CDM customers and their employ-
ees is also part of the initiative. CDM
also is developing a robust online
learning management system plat-
form to provide targeted, on-demand
training to technicians whether they
are in the classroom or in the field.
Sundyne
Sundyne is merging with Pres-
sure Products Industries (PPI), a
manufacturer of sealless reciprocat-
ing diaphragm compressors for the
refining, petrochemical, chemical,
liquefied natural gas and semicon-
ductor markets.
For more than 60 years, PPI has
made compressor packages that
deliver noncontaminating compres-
sion of critical gases, complying
with API Standard 618 for leak free
performance.
Sealless diaphragm compres-
sors are designed for cylinder fill-
ing, fuel cell technology, or transfer
applications that require high purity
or handling dangerous gases under
pressure. Sundyne PPI sealless com-
pressors are available in single- and
multistage packages with displace-
ments to 150 cfm (255 m3/hr), pres-
sures to 17,000 psi (1170 bar) and up
to 250 hp (187 kW) of power.
The Sundyne PPI portfolio of
compressors is designed to safely
operate in the most demanding ap-
plications, and naturally comple-
ment our commitment to innovative
and reliable sealless magnetic drive
pumps, Sundyne President Jeff
Wiemelt said.
PPI was a member of the Milton
Roy family of pump products, another
Accudyne Industries company. PPI
sealless diaphragm compressors are
available now through the global net-
work of Sundyne channel partners.
Shell
Shell has indefinitely postponed a
project to install subsea compression
at Ormen Lange field in the North
Sea due to rising costs in Norways
offshore oil sector.
The company explained that com-
pression was not time-critical to the ul-
timate recovery from the field, the sec-
ond-largest Norwegian gas reservoir.
The oil and gas industry has a
cost challenge, said Odin Este-
nsen, chairman of the Ormen Lange
management committee. This, in
combination with the maturity and
complexity of the concepts and
the production volume uncertainty,
makes the project no longer eco-
nomically feasible.
Shell is the operator of the field with
a 17.8% interest, Norways state-
owned Petoro has 36.5%, Statoil
25.4%, Dong Energy 14% and Exx-
onMobil 6.3%. Petoro reportedly
was the only partner objecting to the
project delay.
Statoil is proceeding with a pioneer
seabed compression development at
sgard field in the North Sea. That
US$2.5 billion project is due online
next year.
5/20/14 3:02 PM
 Machinery And
Lubrication Terms
And Definitions For:

Centrifugal Pumps
Rotary Pumps
Reciprocating Pumps
Centrifugal Compressors
Author Bio: Reciprocating And Rotary
Robert X. Perez Compressors
has over 30 years of Fan And Blowers
rotating equipment Electric Motors
experience in the Gas Turbines
petrochemical industry. Steam Turbines
Turboexpanders
He earned a BSME
Ancillary Equipment
degree from Texas A&M
Components
University (College
Condition Monitoring
Station), a MSME degree
Vibration Analysis And
from the University of
Rotordynamics
Texas at Austin, and is a Reliability Engineering
licensed professional And Machine Shop
engineer in the Methodologies
state of Texas.

Paperback (204 Pages) US$24.95

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ORDER TODAY!
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Or By Phone: 1-800-558-4322

Dictionary_NewsletterAD.indd 1 5/1/14 1:52 PM

 5/22/14 10:14 AM
Compressortech2
snapshot

78
Eastern Gas Compression Roundtable Convenes

Photo By DJ Slater
More than 160 companies exhibited at, and about 1400 people attended, the
annual Eastern Gas Compression Roundtable at Robert Morris University

JUNE 2014
near Pittsburgh, Pennsylvania, on May 13-15. The event included about 70
lectures and hands-on workshops, many of which focused on topics relating
to Appalachias Marcellus and Utica shales.

CT402.indd 1
TurboMachinery_May14_WW.indd 1 4/14/14 9:34 AM
 2
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7 5
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I B K R P I R E L Q I S P W R L R X A I Buildup Reserve
P Z M O V E M E N T N P O T U I W N P P Cache Reservoir
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L M N O I T A C O L L A T V J O A W D I Depot Shipment
I D U H I N O I E I N C R V V M I R L N Displacement Shipping
N S S O V T R A N S F E R E N C E S I G Excess Shortage
Export Station
E Q N T S G A G I A S M R H F L U N U W
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X Q U A N T I T Y E U E G I O R M X B T Handover Stockpile
P E R E F S N A R T P N K C P S R O A R Haul Storehouse
O L G R S R V V N O I T A L U M U C C A Import Surplus
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A B V A V R J X B G B Z B W E R O S L F Quantity Voyage

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 Marketplace
ARLA
Custom Reprints Available Engineering Service
to Simulate Vibrations in Drive Systems
Articles in COMPRESSORtech2 can be reprinted at a very reasonable cost torsional and lateral vibration analysis
and used for effective direct mail purposes, answering inquiries, trade show rotordynamics & bearing analysis (fluid-film)
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9th EFRC CONFERENCE

September 11-12, 2014 Hofburg, Vienna - Austria

9th EFRC CONFERENCE

CONFERENCE FOCUS:
The Reciprocating Compressor and the Environment:
Why Recips are the Better Answer to Compression Problems

SPECIAL FEATURE:
Compressor Training:
Foundation Design for Reciprocating Compressors
September 10, 2014

For Programme and Online Registration: www.recip.org

JUNE 2014
EFRC_Advert.indd 1 81 Compressortech
11.02.2014 18:13:58
2

EFRC.indd 1 2/13/14 9:39 AM

CT2_June14_Mrktplc.indd 1 5/20/14 9:38 AM

 Advertisers Index
*Further information on this companys products can be found in the 2014 Edition of the Diesel & Gas Turbine Sourcing Guide
(at www.Dieselandgasturbineguide.net) and/or 2014 Compression Technology Sourcing Supplement (at CTSSnet.net).

ACI Services, Inc. .........................................................................21 Mayekawa .....................................................................................45

Air-Cooled Heat Exchangers .......................................................47 MIRATECH ....................................................................................73
Altronic, LLC ............................................................................10-11 MOTORTECH GmbH ....................................................................37
*ARIEL ..............................................................................................1 Murphy by Enovation Controls ..................... 28-29, Fourth Cover
Beta Machinery Analysis .............................................................35 Neuman & Esser Group ...............................................................49
BG Service Co., Inc., The .............................................................57 Nord-Lock/Superbolt ...................................................................63
*Burckhardt Compression AG ......................................................39 Peerless Mfg. Co. .........................................................................65
Cameron ........................................................................................15 PROGNOST Systems GmbH .......................................................31
Camfil Power Systems AB ..........................................................55
Reynolds French ..........................................................................69
CECO .............................................................................................25
*Rolls-Royce ....................................................................................9
*Compressor Products International .............................................5
Shinkawa Electric..........................................................................63
Cook Compression ......................................................................41
*Siemens AG Oil & Gas .................................................................59
DCL International Inc. ....................................................................7
SKF.................................................................................................19
*Dresser-Rand ................................................................................33
Summit Industrial Products ........................................................53
EFRC 2014 ....................................................................................81
E Instruments International .........................................................73 Switch Filtration ...........................................................................51

*Elliott Group .............................................................Second Cover SYNTHOSOL .................................................................................75

*Ellwood Crankshaft Group ..........................................................23 *Tech Transfer, Inc. ......................................................................2-3

Hahn Manufacturing Company ...................................................71
Harsco Industrial Air-X-Changers ..............................................17
*KB Delta Compressor Valve Parts Mfg. ................................42-43
Kiene Diesel Accessories ............................................................71
*MAN Diesel & Turbo .....................................................................13
TEDOM a.s. Engines Division ..................................................23
*Testo, Inc. .....................................................................................27
Toshiba International Corporation .............................Third Cover
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*Voith Turbo Inc. ............................................................................67

COMPRESSOR
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 Cornerstones Of Compression story continued from page 84
Ingersoll Rand XVG Series Integral Engine Compressor Rating and Production Summary
Power/ Power Cylinder
Engine Rated Speed
Cylinder Bore Diameter
Model (rpm)
hp (kW) in. (mm)
XVG 350 41 (31) 11.0 (279)
XVO** 350 30 (22) 9.5 (241)
JVG 550 30 (22) 8.25 (210)
SVG 400 55 (41) 11.75 (298)
SVO** 400 50 (37) 11.75 (298)
**Diesel Engines; All Others Spark-Ignited Natural Gas Engines
Total Production: 4282 units
internal combustion engines in the 2004 edition of Bores &
Strokes, published by the Coolspring (Pennsylvania) Power
Museum, noted that the XVGs rotary sleeve type gas/air
mixing valve design employed a sleeve with air and gas
ports located inside a body with fixed air and gas ports.
The air/fuel ratio was set manually by rotating the
sleeve to adjust the opening of air and gas ports rela-
tive to one another, while throttling of the air/fuel mixture
was accomplished by moving the sleeve linearly which
opened the air and gas ports in unison, but at the ratio
set by the sleeve rotation.
This basic mixer design, first introduced on the earlier
model XG, continued to be used on all subsequent models
of IR naturally aspirated engines produced into the 1960s.
The power cylinders were built with an L-head design.
The XVGs power cylinders were located opposite each
another, with no offset of centerlines, which necessitated
the use of articulated connecting rods. In this arrangement,
the compressor connecting rod is the master rod and the
two power connecting rods are link rods that connect to
wrist pins in the ears of the master rod. The articulated
connecting rod arrangement continued to be used on later
models of this series, and it soon became a basic feature of
other manufacturers engines.
The XVG was built continuously with only minor evolu-
tions, and 1994 units were made between 1932 until 1958.
Gas and diesel power engine versions were also produced.
The naturally aspirated XVO diesel integral engine com-
pressor was introduced in 1938 and remained in production
through 1957 with 147 units manufactured. The frame and
lower end components of the XVO were common with the
XVG, but the power pistons, cylinders and cylinder heads
were different.
The XVO used an overhead valve (I-head) arrangement,
and the fuel system and combustion were the same as
used on other Ingersoll Rand diesel power engines. The
XVO was available in two, four, six and eight power cylin-
der versions with numbers of compressor cylinders equal
to half the number of power cylinders. With a power bore
and stroke of 9.5 in. (241 mm) by 12.0 in. (305 mm) and
compressor stroke of 10.5 in. (267 mm), initial XVO models
were rated 30 hp (22 kW) per cylinder at 350 rpm. The pow-
er cylinder bore was later increased to 10.5 in. (267 mm).
JUNE 2014 83 Compressortech2
CT389.indd 2
Compressor
Power Stroke Production Quantity
Stroke
in. (mm) Years Produced
in. (mm)
12.0 (305) 12.0 (305) 1932-1958 1994
12.0 (305) 10.5 (267) 1938-1957 147
9.0 (229) 9.0 (229) 1947-1967 558
12.75 (324) 12.0 (305) 1947-1982 1471
12.0 (305) 12.0 (305) 1956-1962 112
In 1947, Ingersoll Rand introduced the JVG (Junior Vee
Gas) and SVG (Senior Vee Gas) models, which were small-
er, upgraded and modernized versions of the XVG. These
basic models were naturally aspirated and used the same
L-head valve arrangement and bank angle of the XVG.
The outward appearance of the JVG and the larger SVG
were very similar. Both had articulated connecting rod de-
signs. The JVG featured a power bore and stroke of 8.25 in
(210 mm) by 9.0 in (229 mm) and compressor stroke of 9.0
in. (229 mm). The earliest series produced 25 hp (19 kW),
and the later series 30 hp (22 kW) per cylinder at 550 rpm.
JVG models were available with four, six and eight power
cylinders and two, three and four compressor cylinders, re-
spectively. Production ended in 1967 with 588 units having
been made.
The SVG featured a power bore and stroke of 11.75 in.
(298 mm) by 12.75 in. (324 mm) and compressor stroke of
12.0 in. (305 mm). It produced 55 hp (41 kW) per cylinder
at 400 rpm, which was much larger than the XVGs 37.5 hp
(28 kW) per cylinder at that time. The 6SVG model had six
power cylinders and three compressor cylinders. The 8, 10
and 12SVG models all had four compressor cylinders. Pro-
duction of the popular SVG model ended in 1982 with 1471
total units manufactured.
During production of the JVG and SVG models, some
units installed at high altitudes were turbocharged to main-
tain the sea-level power ratings. The pressurized air from
the turbocharger fed into the air inlet of the mixing valve,
and the fuel supply pressure was balanced against the
air inlet pressure so that the fuel gas supply pressure in-
creased according to the air inlet pressure.
The SVO, a diesel version of the SVG, was introduced
In 1956. With a power bore and stroke of 11.75 in. (298
mm) by 12.0 in. (305 mm) and compressor stroke of
12.0 in. (305 mm), the SVO was rated 50 hp (37 kW) per
cylinder at 400 rpm. Available SVO configurations were
comparable to the SVG, except that a four-power cylinder
SVO model was also available, having two compressor
throws. SVO production continued through 1962 with 112
units made.
In total, Ingersoll Rand produced 4282 of the XVG and
related models of integral vee engine compressors over a
span of 50 years. CT2
5/20/14 2:17 PM
 C ornerstones Of Compression

n Ingersoll Rand introduced the industrys first vee integral engine compressor, the XVG,
in 1932. The earliest 2XVG engines, like the one shown here, were equipped with double
flywheels, but later 2XVG series and all other sizes were equipped with a single flywheel.

Ingersoll Rand Supplements

Integral Engine
Compressor Series > Model XVG was first vee integral
engine compressor
By Norm Shade

In 1929, Ingersoll Rand introduced the model XOG, an
integral angle gas engine compressor, developed in re-
sponse to Worthingtons introduction of the first of that type
of integral a year earlier. But with the natural gas industry
growing rapidly and demanding larger, lower cost alterna-
tives to the big horizontal integral engine compressors of
the day, Ingersoll Rand soon brought an even more impor-
tant breakthrough to the market in 1932.
Ingersoll Rands model XVG was the first integral gas en-
gine compressor with a vee arrangement of power cylinders
and horizontal compressor cylinders. This basic arrange-
ment was the basis for all Ingersoll Rand four-cycle integral
engine compressors to follow.
The XVG was built in two, four, six or eight power cylinder
versions, with half that number of compressor cylinders for
each version (i.e., one, two, three or four, respectively).
Immediately successful, by 1938 the XVG had completely
displaced the XOG. With a power bore and stroke of 11.0
in. (279 mm) by 12.0 in. (305 mm) and compressor stroke
of 12.0 in. (305 mm), initial XVG models were rated 32 hp
(24 kW) per cylinder at 300 rpm. Shortly into production,
the speed was uprated to 350 rpm, and by the end of pro-
duction the power had been increased to 41 hp (31 kW)
per cylinder.
An article by Mac and Betty Sine about Ingersoll Rand
continued on page 83

JUNE 2014 84 Compressortech2

CT389.indd 1 5/20/14 2:17 PM

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