Caterpillars New

3516C (HD) Engine MAY 2013

LuFKin

GE To buy

Expansions Abound

Compression Industry

COMPRESSOR
Wrtsil Converts Heavier Fractions Of Gas For Engine Fuel Myanmar Opens Its Doors To Offshore Oil Firms

Dedicated To Gas Compression Products & Applications

www.compressortech2.com

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COMPRESSOR
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CT2 Founder ........................... Joseph M. Kane Publisher .................................Brent D. Haight Associate Publisher ...............Roberto Chellini Editor ...........................................Patrick Crow Executive Editor ............................... DJ Slater Senior Editor .................. Michael J. Brezonick Senior Editor .............................. Mike Rhodes Associate Editor ................................ Jack Burke Associate Editor .............................Chad Elmore Copy Editor ................................ Jerry Karpowicz Digital Content Manager............Catrina Boettner Advertising Manager ...........Christa L. Johnson Circulation Manager ...................Sheila Lizdas Production Manager ............. Marisa J. Roberts Graphic Artist ........................Brenda L. Burbach Graphic Artist .............................Carla D. Lemke Graphic Artist ........................... Amanda J. Ryan Graphic Artist ................................ Alyssa Loope

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ver the years, I never gave this question much thought. That probably was an error of judgment. However, I credit this oversight to being completely absorbed in the all-consuming task of promoting the well-being of the compressor industry. I find all aspects of the industry fascinating, to say the least. Tracking the industry for nearly 50 years and observing the advancement in design, use of materials, the explosion in control technology, the changing modes of equipment selection and techniques of assembly, component selection and monitoring the ebb and flow of the highly volatile natural gas industry have been highly stimulating to the publisher and staff of this technical journal. But, most of all, and high on the list of the best experiences, has been meeting and engaging in discourse with leaders in the industry manufacturing, engineering, management, marketing, and sales along with purchasing, installation, operation and maintenance of compressor packages. The variety of topics and things to talk about seems to be infinite. The question about having a purpose in life was addressed a while back in an article published in The Wall Street Journal. The issue underlying the article was that any single facet of a persons career never lasts forever and the loss of stimulation of a very active working life leaves a seemingly insurmountable vacuum. The particular article in question was written by Diane Cole, an independent writer from New York City. She said studies of 1500 men and women at the Chicago-based Rush University Medical Centers Alzheimers Disease Cen-

ter show that having a purpose in life can help stave off cognitive decline and promote a broadly healthier, longer life. The article was based on a discussion with Dr. Patricia A. Boyle, a neuropsychologist and researcher for the Rush Memory and Aging Project, who also is an associate professor at the medical center. Our study showed that having purpose in life is robustly protective, Dr. Boyle said. Those who reported having purpose in life showed a 30% slower rate of cognitive decline than those who did not. Having purpose reduced the risk of Alzheimers and its precursor, mild cognitive impairment. Even those whose brains had the plaques and tangles associated with Alzheimers had better cognitive brain function. Its a remarkable finding. Dr. Boyle couldnt say for sure what the underlying cause of this phenomenon was. Her theory is that because people who are purposeful are actively pursuing goals, by doing so they are enhancing their mental activity, either including or developing other areas of the brain. Its the sense, she said, that your life has meaning. Youre engaged in things that energize and motivate you, and that you think are important on a broader level, beyond just yourself. She said many people choose to become mentors. They have a lot of wisdom as a consequence of their having done so much in their lives, and they want to pass along that knowledge to others, she said. The article included a list of mentally stimulating encore career activities for retirees. It included volunteerism in social services, health care, religious or faith-based issues/areas, human rights or social justice, arts and culture, at-risk youth, environment, education, poverty alleviation and economic development. The popularity of these activities ranged from 28% of the surveyed individuals down to 14%, in the order listed above. May the Lord hold you in the hollow of His hand. CT2

May 2013

COMPRESSOR
Featured Articles
16 GE To Buy Lufkin 18 Caterpillar Boosts Power Offering For Well Locations 20 Supercharging A CO2 Reciprocating Compressor 26 Wrtsil Converts Heavier Fractions Of Gas For Engine Fuel 30 Growth Keeps Sloan Brothers On the Move 36 Imes, Morris Develop New Gas Engine Balancer 40 Test-And-Inspection Rig Stormbringer 44 Methane Hydrate Production Inches Closer To Feasibility 48 Compressing Space

Dedicated To Gas Compression Products & Applications

Cover Designed By Amanda Ryan

72 New Hudson Subsidiary Targets Compression Cooling 76 Using Torque Flanges To Control Compressors

Compressortech 2 (ISSN 1085-2468) Volume 18, No. 4 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 53186-1873, U.S.A. Subscription rates are $85.00 per year/$10.00 per copy worldwide. Periodicals postage paid at Waukesha, WI 53186 and at additional mailing offices. Copyright 2013 Diesel & Gas Turbine Publications. All Rights Reserved. Materials protected by U.S. and international copyright laws and treaties. Unauthorized duplication and publication is expressly prohibited.
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TECHcorner
54  Assessment Of Onboard Diagnostics And Monitoring For Pipeline Engines

Departments
4 Page 4 Have We A Purpose In Life? 8  Global Perspective Myanmar Opens Its Doors To Offshore Oil Firms 10 Meetings & Events 12 About The Business Compression Industry Expansions Abound 14  Monitoring Government Dispute Continues Over Spurned Colorado Compressor Station 24 Recent Orders 24 Prime Movers 74 Featured Products 80 Scheduled Downtime

MEMBER OF BPA WORLDWIDE PRINTED IN THE U.S.A.

81 Marketplace 82 Advertisers Index 84  Cornerstones Of Compression Elliott Began The Turbocharging Of U.S. Recip Engines

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Global Perspective

By Roberto Chellini Associate Publisher

Myanmar Opens Its Doors To Offshore drops local partner requireOil Firms > Nation ment to attract investors
424 Bcfy (1.2 x 1010 m3/yr) of gas, mostly from the Yadana and Yetagfun offshore fields, operated by Total and Petronas, respectively. Daewoos Shwe and PTTEPs Zawtika offshore fields are expected to start production by 2015, adding 8 bcm to gas output. This would be a considerable leap forward in proving the commercial viability of the countrys hydrocarbons potential. The governments strategy is to increase energy production to supply fast-growing domestic demand. Business Monitor International (BMI) forecasts the countrys real GDP to grow by 7.5% over the next five years. If energy demand follows at a similar rate, oil and gas consumption could double within the next 10 years. Although the nation will honor its existing international contractual obligations, Htin Aung has announced that any new discoveries would be directed at meeting domestic demand. Myanmar also has acted to ensure that the uses of its revenues from natural resources are fully disclosed. The government planned to adopt and implement the international Extractive Industries Transparency Initiative standards before the end of the year. Finally, Myanmar is making progress toward building the legal framework and infrastructure that would allow producers to export gas from the existing Shwe offshore fields to China. A pipeline from the coastal city of Sittwe in Rakhine state to southwestern China is under construction, but violence between the government and ethnic Kachin fighters, who want greater self-rule in the countrys northeast, will most likely delay final operations. The pipeline line would have an initial capacity of 145 Bcfy (4.1 x 109 m3/yr) when completed this year, and could be tripled in capacity later with the addition of compression. The country expects to start a parallel oil pipeline in 2014. However, BMI reports that the largest risk for Myanmar remains its political stability. The recent development and rapid opening of the country to outside investment is promising, but the continued dominance of the military junta, associated to growing tensions in the countrys northeast region, could create risks for the long-term stability of business-friendly policies. CT2 8 Compressortech2

In early March, Myanmar energy minister, Than Htay, announced that his nation will proceed with a long-awaited offshore licensing round for 25 oil and gas exploration blocks, 18 in deepwater and seven in shallow water, covering much of the eastern half of the Bay of Bengal. The tender was initially planned for 2012, but was delayed while the government sought to improve and test investor sentiment. Increased involvement by foreign oil companies, such as Woodside Petroleum and Total, already suggests that market perception is improving. According to an official at the Ministry of Energy, international oil and gas giants such as Shell, Chevron, ConocoPhillips and ExxonMobil were waiting to bid for the offshore blocks. The launch of the offshore round was crucial for Myanmar and suggests that the government expects that it has largely overcome the stigma that prevented foreign investors from diving deeply into the countrys hydrocarbon potential. Myanmar (formerly known as Burma) ended 15 years of military rule in 2010 with an election that the international community viewed as a step toward political reform and democracy. As a result, the U.S. and other Western governments lifted sanctions that barred companies from investing there. But Myanmars government still is under criticism for its close ties to the former military junta and a lack of transparency. The nation has been progressively building the framework for a strong and secure business environment. Soon after announcing the schedule for the offshore round, Than Htay declared that there would be no local ownership requirement for foreign investors. Deputy Minister of Energy Htin Aung explained that the deepwater exploration would be too technical, risky and capital-intensive for local companies, and their inclusion would only deter competent foreign investors. Myanmars rule to limit ownership to three blocks per company also was seen as a positive development. Providing that a sufficient number of companies bid, this would increase competition and skills diversity in the countrys upstream. The major beneficiaries of this regulation will clearly be deepwater specialized oil field services companies, such as Saipem or GE Oil & Gas, whose experience in frontier markets will give them a strong bargaining position. Myanmar currently produces about 20,000 b/d of oil and MAY 2013

Its all in the name...

A proud past leads to a new future

They may display a proud old name on the outside, but the driving force within the worlds best-engineered, most efficient, pipeline gas compressors is Rolls-Royce. The heritage name, Cooper-Bessemer, still carried by older machines, echoes the engineering excellence that has earned Rolls-Royce an unparalleled reputation for quality. Today, in a business where productivity and dependability mean so much, the unsurpassed engineering experience of the past makes Rolls-Royce the compressor name of the future. Trusted to deliver excellence

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

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Meetings & Events

For a complete listing of upcoming events, please visit our website at www.compressortech2.com

May
May 1-4 Baghdad International Oil & Gas Conference & Exhibition Baghdad Tel: +90 212 356 00 56 Web: www.baghdadoilgas.com May 6-9 *Offshore Technology Conference Houston Tel: +1 (972) 952-9494 Web: www.otcnet.org May 14-16 *Eastern Gas Compression Roundtable Moon Township, Pennsylvania Tel: +1 (412) 372-4301 Web: www.egcr.org May 14-16 *Sensor+Test 2013 Nuremberg, Germany Tel: +49 5033 9639-0 Web: www.sensor-test.de

May 14-16 Uzbekistan International Oil & Gas Exhibition Tashkent, Uzbekistan Tel: +44 207 596 5233 Web: www.oguzbekistan.com/2013

Tel: +44 207 596 5000 Web: www.caspianoil-gas.com June 5-6 *Energy Exposition Gillette, Wyoming Tel: +1 (307) 234-1868 Web: www.energyexposition.com June 11-13 *Calgary Oil & Gas Expo Calgary, Canada Tel: +1 (403) 209-3555 Web: www.gasandoilexpo.com

June
June 3-7 *ASME Turbo Expo San Antonio Tel: +1 (404) 847-0072 Web: www.asmeconferences.org/ TE2013 June 4-6 *Power-Gen Europe Vienna Tel: +44 1992 656 617 Web: www.powergeneurope.com June 4-6 Sensors Expo & Conference Rosemont, Illinois Tel: +1 (617) 219-8375 Web: www.sensorsmag.com/ sensors-expo June 4-7 Caspian Oil & Gas Baku, Azerbaijan

September
Sept. 17-19 *Gas Compressor Conference Norman, Oklahoma Tel: +1 (405) 325-3891 Web: www.engr.outreach.ou.edu/ gascompressor Sept. 17-19 Developing Unconventional Gas Eagle Ford Conference & Exhibition San Antonio

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*Indicates shows and conferences in which Compressortech2 is participating

Tel: +1 (713) 260-6492 Web: www.dugeagleford.com Sept. 18-20 *Wyoming Natural Gas Fair Jackson, Wyoming Tel: +1 (307) 234-7147 Web: www.wyogasfair.org Sept. 25-26 ChemInnovations Conference & Expo Galveston, Texas Tel: +1 (713) 343-1884 Web: www.cpievent.com Sept. 30-Oct. 3 *International Pump Users Symposium Houston Tel: +1 (979) 845-2924 Web: www.turbolab.tamu.edu Sept. 30-Oct. 3 *Turbomachinery Symposium Houston Tel: +1 (979) 845-7417 Web: www.turbolab.tamu.edu

October
Oct. 1 Pittsburgh Chemical Day Pittsburgh Tel: +1 (855) 807-9814 Web: www.pittchemday.com Oct. 2-4 *Power-Gen Asia Bangkok Tel: +1 (918) 835-3161 Web: www.powergenasia.com Oct. 6-9 *Gas Machinery Conference Albuquerque, New Mexico Tel: +1 (972) 620-4026 Web: www.gmrc.org Oct. 7-10 *Argentina Oil & Gas Expo Buenos Aires, Argentina Tel: +54 11 4322 57 Web: www.aog.com.ar Oct. 22-24 *Louisiana Gulf Oil & Gas Exposition Lafayette, Louisiana

Tel: +1 (337) 235-4055 Web: www.lagcoe.com Oct. 28-30 Shanghai International Petroleum Petrochemical Natural Gas Technology Equipment Exhibition Shanghai Tel: + 86 21 36411666 Web: www.sippe.org.cn/en Oct. 28-31 10th International Rotor Dynamics Seminar Cologne, Germany Tel: +49 2267 6585-0 Web: www.arla.de Oct. 30-Nov. 1 EP Shanghai 2013 Shanghai Tel: +86 10 5129 3366 Web: www.epchinashow.com

November
Nov. 10-13 *Abu Dhabi International Petroleum Exhibition & Conference Abu Dhabi, United Arab Emirates Tel: +971 2 4444 909 Web: www.adipec.com

About The Business

By Norm shade

Compression Industry Expansions boost fabrication, training Abound > Firms to match energy boom
Recently, a representative of a mainline gas transmission company commented (unofficially) that the combination of system expansions and loss of experienced personnel to retirements and recruitment by other companies was so serious that the senior operator at one of their compressor stations had only three months of experience. Recruitment and training are urgent ongoing priorities for the development of the necessary workforce. Many upstream and midstream companies have expanded their internal training capabilities, and third-party training providers fill in some of the gaps. Several regional colleges have developed entry-level compressor operator and maintenance training programs and more are following suit. Compression industry trade associations, such as the Gas Machinery Research Council (GMRC), Gas Compressor Association (GCA) and Eastern Gas Compression Roundtable (EGCR) have also increased their focus on training in recent years. GCAs annual conference this April focused on several hot topics, including keynote addresses on energy market trends and a presentation on federal air emissions rules and regulations affecting the gas compression industry. Attendance was projected to be 5% above last years record turnout. The GCA event provides financial support for a number of the colleges with energy technology and gas compression training programs. It also gives the schools a venue for networking with compression equipment and service providers and with each other. EGCR predicted that attendance at its annual training and technology conference in May would increase by about 10%. The event focuses on engine and compressor maintenance, with intensive training track programs for compressor operators and maintenance technicians taught by industry experts. Topics added this year include environmental health and safety and OEM training for Superior engines and compressors and Solar turbines. Several compression-industry companies noted significant milestones recently. Late last year, Ariel shipped its 40,000th gas compressor and Harsco Industrial Air-XChangers (AXC) of Tulsa, Oklahoma, shipped its 75,000th ASME-certified cooler section. CT2 12 Compressortech2

he compression industry is continuing to expand its capacity to satisfy demand for gas compressors and processing equipment. Last June, Enerflex completed a US$24 million expansion that almost doubled the capacity at its Houston manufacturing complex. The facility now has 35 bays, including 20 bays with double-deck manufacturing and 100 ton (90.7 tonne) lifting capacity. The plant is strategically located to serve growing southern U.S. demand, as well as Latin American and other export markets. In September, UE Compression opened a 95,200 sq.ft. (8850 m2) facility in Henderson, Colorado, to handle larger packages. In June of this year, SEC Energy Products and Services will complete an additional 155,000 sq.ft. (14,400 m2) of fabrication space at its Houston plant. An additional 40,000 sq.ft. (3700 m2) of warehouse and 32,000 sq.ft. (2975 m2) of office space are scheduled for completion in September. To meet the demand in the rapidly developing Marcellus and Utica shale plays, Dearing Compressor and Pump Co. is adding another 25,000 sq.ft. (2325 m2) to its large plant at Youngstown, Ohio. And Exterran built a 65,000 sq.ft. (6040 m2) production equipment fabrication facility at Youngstown during 2012. More packagers are getting established outside North America, too. The latest is Euro Gas Systems, which opened a 26,000 sq.ft. (2400 m2), high-bay compressor assembly plant in Romania late last year. Along with the continuing strong demand for compressors comes the need for more trained and experienced engineers, operators and maintenance technicians. In parts of the country affected by the ongoing shale plays, the demand for experienced compressor hands has reached critical proportions. The problem has been exacerbated by retirements in the current workforce, leaving many companies with a serious shortage of experienced workers and forcing them to recruit from each other and their service providers or to reach outside the industry.

Norm Shade is senior consultant and president emeritus of ACI Services Inc. of Cambridge, Ohio. A 43-year veteran of the gas compression industry, he has written numerous papers and is active in the major industry associations.

MAY 2013

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Monitoring Government

Dispute Continues Over Spurned Colorado Compressor pipeline litigate over who pays Station > College, development costs
By Patrick Crow
How this controversy affected relations between President Jensen and the trustees isnt known. However, in late December the trustees said they had accepted his resignation. The reason for Jensons departure wasnt disclosed, due to a confidentiality clause in his severance agreement, but one trustee said it was unrelated to the compressor station controversy. An article on the colleges website stated, perhaps a bit wishfully, that It is unlikely that the general public will ever know the reasons behind the former presidents seemingly swift exit. Such things might become known should the county court summon Jensen to testify about the events surrounding and following his approval of the SourceGas lease. The Colorado Observer, which monitors politics in the state, was outraged that the CMC board had repudiated a contract that its president had signed. It editorialized, Whats particularly troubling about this situation is watching a public entity thats governed, at least in theory, by an elected board of trustees engage in this kind of not in my back yard obstructionism in an obvious attempt at placating a handful of leftist students and professors who prefer to ignore what it is that keeps the lights on in their sustainable energy studies courses. Furthermore, the Observer said local residents should be aware that taxes on the natural gas industry contribute heavily to the upkeep of the junior college district. Perhaps one of them (the residents) will remind the know-it-alls at CMC that responsible energy development, not eco-tourism or Strawberry Days, pays the bills in Garfield County. This spring, CMC did show its concern about the importance of energy for Coloradoans. It announced that it had bought a truck, fueled by compressed natural gas (CNG), which it will use to pull a new mobile learning lab throughout the state, demonstrating the advantages of using hybrid energy. The college explained, The truck will be a valuable educational tool for CMCs integrated energy technology programs and is part of our initiative to make our energy courses and programs more accessible. It did not say whether the CNG truck would be visiting the Spring Valley campus. CT2 14 Compressortech2

lashes over the location of compressor stations often leave unsavory aftertastes. Take, for example, an ongoing controversy in Colorado. Two years ago, SourceGas decided to add a US$14 million compressor station on its distribution pipeline that serves 42,000 customers between the towns of Rifle and Avon. It approached Colorado Mountain College (CMC), which operates a string of community junior colleges across six counties, and asked to lease a five acre (two hectare) site on a corner of the 688 acre (280 hectare) Spring Valley campus near Glenwood Springs. After briefing the CMC trustees regarding his negotiations with SourceGas, CMC President Stan Jensen signed a 20-year, US$240,000 lease in April of 2011. The booster station would not have been visible from the college buildings. It was designed for two 1500 hp (1100 kW) packages with room for a third. When the compressor station project went to the county zoning board and became public knowledge, some CMC faculty and students protested. So did ranchers who had donated land for the campus. SourceGas offered to shift the station to another location on the CMC acreage, to no avail. The trustees disavowed the lease, citing procedural missteps as justification. More to the point, several of them declared that the compressor station was incompatible with the mission of the college. The gas company then sued the college in Garfield County District Court, accusing it of acting in bad faith and terminating the lease without cause. Judge James Boyd ruled last August that state law did not permit him to order a public entity to honor a lease. That killed any possibility that the compressor station would be built on the colleges land. But it left the question of whether an unenforceable lease was nevertheless a valid contract. SourceGas maintained it was, and said the college should reimburse it for its development expenses. The CMC board responded that it should not be held liable for damages stemming from a lease that it never formally approved. Boyd has set the case for trial next February. The location of the needed station remains in limbo. SourceGas has not announced a different site.

MAY 2013

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will help company expand GE To Buy Lufkin > Move energy portfolio
By Patrick Crow
expanded into oil pumps in 1925 and remained privately held until launching an initial public offering in 1990. When he toured a Lufkin plant the day following the acquisition announcement, GE CEO Jeffrey Immelt indicated that the Lufkin trademark would be retained, but perhaps would be integrated with the GE brand. The reason why we bought the company was really because it has a great reputation, and a good workforce, and all that stuff gets embedded in the marketplace, Immelt said. Lufkin has a great brand in the marketplace, and we hope to build on that, Heintzelman told reporters. When he announced the purchase, Heintzelman said, Advanced technologies, combined with new drilling practices, are revolutionizing the oil and gas industry. The artificial lift segment is at the heart of critical changes that are helping producers maximize well potential which translates into increased output at lower operational cost. Lufkins world-class people, equipment and services fit perfectly in our portfolio and will enable us to offer a wide range of artificial lift solutions to our customers in this fast-growing artificial lift sector. John Glick, Lufkins president and CEO, said, The global scale that GE offers, combined with its deep service offerings and network of research labs, will create new opportunities for our customers and employees around the world. This transaction allows us to realize our strategic objectives for expanding both our portfolio and our global platform and will allow us to reach global customers much faster and more effectively than we could have done as a standalone company. Lufkin has been a major supplier of turbomachinery gears and specialty bearings products for GE in recent years. The companies said that Lufkin will continue to sell those products to other customers as well. CT2 Compressortech2

n GE officials have indicated that Lufkins familiar brand will not disappear soon.

E is buying Lufkin Industries Inc., a provider of pumping systems for the oil and gas industry, for US$3.3 billion. The acquisition, which will be completed in the second half of this year, brings GEs buying spree in the oil and gas sector to about US$11 billion since 2007. GE had purchased John Wood Groups well services business for US$2.8 billion in early 2011. GEs oil and gas portfolio is its fastestgrowing business sector, accounting for about 10% of its revenues. Lufkin posted record revenues of $1.3 billion last year while GEs energy sector reported $1.92 billion (a 16% increase over the prior year). The deal complements GEs electric submersible pumps (ESP) with Lufkins rod lift, gas lift, plunger lift, hydraulic lift, progressive cavity pumps. Lufkin also has an array of well automation and production optimization controls and software. Because Lufkin has not been in the ESP business, GE officials said they anticipate no antitrust objections from federal regulatory agencies. Daniel Heintzelman, GE Oil & Gas president and CEO, said his company expects the oil pump market to grow 12 to 13% per year for at least the MAY 2013

next decade. He added that at least 94% of the worlds 1 million oil wells will need pumps or artificial lifts during their lifetime. GE said that with the addition of Lufkins artificial lift and other oilfield products, it will be able to offer its global exploration and production customers a complete portfolio of offerings to address a wide variety of well types at all stages of the production life cycle. Eric Gebhardt, vice president of engineering for GE Oil & Gas, said Lufkins strong pump business seemed like a perfect fit with GEs other oil services operations. He about 80% of Lufkins business is in the U.S. Our plan is to take it more and more globally as we move forward, he said. The goal is to cut out a global expansion for the capabilities that Lufkin has. Lufkin, based in the Texas town of the same name, has 4500 employees in more than 40 nations. Its pumping equipment business has a global network of more than 110 service centers and nine manufacturing facilities. It also has three turbomachinery production plants that make industrial gears and engineered bearings. The Texas company was founded in 1902 to make railroad equipment. It 16

Sleepless Nights?
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Caterpillar Boosts Power Offering 3516C engine responds to For Well Locations > New Chinese requirements
By Brent Haight
3512C (HD), Roberts said. Maintenance requirements will match those of the 3512C (HD). The engines have the same maintenance schedules, life expectancy, and time to major overhaul. Manufactured in Lafayette, Indiana, the 3516C (HD) engine is offered in a separate circuit aftercooler (SCAC) cooling configuration. It also has a single ADEM A3 Engine Control Module that facilitates additional input/output capability and integrated controls. The ADEM A3 monitoring system provides engine deration, alarm or shutdown strategies to protect against adverse operating conditions. Selected parameters are customer programmable. Status available on enginemounted instrument panel, and can be broadcast through Modbus to the rigs power management system. Caterpillar will offer attachment options such as transmission oil coolers, charging alternators, air cleaners and mufflers for simplified installation. The engine meets U.S. Environmental Protection Agency Tier 2 emissions for North America as well as Tier 1 emissions for international markets. What is most special about the 3516C (HD) is that it matches very well with our TH55 transmission, Roberts said. The TH55 can handle all the power ratings we are rolling out. An OEM that wants to build a 3000 to 3300 hp (2235 to 2600 kW) well stimulation package can have the complete Caterpillar solution. They are going to get the best performance out of the complete drive train because of the torque rise and speed range that we have on the engine, Roberts said. Combine that with global Cat dealer network support and this is an excellent option for the pressure pumping market. CT2 Compressortech2

n Caterpillar has introduced the

16-cylinder, 78 L 3516C (HD) engine for well stimulation.

aterpillar Global Petroleum has introduced the Cat 3516C (HD) engine for well stimulation. The new 16-cylinder, 78 L engine will be available in three ratings: 3300 bhp (2461 bkW), 3150 bhp (2349 bkW) and 3000 bhp (2237 bkW) at 1900 rpm. The Chinese well stimulation market drove us to move forward with this engine, said Scott Roberts, well service manager at Caterpillar Global Petroleum. Well stimulation operations in China are starting to utilize higher horsepower much more so than in North America, which primarily uses the 2250 to 2500 hp (1675 to 1865 kW) engine range for well service trailers. According to Roberts, the demand in China for higher horsepower is primarily driven by the maneuverability requirements of vehicles in that nation as well as the bridge loading requirements. Well stimulation vehicles in China use body load chassis versus a trailer chassis in the U.S., because they are easier to maneuver in remote locations compared to a trailer, he said. The bridge loading and axle weight

distribution requirements in China allow the vehicles overall to be a lot heavier than in the U.S. and can subsequently put a heavier weight, higher horsepower engine on the truck. Seeing this trend for higher horsepower, Caterpillar reconfigured its 3516C engine for well stimulation applications. Caterpillar first introduced the 3516C engine in 2006. Since then it has become a stalwart in rail and marine applications. Well stimulation engines have a higher displacement in order to produce higher horsepower and higher torque, Roberts said. To date, we did not have a 3000 hp (2235 kW) solution for pressure pumping. We relied on the 3512C (HD) for well stimulation or pressure pumping applications. According to Roberts, the 3516C (HD) is essentially an extended version of the 2500 hp (1864 kW) 3512C (HD) engine. Customers will find many similarities with mounting and connection points. The 3516C (HD) will provide the same level of reliability and durability that customers depend on from the 18

MAY 2013

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n For the first stage of CO2 compression,

the project uses an Aerzen 536 VMY oilflooded rotary screw compressor with a Lufkin speed increaser.

Supercharging A CO2 Reciprocating resolve problems, Neuman & Esser drops a Compressor > To stage of compression but supercharges others
By Robert Crow
n international oil and gas exploration and production company operating a gas plant in West Texas required a unique and challenging carbon dioxide (CO2) compressor application. The requirement was for compression of 95% CO2 with suction pressure from 0.5 psig (0.034 bar), disRobert Crow is Neuman & Esser USA Inc.s business manager, upstream and midstream. He has an extensive background in gas compression, with more than 17 years of oil, gas and energy industry experience. A graduate of Texas A&M University, he joined Neuman & Esser in 2009.

charge pressure to 2000 psig (138 bar), a total facility design flow rate of 25 MMscfd (700 x 103 m3/d), and at an elevation of 2800 ft. (850 m). The operator had been contracting compression services from a third party using antiquated, slow-speed, integral compressors. Due to emissions, reliability, parts and service availability issues, the gas plant required a new compressor solution. Another key problem for the operator was that medium-voltage electricity was unavailable at the plant, so the new CO2 compressors would have to be driven by natural gas fueled engines. 20

Solution Initially, the operator requested Neuman & Esser to provide multistage reciprocating compressors driven by natural gas engines running at 1000 rpm. Initial performance calculations indicated that the operator required approximately 10,000 hp (7355 kW) in at least five stages of compression. However, Neuman & Esser had multiple concerns with such low suction pressure requiring very large first-stage cylinders with very high piston weights. From its experience, Neuman & Esser knew that rotating 24 to 28 in. (61 to 122 cm) cylinders at such high speeds would Compressortech2

MAY 2013

be problematic for existing compressor models. And high-mass forces and inertia loading, combined with poor volumetric efficiency and excessive valve masking, would challenge even the best of currently available compressor models. The operator also faced a potential requirement for a tandem/step piston-cylinder arrangement for final stages and very high discharge temperatures that would result in poor valve performance and shortened ring and packing life. Because of the challenges posed at this gas plant, Neuman & Esser proposed a creative solution based on its NEA Seismic Air Packages product line. NEA SAPS is a compressor application that Neuman & Esser pioneered and engineered for offshore seismic compression applications using rotary screw and reciprocating compressors with a common driver. The use of a common driver results in fewer number of packages needed to compress air to high pressure, allowing for a more efficient and cost-effective operation with minimal service work. Results Neuman & Esser began working closely with the operator, its engineering firm and a key fabrication partner to develop and evaluate a compressor design based on the its SAPS-style compressor package. It had had proven experience with 1000 to 1500 hp (735 to 1123 kW) applications compressing air from ambient suction pressure to 3000 psig (200 bar) using the combination rotary screw/reciprocating compressor on a common driver, both electric and engine driven. Because the operator requested the minimum amount of compressor packages to solve the application, the best solution was to divide the application up into three units, each requiring approximately 3200 hp (2350 kW), driven by natural gas engines. Neuman & Essers calculations resulted in compression flow requirements of about 6 MMscfd (170 x 103 m3/d) at the first-stage inlet, at a suction pressure of 0.5 psig (0.03 bar), and an MAY 2013

additional 2.33 MMscfd (66 x 103 m3/d) sidestream coming in at approximately 80 psig (5.5 bar). With an appropriately sized rotary screw compressor, along with a Neuman & Esser reciprocating compressor designed for a full 8.33 MMscfd (236 x 103 m3/d), this application appeared much more feasible to operate effectively at 900 to 1000 rpm. The rotary screw compressor allowed the removal of the large first-stage cyl-

Carryover ad_Layout 1 2/14/2012 3:17 PM Page 1

inders by increasing and supercharging the reciprocating compressor into the second, third and fourth stages. This application turned out to be an ideal high-performance solution. Neuman & Esser was awarded the project in early 2011 and all partners began working on detailed engineering. Equipment was delivered to the site in early 2012, and installed, commissioned and started up by September 2012. continued on page 22

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n For the second through fourth stages, the project uses a Neuman & Esser 3 SVL 320hs reciprocating compressor driven by a Caterpillar G3612 TA natural gas engine.
Benefits Drawing on its experience, Neuman & Esser was able to provide an alternative solution through advanced drive train design techniques. Working with vendor partners, who played an integral role in the success of this project, Neuman & Esser reduced the overall required stages of compression and was able to complete the application with the fewest number of units, saving the operator time and money. Based on the success of this gas plant installation, Neuman & Esser has developed a concept that can be successfully applied in future anthropogenic CO2 enhanced oil recovery compressor applications. CT2

Altronic.indd 1

Recent Orders
GE Oil & Gas
GE Oil & Gas has received a 22year, US$620 million contract to provide services for QGCs Queensland Curtis liquefied natural gas (LNG) plant under construction off the east coast of Australia. The plant will be the worlds first facility to turn coal seam gas into LNG. It is the first of four LNG projects scheduled for Curtis Island and is expected to begin production in 2014. GE will provide maintenance for its equipment being installed at the LNG plant, including 15 of its PGT25+G4 aeroderivative gas turbines, 28 centrifugal compressors, gearboxes, generators and auxiliaries. Maintenance activities on the power turbines and compressors will take place at GE Oil & Gas facilities in Jandakot, Western Australia, and in Florence, Italy. Monitoring and diagnostics will be provided from GE centers in Florence, Houston and Kuala Lumpur, Malaysia. CT2 MAY 2013

PRIME
Movers
Cummins
Cummins Inc. has named Jennifer Rumsey vice president Engineering for Heavy, Medium and Light Duty Products. Rumsey has led J. Rumsey Cummins Heavy Duty Engineering since 2010. From 2007 to 2009, she was a technical project leader in Midrange Engineering, as well as a member of the Cummins Turbo Technologies business team. She also held multiple roles in the Advanced Engineering Organization. Prior to joining Cummins, she worked for Nuvera Fuel Cells, where she led control system development and system integration for fuel processing/fuel cell technology.

4/18/13 1:00 PM

vironmental Protection (DEP) has proposed much tougher emissions limits for natural gas-fired engines and other equipment at compressor stations. The final revisions to General Permit 5 affect companies in the Marcellus Shale boom. The new standards are 75 to 90% stricter than current limits for the largest, most common types of engines used at compressor stations. The revised permit also would give operators the flexibility to install controls to achieve even lower emissions, allowing for the use of additional engines. Operators of facilities operating under the general permit must demonstrate that their facilities continue to be minor sources as defined by the Clean Air Act.

GE Oil & Gas

Petrobras has given GE Oil & Gas a US$500 million-plus contract to supply turbocompression trains and other equipment for four floating production, storage and offloading units (FPSOs) Compressortech2

Pennsylvania DEP
The Pennsylvania Department of En24

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in the Santos Basin off the state of So Paulo, Brazil. The company will supply the main turbomachinery equipment to the new FPSOs (P-74, P-75, P-76 and P-77) to be placed over pre-salt fields in Cesso Onerosa region of the basin. GE said its technology will generate primary energy for the FPSOs using gas turbines and advanced generators, moving gas through pipelines using compressors and re-injecting CO2 and natural gas in the well to enhance oil recovery. The contract includes: 16 powergen turbogenerators composed of PGT25+ gas turbines and electric generators; eight turbocompression trains driven by LM2500+ gas turbines; and 32 electricmotor-driven compressors for gas main, export services and CO2 reinjection.

Klber Lubrication
Klber Lubrication, a worldwide manufacturer of specialty lubricants, MAY 2013

has appointed Ralf Kraemer as chief executive officer. Kraemer assumes the role from Dieter A. Becker, who returns to Klbers global headquarters in Munich, GermaR. Kraemer ny, after leading the North American operations for nearly three years. Born in Germany, Kraemer has more than 15 years of sales, marketing and management experience in the metal cutting, woodworking, industrial equipment and power transmission industries to his new role at Klber. Prior to joining Klber, Kraemer managed operations at a Swiss technology company in the Chicago area and established and developed the North American manufacturing facility and business operations for a German machine tool accessories company near 25

Raleigh, North Carolina. For the past nine years, he was responsible for the North American operations of a German machine tool company in Pittsburgh.

Turbines Inc.
Turbines Inc. has opened its Odessa, Texas 3197 sq.ft. (297 m2) sales, distribution and service location in response to heavy local demand for turbine flow metering products. The company serves as the local resource for turbine meters and accessories for oil and gas applications, and is staffed by field engineers and customer service representatives with direct knowledge of the local oil and gas industry. Turbines Inc.-Odessa also launched its new website, www.turbinesodessa. com, which will assist customers and partners by providing product information, special offers and updated event guides highlighting local activities in the area. continued on page 71 Compressortech2

n The GasReformer unit measures 17 x 10 x 11 ft. (5.3 x 3 x 3.3 m) and weighs 18.7 tons (17 tonnes). It is equipped with its own 133 hp (99 kW) electrical heater to control the process temperature.

Wrtsil Converts Heavier Fractions Of Gas For Engine Fuel

GasReformer also cuts risk of condensation in compressors

By Bo Svensson

rtsil has introduced a steam reforming technology to convert rich gas into a quality fuel for engines. The Wrtsil GasReformer enables associated gases recovered during oil production, which are rich in heavy hydrocarbons, to be converted into a natural gas product suitable for dual-fuel engines operating at full performance levels. The uniqueness of our GasReformer is its ability to convert unwanted heavier fractions from the gas into methane, said Tore Lunde, director of Wrtsil Oil & Gas Systems. By turning waste gas into fuel, the system significantly lowers operating costs while notably enhancing environmental sustainability. In locations where flaring is prohibited, this is especially important. Because it converts the heavy hydrocarbons in gas feedstock, the Wrtsil GasReformer lowers the danger of condensation in compressors. In liquefied natural gas production, the heavier fractions that had been separated by MAY 2013

cooling could be run through the GasReformer for either reinjection to the stream or for powering the trains. While catalytic conversion of hydrocarbon feeds into hydrogen is a known process dating back to the early 20th century, the Wrtsil GasReformer represents a new application under quite different conditions than those of the traditional process. The new gas reformer is a result of the considerable experience Wrtsil gained when the company was involved in the development of the treatment of gaseous fuels for fuel cells, Lunde said. It is yet another example of the companys ability to develop solutions that combine both economic and environmental benefits. Associated gas from oil production is often flared because it is uneconomic or impractical to utilize. Offshore gas flaring is increasingly recognized as a major environmental problem, contributing more than 1% to global carbon dioxide (CO2) emissions, not to mention the wasted resource. 26

The World Bank-led Global Gas Flaring Reduction Partnership has estimated that 5.3 Tcfy (150 x 109 m3/y) is burned. This is equivalent to 30% of the European Unions gas consumption and causes emissions of 440 million tpy (400 million T/yr) of CO2. Wrtsil said because its reformer converts associated gas into a stable composition, oil platforms and floating, production, storage and offloading (FPSO) vessels could use the gas for their high power demands. That could mostly eliminate the use and bunkering of marine diesel oil. It said another promising application for the reformer technology is in crude oil handling. During the storage of heavier fuel oils, a considerable amount of volatile organic compounds (VOCs) are formed above the oil surface in a tank. In order to pump the crude oil, it is heated to improve the viscosity and during heating and the lighter hydrocarbon fractions escape into the atmosphere. VOCs, which are recovered from oil continued on page 28 Compressortech2

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n Wrtsil said in this actual field example, although the methane content of the associated gas was high at 78%, the methane number was just 56. After the GasReformer, the outlet methane number was 98, with all the hydrocarbons transformed to primarily methane, hydrogen and carbon dioxide.
In the Wrtsil GasReformer, the methane number of any fuel gas is improved up to 1005 by converting the heavier hydrocarbons to synthesis gas (H2 + CO) and to methane (CH4) eventually. The Wrtsil GasReformer operates under a pressure of 72.5 to 138 psi (5 to 9.5 bar). The desulfurization adsorbent is zinc monoxide. The desulfurization temperature varies between 390 to 750F (200 to 400C). The reformer catalyst is Ni/MgAl2O4 working at a reformer temperature span of 660 to 790F (350 to 420C). Beside the primary gas the reformer process utilizes only steam. The steam is brought to the process at 356F (180C). For a ship installation, the steam could be supplied from a waste heat recovery boiler coupled to one of the main engines. The reformer is equipped with its own 133 hp (99 kW) electrical heater to control the process temperature. The water consumption of the process is as low as 13.2 gal. (50 L) per MW/hr. With a Wrtsil GasReformer sufficient for a 10,700 hp (8 MW) dual-fuel engine and utilizing associated gas, the operator can reduce the need for bunkered fuel oil by about 22 tons (20 tonnes) per day, Jansson said. With a Wrtsil DF engine the system produces electricity with an overall efficiency of up to 44.5%, including the operation of the gas reformer. The first 10,700 hp (8 MW) GasReformer, which will fuel two eightcylinder Wrtsil 34DF inline dualfuel generators, will be installed this spring on a drilling rig in the South China Sea. The factory acceptance tests, classified by Det Norske Veritas, were successfully concluded last December. CT2

production and handling, can be processed by the Wrtsil GasReformer, said Peik Jansson, product manager, Wrtsil Oil & Gas systems, Gas Recovery. The Wrtsil GasReformer has been developed and designed to meet the standards of the oil and gas industry and is the first of its kind. Large amounts of VOCs also are created, and escape during the tankering of crude oil. By using the gas reformer, during transport the VOCs can be converted into usable engine fuel, which can be used during the unloading. In cases with very large tankers over very long routes, VOC losses can be as high as 1%. It is like charging a battery during the ship transport and then using the power during unloading, Jansson said. For a regular oil tanker a large amount of power is used for the pumps, maybe in the range of 20,100 hp (15 MW), and the refined VOCs can then be used as engine fuel. This offers a great saving in fuel costs. He said FPSOs, where the cycle of loadings and unloadings are frequent, are a perfect fit for the GasReformer.

The technology behind the Wrtsil GasReformer is based on steam reforming, a catalytic process used at refineries and petrochemical plants to make hydrogen from various hydrocarbon feeds. Wrtsil exploited the same catalytic process, but operating under different conditions. The catalyst material, placed in a pressure vessel, consists of reduced nickel pellets, and has a lifetime of three to four years. The two desulfurizer reactors, one of which acts as a backup, use zinc oxide as an adsorbent and can be continuously operated for a year. Wrtsil has developed a sales and service concept for the GasReformer that includes maintenance. The reactor of the GasReformer is replaced every three to four years with a unit serviced ashore, to avoid service work on platforms or vessels.

n The Wrtsil GasReformer coupled with a Wrtsil DF engine can produce electricity with an overall efficiency of up to 44.5%, including the operation of the GasReformer.
MAY 2013 28 Compressortech2

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Growth Keeps Sloan Brothers On The Move > Lube systems firm is well positioned to serve Marcellus play

By DJ Slater

n The recent expansion provides Sloan Brothers with ample space for several pieces of equipment, such as the Mazak-Nexus 4000 horizontal machining center with sixstation Palletech.
trend is apparent at Sloan Brothers. Four years ago, the lubrication systems manufacturer moved into a 20,000 sq.ft. (1858 m2) facility, which provided Sloan Brothers with more floor space to accommodate CNC machine tools as well as other machinery and equipment. It was the companys eighth move in 86 years of operation. Make that the companys ninth move in 90 years. Sloan Brothers Lubrication, based in Freeport, Pennsylvania, has expanded its footprint another 11,000 sq.ft. (1022 m2), with a climatecontrolled manufacturing facility dedicated to current and future manufacturing operations. The move comes with MAY 2013

n Sloan Brothers new 11,000 sq.ft. (1022 m2) expansion (far right) allows the company
to focus on current and future manufacturing projects.

several new manufactured product lines to be introduced in the coming months. The expansion, as well as the new manufacturing capability, is part of Sloan Brothers gradual evolution from a sales company to a self-sufficient manufacturer. The company, which employs 29 people, designs and builds automatic and protected lubrication systems for reciprocating and rotary equipment. It offers a 24hour supply of lube system parts and services for compression equipment. We now make most of the critical components (for our lubrication systems), said C.J. Sloan, the companys vice president. Were not depending 30

on an outside supply chain. Its up to us to control our own destiny. That really lets us respond to market demand a lot better. Sloan Brothers was never supposed to be anything more than a lubrication system sales company when Walter Sloan came onboard part-time in 1971. At that time, the company operated out of an office building in a Pittsburgh, Pennsylvania neighborhood known as East Liberty. Walter Sloans father, John Sloan, would travel to meet with customers, take lube system orders and send them to Manzel Lubricators continued on page 32 Compressortech2

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HEINZMANN Contacts in North America

Subsidiaries

n While Sloan Brothers isnt able to fill its new space, C.J. Sloan, the companys
vice president, said its all about being prepared for future demand.

USA
HEINZMANN AMERICA, INC. 1305 Duff Drive, Unit 1A Fort Collins, CO 80524 Phone: +1-970-484-1863 Email: info.usa@heinzmann.com

in Buffalo, New York. Manzel would fulfill the order, ship it to those customers and let them install it. We never touched anything, said Walter Sloan, now the companys president. Sometimes, however, orders would arrive incomplete or the lead time on a small component would hold up the shipment. The lack of control on Sloan Brothers part led Walter Sloan to suggest stocking common components, such as pumps and valves. We realized that we could not satisfy our customers unless we started handling some product, he said. So we did. Stocking purchased parts was the first move. Then, another company bought out Manzel Lubricators and moved the plant to Cleveland, Ohio, with the promise that there would be no shipping interruptions. There were, and John and Walter Sloan drove out to the plant, collected several partially assembled lubrication systems and finished them before sending them off to their customers, Walter Sloan said. That was in the late 1970s, and was the start of our getting into the system assembly part of the business, Walter Sloan said. We then started manufacturing the pieces that were required for the assemblies. It has been awesome to be a part of our growth. Every day it seems almost unbelievable. At first glance, it seems there is too much room, with about half of the available 11,000 sq.ft. (1022 m2) manufacturing area consisting of empty space. MAY 2013

That was part of the plan, C.J. Sloan said. We built that facility for our future demand. You can see were not utilizing the space quite as well as we might like now, but its there for the future. The additional space also cleared out the companys new inventory room. Before the move, the room housed machining centers that required 24-hour cooling from two central air conditioning units, even in the winter, to accommodate the excess heat coming off the machinery. Now, the room serves its sole inventory purpose, while the production machinery carries on in more open quarters. The new space includes a manufacturing office as well as a research and development department, where the company evaluates all of its manufactured products with an eye toward constant improvement, C.J. Sloan said. Two principles are instrumental when tackling new products or redesigning them modularity and manufacturability. With modularity, Sloan Brothers tries to design a family of products that are customizable out of all the same components. For example, we can make 16 different arrangements of one product line and only have two pieces that vary between each of those models, C.J. Sloan said. All of the other parts are the same. The principal of manufacturability goes together with modularity. Sloan Brothers analyzes how it can quickly manufacture a component and use it in several products. The company continued on page 34 32

Canada
HEINZMANN GmbH & Co. KG 1013-14 Avenue Wainwright, Alberta, T9W 1K5 Phone: +1-780-231-2280 Email: b.powers@heinzmann.com

Agents
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Kraft Power Corporation 199 Wildwood Ave. Woburn, MA 01801-2024 Toll free: +1-800-969-6121

Further ofces:
Suwanee, GA Phone: +1-800-394-0078 (Toll free) Email: GAinfo@kraftpower.com Gaylord, MI Phone: +1-866-713-2152 (Toll free) Email: MIinfo@kraftpower.com Charlotte, NC Phone: +1-704-504-3033 Email: NCinfo@kraftpower.com Houston, TX Phone: +1-800-394-0078 (Toll free) Email: aschaub@kraftpower.com Massillon, OH Phone: +1-330-830-4158 Email: bschleifer@kraftpower.com Pompton Plains, NJ Phone: +1-800-221-3284 (Toll free) Email: NJinfo@kraftpower.com Syracuse, NY Phone: +1-877-349-4184 (Toll free) Email: NYinfo@kraftpower.com Sturtevant, WI Phone: +1-262-884-8666 Email: WIinfo@kraftpower.com

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n The Haas VF2 vertical machining center is housed in Sloan Brothers 11,000 sq.ft. (1022 m2) expansion.

can then have those pieces, which are compatible with several products, readily available for customers. This allows us to respond to our customers needs quickly as opposed to having them wait six weeks for a finished product, C.J. Sloan said. We can get it out the door in 48 hours. Thats a huge benefit. We know we need all these common components, and weve got them all on the shelf. All we have to do is put them together. Brian Sloan, the companys secretary and treasurer, agreed, adding that having those components in hand also helps get customers machinery up and running at a swift pace.

Having parts and components at the ready is also beneficial in ensuring that a customer wont have to experience lengthy downtime, he said. When a process is down because a critical engine or compressor cant run due to a failed lubrication system component, the costs can be very high. Now is sometimes not soon enough. Its all about making sure that customer downtime is as minimal as it can be. It just sets people back how were able to react as quickly as we can. As the future stares back at Walter Sloan in the form of the new manufacturing space, he cant help but reflect on the outlook for the company, which will someday no longer involve

himself. While the loose family model of running the business has kept the company progressing for the past 90 years, Walter Sloan knows that a more defined structure will be needed to keep Sloan Brothers viable for the next 90 years. Thats where we are right now, Walter Sloan said. Were putting together a management framework where everyone has defined duties and expectations, but also where everyone is also encouraged to speak up with innovative ideas. We need more structure. Obviously, weve been very successful but in my mind, if you say, Hey, were doing fine. This is all were going to do, then thats going to be the beginning of the end. Sloan Brothers isnt slowing down, either. C.J. Sloan said the company is looking to roll out more revolutionary products in the near future. Additionally, the company is also positioned in the center of the booming Marcellus Shale gas play, with the prospect of massive pipeline growth in the future. Natural gas only used to come from elsewhere and get pumped here, C.J. Sloan said. Now theyre producing gas in places like right here in Western Pennsylvania and piping it in all directions. It is a level of growth that I think is going to work out very well for us. If it all pans out the way the Sloan family expects, then C.J. Sloan anticipates that the companys historical and recent growth trend will continue. CT2

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MAY 2013

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Insight onsite.

n Morris Control Systems is the North American distributor for the Imes EPM-XG handheld gas engine balancer.

Imes, Morris Develop New Gas Engine Balancer > Model builds on existing IPT sensor technology for recips
By Roberta Prandi
ngine controls specialist Morris Control Systems and cylinder pressure data specialist Imes have partnered to release their new EPM-XG gas engine balancer. Imes, based in Kaufbeuren, Germany, manufactures the device while Morris Control Systems, of Abingdon, Virginia, is the primary sales representative and distributor for the North American market, where the product already is in use. The new engine balancer builds on the success of Imes and Morris Control Systems in the North American gas compression market. Their integrated pressure transducer (IPT) sensors are utilized for continuous monitoring of output pressure on reciprocating compressors driven by gas engines in pipeline compressor stations. Worldwide, more than 4000 Imes IPT sensors are in use. EPM-XG is designed as a comMAY 2013

pact, lightweight and affordable handheld device, specially tailored to periodic cylinder pressure monitoring and output balancing on the types of gas engines found in North American natural gas pipeline compressor stations, Morris Control Systems CEO Dave Morris said. It employs technology well proven on diesel and gas engines in marine propulsion and power generation applications, adapted to two-stroke gas engines with rated speeds from 40 to 500 rpm and four-stroke gas engines with rated speeds from 200 to 1500 rpm. Morris said the EPM-XG already has been used on several gas engine models, including the Clark TCV, Cooper GMV, Ingersoll-Rand KVR, and the Worthington 330. He said customers appreciate the accuracy and ease-of-use characteristics of the EPM-XG, combined with its sophisticated analysis software. 36

As well as immediate readouts of peak cylinder pressure on the EPMXG display, customers can download recorded data to PC running software specially designed by Imes and Morris Control Systems for visualization, analysis and storing of data, Morris said. Special features include compiling 50-cycle peak pressure histories for each engine cylinder, as well as peak pressure and balancing charts, and the ability to generate engine balance reports in Excel or PDF formats. The generated files can then be transmitted electronically to the pipeline operators control center or serv ice organization, where they can be used as an input for monitoring, diagnosis and control of the gas engine and compressor station as a whole. The EPM-XG gas engine balancer continued on page 38 Compressortech2

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uses the proven Imes HTT-04 cylinder pressure sensor. Like all Imes sensors, the HTT-04 uses a TION thin film-measuring cell and is designed for a 16,000 hour operating life with minimal signal drift. More than 30,000 HTT-04 pressure sensors have been delivered to engine builders and operators, Imes said. The EPM-XG also relies on the same basic technology used in the Imes EPM-XP electronic cylinder pressure indicator, of which 1000 units are in worldwide use in ships and cogeneration plants. The battery powered, handheld EPM-XP Electronic Indicator EPMXP is designed for periodic monitoring of cylinder pressures on large diesel, gas and dual-fuel engines. It provides important measurement data for engine diagnostics and condition monitoring directly at the point of use. EPM-XP gives immediate readouts for peak pressure (Pmax) and pressure compensation (Pcomp) from a number of pressure cycles per cylinder. The acquired data can then be downloaded to a computer where the Imes visualization and evaluation soft4:42 PM ware is used to calculate IMEP and Ipower including p/v diagrams. The EPM-XP electronic cylinder pressure indicator is designed for use on two-stroke engines in the range of 40 to 300 rpm and fourstroke engines in the range of 200 to 1500 rpm. About 90% of Imes products are sold outside Germany. Its sensors, electronic pressure indicators and combustion monitoring systems are employed on a wide range of diesel, gas and dual-fuel engines, on ships and locomotives and in power and cogeneration plants and pipeline compressor stations worldwide. Morris Control Systems specializes in control system specification, design, algorithm development, system calibration, and diagnostics. It has experience with two- and fourstroke engines ranging from two to 20 cylinders and from 10 to more than 1000 hp (7.5 to 750 kW). Fuels include gasoline, diesel, LPG and natural gas. CT2 Compressortech2

MAY 2013
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More than 1,000 DATUM compressors producedeach one engineered for your specic application. The DATUM compressor boasts the ideal mix of standardized components and custom-tailored featuresresulting in a compressor solution as unique as your challenge. Our solutions are designed to deliver maximum performance, efciency and reliability for your specic ow and pressure applications. In fact, a single DATUM casing can deliver high compression ratios where others may require multiple casings to do the same work. So, give yourself a competitive edge by choosing the compressor that will give you the highest performance and lowest total cost of ownershipthe DATUM compressor. For more information visit datum.dresser-rand.com Visit us at OTC2013, Booth 9659, Houston, TX, May 6-9; the EGCR, Robert Morris University, Moon Township, PA, May 14-16; ASME/IGTI Turbo Expo 2013, Booth 513, San Antonio, TX, June 3-7; and POWER-GEN Europe, Booth A1371, Vienna, Austria, June 4-6
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Test-And-Inspection Rig avoid potential future disturbances, Stormbringer > Helps monitors multiple parameters

By Bo Svensson

n The Camfil Farr air intake filter

systems test rig has been developed for air filter testing and inspection according to EN 779 and ASHRAE 52.2 standards. The test duct is divided into three sections and constructed airproof.

amfil Farr has inaugurated its test-and-inspection facility for gas turbine air intake filter systems, built near the companys head office in Trosa, just south of Stockholm. The test rig, named Stormbringer, has been calibrated according to EN 779 and ASHRAE 52.2 standards and was developed to simulate the harsh climate conditions where gas turbines are often located, including desert, offshore and arctic applications, the company said. By testing filter systems, potential future disturbances during operation can be avoided. Testing and inspection of filter systems already in use may provide solutions for performance improvements. The test facility makes it possible to monitor parameters such as differential pressure and efficiency; dust-holding capacity; efficiency after different dust-loading phases and average efficiency; salt-removal efficiency; and testing with water spray. With this new GT test rig, we now have the potential to simulate the most demanding ambient conditions, said Richard Ringstrm,

product manager, Camfil Farr Power Systems. While monitoring pressure drop and filter efficiency, we can also control relative humidity, change in temperatures, load with dust and spray with saltwater. We can not only study the performance under various conditions but also test the strength of the filter, since GTs needs to be well protected. The test duct is divided into three duct sections and constructed to be airproof. The incoming air is mixed with particles, sucked through the filters placed in the three following sections, and then recirculated and cleaned in a final E12 filter stage. Pressure drop transducers in these three duct sections are used for determining the differential pressure over the respective air filters. The company said the filter test rig is designed with easily movable duct sections based on a universal filter-holding system. The test procedure is fully automated as to keeping the dust feeding, pressure drop, DEHS and salt aerosol generation to preset levels. Also, temperatures, humidity and the pressure 40

drop over a test filter can be varied, and the particle size measured. Quick response time when testing temperature and humidity is important and is achieved thanks to the integrated valves, said Erik Lans, GT team manager, Camfil Farr AB. The automation of the test facility enables the running of standardized test procedures around the clock. Another feature of the test stand is that it is possible to switch between over- and under-pressure systems. The test rig has a capacity of a flow rate ranging from 60,035 to 1.1 million cfh (1700 to 30,000 m3/hr) and a differential pressure from zero up to 12,000 Pa (0.12 bar). The rig offers alternative testing of three static cassette filters, a combined with a horizontal self-cleaning pulse module, or a vertical pulse module. The dimensions of the pocket and cassette filters to fit the rig are 24 x 24 in. (610 x 610 mm). Filter cartridges of <21.7 in. diameter and 63 in. length (<550 mm diameter and <1600 mm length) can be tested as well, the company said. CT2 Compressortech2

MAY 2013

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OFFSHORE Technology
Methane Hydrate Production Inches Closer To Feasibility > Japanese breakthrough could lead to commercialization
By Roberto Chellini

n
apanese researchers claim to have achieved the worlds first production of natural gas from methane hydrates, a technological development that potentially could open vast energy resources worldwide. Japan Oil, Gas & Metals National Corp. (JOGMEC), in partnership with the Japanese National Institute of Advanced Industrial Science and Technology, conducted the flow test March 12 to 18 in the Eastern Nankai Trough, about 30 mi. (50 km) offshore Honsh Island. The test is expected to be followed by a long series of additional production tests, analysis and data collection. Japan imports most of its energy, and the government wants to develop cost-efficient technology to make production from methane hydrates sources commercially viable by 2018. As natural gas from shale becomes a global energy game changer, researchers are working to develop technologies to produce natural gas from methane hydrate deposits. This research is important because methane hydrate deposits are believed to be a larger hydrocarbon resource than all of the worlds oil, natural gas and coal resources combined. If these deposits can be efficiently and economically developed, methane hydrates could become the next energy game changer. Vast amounts of methane hydrate have been identified beneath Arctic permafrost, beneath Antarctic ice and in sedimentary deposits along continental shelves worldwide. In some parts of the world they are much closer to highpopulation areas than any conventional natural gas field. These deposits might allow nations that currently import gas to become energy self-sufficient. The challenge has MAY 2013 44

Clumps of gas hydrates recovered from the ocean floor. Source: U.S. Geological Survey

been to inventory this resource and find safe, economical ways to develop it. Methane hydrate is a crystalline solid that consists of a methane molecule surrounded by a cage of interlocking water molecules. It is an ice that only occurs naturally in subsurface deposits where temperature and pressure conditions are favorable for its formation. If the ice is removed from this temperature/pressure environment it becomes unstable. Methane hydrate has a very high concentration of methane. Melting 1 cu.ft. (0.03 m3) of methane hydrate yields about 160 cu.ft. (4.5 m3) of gaseous methane. Most methane hydrate deposits also contain small amounts of other hydrocarbons including propane and ethane hydrates. Four earth environments have the temperature and pressure conditions suitable for the formation and stability of methane hydrate: sediment and sedimentary rock units below Arctic permafrost, sedimentary deposits along continental margins, deepwater sediments of inland lakes and seas, and under Antarctic ice. With the exception of the Antarctic deposits, methane hydrate accumulations are not very deep and in most situations are within a few hundred yards (meters) of the sediment surface. In 2008, the U.S. Geological Survey (USGS) estimated the gas hydrate resource for the Alaska North Slope area between 25.2 and 157.8 Tcf (713 x 109 and 4.4 x 1012 m3). Because very few wells have been drilled through gas hydrate accumulations, the estimates have a very high level of uncertainty. continued on page 46 Compressortech2

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OFFSHORE Technology
One of the most extensively studied gas hydrate deposits is Blake Ridge, offshore North Carolina and South Carolina. The challenges of producing methane from this deposit are the high clay content and the low methane concentration. In early 2012, a joint project between the United States and Japan produced a steady flow of methane by injecting carbon dioxide into the methane hydrate zone. The carbon dioxide replaced the methane in the hydrate structure and released the methane to flow to the surface. This test was significant because it allowed the production of methane without the instabilities associated with a melting gas hydrate. The most likely methane hydrate deposits to be selected for initial developments will have high concentrations of hydrates, reservoir rocks with high permeability and nearby pipeline infrastructure. Deposits meeting these criteria will likely be on the Alaskan North Slope or in northern Russia. Although methane hydrate accumulations are found in difficult environments and present numerous technical challenges, they are widely distributed and the largest source of hydrocarbons on earth. A variety of technologies could be developed to produce them using pressure reduction, ion exchange and other processes that take advantage of their unique chemical and physical properties. The United States, Canada, Japan, China and India have research programs working to discover technologies that could make methane hydrates an important component of the future energy mix. Japan has been a leader in methane hydrates research, which is unsurprising given the countrys rising import bill and limited domestic deposits of conventional energy resources. The nation already has initiated extensive attempts to leverage its sparse shale resources, in order to partially alleviate the burden of its gas imports. JOGMECs recent test is said to be the first offshore drilling operation targeting the extraction of natural gas trapped in ice, but is the latest in a succession of technological trials on the matter. Preparatory drilling for methane hydrates offshore the Nankai Trough started in February 2012. It is thought to hold 42.4 Tcf (1.2 x 1012 m3) of methane hydrates in place, according to MH21, the industrygovernment-academia consortium to promote hydrates development. Based on current consumption rates, the Gas hydrates burn freely in their natural state. Source: U.S. Geological Survey

Nankai Trough could hold resources sufficient to meet about 11 years of Japanese gas needs. The Japanese researchers had collaborated with the U.S. Department of Energy and ConocoPhillips to test methane hydrate extraction in the North Slope of Alaska early last year. JOGMECs research could have important learning curve effects if it leads to the development of technology for commercially viable gas production from methane hydrates. The USGS has estimated that gas resources from methane hydrates could be between eight and 24,000 times the amount of current estimates of conventional proven gas reserves. Japans successful test extraction of methane hydrates prompted China to accelerate efforts to tap its own resource

Gas hydrate resources are spread around the globe. Source: U.S. Geological Survey 46 Compressortech2

MAY 2013

OFFSHORE Technology
pool. Peoples Daily reported on March 18 that China has started a new round of methane hydrates R&D, one of the 863 areas prioritized by the government for research. According to Xinhua News Agency, Chinas methane hydrates resources could contain much as 58.9 billion barrels of oil equivalent (boe) in place, of which 25.7 billion boe could be recoverable, according to the Ministry of Land and Resources. A prospective area has been identified, the Shenhu region in the northern part of the South China Sea. This is in the Pearl River Mouth Basin, where offshore exploration for conventional oil and gas is occurring. This targeted research will be headed by Wang Hongbin, who said that China has been studying the production of gas from methane hydrates since 1999. The latest round of research seeks to understand the physical and chemical properties of methane hydrates and the pressure control techniques needed for extraction. Results are expected by the end of the four-year research period in 2016. However, the cost of production could be more expensive than relying on gas imports. Specifically for China, national attention to methane hydrates production would have to be split with existing efforts to explore and produce its shale gas resources, which the U.S. Energy Information Administration estimates could be the worlds largest at 127.3 Tcf (3.6 x 1012 m3). In the short to medium term, shale gas could be a more profitable venture. Technology has been developed for shale gas extraction and international oil companies have shown interest in tapping Chinas shale plays. In contrast, methane hydrates extraction looks to remain a government effort until its commercial viability is established. CT2

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OFFSHORE Technology
platforms requiring smaller Compressing Space > Offshore and lighter compressor equipment
By DJ Slater

This offshore platform, situated 93 mi. (150 km) off the Brazilian coast in the Campos Basin, uses gas turbines from MAN Diesel & Turbo. Platforms like this are requiring lighter and more compact compressor equipment to keep costs down.

hen it comes to compression in offshore applications, industry experts are hearing a clear message: Its all about size and weight. Specifically, companies that operate offshore platforms are looking for smaller and lighter packages, a trend that has forced OEMs and compressor packagers to scale down their equipment. The biggest thing, which is real critical to offshore applications, is size, said Gary Tas, global sales manager with Dresser-Rand. They want compressor OEMs to shrink (their compressors). Its all about space and doing more with less. Several years ago, Dresser-Rand conducted a voice of the customer process in order to gauge the needs of end users in the compression industry over the next 10 to 20 years, said Pascal Lardy, the companys vice president of technology development and commercialization. The results indicated that a trend for compact compression systems was evident, especially in light of keeping costs down for floating production storage and offloading (FPSO) units and offshore platforms. Aung Than, a marketing application engineer for Ariel Corp., said reciprocating compressors in the 5000 to 6000 hp (3729 to 4474 kW) range are a difficult sell in the offshore market when the demand is for lighter and more compact options. Platform operators, however, find Ariels compressors in the 2000 to 4000 hp (1491 to 2983 kW) range as a better fit. The cost goes with the footprint, Than said. You have MAY 2013 48

very limited space (on platforms). The cost increases if you increase the size and weight of the platform. While the trend has been more apparent in todays market, the shift toward lighter and smaller equipment actually began about 20 years ago when the industry started venturing out of shallow water production and into deeper waters, according to MAN Diesel & Turbo. Platform operators demanded compressor designs with a tighter installation footprint, weight considerations and operation with upstream gases with higher mole weights, corrosive gas elements and other contaminants not normally seen on most onshore natural gas installations. Higher gas flow rates associated with deep water development also shifted the compressor type from reciprocating compressors, which were predominant during the early stages of offshore development, to larger capacity centrifugal compressors, MAN Diesel & Turbo said. To meet the demands of floating structures, such as FPSOs, MAN Diesel and Turbo had to incorporate several design features onto their centrifugal compressors, such as a more rigid structural steel base suitable for three-point mounts using vibration isolators. Other accommodations included special designs for the lubrication system; special considerations regarding the lube oil line routing and draining and selection of other subsystem subcomponents; and integrating the lube oil system on to the compressor base continued on page 50 Compressortech2

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Photo credit: yvind Hagen Statoil ASA

The Troll A platform, operated by Statoil, lies in the North Sea near Norway. Recently, Statoil turned to Bergen Group Rosenberg AS to replace a compressor motor on the platform.

plate and combining multiple casing services on to one train arrangement on a common single-lift skid base, MAN Diesel and Turbo said. Keeping costs in check on offshore platforms is vital, especially when the structures are expensive to support, said Jon Bygrave, a former chief engineer, Industrial Compressors, for Rolls-Royce Energy Systems Inc. A rough rule of thumb, he said, is that for every ton of equipment that you put offshore, you need another 5 tons (4.5 tonnes) of structural steel. Adding more weight to a platform requires additional steel and, therefore, more money. For example, an offshore operation would need an additional 250 tons (227 tonnes) of structural steel to support a jump from a 150 ton (136 tonnes) train to a 200 ton (181 tonnes) train, he said. This trend has been developing for years, but it was never really a major issue, Bygrave said. Its something that, in the last couple of years, has received more attention. (The trend) is driven by people on the OEM side looking for differentiators for their equipment, and looking to differentiate their equipment by having a smaller package, he said. On the customer side, they have to pay for these structures, and they look at one OEM that has this weight and another who has that weight, and they see the advantage of going smaller. Dresser-Rand found a specific way to adapt to the trend by developing a family of compact compression systems based on the companys own Datum compressor technology. That system is the Datum integrated compression system (ICS). The main feature of this technology, Lardy said, is the integration of the liquid separator, compressor and process piping and coolers into a single lift package, which creates a weight and footprint savings up to 50% MAY 2013 50

compared to traditional compression modules. The package can be connected in the field to the process piping and power source. Other features of the Datum ICS, which can be applied to the upstream, midstream and downstream markets, include a Datum I compressor; Dresser-Rands proprietary centrifugal separation technology; a high-speed, close-coupled, gascooled motor; a magnetic bearing rotor system; unit controls; valves; instrumentation; and interconnecting piping. While weight and space reductions have gained prominence in the offshore markets, it is not the only trend affecting the industry. Maintenance and equipment reliability are imperative to offshore compression, especially when downtime can cost companies millions of dollars. Historically, most offshore applications contained compressors with up nozzle configurations, which made it challenging to perform maintenance on the compressor when all of the additional parts, such as piping and coolers, were above the machinery, Bygrave said. Now, Bygrave is noticing more requests for compressor packages with down nozzle assemblies. If you need better access to the compressors accessories, you put in up nozzles, he said. If you need better access to the compressor for maintenance purposes, then you put the compressors on the top deck (down nozzle configuration). These configurations are not simply a matter of preference. Bygrade said that each setup generates a different array of challenges, especially when operators are looking for smaller and lighter compressor packages. For example, down nozzle configurations need an extended base plate in order to keep the lube oil system on it, whereas the up continued on page 52 Compressortech2

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Start permissive check Start-up Normal operation Shutdown (both normal and emergency) Anti-surge control and anti-surge protection Control (maintaining) of the main process variable gas pressure (or flow) Optimized load distribution (load sharing) between the units Automatic sequenced transfer of compressors between Idle and Run Automatic limiting control (limiting), including digitally controlled parameter set points Automatic disabling of operator errors

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OFFSHORE Technology
nozzle arrangement does not, allowing the base plate to be shorter. The down nozzle option also requires access holes in the base plate so the main process pipes can attach to the compressor unit. If youre being directed to make it smaller and make it lighter, then there are some engineering challenges you need to address, he said. With some outside-the-box thinking, you can do it. Another trend Bygrave has seen lately is the quality of gas that is being extracted from offshore applications. He said some gas compressor professionals are extracting gases that have carbon dioxide levels as high as 40%. We are scraping the bottom of the barrel and seeing some nasty things coming out of the gas, Bygrave said. The industry is seeing a lot more CO2, mercury and hydrogen sulfide. Gas with high levels of CO2 or H2S would be a death sentence for past machinery, but manufacturers are crafting equipment to handle the gases corrosive nature, such as by using more stainless steel in the design or a protective coating, he said. Other options including using nonaluminum labret seals, PEEK material, and Teflon polymer rings. There are various things you can do to make the machinery last, but it all comes at a price, Bygrave said, adding that some professionals will opt for extreme filter methods, such as filter coalescing scrubbers, to remove the liquids and solids from the gas in order to produce a cleaner counterpart. Gas heavy with impurities wouldnt have been considered several years ago, but in certain areas where energy prices are steep, such as Thailand and Malaysia, it makes economic sense to extract the gas and treat it, Bygrave said. Developing local supplies, even though its lower quality gas and requires more treatment, is still more economically viable then getting it from other sources, he said. MAN Diesel & Turbo also has designed its equipment to accommodate corrosive gases. Depending on the installation and process gas requirement, corrosion-resistant materials, such as duplex stainless, super duplex stainless, titanium and other alloys, are incorporated into the design, the company said. As these trends continue to shape the offshore compression industry, the best thing OEMs and industry professionals can do, Bygrave said, is adjust their strategies and act accordingly. CT2

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Assessment Of Onboard Diagnostics And Monitoring Better diagnostic tools needed For Pipeline Engines > to assist incoming engineers
By Greg Beshouri

TECH

corner

Editors Note: This article is based on a paper the author presented at the Gas Machinery Conference on Oct. 3, 2012, in Austin, Texas. For additional information, contact the author at greg.beshouri@aetco.com. The pipeline workforce faces several challenges over the next few years. Unprecedented numbers of experienced staff with hands-on compressor-engine specific expertise are retiring. The replacements are a smaller, younger workforce tasked with more responsibilities but less time and opportunity to develop engine-specific expertise. This younger workforce generally has well-developed skills for accessing information from computers, microprocessors and networks. If presented with diagnoses and procedures at suitable portals, this workforce could investigate and resolve problems as quickly as their more expert predecessors. By making this data available at a central remote location, a very few experts could handle those unique problems not diagnosed with the standard tools. Consequently, better diagnostic tools are needed to address the changing experience and expertise environment and assist with monitoring, troubleshooting and diagnosis. Many compressor engines, particularly the larger units, units operating under emissions permits and units requiring high dispatch reliability are already fitted with sophisticated programmable logic controller (PLC) based automation systems. Data from those automation systems is usually displayed at one or more human machine interfaces (HMI) and is
Greg Beshouri, president of Advanced Engine Technologies Corp. (AETC), holds a bachelors degree in mechanical engineering from the University of Michigan and a masters from the University of California-Berkeley. He joined Enterprise Engine Co. in 1980 and rose to become manager of the R&D, service and controls departments. In 1988, Beshouri was a founder of AETC. He has written many papers on engine modeling, testing and analysis. Beshouri is a member of the ASME Internal Combustion Engine Division.

often archived in a database. However, unless a skilled technician is manually trending and reviewing the data, the available information is rarely used for diagnostic purposes. Rather, that data is only reviewed after a significant problem or failure occurs. Regulatory opportunity During a recent review and revision of South Coast Air Quality Management District (SCAQMDs) Rule 1110.2 governing internal combustion engines (ICE), staff expressed a strong interest in Greenlight/Red-light automotive-like onboard diagnostics (OBD). Developed in the 1980s, automotive OBD both protects the engine and monitors emissions performance. With regard to emissions OBD focuses on two objectives: Improving in-use emissions compliance by continuously monitoring the efficiency of the emissions control system and alerting the operator when a malfunction exists. Helping the operator quickly identify and repair malfunctioning circuits in the emissions control system. The California Air Resources Board (CARB) designed and implemented emissions related onboard diagnostic requirements for mobile ICEs in 1988. A second-generation called OBD II with expanded capabilities was then developed, to ensure that the vehicle remains as clean as possible over its entire life, and assists repair technicians in diagnosing and fixing problems. (1). The state of Illinois considers OBD II superior to extractive emissions tests: OBD-II is a shift to pollution prevention. OBDII can identify problem(s) with the emissions control system before the vehicle becomes an excessive polluter, allowing time to repair the vehicle before emissions increase (2). This may represent a move among regulators governing stationary sources from pollution quantification using CEMS and PEMS to pollution prevention based on OBD. This represents a unique opportunity for the pipeline industry. By focusing on pollution prevention, OBD strategies rely on the proper operation of sensors and actuators to maintain emissions compliance. OBD generally requires no additional sensors or actuators. Consequently, emissions compliance can be continued on page 56 54 Compressortech2

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suppler what the new pressure drop will be and make sure that there is sufficient capacity available to tolerate the increase. When there is damage to the substrate resulting in cells that are deformed, bent over or closed off. If you have had a event where a turbo came apart, the element had something dropped on it while it was out of the housing, the internal supports came loose and the element walked around while running, or if the pressure drop has increased by 2 inches of water or more, and ashing Part 23 My Back Pressure is Killing Me is not suspected as the cause, the elements faces needs to be checked for damage. A severe misfire can do more than damage or destroy the An engine is designed to tolerate a certain amount of catalyst. The force of the explosion can pinch off the opening backpressure on the exhaust without sacrificing performance. to any tubes inside the silencer section of the combo unit or The entire exhaust train from the header connection through the stand-alone silencer. The damage looks similar to a soda straw catalytic converter, silencer and the piping runs that tie everything thats been pinched between the fingers. This type of damage together impose a restriction to the flow of the exhaust gas. The can be so severe that the exhaust is essentially blocked and the engine may not start pressure that is lost at all. Inspect silencer during this flow through Pressure Drop Across a Catalyst Eect of Face Area Closure the system is what we call internals after an 10 unusually bad misfire. backpressure. So what Changes to the excould go haywire with the 9 haust system happen system to result in higher 8 as equipment is moved backpressure than the 7 around from site to site engine can stand? Lets or otherwise modified look at some common 6 over time. When this possibilities. 5 occurs the physical 4 limitations between A Range of Possibilities components someThere is ash buildup on 3 times result in alterathe catalyst. Ash is an 2 tions where the exexpected phenomenon Engine: 7042 GSI haust passes through caused by the combustion 1 Cell Density: 200 cspi either sudden expanof lube oil in the cylinders, 0 0% 2% 4% 6% 8% 10% 12% 14% sions or contractions and all engines naturally Percent of Element Face Closed to Flow in the diameter of the consume oil as they run. 30.25" Diameter 26.5" Diameter piping. These types of As ash builds up on a changes in the flow catalyst element it forces pathway contribute additional pressure drop due to the laws the flow to pass through the cells that remain open. This increases of fluid dynamics. When planning any change to the piping of the pressure drop across the catalyst and consequently reduces its the exhaust, especially when outfitting an existing engine with conversion efficiency. To ensure that the catalyst is doing its job, its first catalytic converter/combo or retrofitting a larger one to EPAs ZZZZ rules now limit the gain in pressure drop by the catalyst comply with tighter regulations, consult with your converter, to 2 inches of water with the engine running at full load. If its above combo or silencer supplier for their help in evaluating the presthat level, the catalyst must be inspected and cleaned of ash. sure drop of the revised exhaust piping. The converter system was designed for a substrate with a given Monitoring the pressure drop across the exhaust system and cell density and a higher one has been installed. In order to gain taking appropriate action when needed will help maintain the increased performance from the catalyst, increasing to a higher performance of both your catalyst and engine to achieve the cell density or switching to a patterned cell geometry is an option expected results. available to the user. Before doing this though, ask your catalyst

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demonstrated very cost effectively. If the pipeline can identify robust, reliable and representative OBD for emissions compliance monitoring this could result in substantial savings over more traditional methods. Prior PRCI funded work As noted, many pipeline engines have sophisticated automation systems capable of supporting diagnostic monitor (DM) and OBD. Prior and ongoing PRCI funded projects have developed a substantial body of knowledge on the control and monitoring of engines and related equipment (3-9). The 2008 Pipeline Research Council International Inc. (PRCI) diagnostic monitoring study (10) reviewed the opportunities, identified what might be achieved and the potential benefits. The study concluded: The pipeline faces two possible scenarios. In the first, a generalist workforce will not have access to important diagnostic data stranded in islands, invisible and inaccessible to them. Even when they access the data after the fact, there is nothing to guarantee it was properly logged and archived, preventing the use of that data for emissions compliance verification. In the second scenario, those same generalists will have access to all required data, processed with integrated analytics and displayed in a usable fashion consistent with their job responsibilities. No data will be lost by virtue of robust database design and data validation algorithms. Consequently the data will be available for emissions compliance verification. For the rare situations where the automatic analytics do not work, remote experts with access to the same information can collaborate with them on troubleshooting these unique problems. The data available for diagnostics in todays engine rooms probably represents one of the greatest unexploited assets of pipeline companies. The pipelines should consider the potential value of this asset. This project reported on in this article is an important step toward that second scenario. Technology status Most newer and upgraded pipeline engines are fitted with sophisticated automation and control systems. The sensors, data collection, data analysis and data warehousing tools all exist and are commercially available. What is lacking is the concentration of the data in a single location and its transformation into usable information for the work force and management team. Rather the data is usually siloed in numerous separate databases in different formats, over different timescales and averaging routines. Even when compiled into a common database the resultant data file is massive, taxing the most commonly used analysis tools such as Excel. Even when short periods of data (similiar to one month) are pulled into Excel, the analyst must manually trend and scrutinize the data to detect and diagnose faults. The problem is further compounded when an analyst must diagnose potential faults in real time since the required data is often distributed over a number of different displays. MAY 2013 56

The next step The next step is to develop and demonstrate the analytic tools to transform the wealth of unused data into usable information for end users and then demonstrate and assess the benefits for day-to-day enginecompressor operation. Specifically, this project will demonstrate the ability to automatically detect and flag a fault and provide the local operator with sufficient diagnosis that they can implement appropriate remedial action. Methodology The question was not if OBD can be implemented. It has been implemented in mobile engine applications for years. In addition, engine analysts solve these complex multidimensional riddles all the time in the engine room. The question was how to implement an automatic methodology that can simultaneously analyze and cross-check dozens of parameters in a fast, efficient, precise and accurate manner. This required careful consideration of issues such as: Which parameters to use; Methods of parameter symptom definition and detection; Methods of fault detection and definition based on analysis of multiple parameters; User interfaces. Further, in developing a methodology for automating OBD, AETC wanted to use an open architecture approach in which the parameters, symptoms, faults and diagnoses could be easily updated and expanded based on experience. AETC also wanted a simple user interface, which did not require a significant learning curve for configuration. Based on these criteria, AETC developed a simple model based diagnostic methodology, which uses a spreadsheet as the primary configuration tool. The design and methodology can be used by any software capable of reading an Excel configuration file. A description follows. Parameter definition Sensor grouping AETC defined all the parametric data that might be available from a compressor engine, whether two-stroke cycle (2SC) or four-stroke cycle (4SC), lean or rich. AETC then grouped these parameters into the following major categories: Air (1) Fuel (2) Ignition (3) Engine Systems (4) Compressor Monitoring (5) Combustion Propagation Monitoring (6) Combustion Initiation Monitoring (7) NSCR (8) Virtual Sensors/Calculations (9) Miscellaneous (10) ECM (11) CPU 2000 (12) continued on page 58 Compressortech2

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 SDM/iFuel (13) Electronic Governor (14) Vibration (15) Each parameter within these groups is assigned a fivedigit identification number with the first digit representing the group and the second and third the parameter. The last two digits are left for later use. Each parameter is also assigned a standard tag label and engineering units (see Figure 1, for sample). When a parameter is in alarm (see below) the ID for that parameter is flagged.

n Figure 1. The chart shows typical parameter assignment.

Sensor fusion/virtual sensor In addition to traditional sensors, AETC also utilizes sensor fusion and virtual sensors in its approach (group ID 9). Sensor fusion combines data from multiple sensing devices or sources to create information exceeding the value of the information from the individual sensor measurements. Virtual sensors are software algorithms that process several measurements to calculate new quantities not measurable or not easily measured by conventional sensors. Both sensor fusion and virtual sensors exploit the power of modern microprocessors to create new measurements where none previously existed or simulate measurements on units lacking a complete instrumentation package. The pipeline has used both for some time. When a combustion analyst determines a high standard deviation of peak pressure and early location of peak indicates an igni-

tion problem creating intermittent misfire they are performing sensor fusion. Likewise, trapped equivalence ratio (f) and effective bulk temperature (Teb) are both model based virtual sensors (22). There are many other examples of both. Figure 2 shows the preliminary list of such sensors utilized in AETCs methodology. Model-based estimation, limits Typically, engine faults are first detected as symptoms in engine parameter values. For example a sticking precombustion chamber (PCC) check valve might first be detected by a high standard deviation of peak pressure (SdPP). Of course a high SdPP could also indicate a number of other problems. To move from symptoms to fault detection and diagnosis, an expert human analyst will often trend visual data (a sort of visual graphical approach). Or they might compare the parameter of interest with the value they have in their head, i.e.: At 100% load the air manifold pressure (AMP) should be 30 in. Hg! Is the wastegate stuck? This is effectively a model-based approach. Automating either of these methods as a software algorithm with no human in the loop poses a major challenge. However, the pipeline industry has considerable experience with model-based analyses of engines starting with parametric emissions monitoring system (PEMS) (3) and more recently with model based air/fuel ratio controls (4) and even model predictive control. These mean value engine models (MVEM) treat the engine and associated systems as a process box. The MVEM then use the underlying physics to establish the relationship between the measured parameters and the processes those parameters indicate. Like more commonly used statistical approaches, MVEM based diagnostic approaches require mapping to calibrate the detection algorithm in order to accurately and precisely detect symptoms. The main advantage with MVEM is that the interrelationship between parameters is defined permitting the use of controlled experiments to map the model. For example, five parameters govern engine NOx. If approached from a purely statistical basis more than 100 tests would need to be conducted to establish the interrelationship on NOx formation. However, by using a simple trapped equivalence ratio (TER) MVEM (4) the mapping test can be collapsed to about a dozen points that can be completed in one-two days. In the AETC methodology, the mapping data is used to develop MVEMs of key engine parameters ranging from fuel flow to NOx emissions, combustion pressure and ion sense parameters. In general AETC based these models continued on page 60

n Figure 2. This chart

shows virtual sensors used in AETCs methodology.

MAY 2013

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n Figure 3. The chart displays sample fit data.

on fits of speed, BMEP and TER as required. For example, the relationship between TER and NOx is well established. Likewise, PP is primarily a function of BMEP with secondary TER effects. The fit parameters are contained in the same Excel file as the parameter definition, simplifying configuration (Figure 3). MVEM for the compressor side would likewise be based on throughput, speed and pressure ratio. Fault definition and detection The 2008 PRCI study defined the following five most common faults: Ignition failure; Poor power cylinder balance; Loss of air/fuel ratio control leading to detonation or potential emissions excursions; Poor compressor performance; Combustion chamber seal leaks. In the current project, AETC began developing a table of logical analytics or rules that associated typical parameter symptoms with the most likely faults/causes for each of these faults. These analytics were then used to automatically perform diagnostics on data. Detection of a symptom and progression to the diagnosis of a fault proceeds as follows: 1. Each MVEM has an upper and lower error limit defined as a percentage of the calculated value (Figure 3). 2. If the actual measured parameter falls outside the error window, the ID number for that parameter is flagged. 3. For each timestamp, all flagged IDs are accumulated and compared to an analytic table. 4. For any faults in which all the parameters are flagged true, the diagnostic message appears for the applicable cylinder. The approach is very flexible. The user can refine current faults or add additional faults by simply extending the table. Data display Once an OBD diagnosis is offered, the operator or analyst may want to review the data to confirm or refine the diagnosis. Normally, data is displayed in groups, i.e., all the PPs are displayed together or all the SdPPs. However, since the diagnosis is based on crosschecking multiple parameters, this approach offers little benefit. Therefore AETC developed a display format specifically to support OBD diagnosis (Figure 5). The HMI displays the fault time, diagnosis, cylinder and event duration in the upper left box. Immediately below is a graph of user-selected data. A pull-down interface on the upper right allows the user to select a diagnosis and then displays all the parameters associated with that diagnosis from the analytic table (Figure 4). An additional pull-down menu on the lower left allows the user to add additional trends. The user can compare actual values with the MVEM value and the limits by selecting Show Ideal and Show Min/Max respectively. Using this interface which groups parameter values based on the analytic table the user can concurrently review and assess whether or not the parameters are cross correlated and the diagnosis is correct.

n Figure 5. This display is a playback simulator interface.

Playback simulator To validate this methodology, AETC has developed a tool to simulate real time OBD (Figure 6). A data translator creates time stamped master OBD data files similar to the files a real time OBD program would create. The real-time version would also create an event log. In the playback mode, the playback utility loads the daily continued on page 62

n Figure 4. This is a sample analytic table.

MAY 2013 60 Compressortech2

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n Figure 6. This chart shows a

simulated OBD system.

files, checks against the faults and diagnosis contained in the setup template and then creates the event log. The user can then review data trends to confirm the diagnosis with the HMI. In the real-time system, this would all be integrated into a common package. Results At the time of writing of this paper, AETC has just completed development of the playback simulator, made a first pass at model development and obtained some initial results focusing on combustion diagnostics using six months of data from a single engine. A review of these very preliminary results follows. Available data To test the general approach and confirm the ability to automatically detect faults, AETC obtained long-term operating data from PRCI members for several of their engines. Most of these engines were fitted with typical engine monitoring in addition to combustion pressure monitoring, ion sense and some had continuous emissions monitoring. AETC had previously mapped several of these engines while installing its continuous pressure monitoring system or Hoerbigers HyperBalance III. As the first step, AETC selected a KVS412, which was reasonably well mapped and had approximately six months of near continuous run time. The unit is fitted with PCCs and mechanical check valves. The original mapping focused on calibration of the ion sense and combustion pressure system not for emissions mapping. Using the mapping data AETC developed models for the engine and then tested the fault rules. The mapping at the time focused primarily on air/fuel ratio effects and did not include variable torque or variable speed data. While the engines do not operate at variable speed, they do operate at variable torque. Therefore, AETC added MAY 2013 62

some variable torque data from the run data to improve model performance. Detected combustion faults The playback simulator detected 51 combustion-related faults in the available data that each lasted 15 minutes or more. Table 1 shows a sample. In general, most faults were related to engine start-up/ warm-up or brief transients. However two faults stood out due to their duration and/or repetition as described below.

n Table 1. This is a typical alarm summary.

Sticking PCC check on start The playback utility automatically detected that on Sept. 3, 2011 cylinder 2L indicated a prechamber valve stuck. The event occurred immediately after start-up and lasted approximately five or six hours. continued on page 64 Compressortech2

n Figure 7. The display

shows the PCC check valve fault for cylinder 2L. The data in Figure 5 is for the same period.

n Figure 8. This is a comparison of measure PP (orange), with

MVEM high (green) and low (red) estimates.

n Figure 9. This is a comparison of measured CCovPP (purple),

with MVEM high (green) and low (grey) estimates. MAY 2013 64

Manual review of the data confirmed: Peak Pressure (PP) was slightly low of the modeled value (Figure 8). PPCOV was quite high (Figure 9). LoPP was slightly later than the upper limit. ChemiPeak was half the lower limit. ChemiPeakLoc was several degrees late. ChemiIntegral was below the lower limit. ChemiIntegralCOV was double the upper bound. All these symptoms suggest the PCC was fueling inconsistently and the engine was running intermittently on the PCC and the rest of the time on the MCC spark plug resulting in late, low and unstable combustion. The automatic diagnosis appears correct. In comparison, other cylinders, such as 1L (Figure 5) looked fine. The alarm cleared after 5-6 hours as noted, presumably due to operator intervention. PCC check valve failure The playback simulator automatically detected that on Dec. 12, 2011, cylinder 4R indicated prechamber valve stuck. This event lasted 4.5 hours (Figure 10). Manual review of the data indicated the engine had been operating satisfactorily, when combustion in that cylinder stopped. At that point: PP was at the cold compression level (Figure 11). PPCOV was five times normal levels. LoPP was approximately half the normal value. ChemiPeak was very low. ChemiPeakLoc was very late. ChemiIntegral was very low. ChemiIntegralCOV was NAN. In addition, many other cylinders exhibited signs of continued on page 66 Compressortech2

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n Figure 10. Shown

is the cylinder 1R PCC check valve failure.

n Figure 11. This display shows the comparison of measured PP

(purple), with MVEM high (green) and low (red) estimates.

overload/overfueling (Figure 13) in the main combustion chamber (MCC) and PCC. This data indicates the PCC in 1R stopped fueling completely with only intermittent late combustion occurring from the firing of the MCC plug. This overloaded the remaining cylinders resulting in overly rich MCC that in turn made the PCC overly rich, further impacting combustion stability. Under these unstable and unbalanced operating conditions NOx increased dramatically (Figure 14). With regard to global engine parameters, BSFC changed by similar to 4 to 5% and engine average TER by similar to 2.5%. Most strikingly, the NOx MVEM1 dramatically captured the emissions excursion (Figure 15). The alarm cleared after 4.5 hours as noted, presumably due to operator intervention. Discussion of results Nature of current simulated test In general, the subject engine ran quite well, with few faults over the sixmonth period. When faults did occur the staff responded promptly, aided by the information provided by the CPM system. This resulted in a few events of relatively short duration as noted above. Calibration of the alarm limits also proved challenging. Initial levels were set based on the mapping data and the alarm thresholds verified by playing data back. The limits were then adjusted as required to eliminate false positives and better detect real events. On a real-time system, once the models are developed and uploaded, real faults can be temporarily induced to verify the alarm threshold levels and fault detection. This should speed setting of the alarm limits. Averaging periods The historic data used in the 66 Compressortech2

n Figure 12. This display shows the comparison of measured ChemiPeak (purple) with MVEM high (green) and low (red) estimates. MAY 2013

n Figure 13. The display

shows combustion data Einstruments.indd for cylinder 1L during the same time period shown in Figure 10.
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n Figure 14. This chart shows NOx (yellow green) and PP 1R (red).
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n Figure 15. This chart shows Nox (yellow green) with MVEM upper (green) and lower (red) limits).
analysis range from one-minute values for the engine and emissions data to 15-minute averages for the combustion pressure and ion sense data. Due to the slow nature of changes in pipeline engine operation, AETC interpolated the combustion data to obtain one-minute estimated average values to match the other data. However, the oneminute fuel flow data, measured with a roots meter and frequency counter, proved too noisy at the one-minute level. Consequently, AETC used 15-minute running averages of fuel flow to improve model stability. 4:01 PM Not surprisingly, under these conditions it proved impossible to reliably detect faults lasting fewer than 15 minutes. In general, the most reliably fault detection was for 30 minutes or longer. This eliminated typical start-up/warm-up nuisance alarms and transient effects. Not surprisingly, there is a trade-off between the data sampling/alarm determination period and the precision of the alarm threshold settings. Fault determinations based on 30 minutes or more of data proved quite accurate and allowed relatively tight alarm window settings. Model development Model types While MVEMs for emissions such as NOx are well developed, almost no work has been done on developing MVEMs for parameters such as peak combustion pressure, location of peak pressure, etc. In many cases, such as location of peak pressure, the range of variation for normal operation is small (2 on an average of similar to 22) while a major fault such as misfire will result in extreme changes in parameter value. In these cases the model can consist of a constant (22) with generous alarm limits (25%). In other cases, such as peak pressure, the model must account for the effects of load, air/fuel ratio and possibly speed and ignition timing dependencies. More work in this area is clearly warranted to develop good models. Mapping It is proven that a model is no better than the data on which it is based. If the mapped range is too narrow, 68
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and the model not sufficiently robust, the model can generate false values when the engine operates outside that range. All the work in emissions modeling and mapping has resulted in robust models. These models work well outside the mapped range and reduce the required testing to less than a dozen test conditions. Until better models are developed for the other parameters of interest, more test conditions, particularly variable speed and variable torque, are required for reliable OBD fault detection. Inducing known faults to set alarm thresholds would also be very helpful. Minimum sensor set The test engine has a nearly complete suite of monitoring parameters including combustion pressure and ion sense monitoring. In addition to validating automatic OBD, a secondary goal of the PRCI project is to define the minimum data suite required to reliably detect, if not fully diagnose, faults. Based on global parameters normally monitored by a PLC, the first fault (could be prechamber valve stuck as discussed earlier) would have probably gone undetected. Using sensor fusion to calculate BSFC or the virtual TER sensor the second more major fault (See Figure 10) could be detected providing the data collection system has sufficient precision. Rather interestingly, the exponential nature NOx emissions as a function of TER, captured by the MVEM, greatly simplifies detection of the event (Figure 15). However the required precision of the inputs to the TER calculation remains unchanged. AETC and others have demonstrated successful emissions trending using lean in-situ NOx sensors on pipeline engines. Based on the exponential sensitivity of NOx to combustion problems, it might make sense to include them in a lean burn OBD package as an indication of overall engine combustion performance. User interface As noted, accurate fault definition requires the simultaneous review and cross-checking of multiple parameters. Developing a user interface to display the relevant information in a useful way is quite challenging. While the current HMI displays all relevant data for a given fault, the graph quickly becomes cluttered and the scales ambiguous. Adding the high and low limits for each parameter compounds the problem. AETC will revise the HMI to use up to eight horizontal strip chart graphs, with each graph displaying a single parameter and the high and low alarm limits in the appropriate units. Up to seven of the charts will be for the parameters used in the fault definition. The eighth will be user configurable for crosschecking additional parameters not used in the diagnosis such as speed or load. This should simplify manual data review and analysis. Next steps AETC will continue to refine the models and playback data to confirm this methodology will detect and diagnose the four other fault modes. AETC will also test the methodology on available data for two-stroke cycle continued on page 70 MAY 2013 69

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Compact design is safe no need for separate nipples or

adapters.

Vent Valve safely relieves pressure prior to removing transducer. 2000 PSI, 250 (F) capacity. Quarter-turn for fast operation
Safety Locking Handle option is also available
THE CV-SERIES INDICATOR VALVES ARE DESIGNED SPECIFICALLY FOR COMPRESSOR ANALYSIS. CALL NOW FOR INFORMATION.
Ellwood.qxp 1/27/10 11:51 AM Page 1 DIESEL ACCESSORIES, INC. Telephone: 1-800-264-5950 Fax: 630-543-5953 E-mail: info@kienediesel.com Website: www.kienediesel.com

KIENE

We Manufacture and Remanufacture the Worlds Largest Crankshafts

Ellwood Crankshaft Group
Irvine, PA, USA 16329 Hermitage, PA, USA 16148 1-800-247-1326 or 724-347-0250 ecgsales@elwd.com www.ellwoodcrankshaftgroup.com

Compressortech2

engines. Based on the results AETC will refine the methodology as required. Then, hopefully, in 2013 AETC will install a real time system on a typical pipeline engine as the next step in the OBD demonstration project. Conclusions and recommendations AETC has demonstrated a simple multiparameter methodology using a spreadsheet set up tool in conjunction with MVEMs and an analytic table to automatically detect and diagnose engine faults. OBD systems using this approach in conjunction with the full suite of monitoring technologies appear to be very capable of detecting and diagnosing combustion problems. Further work on MVEM for engine parameters such as peak pressure is warranted. References 1. U.S. Environmental Protection Agency, On Board Diagnostics Basic Information, http://www.epa.gov/otaq/regs/ im/obd/basic.htm. 2. Illinois Environmental Protection Agency, Understanding On Board Diagnostics, http://www.epa.state.il.us/air/ vim/faq/obdlong.html. 3. Enhanced Monitoring Guidelines for IC Engine Parameter Based Compliance Monitoring Systems, prepared for the Compressor Research Advisory Committee of PRC International and the Gas Research Institute (GRI), July 1997. 4. Functional Specification Advanced Controls for Two-

Stroke Cycle Stationary Engines, prepared for GRI by AETC, Sept. 3, 2004, Revision 1. 5. Carbon Pollutant Emissions and Engine Performance Trade-Offs vs. NOx Emissions for Reciprocating Internal Combustion Engines Utilized in Gas Transmission Service, Gas Machinery Conference, Oct. 6, 1999. 6. Pressure Based Carbon Pollutant PEMS, prepared for GRI by AETC, September 2002. 7. Field Testing of Ion Sense and Pressure Ratio Technology on a TLA-6 Installed at Southern California Gas Needles Facility, AETC report, PRCI Project 8xxx, 1001.07RPT01, Sept. 26, 2005, Revision 1. 8. Chapman, K.S., Keshavarz, A., and Dolbee, C., Quantification of the Effect of Dust Ingestion on Turbocharger Compressor Performance, GRI, GRI-04/0010. 9. Pipeline Research Council International Inc., Development of a Turbocharger Monitoring System, contract PR325-05216, performed by ScavengeTech Inc., 2006. 10. Greg Beshouri et al, Diagnostic Monitoring and On Board Diagnostics for Engine-Compressors, Needs and Opportunities, 2009 Gas Machinery Conference. 11. Matthias Huschenbett et al, Emission Reduction and Stability Improvement by Predictive Model Based Control of Legacy Gas Engines, GMC 2007. 12. Geoffrey Ashton et al, Long Term Field Test of InSitu NOx Sensors in Typical Pipeline Lean Burn Engines and Gas Turbines, contract PR-09202 Pipeline Research Council International Inc., April 2011. ct2

Fabreeka Products for Gas Compression Applications

Photo courtesy of ESEErdgasspeicher Etzel (North Germany) E.ON Gas Storage Facility Installation with Fabreeka PTFE, Fabcel Pads and Hesterberg Clamps

Fabreeka & Fabcel PTFE Pads in mechanical restraints control pipe pulsation vibration and provide thermal insulation and expansion.

Vibration Isolators provide vibration isolation for compressors, generators, pumps, electrical cabinets, engines and more.

Fabreeka Isolation Washers & Bushings eliminate metal-to-metal contact breaking the vibration or shock transmission path.
Taiwan: 886-935 273732 info@fabreeka.tw www.fabreeka.com.cn

For more information on Fabreekas products and services please contact us: United States: United Kingdom Germany: 781-341-3655 44 (0)1274 531333 0049-6152-9597-0 info@fabreeka.com info@fabreeka-uk.com info@fabreeka.de www.fabreeka.com www.fabreeka.co.uk www.fabreeka.de

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PRIME
Movers
ITW Polymer Coatings
ITW Polymer Coatings has opened a 71,000 sq.ft. (6596 m2) manufacturing plant in Houston, less than a year after breaking ground on the facility in May 2012. The plant, which is ISO 9001:2008 certified, combines the operations of two smaller facilities and joins the companys other existing operations in Oxford, Michigan, and Montgomeryville, Pennsylvania. company, developing and directing the implementation of operational and strategic planning with direct supervision over operations, engineering, finance and global sales. Strojinc has more than 30 years of industrial manufacturing experience at both middle market and OEM companies, where he held many leadership roles. Before coming to Universal AET, he was managing director at Envisage Group Inc. Dawn Auby, the former director of OEM sales, was named vice president of sales and oversees the Americas market. She is a former business development manager at Universal AET and, prior to that, a sales manager at Cummins.

Siemens
The Petronas Bintulu liquefied natural gas (LNG) complex in Sarawak, Malaysia, has ordered Siemens turbo compressors and mechanical drive gas turbines to reliquefy boil-off gas (BOG) from LNG storage tanks. Siemens said the project will deploy the worlds first gas-turbine-driven cryogenictemperature BOG turbo compressor. The company will provide a tandemcasing, cryogenic-temperature BOG turbo compressor and a single-casing LNG-refrigerant turbo compressor, both of which will be direct-driven by Siemens SGT-700 mechanical drive gas turbines. The equipment will be delivered by April 2014. Plant start-up will be in October 2014.

QUALITY LUBRICANTS YOU CAN DEPEND ON.

Monico
Monico has hired Matt Olinger to serve as a senior electrical engineer. Olinger, who has more than 10 years of experience in programming, hardware and control systems, previously worked for TAC Americas (Schneider Electric), Bradley University and Belcan Engineering. Olinger is the 11th employee on Monicos staff and the third added in the past seven months.

Stocking locations in the U.S. & Canada

SERVICES Customized Lubricant Application Selection Oil Analysis Lab and Problem Application Support New Product Development PRODUCTS Semi Synthetics Synthetic Polyalkylene Glycols (PAGs) Synthetic Polyol Esters (POEs) Synthetic Diesters Synthetic Polyalphaolefin (PAOs)

Universal
Universal Acoustic & Emission Technologies has promoted two company executives to top leadership positions. The companys board of directors elected Dick Strojinc, the former senior vice president of Global Operations, to be the executive vice president. He will serve as general manager of the MAY 2013

866.366.5699 Fax: 281.367.5685 Synthosol.com mpe@mastersprocess.com

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New Hudson Subsidiary Targets plant offers delivery, Compression Cooling > Houston-area turnaround advantages
By Patrick Crow

n Hudson Compression Coolings Rick

Ketchum (left) and Samuel George are shown with one of the companys big heat exchangers.

udson Products Corp. has formed a business unit, Hudson Compression Cooling (HCC), to provide air-cooled heat exchangers for gas compression packagers and end users. The company will design and make compression coolers at its Beasley, Texas, plant 42 mi. (67 km) southwest of downtown Houston. We saw a need for compression cooler manufacturing on the Gulf Coast, where there is a lot of packaging activity, said Grady Walker, CEO of Hudson Products. Until now, most compression coolers were supplied from the Tulsa, Oklahoma, area. Hudsons packaging customers will be able to take advantage of our world-class

capabilities in Beasley, while reaping substantial transportation savings. HCC Vice President and General Manager Rick Ketchum and Sales Manager Samuel George have extensive experience in custom-engineered compression cooling. Ketchum said the subsidiary will focus on the middle of the market, making quality cooling units at competitive prices for engine and electrical drives. HCC already has shipped a dozen units and has orders for more. Hudson has manufactured compression coolers in Tulsa since 1985 through its Amercool subsidiary, which is continuing to operate as a separate business unit. The initial response from packag72

ers has been very positive, Ketchum said. Theyre pleased to see that a supplier is making cooler equipment in the Houston area. He said not only can HCC offer low shipping costs, but it also can offer a fast turnaround. We typically can deliver a unit within 12 to 14 weeks, he said. We can work even faster than that, though. If we have the tubes, we can start on a project tomorrow. Ketchum said HCC can make coolers quickly because all manufacturing and inspection functions, except for galvanizing, are performed in-house. That minimizes the delays normally associated with outsourcing various components and processes. Compressortech2

MAY 2013

Just as with all Hudson cooler applications, we will perform the thermal design of all equipment instead of relying on third parties for this critical function, George said. Our compression customers benefit from Hudsons extensive thermal and mechanical design experience and capabilities, while HCC maintains full control and responsibility for all aspects of product design and manufacturing. This allows us to respond much more quickly and effectively to our customers needs. Hudson is experienced at designing very high specification coolers that require utilizing exotic materials such as Inconel, Hastelloy, etc. Ketchum said the company has the reputation of taking on difficult thermal and mechanical projects. Header construction complies with designs requiring 11,150 psi (770 bar), heavy-gauge steel, shoulder-type access plugs for easy maintenance, low-noise/high-efficiency fans and heavy-duty bearings. Model configurations include 4 to 14 ft. (1.2 to 4.2 m) vertical, engine driven, forced or induced draft; 2.5 to 5 ft. (0.75 to 1.5 m) vertical, motor-driven forced/induced draft; up to 5 ft. (1.5 m) horizontal-coil, vertical fan, engine-driven, forced-draft; and up to 60 ft. (18 m) horizontal electric-motor-drive, forced/induced draft. For compressor applications with ultra-low noise requirements, Hudson offers its CX Fan with sound ranges 20 to 25% lower than standard axial fans. The fans operate at 40 to 50% lower tip speeds than standard fans, resulting in lower noise generation. They range in diameter from 7 to 14 ft. (2.1 to 4.2 m) and are made of a hollow, lightweight, corrosionresistant fiberglass. The Beasley plant has 350,000 sq.ft. (32,500 m2) of space under roof, of which 41,000 sq.ft. (3800 m2) are currently dedicated to compression cooling manufacturing. Hudson cuts, bevels, pre-drills, welds and finish drills the raw plate to make its headers. It also welds and attaches nozzles to the headers to ASME Code 150 and API 661 specifications, if required. The plant has an 18 x 70 ft. (5.5 x 21.3 m) pneumatic water test tank and can also perform glycol, oil, nitrogen and helium testing. If required, sandblasting and painting are performed on-site as well. Hudson Products was founded in the 1930s by Ed Hudson, who invented heat transfer products for the energy and process industries. The company remains a global leader in the design and manufacturing of equipment for the energy and process industries and is the largest North American provider of coolers across the entire natural gas segment. Hudson makes Fin-Fan and Solo-Aire air-cooled heat exchangers at Beasley and Tulsa (through its wholly owned Smithco Engineering subsidiary) and at Edmonton, Canada. It manufactures them at Dammam, Saudi Arabia, through its joint venture with Zamil Industrial. Hudson makes Tuf-Lite axial-flow fans in Beasley. Its Cofimco axial-flow fans are manufactured at Beasley; Pombia, Italy; Chennai, India; and Changshu, China. CT2 MAY 2013 73

FEATURED
PRODUCTS
High-Temperature Accelerometers
IMI Sensors, a division of PCB Piezotronics Inc., has launched its high-temperature accelerometers for vibration measurement in gas turbines in areas of up to 900F (482C).

Analyzer Flow Switch

The Model FS10A analyzer flow switch/monitor from Fluid Components International (FCI) has received FM and FMc (Canadian) approvals. With these approvals, the device is suitable for continuous flow verification applications that support process analyzer sampling systems operating in hazardous plant areas.

dates wide turndowns with a ratio up to 100:1. www.fluidcomponents.com

Sensor System
Ludeca has launched sensALIGN, a sensor system for machinery alignment. The system combines Prueftechniks intelligent sensor technology into the Rotalign Ultra iS platform, which provides instant data acquisition and displays real-time results with 100% accuracy, the company said.

The new EX600B13 sensors feature one-piece construction with hermetically sealed integral hardline cable designed to withstand extreme heat environments. They have significantly improved performance for dealing with transient temperature changes, a common condition in gas turbines. Also, by incorporating an integral sensor, cable, and charge amplifier in a single hightemperature accelerometer, gas turbine operators have a complete measuring chain that eliminates contamination and common mode noise concerns, the company said. The integral ICP charge amplifier allows for use with standard data acquisition equipment. www.imi-sensors.com

The FS10A is designed for use with nearly all types of process and emissions sampling systems, including gas chromatographs, mass spectrometers, optical spectrometers, photometers and others. Standard configurations will accommodate 0.13, 0.25, 0.37 and 0.5 in. (0.32, 0.64, 0.95 and 1.27 cm) sampling tubes as well as an SP76 adapter. Depending on the tube size, the FS10A Analyzer Flow Switch/Monitor operates over a wide flow range in air/gas from 10 to 100 000 cc/ min (6.014 to 144 m3/d), and in water/ liquids from 0.70 to 750 cc/min (0.001 to 1.08 m3/d). It accommo-

The sensALIGN system automatically considers the effects of ambient vibration, acceleration of rotation, backlash, speed of rotation and other factors in determining the quality factor (QF) of alignment readings. This makes the system ideal for long-term, standalone monitoring of machine positional change (live trend) as well as routine everyday shaft alignment, Ludeca said. www.ludeca.com

Food & Beverages

Chemistry

Raw Materials

Environment

Machine Construction

Special Engineering

Petrochemistry

Compressor solutions for

BREWERIES, BEVERAGE PRODUCTION AND FOOD INDUSTRY

OIL-FREE COMPRESSION WITHOUT FILTRATION HIGHEST PROCESS AVAILABILITY

HIGHEST EFFICIENCY LOW RUNNING COSTS

Josef Mehrer GmbH & Co KG Maschinenfabrik Rosenfelder Str. 35 72336 Balingen Germany Phone +49 (0)7433 2605-0 Fax +49 (0)7433 2605-41 www.mehrer.de service@mehrer.de

FEATURED
PRODUCTS
Thermometers
Systems Universal Monitoring Module is configured for enveloped acceleration, it now returns seven parameters. Using bearing tables for the particular bearing geometry, bandpass filter corners for each of the above parameters can be set. Alarms can also be set independently for each parameter. Users can then alarm and trend the vibration levels within these frequency bands for a sophisticated and effective monitoring strategy. These new measurement capabilities can be enabled in existing hardware in the field by downloading the appropriate firmware and reconfiguring the new channel types as desired. www.metrixvibration.com

Ashcroft bimetal thermometers are designed to eliminate use of mercury to measure temperature. Available in dial diameters from 2 to 5 in. (50.8 to 127 mm) and ranges from -80 to 1000F (-62.2 to 538C), these instruments are available in standard stem lengths from 2.5 to 24 in. (63.5 to 609.6 mm) and special order stems up to 60 in. (152.4 cm). Ashcroft Maxivision thermometers provide a fixed rear or bottom stem while the Everyangle design allows the stem angle to be adjusted. Hermetically sealed for easy wash down or liquid filled to counter high vibration, Ashcroft stainless-steel bimetal thermometers are suited for difficult installations. www.ashcroft.com

Bearing Monitoring
Metrix Instrument Co. announced that its SetPoint Machinery Protection System now supports multiple frequency passbands and acceleration enveloping, commonly used to monitor rolling element bearing condition.

testo 350.

Compliance testing and tuning the easy way.

Superior performance for state and federal testing Menu-guided HD display Powerful on-board & PC data management Wireless operation simple data collection Rugged construction

Rolling element bearing support is the most recent in a long succession of completed and planned system upgrades. SetPoint was launched in 2011 with functionality to support basic turbo machinery measurements. When a channel in the SetPoint MAY 2013
Testo.indd 1

O2 CO NOx SO2 CO2

800-227-0729 www.testo350.com
75 Compressortech2
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Using Torque Flanges To Control enables direct measurement Compressors > Technique of computer operation

n The chart shows the relationship of brake means effective pressure and air/fuel ratio in a gas engine, which enables knocking and misfiring areas to be visualized. For the engine to enter one of these areas at any operating point means the risk of costly damages. Source: Wrtsil

as pipeline pressure variations need to be monitored and adjusted within compressor stations, using as little energy as possible. These variations can result from the large number of entry and exit points along a pipeline, pressure loss during transportation, temperature gradients and varying gas quality. Monitoring a multitude of process parameters ensures that the systems performance is always adapted to the permanently and sometimes rapidly varying operating conditions while at the same time maintaining high efficiency. According to Klaus Weissbrodt, key account and project management for high-capacity torque applications at Hottinger Baldwin Messtechnik, this is a major challenge in particular for mechanical propulsion systems. One of the most important process parameters is the propulsion power

transmitted to the gas compressor whether from an electric motor, a gas turbine or a gas engine. It is essential to control its generation so that the minimum propulsion power required for the compressors particular operating situation is permanently available, even with fast-changing loads. At the same time, generating excessive propulsion power reduces efficiency. It also can cause increased pollutant emissions (with mechanical propulsion systems) as well as in critical operating states (in particular with mechanical propulsion systems with gas engines). Permanent monitoring and control of the propulsion power of such systems therefore requires the compulsory measurement of rotational speed and, in addition, the measurement of the torque transmitted to the compressor. Weissbrodt said contrary to rotational speed measurement that can be implemented directly and relatively 76

easily, implementing torque measurement is rather difficult. For this purpose, measurement quantities such as cylinder pressure and temperature are often used as auxiliary methods and as the basis for calculating torque and, thus, power. While this method has been used for many years and has been permanently refined, it has the disadvantage that the measurement uncertainty related to torque significantly increases due to a number of parameters with higher tolerances used for this purpose and, moreover, usually cannot be convincingly proven. Greater tolerances of measurement quantities required for control purposes, however, inevitably result in larger deviations from the optimal operating parameters. This can have undesirable effects, in particular with gas engines. For a gas engine, the optimum operating window is the narrow area between Compressortech2

MAY 2013

knocking and misfiring; this means that operating the gas engine at maximum power while maintaining low pollutant emissions requires a sensitive control mechanism with small tolerances. Higher tolerances necessarily mean reduced maximum power to increase the distance between the operating point and the knocking and misfiring areas. At the same time, it is essential that the control is very fast, since large pressure fluctuations can occur at the compressor within a small time frame, which become noticeable as load variations at the engine. They need to be quickly and precisely compensated for by the engine to ensure that the operating point remains in the safe operating window. Besides the method previously described there are other methods for determining the torque transmitted to the compressor that involve the evaluation of the input shafts elastic torsion resulting from the application of torque. For example, among the methods are strain, displacement, angle, and frequency measurement. All are based on the measurement of an auxiliary quantity and the subsequent calculation of torque and therefore provided that they are merely mounted onto the drive train also must be considered indirect methods. In these cases too, the tolerances of the parameters to be taken into consideration (e.g., the material and the shaft geometry) result in relatively high measurement uncertainty of the measure and torque. Weissbrodt said the indirect torque measurement methods based on the input shafts elastic torsion can be translated into the direct torque measurement method by calibrating the measurement system for the measure and torque; as explained earlier, calibration for the respective auxiliary quantity is not sufficient. This requires that an input shaft section fitted with the measurement system is calibrated using a torque calibration machine to determine the exact relationship between the applied torque and the measurement systems output signal. This approach presents a number of difficulties. First of all is the adaptation of the shaft section during installation MAY 2013

in the calibration machine. Secondly, there might be a low elasticity of the shaft section resulting from the input shaft design resulting in low sensitivity of the measurement system. Finally, the measurement system must not be dismounted from the shaft section after calibration since otherwise the calibration certificate is no longer valid. Weissbrodt said the installation of a torque flange, that is, a specially optimized shaft section or adapter into the drivetrain, is an elegant way of directly

measuring the torque transmitted to the compressor. This method means that the measurement system is an integral part of the measuring body and thus of the shaft section; both components can only be calibrated together. The torque flange is designed in such a way that it can reliably transmit the maximum torque while at the same time offering high sensitivity. The manufacturer uses a torque calibration machine to calibrate and continued on page 78

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n The MDEX torque flange from Hottinger Baldwin Messtechnik can be used for precise measurement and control purposes in gas compressor trains.

accordingly certify the torque flange for the required torque. Its design allows easy installation in and removal from both the drive train and a calibration machine.

Using a torque flange provides further advantages in addition to direct and very precise measurement of the torque transmitted to the compressor,

such as a very short signal propagation delay that allows very fast control to be implemented; a wide bandwidth of the dynamic torque signal (up to 6 kHz) that enables dynamic effects on the engine or shaft train to be examined; no bearings, brush contacts, slip rings, or batteries, which means the system is completely maintenance free. Also, a torque flange will assure a very long service life with a MTBF of over 20 years. Torque flanges are also available with optimized design for specific applications and can be ATEX-certified. Torque flanges have primarily been used in automotive power test stands over the past decades. Rising energy costs, ever more stringent regulations for emission values and related developments in drive technology have resulted in this technology having been adopted in other industries, as for example in the oil and gas and marine industries. High operating costs in applications in these fields have also led to torque flanges increasingly being used for control tasks in addition to their classical field of application in power test stands, Weissbrodt said. CT2

Protect your drive line. Increase your uptime. TurboCool reliable cooling power control.

2 3 4 6 5

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DJ Slater, Puzzlemaster

Going Offshore
I H A N G D E L Y T S B D S R E L O O C E R U T X I M X F G U A E P M L E F R V Y V T T C E J O R P B X L R A U V F M A C R S R D A F F N D S J I E R D E S I L H F A G R P R B M J E O V S K O L H D V S O E N N O I T A R A P E S E M I O S E C O H M G U T H N H O E R U T C U R T S H T T S O E S O S O I F Y R C Y E E R A G P U N I T S N R R C G T E D I Q D E H P R O P U L S I O N E H H A N B U W A P D I S T R I B U T I O N W S L Y I S M B P N F R A M E B C F T I T R P P P Y A Z I T U E O I L A N D G A S R H E M S E K P R O C E S S S J D L S C S A Q E Z R W I L C O M P A C T L E U P I E P N D T E N Z E V N O I T A C I R B U L R T Y S D G T A E S W C T C C N F B A S P P E N G S P N R M W I A M A E R T S P U P M W N Y B S Y G O L O N H C E T Q A S M A O L Z P O A N O Z Z L E S P A C E K C E D C
Applications Access Base Plate Compact Compression Contract Coolers Custom Deck Delivery Distribution Downstream Equipment Footprint FPSO Frame High Speed Installation Level Lift Lubrication Market Midstream Mixture Module Nozzles Ocean Offshore Oil and Gas Partnership Phase Platform Piping Pressure Process Project Propulsion Range Recovery Rotor Separation Southeast Space Structure Style Subsea Technology Units Upstream Valves

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Advertisers Index
*Further information on this companys products can be found in the 2012 Edition of the Global Sourcing Guide (at GSGnet.net) and 2013 Compression Technology Sourcing Supplement (at CTSSnet.net). ACI Services, Inc. .............................................11 www.aciservicesinc.com Altronic, LLC.................................................24-25 www.altronic-llc.com ARIEL ...................................................................1 www.arielcorp.com Argentina Oil & Gas Expo 2013 .......................79 www.aog.com.ar ARMCO Compressor Products Corp. .............23 www.armcocompressor.com AXH air-coolers .................................................38 www.axh.com BETA Machinery Analysis ...............................49 www.BetaMachinery.com BG Service Co. Inc, The ................................. 27 www.bgservice.com BORSIG ZM Compression GmbH ...................34 www.borsig.de/zm Burckhardt Compression AG ..........................45 www.burckhardtcompression.com Cameron .......................................................42-43 www.c-a-m.com Catalytic Combustion Corporation .................55 www.catalyticcombustion.com CECO, Compressor Engineering Corp. ..........22 www.tryceco.com Compressor Products International ...............13 www.c-p-i.com Continuous Control Solutions ........................51 www.ccsia.com Cook Compression ...........................................53 www.cookcompression.com DCL International Inc. ........................................7 www.dcl-inc.com *Dresser-Rand....................................................39 www.dresser-rand.com ECOM America ..................................................77 www.ecomusa.com E Instruments International .............................67 www.E-Inst.com Elliott Group ..................................Second Cover www.elliott-turbo.com Ellwood Crankshaft Group ..............................69 www.ellwoodcrankshaftgroup.com Exterran .............................................................59 www.exterran.com Fabreeka GmbH Deutschland .........................70 www.fabreeka.de FLP, Fluid Line Products .................................73 www.fluidline.com FLUID 2013 ........................................................81 www.fluid-sh.com FS-Elliott Co., LLC ............................................61 www.fs-elliott.com GE Oil & Gas .....................................Third Cover www.geoilandgas.com GUARDIAN Engine + Compressor Control ......5 www.guardiancontrol.com Hahn Manufacturing Company .......................67 www.Hahnmfg.com Harsco Industrial Air-X-Changers ...................35 www.harscoaxc.com Heinzmann GmbH & Co. KG .......................32-33 www.heinzmann.com IMES GmbH .......................................................68 www.imes.de Josef Mehrer GmbH & Co. KG .........................74 www.mehrer.de KB Delta Compressor Valve Parts Mfg. ..........15 www.kbdelta.com Kiene Diesel Accessories, Inc. ........................69 www.kienediesel.com Kobelco/Kobe Steel Ltd. ..................................57 www.kobelcocompressors.com *MAN Diesel & Turbo ........................................19 www.mandieselturbo.com MIRATECH .........................................................10 www.miratechcorp.com MOTORTECH GmbH .........................................17 www.motortechamericas.com Murphy, FW ......................29, 31 & Fourth Cover www.fwmurphy.com Neuman & Esser Group ...................................41 www.neuman-esser.com Nord-Lock ..........................................................38 www.nord-lock.com PROGNOST Systems Gmbh ............................37 www.prognost.com Reynolds French ..............................................47 www.r-f.com *Rolls-Royce .......................................................9 www.rolls-royce.com Siemens Oil & Gas ............................................65 www.siemens.com/oilandgas SKF ....................................................................52 www.skf.com Summit Industrial Products .............................21 www.klsummit.com SYNTHOSOL .....................................................71 www.mastersprocess.com Tech Transfer, Inc. ..........................................2-3 www.techtran-hou.com Testo, Inc. ..........................................................75 www.testo350.com *Voith Turbo BHS Getriebe GmbH ................. 63 www.voith.com *Voith Turbo Inc. ...............................................78 www.voithturbo.com

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Cornerstones Of Compression story continued from page 84

Elliott Turbocharger Lines - c. 1965

Approximate engine power range covered, maximum continuous inlet temperature, pressure ratio range and number of turbine inlet ports. The frame (model) number multiplied by 100 is the approximate cfm capacity at the units design point. Turbocharger Frame BC025GA BC035GA BC045GA BC065GA BC090GA BC150GA M-5 M-10 MH-10 L-10 L-20 L-40 L-60 L-100 H-15 H-30 H-35 H-50 H-70 H-72 H-110 H-31 H-36 H-51 H-56 H-58 H-71 H-73 H-78 H-111 H-115 Maximum Continuous Inlet Temp. F (C) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1350 (732) 1350 (732) 1350 (732) 1100 (593) 1100 (593) 1100 (593) 1100 (593) 1100 (593) 1200 (649) 1200 (649) 1200 (649) 1200 (649) 1200 (649) 1200 (649) 1200 (649) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1300 (704) 1300 (704) Pressure Ratio Range 1.7 to 3.5 1.7 to 3.5 1.7 to 3.5 1.7 to 3.5 1.7 to 3.5 1.7 to 3.5 Up to 1.7 Up to 1.6 Up tp 2.1 Up to 1.6 Up to 1.6 Up to 1.6 Up to 1.6 Up to 1.6 1.4 to 2.2 1.4 ro 2.3 1.4 ro 2.3 1.4 ro 2.3 1.4 ro 2.3 1.4 ro 2.3 1.4 ro 2.3 2.0 to 3.0 2.0 to 3.0 2.0 to 3.0 2.0 to 3.0 2.0 to 3.0 2.0 to 2.8 2.0 to 2.8 2.0 to 2.8 2.0 to 3.0 2.0 to 3.0 6000 (4474) 700 (522) 5000 (3729) 300 (224) 4000 (2983) 225 (168) 1000 (746) 160 (119) 7500 (5593) Approximate Engine Rating hp (kW) 500 (373) Number Of Turbine Inlet Ports 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1 or 2 1 or 2 1 or 2 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1,2,3 or 4 1 or 4 1 or 4

diesel engine turbochargers. Annual production increased from roughly 1000 units in the late 1940s to 4500 units in 1955 and 5000 units in 1956. Starting in 1963, Elliott supplied hundreds of turbochargers to GE for locomotive engines. The 1965 Diesel and Gas Turbine Catalog reported that Elliott had turbocharged over 25 million hp (18,642 MW) of diesel and gas engines. Models distributed within MAY 2013

four basic turbocharger frame sizes were arranged to match various engines and applications. The H Series was the high pressure design, with its compressor eventually capable of pressure ratios of 3.0 for engines in excess of 200 psig (13.8 bar) BMEP. The L Series was for lower rated engines and the M series was for small high-speed engines. Models were available with either axial flow or radial 83

flow turbines. Each series had a family of casings, nozzle rings, diffusers, impellers and other parts. In the early 1960s, the G Series was introduced as a high-performance, high-pressure unit capable of operating continuously at a compressor pressure ratio of 3.0 and an overload pressure ratio of 3.5 with a turbine inlet temperature of 1300F (704C). In 1968, the company produced 10 of the largest turbochargers ever built in the U.S. Used on large-, mediumand slow-speed engines of 7500 hp (5593 kW) and higher, the model 280G weighed 7500 lb. (3401 kg). A 27 in. (686 mm) impeller operating at 12,000 rpm could compress 33,000 cfm (934 m3/min) of air to a boost pressure of 47 psig (3.24 bar). Elliott turbocharger construction was simple and rugged. The compressor and turbine wheels were mounted on a single, common shaft. A watercooled intermediate casing housed two steel-backed precision sleeve and thrust bearings that supported the rotor between the two wheels. Bearings were lubricated by the engine oiling system. The turbine and compressor casings could be removed from the intermediate casing without disturbing the rotor assembly or the bearings. By 1975, Elliott produced most of the turbochargers sold to large engine manufacturers in the U.S. A strike in 1974, however, disrupted production and led GE to begin manufacturing its own locomotive engine turbochargers a few years later. By the time Elliott sold the turbocharger business in 2001, the company had made more than 42,000 turbochargers for diesel and gas engines. As the industry matured, sales to engine manufacturers peaked, and European suppliers entered the U.S. market. In the 1990s, Elliott changed its focus to the turbocharger repair business. The company bought Turbine Specialties Inc. (TSI) in 1993 and American Diesel Engineering in 1994. The TSI facility completed its 20,000th turbocharger repair in 1998. Elliott sold the turbocharger group to Cooper Cameron (now Cameron) in 2001, which continues to operate the Salina, Kansas, business. CT2 Compressortech2

C ornerstones Of Compression

n In a historical photo, a worker is shown with one of Elliotts

many turbocharger models.

Elliott Began The Turbocharging made more than 42,000 Of U.S. Recip Engines > Company units over 50 years
By Norm Shade

he Elliott Group, a division of Ebara Corp., is best known today as a producer of large turbomachinery products. But the company actually started in 1901 as the Liberty Manufacturing Co., producing boiler cleaning equipment based on the patents of William Swan Elliott. It incorporated as the Elliott Co. in 1910 in Jeannette, Pennsylvania, in 1914, has maintained a factory and offices there ever since. With the purchase of the Kerr Turbine Co. in 1924 and Ridgway Dynamo & Engine Co. in 1926, Elliott entered the rotating machinery market, manufacturing turbines and compressors. In the 1930s and through the end of World War II, Elliott supplied the U.S. Navy with electric motors and generators used in fleet submarines under the name Elliott Motor Co. One of Elliotts most significant developments occurred in 1940, when the company obtained the first U.S. license to manufacture Bchi turbochargers for diesel engines. The technology of combining a single-stage expansion turbine and a single stage centrifugal compressor on a common shaft was already familiar to the company, and it manufactured and installed the first turbocharger on a diesel engine in the U.S. in 1941. Turbochargers were found to be an effective mechanism for increasing the design power of reciprocating engines used for locomotives, drill rigs, power generation, marine and compressor drives. 84

Power increases of up to 100% were often achievable with turbocharging. Engine ratings could also be sustained at higher altitudes, and constant torque could be sustained at reduced speeds down to 50% or less. Lower fuel consumption and, later, lower exhaust emissions also resulted from turbocharging. The idea of forced induction of air into an internal combustion engine originated in the 1880s, when Gottlieb Daimler patented the technique using a gear-driven pump. The concept of using a compressor driven by exhaust gasses to force air into an engine to increase power output came in 1905 from Alfred Bchi, an engineer at the Gebrder Sulzer engine manufacturing company in Switzerland. Ships and locomotives equipped with turbocharged diesel engines began appearing in the 1920s. Turbocharging grew during World War II for aircraft, vehicles, ships and locomotives. But the need for advanced high-temperature metals in the turbine kept them out of widespread use. After World War II, Elliotts turbocharger business grew rapidly. A turbocharger facility was constructed at the Jeannette plant in 1947, and the foundry was expanded in 1952 to support turbocharger and electric motor production. The market exploded in the mid-1950s, with Elliott becoming the leading manufacturer of four-cycle continued on page 83 Compressortech2

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