compressor tech2 may2016
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n Customer: Vertically integrated global
petrochemical company, Texas.
n Challenge: Build a world-scale olefin plant to
process plentiful, low-cost shale gas.
n Result: Three trains of reliable, efficient
Elliott steam turbines and compressorsensure the customer’s competitive
advantage in world markets.
They turned to Elliottfor a long-term partnership and long-term service.
World-scale olefin processors turn to Elliott for steam turbines and compressorsthat deliver unmatched reliability, efficiency and value over the life of their investment.Who will you turn to?
C O M P R E S S O R S n T U R B I N E S n G L O B A L S E R V I C E
www.elliott-turbo.com
The world turns to Elliott.
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ARIEL’S TORQUE REFERENCES
AT YOUR FINGERTIPS
With the all new Ariel Torque Guide App
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Featured Articles
12 GE Completes Metem Acquisition
14 Test Facilities Improve Compressor Reliability, Performance Predictability
24 Active Magnetic Bearing System For Large Machines
30 GE Tested, REP Approved
34 RMS Expands Its Footprint
42 Analysis: Valve Performance On Booster Primary Compressor For LDPE
48 Inlet Cooling For Gas Turbines Driving Gas-Gathering Compressors
Departments
4 Page 4 — Australia Leads The LNG Export Race
6 Global Perspective — Emerging Markets Eye LNG
8 About The Business — Domestic Oil & Gas Downturn Continues
While Political Stances Threaten Its Survival
10 Events & Meetings
26 Featured Products
41 Literature
46 Prime Movers
52 Scheduled Downtime
53 Marketplace
54 Advertisers’ Index
56 Cornerstones Of Compression — Sullair Rotary Screw Compressors
May 2016
COMPRESSORtech 2 is the premier resource for gas compression news and information.
Cover Designed By
Alyssa Loope
COMPRESSORtech 2 ( ISSN 1085-2468)
Volume 21, No. 4 — Published 10 issues/yearJanuary-February, March, April, May, June,uly, August-September, October, November,
December) by Diesel & Gas Turbine Publications,0855 Watertown Road, Waukesha, WI 53186-873, USA Subscription rates are $85.00 perear/$10.00 per copy worldwide. Periodicalsostage paid at Waukesha, WI 53186 and at addi-onal mailing offices. Copyright © 2016 Diesel &
Gas Turbine Publications. All Rights Reserved.Materials protected by U.S. and internationalopyright laws and treaties. Unauthorized dupli-ation and publication is expressly prohibited.rinted in the USA.
Canadian Publication Mail Agreement # 40035419.
Return Undeliverable Canadian Addresses to:
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mail: [email protected]. POSTMASTER:
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COMPRESSORtech2, 20855 Watertown Road, Suite
20, Waukesha, WI 53186-1873 USA.
www.compressortech2.com
ollow @COMPRESSORtech2 on:
MEMBER OF …
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NEUMAN & ESSERAmérica do Sul LtdaLocated in Belo Horizonte, Brazilwww.neuman-esser.com
Contact me for Central and South America:
Marcos RihanSales [email protected] line: +55 (31) 2126-9503
NEA GROUP Headquarters in Germany
THINK GERMAN,ACT LOCAL.LOOKING FOR AN ALL-IN-ONECOMPRESSION PROVIDER?
OVER 30 YEARS OF EXPERIENCE IN BRAZIL -FROM CONCEPT TO SERVICE, ANY APPLICATION.
NEUMAN & ESSER América do Sul is the expert forany compression needs in Central and South America.Located in Brazil, NEA's team works as the single-contactprovider for: Sales, Engineering, Packaging and Service.This includes care for the entire reciprocating compressorsystem - from the initial drawings to complete life-cycleservice. Hydrogen, technical and natural gases, LNG, airand more, we are here to serve you.
COMPRESSORSYSTEMS
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Page4CT2 Founder .......................... Joseph M. Kane
PUBLICATION STAFFAssociate Publisher ...................Mark Thayer
Associate Publisher ..............Roberto Chellini
Senior Editor ................................... DJ Slater
Senior Editor ................. Michael J. Brezonick
Associate Editor ...............................Jack Burke
Associate Editor ............................Chad Elmore
Associate Editor ...................................Art Aiello
Copy Editor ............................... Jerry Karpowicz
Digital Content Manager ...............Catrina Carne
Advertising Manager .................. Katie Bivens
Circulation Manager ............. Margaret Pieper
Production Manager ................Marisa Roberts
Graphic Artist ...........................Brenda Burbach
Graphic Artist .................................Carla Lemke
Graphic Artist ...............................Alyssa Loope
PUBLICATION HEADQUARTERS
20855 Watertown Road, Suite 220
Waukesha, Wisconsin 53186-1873
Telephone: (262) 754-4100 Fax: (262) 754-4175
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Norm Shade – Cambridge, Ohio
Mauro Belo Schneider – Rio Grande du Sul, Brazil
HOUSTON, USA
Mark Thayer, Associate Publisher
12777 Jones Road, Suite 225
Houston, Texas 77070
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DIESEL & GAS TURBINE PUBLICATIONSPresident & CEO ....................Michael J. Osenga
Executive Vice President ....Michael J. Brezonick
COMPRESSORA Member of the Diesel & Gas Turbine Publications Group
Australia Leads TheLNG Export Race
The country that introduced latex
gloves, vegemite and Crocodile
Dundee is now home to one
the largest LNG projects in the world.
Australia’s Gorgon project, located on
Barrow Island off the coast of north-
western Australia, shipped its first
cargo this spring, strengthening the
lead of the Land Down Under in the
global LNG export race.The U.S. made headlines in February
when Cheniere Energy dispatched the
first shipment of LNG from its facility
at Sabine Pass, Louisiana, bound for
Brazil. But the sheer size and scope
of the Gorgon Project quickly negated
any strides gained by Sabine Pass.
The Gorgon project includes a do-
mestic natural gas plant, a carbon
dioxide injection project and an LNG
export facility. Its three liquefaction
trains have a combined capacity of2.1 Bcfd (59 x 106 m3 /d). The first train
was commissioned in March, with
the second and third trains to follow
at six- to nine-month intervals. The
Gorgon project, taking more than six
years to develop at a cost of US$54
billion, is the world’s most expensive
LNG project to date.
Ultimately, Asia is the LNG prize.
The U.S. will benefit from the US$5.3
billion Panama Canal expansion set
to open this year, cutting costs andtravel time from the U.S. Gulf Coast to
Asia by 11 days (See November 2014
CT, LNG Vessels Will Run Through It ,
p. 38). But the infrastructure required
to meet Asia’s thirst for LNG is lacking
in the U.S.
Including the first train from Gorgon,
Australia’s LNG export capacity current-
ly stands at 6.2 Bcfd (157 x 106 m3 /d).
If the additional LNG capacity currently
under development is fully operational
as planned by 2019, the country’s LNG
exports capacity would likely increase
to the largest in the world, at 11.5 Bcfd
(325 x 106 m3 /d), equivalent of one-third
of global LNG trade in 2014.
Three projects in eastern Australia
have been fully or partially commis-
sioned since 2014. Queensland Curtis
commissioned its two trains in 2014-
15, Gladstone commissioned its first
train in October 2015 and AustraliaPacific sent its first cargo in January
of this year. All three projects process
coal bed methane into LNG and have
a current combined capacity of 2.3 Bcfd
(65 x 106 m3 /d). Once fully completed,
they will have a combined capacity of
3.4 Bcfd (96 x 106 m3 /d).
Gorgon LNG is the first of the four
new projects off the northern coast of
Western Australia to be partially com-
missioned. Three other projects in the
northwest — Prelude, Wheatstone andIchthys — are still under construction.
These three projects have a combined
capacity of 2.8 Bcfd (79 x 106 m3 /d)
and are expected to come online be-
tween 2016 and 2018.
Most new Australian liquefaction
capacity is already contracted on a
long-term basis to countries in the Asia
Pacific region. Among destinations for
Australian LNG, Japan accounts for the
largest share of contracted liquefaction
output, with contracts for 79% of outputfrom the existing liquefaction projects
(in operation prior to 2014) and 35%
from the new projects, according to the
U.S. Energy Information Administration
(EIA). China is the second-largest des-
tination, with 15% of contracted LNG
from the existing liquefaction projects
and 23% from the new projects.
The U.S., mired in red tape and fa-
cility delays, is quickly losing ground
to Australia in the race to become a
global LNG supplier. CT2
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Proliferation of innovative and cost-competitive lique-
fied natural gas (LNG) terminal solutions within the
Asia-Pacific region will facilitate more-efficient LNG
deliveries to its emerging markets. Many of those markets
are forecast to see substantial growth in LNG import re-
quirements over the coming years.
Singapore’s marine and offshore engineering firm SembCorp
Marine has increased its stake in near-shore LNG terminal
specialist Gravifloat AS to 56%, or US$27.5 million. In ad-
dition, it secured the right to raise its share by an additional
44% to take full ownership through an equity purchase atthe same price.
The acquisition places SembCorp in a good position to
capitalize on the growing need for flexible LNG solutions
in the Asia-Pacific region. Many of the emerging markets
are projected to see considerable growth in gas demand
and have proposed plans to increase LNG imports over the
coming years.
Nontraditional LNG import markets in Asia — such as
Bangladesh, Myanmar, Pakistan, the Philippines, Thailand
and Vietnam — could add in excess of 15 new LNG re-
gasification facilities, or at least 1.3 Tcf (36.8 x 109 m3) of an-
nual import capacity. Weak LNG prices for at least the nextfive years and robust demand for gas will support long-term
investments in LNG, which in turn will create opportunities
for suppliers to sell into these markets. Given that many of
these projects are either in the proposed phase or pend-
ing final investment decision, BMI Research (BMI) believes
there are opportunities for Gravifloat to offer a cost-efficient
alternative to procuring LNG.
Gravifloat’s near-shore terminal can be situated at water
depths as shallow as 50 to 65 ft. (15 to 20 m), and be
constructed in two to three years. The design utilizes a
modular concept, which allows for flexible adjustment of
capacity, as well as stepwise expansion of storage, power
generation module and berthing platforms, based on need
and investment plans.
Its lower cost structure increases its attractiveness rela-
tive to a conventional onshore import terminal, especially
as firms operate with smaller capex budgets amid the cur-
rent low oil price environment. Furthermore, Gravifloat’s
flexibility to cater to a wide range of market sizes offers it a
competitive edge over standard floating facilities, as over-
supply in the regional LNG market drives investors away
from large-scale LNG projects.
Some countries have already moved to explore the possi-bility of installing Gravifloat terminals to meet rising demand
from the power sector. For instance, Thailand is currently
mulling over plans for a US$45 million LNG-based power
plant in Ben Dam Bay, Con Dao, which will include an LNG
depot, a port and an 18 MW LNG power plant. Myanmar is
also reviewing a proposal from Gravifloat to construct a 127
MW LNG-fueled power plant offshore the Thilawa Special
Economic Zone.
A sustained period of weak LNG prices will create an envi-
ronment whereby countries and companies that perhaps did
not have sufficient financial resources are able to consider
investing in LNG for the long term. BMI forecasts the priceof Asian benchmark Japan Korea Marker (JKM) to remain
below US$5/MMBtu over the period from 2016 to 2020,
lower than the US$13/MMBtu average over 2013 to 2015.
The low prices will place buyers in a strong bargain-
ing position to secure favorable long-term contracts.
Furthermore, floating storage regasification units will
be cheap as shipyards are looking for business amid
a slowdown in the shipbuilding industry. Lower costs of
LNG supply and infrastructure support the view that more
regasification projects will move forward on top of those
under construction, benefitting LNG suppliers who are
looking for export markets. CT2
Emerging MarketsEye LNG >BY ROBERTO CHELLINIASSOCIATE PUBLISHER
Global Perspective
Flexible and cost-competitive LNGterminals provide regasification toemerging Asia-Pacific markets
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U.S. oil production is falling as low prices have stifled
new development. In the first week of April, Baker
Hughes reported that U.S. rigs drilling for oil and nat-
ural gas reached a new low of 443 (354 oil and 89 gas). U.S.
Energy Information Administration (EIA) data shows that
after a 23% decline from 2010 to 2014, crude oil imports ac-tually started increasing again in late 2015. Total 2015 imports
were slightly higher than 2014, and January 2016 imports
soared to 20% higher than the same period last year.
But natural gas production continues to climb due to the
large inventory of drilled wells yet to enter production and to
the amazing productivity of new Marcellus and Utica Shale
wells. The EIA reports that gas storage at the traditional end
of the heating season was 54% higher than the five-year
average, highest ever for that point in the season. This has
kept the Henry Hub price below $1.90/MMBtu.
In the midst of the worst U.S. oil and gas downturn in
decades, environmental advocates, government agenciesand politicians continue to push agendas that endanger the
very survival of the industry that drives the gas compres-
sion market. Uninformed, misinformed or misguided presi-
dential candidates are proposing severe restrictions, and
even bans, on fracking.
In March, an EIA report said that over half of the energy
production in the U.S. comes from fracking, pointing out
that the industry “has allowed the United States to increase
its oil production faster than at any time in its history.” Yet,
some politicians and environmental activists ignore this
fact and push to essentially destroy the U.S. oil and gas
industry. Although green energy development should notbe discouraged, the practical matter is that it cannot meet
demand for decades. And even green energy has environ-
mental consequences, a fact rarely reported by the press
and ignored by the anti-hydrocarbon lobby.
Speaking at the Gas Compressor Association’s Expo
in March, Dr. Ken Morgan, director of the TCU Energy
Institute, explained that solar and winds aren’t as green
and strategically friendly as generally portrayed. Solar cells,
batteries, and turbine generators rely on components that
contain rare earth metals found outside North America. Not
only is that a strategic concern, significant environmental
issues have been reported from mining and manufacturing
them, especially in China.For example, solar, thought to be the greenest of energy
sources, has some serious baggage. A November 2014
National Geographic article, “How Green Are Those Solar
Panels, Really?” pointed out that the fabrication of solar pan-
els requires toxic chemicals and uses large amounts of water
and electricity. The Silicon Valley Toxics Coalition (SVTC),
a San Francisco-based nonprofit that has tracked the envi-
ronmental impact of the high-tech industry since 1982, re-
ported that the solar industry is focused more on survival and
growth than on tackling the dirtier side of an otherwise clean
energy source. These problems undercut solar’s benefits.
Well-organized opponents of oil and gas are energetic,passionate and increasingly effective at influencing public
opinion and politicians. Yet we, as individuals in the oil and
gas industry, do little to counter their messaging and make
our story heard. Talking only among our business associ-
ates is not enough. And, although some of the nastier en-
vironmental facts associated with green energy should be
more widely publicized, negative messaging risks turning
most of the public off from listening to us.
Instead, we should concentrate on constantly educating
the public on the positives of fracking and domestic oil and
gas production to sustain the U.S. and North America en-
ergy needs for the foreseeable future. The benefits — jobs,low costs and security — are obvious to all of us, but the
average citizen rarely hears that message except in some
paid advertisements.
As this column has advocated, it’s up to us to direct
our friends, relatives and neighbors to factual information
that favors our industry, encouraging positive conversa-
tion. There are many good information sources including
the American Petroleum Institute’s (API) Energy Nation
(www.energynation.org) and the Interstate Natural Gas
Association of America’s (INGAA) new Energy Link (www.
ingaa.org/energylink). Make yourself — and your extended
network — familiar with them! CT2
Domestic Oil & Gas
Downturn Continues While
Political Stances ThreatenIts Survival > BY NORM SHADE
About The Business
Informative grass roots conversation isneeded to counter the negative oil & gasmessaging from environmental advocates
BY NORM SHADE
Norm Shade is senior consultant and president emeritus of ACI
Services Inc. of Cambridge, Ohio. A 46-year veteran of the
gas compression industry, he has written numerous papers
and is active in the major industry associations.
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DISCOVER OUR NEW WEBSITE!
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Events & MeetingsBoldface indicates shows and conferences in which COMPRESSORtech 2 is participating
MAY 2016 10 COMPRESSORtech2
JULYJuly 25-27
SGA Operating ConferenceHouston+1 (972) 620-8505www.southerngas.org
AUGUSTAug. 23-25Power-Gen Natural Gas
Columbus, Ohio+1 (918) 831-9160www.power-gennaturalgas.com
SEPTEMBERSept. 12-15Turbomachinery Symposium/Pump Users Symposium
Houston+1 (979) 845-7417http://turbolab.tamu.edu
Sept. 13-15Gas Compressor ShortCourse ConferenceNorman, Oklahoma+1 (405) 325-3136www.ou.edu/outreach/engr/
gascompressor_home.html
MAYMay 24-26Eastern Gas CompressionRoundtablePittsburgh+1 (412) 372-4301www.egcr.org
May 31-June 1Gas AfricaSandton, Gauteng, South Africa+27 11 234 1196www.ingadaevents.co.za
JUNEJune 1-4Caspian Oil & GasBaku, Azerbaijan+44 207 596 5147www.caspianoil-gas.com
June 7-9Global Petroleum ShowCalgary, Alberta, Canada+1 (403) 209-3555www.globalpetroleumshow.com
June 13-16
Nigeria Oil & Gas Conference
Abuja, Nigeria
+234 706 911 7347
www.cwcnog.com
June 13-17
ASME Turbo Expo
Seoul, South Korea
+1 (800) 843-2763
www.asme.org/events/turbo-expo
June 21-23
Power-Gen Europe
Milan, Italy
+44 1992 656 637www.powergeneurope.com
June 21-23
Sensors Expo & Conference
San Jose, California
+1 (617) 219-8300
www.sensorsmag.com/sensors-expo
June 21-23
Developing Unconventional Gas (DUG)
East Conference & Exhibition
Pittsburgh
+1 (713) 260-6492
www.dugeast.com
Don’t replace.
i i ll
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Sept. 13-15
Wyoming Natural Gas Fair
Casper, Wyoming
+1 (307) 258-4708
https://wyogasfair.org
Sept. 14-15
International Rotating Equipment
Conference
Duesseldorf, Germany
+49 69 66 03 12 82
www.introequipcon.com
Sept. 14-15
European Forum for Reciprocating
Compressors (EFRC)
Hofburg, Vienna, Austria
+49 69 6603 1286
www.recip.org
Sept. 20-22
Power-Gen Asia
Seoul, South Korea
+44 1992 656 656
www.powergenasia.com
Sept. 20-23
InnoTrans 2016
Berlin
+49 30 30 38 2376
www.innotrans.de
OCTOBER
Oct. 2-5
Gas Machinery Conference
Denver
+1 (972) 620-4026
www.gmrc.org
Oct. 10-13
International Seminar Rotor Dynamics
& Bearings
Cologne, Germany
+ 49 2267 6585-0
www.arla-online.com
Oct. 11-13
HHP Summit 2016
Chicago
+1 (888) 993-0302
www.hhpsummit.com
Oct. 17-19
Saudi Arabia International Oil & Gas
Exhibition (SAOGE)
Dammam, Saudi Arabia
+39 06 3088 3030
www.saoge.org
Oct. 24-27
Rio Oil & Gas
Rio de Janeiro
+55 21 2112 9079
www.ibp.org.br
NOVEMBER
Nov. 2-4
EP Shanghai 2016
Shanghai
+ 852 2811 8897
www.epchinashow.com
Nov. 7-10
ADIPEC
Abu Dhabi, United Arab Emirates
+971 2 6970 518
www.adipec.com
For a complete listing of upcoming events, please visit our website at www.compressortech2.com/events/
HOERBIGER Engine Solutions
Find a distributor near you at www.altronic-llc.com
Rebuild.ncorporating custom Teon extensions, including special
extensions for the Caterpillar 3300 and 3400 engines, multiple
wire styles, a range of primary and secondary connections, and
an assortment of lead accessories, you can cost-effectively
specify a lead for manufacture by your local Distributor, or
ocally by your own personnel. In either case, leads can be
serviced/rebuilt when necessary with moderately priced, easily
nstalled replacement components, including new O-rings, wires,
The Altronic Flashguard 2.0 Secondary Spark Plug Lead Systemgives you the ability to fully rebuild spark plug leads in the field.
boots, or grommets/terminal pins acquired directly from your
Distributor’s inventory or your own.
This system offers accessibility, reliability, and the performance
that are critical to minimize downtime, while driving the
necessary cost-control and serviceability that are so crucial to
twenty-rst century operation.
Contact your Altronic Distributor for all the details.
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Since the introduction of its first centrifugal compres-
sor in the early 1960s, Solar Turbines has steadily
developed its compressor product line that now
covers a wide range. The compressors are optimized to
match the speed and power ratings of its Saturn, Cen-
taur, Taurus, Mars, Titan (all registered names of Solar
Turbines) gas turbines. They can be matched with electric
motor drives as well.
Solar continues to invest in its product development ef-
forts through its two ISO 9001:2008 certified campuses in
San Diego. Its gas compressor test facility (GCTF), which
began operation in 2009, is part of a substantial invest-
ment in new product development, as well as providing
customers with expanded options for shop testing.
The three-bay GCTF facility at Solar’s Kearny Mesa
Test Facilities Improve Compressor
Reliability, PerformancePredictability > Solar Turbines investment in extensive test
facilities advances compressor developmentBY NORM SHADE
MAY 2016 14 COMPRESSORtech2
n This closed-loop at Solar’s gas compressor test facility is powered by a dedicated
Titan 130 gas turbine driver on a universal driven-equipment skid that enables full load
testing in a hydrocarbon or inert gas closed-loop.
continued on page 16
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INNOVATION IS STANDARD
Contact us for solutions and services.
Phone: 918-317-2641 www.fwmurphy.com/newstandard
FIND OUT HOW WE CAN HELP YOU GROW YOUR BUSINESS
T H E T R U S T E D L E A D E R I N
N AT U R A L G A S C O M P R E S S I O N C O N T R O L S
Murphy by Enovation Controls continues toinvest in products that help you get themost our of your business and reduceunscheduled downtime.
By continuing to add diagnostic capability, performance
improvements and unrivaled support, we will work diligently
to make the Murphy choice the easy choice. With more than
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We are creating new waysto help you grow by:
Continuing
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Developing
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Bundling end devices that you need
to save you more
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complex is used for research, devel-
opment and production, including new
and aftermarket testing of compres-
sors in accordance with ASME PTC-
10 Type I and II.
In the first two bays, a dedicated
Titan 130 gas turbine engine and an
8 MW variable speed electric motor
drive (VFD) — equipped with univer-sal driven-equipment skids — enable
full load testing in a hydrocarbon or
inert gas closed-loop up to 3500 psig
(241 bar).
The third test bay can accommo-
date full compressor package closed-
loop string testing up to 30,000 hp
(22.3 MW). Testing of Solar compres-
sors at the GCTF facility provides
mechanical integrity, accurate mea-
surements and aerodynamic perfor-
mance. It also ensures rotordynamicstability and low vibration that meet
or exceed API requirements.
In addition to testing new compres-
sors, the GCTF facility is available to
test customers’ gas compressors af-
ter overhaul or restage. At its Harbor
Drive complex, Solar has an addi-
tional closed-loop test facility, which
is also used for Type II compressor
testing, with a dedicated Centaur 40
gas turbine driver.
In the closed-loop facilities, produc-tion or aftermarket compressors can
be shop tested under load to repro-
duce the aerodynamic design point.
Field gas properties can be simulated
through a variety of gas mixtures. Per-
formance verification with shop tests
before site commissioning is critical
to many customers.
Solar is aware of customer require-
ments for availability and durability of
compression equipment, which is why
the company emphasizes significantdevelopment testing prior to compres-
sor qualification.
At development, the compressors
are run on natural gas to their speed
and pressure limits, pushing beyond
their normal operation in the field. A
magnetic exciter is used to directly
measure damping in the rotor-bearing
system. This allows verification of ro-
tordynamic stability under actual op-
erating conditions at high speeds and
MAY 2016 16 COMPRESSORtech2
n A significant amount of development and production compressor testing has taken
place at Solar’s closed-loop test facilities, which accommodate ASME PTC-10 Type I and
II testing. One of the closed-loop facilities is driven by a dedicated 8 MW variable speed
electric motor (top). The extensive data gathered during these tests (bottom) is fed into
the company’s prediction database to improve analytical models and to improve compres-
sor durability and reliability.
continued on page 18
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MODULAR RELIABLE EFFICIENT
10
YEAR
In an economy where it is important to reduce operational costs, the ZVI unloader does so by reducing down time, reducing maintenance costs and improving
efficiency. The ZVI piston-style unloader valve can be used in all brands of compressors, at any speed, for both lubricated and non-lubricated applications
OPERATE AT THE NEXT LEVEL
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20/60MAY 2016 18 COMPRESSORtech2MOTORTECH Americas, LLC Phone: 1-504-355-4212 | www.motortech.de | www.motortechamericas.com
tribution partner for DENSO spark plugs
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operate the unit being tested, while measuring and evaluating its performance.
The system establishes specified test conditions, constants and operating
limits. Test data are monitored by video displays as instructed by the test
agenda, selecting various parameters for display, checking values and limits,
and generating reports as needed. When acceptable performance levels are
achieved, the test technician initiates a command to a computerized real-
time data acquisition system that captures all instrumented points, initiates
automatic performance computations and prints the results for review for a
permanent test record.Closed-loop testing is used for development purposes and is often specified by
customers of mission-critical compressor applications. These applications justify the
higher cost of more extensive closed-loop factory validation of compressor aero-
dynamic and mechanical performance.
Product development advances from
equipment tested in Solar Turbines’
production test facilities.
In addition to the closed-loop fa-cilities, two open-loop test facilities
are used to test every Solar Turbines
compressor prior to shipment to eval-
uate mechanical and aerodynamic
performance in accordance with test
procedures and acceptance criteria as
outlined in applicable test specifica-
tions. The suction and discharge noz-
zles are connected to an open-loop
configuration that uses atmospheric
air. The two open-loop test facilities
have dedicated drivers — a Centaur50 and a Saturn 20 gas turbine.
Mechanical testing is performed first.
The dry gas seals are tested statically
with nitrogen. After preliminary checks
and static seal testing, the unit is operat-
ed at break-in speed, then at maximum
continuous speed. Key mechanical pa-
rameters such as seal gas leakage and
separation seal air flow, oil flow, and vi-
bration levels are measured and evalu-
ated against established limits.
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COMPRESSOR LUBRICATION SYSTEMS
MAY 2016 20 COMPRESSORtech2
continued on page 22
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23/60MAY 2016 21 COMPRESSORtech2
i i
n Every gas compressor that Solar builds is tested at one of its open-loop test
facilities, which have dedicated drivers — a Centaur 50 and a Saturn 20 (right)
gas turbine. Larger compressors can also be tested open-loop on a (normally)
closed-loop test facility driven by a Titan 130 gas turbine (left).
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After the mechanical tests, aerodynamic testing on air oc-
curs. The primary objective of the test is to confirm the accu-
racy of the individual stage characteristics used for predicting
compressor aerodynamic performance at the air-equivalent
design speed.
Accuracy is determined by comparing the overall head
vs. flow speed line from choke to surge and the surge line
position against prediction when operating at a speedequivalent to the specified site design speed. Surge points
are determined at various speed points to validate the
surge flow estimate for the entire operating speed range.
Extensive instrumentation, together with the facility data
acquisition and reduction system, validates mechanical
and aerodynamic performance.
A separate aero test facility (ATF) allows for testing
scaled single stages while making detailed measurements
in order to improve prediction capability and help under-
stand component performance. In this facility, exclusively
dedicated to development testing, Solar’s engineers can
test entire compressor stage impellers, diffusers, returnvanes and volutes.
Many different types of compressor stage components
can be tested in the ATF. These stages can either be
scales of existing production stages or experimental stag-
es. For each test article, flange-to-flange performance is
determined. Static and total pressures are measured at
various locations throughout the stage to determine over-
all stage performance as well as the performance of each
individual component.
“This process extends our aerodynamic design knowl-
edge,” Schor said, adding that the ATF tests are used to
validate and establish limits of 1-D and 3-D design codes,
evaluate and understand stage component (impeller, return
vane, etc.) losses, establish guidelines for aerodynamic pa-
rameters, and gather data to help design the next generation
of compressors.
“The objective of the facility is not only to design and test
stages with the best efficiency for direct application to a pro-
duction stage, but also to extend our knowledge of critical
parameters,” Schor said. “For example, a stage can be de-signed deliberately with a sub-optimal surge margin and, by
analyzing test data and predicted data, correlations can be
derived as to what critical parameters, such as diffusion or
flow angle, are responsible for the adverse effect on com-
ponent stability.
“This extends the prediction capabilities of the design
software and improves the ability to design stages with the
best compromise between head, efficiency and flow range.”
Throughout its compressor line, Solar Turbines makes use
of pre-designed, pre-engineered and pretested components
rather than customized stages. Since standardized aero
components are used in Solar compressors rather than acompletely customized design, far more effort can be spent
in careful optimization. The impellers for Solar pipeline com-
pressors have complex 3-D blades with inducer inlet sec-
tions. The optimization process makes extensive use of 3-D
modeling components, using computational fluid dynamics
(CFD) tools, scaled model testing at Solar ’s ATF, and full size
testing in its closed-loop test facilities.
“These modern computational tools, together with the
expanded test capabilities, have been used to design
compressor stages with high efficiency and a wide oper-
ating range,” said Manoj X. Dutt, manager, marketing &
product strategy. CT2
MAY 2016 22 COMPRESSORtech2
n Solar’s aero test facility (ATF) enables
testing of scaled single centrifigal com-
pressor stages while making detailed
measurements in order to improve pre-
diction capability and help understand
component performance.
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2016 EDITION XX WWW.CTSSNET.NET CTSS
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In order to limit the wear of moving components, covering
their surfaces with an oil film is a conventional practice.
For more than a century, this has been the only way to
avoid friction between moving metal components. Oil con-
sumption can be expensive and, in some cases, pollute the
environment or the fluid used by the machine.
An alternative system, applicable to all rotating machines
(specifically high-speed and large-dimension machinery) is
active magnetic bearings. While not new, this system’s big-
gest drawback was its control system. The analog tuning
procedure could take several weeks, sometimes months.
With the advent of digital control systems, this procedurehas been reduced to a few hours and has created new op-
portunities in the design and implementation of all types of
rotating equipment, such as compressors, electric motors/
generators, gas and steam turbines.
With its Simotics Active Magnetic Bearing (AMB) tech-
nology, Siemens has introduced an AMB system for large
machines, such as high-speed, high-voltage motors or in-
dustrial turbines and compressors. The rotors for such ap-
plications are held suspended in the center of the bearing
without any friction or wear. To achieve this, sensors record
the position of the shaft 16,000 times a second and a regu-
lator adjusts the magnetic field to keep the rotor hovering
precisely in the bearing center. Even rotors weighing sev-
eral tons, spinning at maximum speed, can be held in a
position window that has the diameter of a human hair.
The Simotics AMB technology allows the use of standard
components from the Siemens portfolio, such as Sinamics
and Simotion control and converter units. In the context of
Totally Integrated Automation (TIA) and Integrated Drive
Systems (IDS), Simotics AMB technology is a highly effi-
cient and matched solution for large machine applications,
the company said. Simotics AMB technology seamlessly
integrates into the Siemens TIA concept, as all compo-
nents in it are mutually compatible and system tested. TheSinamics standard control components are used both in
the IDS in the drive train to control the magnetic bearings
as well as in the main converter. The PC-based Simotion
P320-4 controller forms a customer-specific, configurable
human machine interface for system monitoring, communi-
cation with the higher-level plant controller and for auxiliary
commissioning functionalities.
Simotics AMB technology is already in use. At NAM/Shell,
two 23 MW high-speed compressor drive trains running at
6300 rpm in the Netherlands’ Groningen gas field utilize Si-
motics AMBs; as well as at Germany’s Jänschwalde power
plant in a 10 MW steam turbine running at 5700 rpm. CT2
Active MagneticBearing System ForLarge Machines > Siemens Introduces Simotics Active Magnetic
Bearing technology for wear-free operation inlarge-machine applications
BY ROBERTO CHELLIN
MAY 2016 24 COMPRESSORtech2
n Simotics Active Magnetic Bearing (AMB) tech-
nology for wear-free operation in large-machine
applications. The system is built around standard
controller and converter units from the Sinamics
family of products from Siemens. The illustration
shows a special split bearing as used in a feed-
pump drive turbine at the Jänschwalde power
plant in Germany.
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From here, you see greater uptime.
PROGNOST is your portal to the world’s most comprehensive and effective machinery
diagnostics expertise.
With PROGNOST, maintenance decisions become clear and fact-based.
Critical assets – from rotating equipment to gear boxes and bearings – achieve true reliability.
Best of all, machinery and people are protected from the unexpected.
See for yourself how machinery uptime grows with the systems, services and lifecycle support
of the leader in online monitoring at your disposal.
[email protected] www.prognost.com
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Protection Relays
Woodward’s new HighPROTEC-2 protection relays are
designed to protect electrical buses and equipment. These
medium-voltage protection relays for generators and
power distribution applications monitor the electrical con-
dition of equipment and discon-nect the power source quickly
when a problem or potential prob-
lem is detected.
Nine separate HighPROTEC-2
products target different electrical
applications, including electrical
feeders, mains decoupling and
line protection, as well as electri-
cal generators, transformers and
motors. Users can configure each
product to address the specific
aspects of a given application.This flexibility reduces the num-
ber of product variations that oc-
curs when matching a solution to
unique application requirements. Broad voltage and cur-
rent inputs (0-800V ac and 1A/5A), wide range input power,
parameter configuration, and communication protocols
(DNP3.0, IEC 61850, Modbus, Profibus) provide application
flexibility. Using the expanded communications capabilities,
the HighPROTEC-2 interfaces with Woodward’s engine
and turbine controls and generator set controllers to form
a complete control and protection solution for generator
systems. Programming and operation menus, available in
seven different languages,reside in each unit.
A graphic display shows
the HighPROTEC-2 con-
nection architecture along
with real-time operating val-
ues and messages, alarms,
and fault data. A PC-based
service tool simplifies con-
figuration and includes pa-
rameter plausibility checks
and an ANSI menu struc-
ture. It includes a displayscreen editor and event,
trends, and disturbance re-
corders and counters to aid
operation and troubleshooting. The HighPROTEC-2 has
worldwide certifications including CE, UL, CSA, EAC and
marine certifications.
www.woodward.com/hpt-2
PRODUCTSFEATURED
Catalyst elements work hard under extreme condions, and even with regular maintenance
a failure is always possible. And a plant operaon shutdown is never a good thing.
A quick replacement with top quality DCL Meta cor products is the key to geng you out o
trouble. We stock a wide range of products in our Houston facility, ready for rush deliver
anywhere in the U.S.
So you won’t be on the spot – we will.
1-877-965-8989 www. c -inc.com
WHEN CATALYST ELEMENTFAILURE PUTS YOU IN A BIND,
DCL WILL BE ON THE SPOT.
O K L A H O M A C I T Y • D A L L A S • G I L L E T T E • H O U S T O N • L O S A N G E L E S • T O R O N T O • D E N V E R
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At its Florence, Italy, facilities last September, GE Oil
& Gas completed the full-load engine test of its 16
MW industrial gas turbine for mechanical drive com-
pressors and power generation.
The test confirmed turbine efficiency, power output and
emissions levels, GE said. Efficiency and power were high-
er than analytical forecasts, while emissions came in lower
than expected, according to the test results.
GE Tested, REP Approved > 16 MW gas turbine slated forRussian installation
BY ROBERTO CHELLINI
MAY 2016 30 COMPRESSORtech2
Russian licensee REP Holding assisted with the engine
development, which involved validating the engine require-
ments and main design parameters. REP Holding also con-
tributed to the preliminary and detail design, as well as the
crafting the low-pressure turbine, and designing the engine
package for the Russian market.
A gas generator full-load test also took place before GE
shipped the module to REP Holding’s Nevsky facility in
n GE Oil & Gas completed a full-load engine test
of its 16 MW industrial gas turbine last September.
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(800) 375-2347
WWW.TULCO.COM
Tulco’s Lubsoil® Synthetic LPG-WS and LPG-WI
Lubricants provide optimal performance and better
equipment protection compared to any other lubricant
on the market. Our eld tested and formulated
products are proven to save downtime and money, all
while increasing your compressor’s productivity. Tulco’s
synthetic lubricants offer:
Reduced gas solubility leading to extended lubricant life
Improved compressor efciency and wear protection
Superior performance in vapor recovery compressors
Excellent performance in H2S and CO
2 rich or “heavy”
gas compression
Tulco Oils has been a top-rated global marketer for
decades, and manufactures petroleum, semi-synthetic
and full synthetic Lubsoil® brand lubricants. We
offer quality products with high-tech support
and comprehensive service. Nomatter the challenge you have
with your compressor, the Tulco
team will have a solution.
DESIGNEDLUBRICANTS.
DESIGNED TOBE THE BEST.
MAY 2016 31 COMPRESSORtech2
St. Petersburg, Russia. At the facility,the licensee performed further joint
testing on the gas turbine as well as
subsequent field installation at a com-
bined heat and power plant.
Two months later in Florence, GE
Oil & Gas finished the assembly of
a fully instrumented unit, which went
through its validation and character-
ization test campaign. The engine was
heavily instrumented with research
and development strain gauges, tem-
perature probes and pressure probes
(among other equipment) in order to map performance, temperatures and
secondary flows.
The measurements will be used to finalize the digital engine model, as well
as fully characterize the performance of each machine component and define a
baseline thermodynamic cycle. The latter will constitute the starting point to further
increase the turbine power output and efficiency, while also improving emissions.
In order to test the complete GE train configuration, a dedicated test stand was
constructed with a gearbox from GE Lufkin and an electric generator from GE
Power Conversion.The instrumented unit will remain on its test stand in Florence for research and
development purposes throughout 2016, the company said.
continued on page 32
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GE Oil & Gas is working on the pro-
duction of three gas generators for
REP Holding, which will be used in
St. Petersburg. REP Holding will com-
plete the manufacturing of the low-
pressure turbine modules and engine
packages to create the T16 gas tur-
bine engine; it is called the NovaLT16
for the Russian oil and gas market.
The three units will be used to drive
REP Holding centrifugal compressorsas part of the modernization of Rus-
sian pipeline infrastructure. The job,
which will see industrial gas turbines
replacing aged turbo-compressors,
requires more than 4000 GT units.
The modernization is expected
to improve transportation efficiency
(amount of natural gas consumed vs.
transported gas and availability) with
longer maintenance intervals and a
smaller environmental impact, GE Oil
& Gas said.In 2014, GE Oil & Gas announced
an all-GE pipeline configuration of
its 16 MW unit, with a dedicated GE
Oil & Gas designed package and
BOP, developed in collaboration with
TransCanada Corp. and launched as
NovaLT16.
GE Oil & Gas is working to produce
one complete turbo compression train
for installation along a Canadian pipe-
line in Alberta. CT2
Intuitive: Simple navigation and “Site” setup
Flexible: Calibrate, test, review, or print anywhere
Efcient: Save testing values into analyzer
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softTEC Testing & EmissionsCompliance Softwarefor the testo 350 Emissions Analyzer
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• New standard calibration template
• Improved calibration screens
• New template with gm/bhp calculations
MAY 2016 32 COMPRESSORtech2
n GE’s 16 MW industrial gas turbine was
heavily instrumented with research and
development strain gauges, temperature
probes and pressure probes (among
other equipment) to map performance,
temperatures and secondary flows.
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repaired motors prior to their installation. Split rings come in mating halves that
simplify field installation around the shafts of in-service/coupled motors.The Aegis Pro SLR Ring is specially designed with O-ring barriers that prevent
the ingress of dust, debris, and excessive contamination that could lessen con-
tact of the ring’s conductive microfibers with the motor shaft. The Aegis Pro-MR
combines a PRO Bearing Protection Ring with a shaft voltage-monitoring ring in
a single unit.
Specially designed universal mounting brackets allow installation of Aegis Pro
Series Rings on large motors. These brackets attach to Pro Series Rings with
screws and have slotted legs that allow mounting to the motor with a bolt circle
of 2.64 to 7.79 in. (67.05 to 197.8 mm) greater than the shaft diameter. They are
provided with 0.5, 1.0 and 1.5 in. (12.7, 25.4 and 38.1 mm) standoff spacers to
provide sufficient clearance for shaft shoulders, slingers, or other end bell protru-
sions. Mounting bolts, flat washers and lock washers are also included.www.est-aegis.com
The Sensor Connection
The Sensor Connection, a division of Harold G. Schaevitz Industries LLC,
has expanded its line of measure-
ment and control instrumentation
with the addition of the model TCA-
MS-K-1. This Single Channel Type K
Thermocouple Amplifier Module con-
verts the low output voltage signalfrom a Type K thermocouple probe
to a single independent linearized 0
to 5 Vdc output voltage. According to
the company, this output is ideal for
interfacing to instrumentation equip-
ment including data loggers, tem-
perature indicators, chart recorders
and controllers.
Product features include a Type K
thermocouple input; temperature
measuring range from 32 to 2282°F
(0 to 1250°C); analog output of 0 to5 Vdc; and a response time of 1 ms.
http://thesensorconnection.com
PRODUCTSFEATURED
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In 1998, a group of experienced turbomachinery engi-
neers with a strong aftermarket engineering background
founded Rotating Machinery Services Inc. (RMS) in
Bethlehem, Pennsylvania. Now in its 18th year, the compa-
ny has steadily grown its business, becoming a major force
in providing turbomachinery aftermarket engineering and
repair services to the refining, chemical, gas transmission,
power generation and steel industries. Earlier this year,
RMS opened a satellite engineering office in Appleton,
Wisconsin, specializing in the support of the former A-C
Compressor line of centrifugal compressors.RMS performs a wide range of services on turbomachin-
ery, including reliability improvements, performance optimi-
zation, repair, component replacement and the supply of
upgraded/overhauled surplus equipment. The company
has experience with repowering turbomachinery pack-
ages and has also supplied new custom-designed equip-
ment skids and lube oil systems. Its experience includes
axial and centrifugal compressors, fluid catalytic converter
(FCC) and nitric acid expanders, gas turbines, aeroderiva-
tive power turbines and steam turbines.
“RMS provides a full range of turbomachinery services,
giving users a complete alternative to the OEM (original
equipment manufacturer),” said Jerry Hallman, company
president and co-founder. “We have a total focus on existing
compressor equipment, as opposed to OEMs, which have
their resources focused on new equipment. We can provide
superior engineered solutions to long-standing problems
that the OEM is unwilling or unable to solve. We also focus
on ‘orphaned’ equipment that is no longer fully supported
by an OEM. And we provide customers with open access
to RMS’ experts.”
Types of projects include rerates for improved performance;
engineered overhauls of rotors and complete machines;mechanical redesigns and upgrades; reapplication of sur-
plus equipment trains; component repairs; new parts sup-
ply including rotor blading, disks, shafts, stators, casings,
bearings and seals; and field service that ranges from in-
spection and turnaround support to providing supervisors
to full turnkey responsibility.
“We take pride in our ability to refurbish turbomachinery
to a condition that ensures long-term trouble-free operation
for our customers,” Hallman said. “Our assemblers, inspec-
tors, machinists and field service supervisors have an aver-
age of 25 years of experience in their respective fields and
RMS Expands
Its Footprint > Rotating Machinery Services Inc. provides full rangeof turbomachinery repair and upgrade services
BY NORM SHADE
MAY 2016 34 COMPRESSORtech2
n The RMS service facility consists of three 10,000 sq.ft. (929 m2) bays that include a rotor assembly shop (left), large-capacity machine
shop with quality control room, and an assembly shop (right) with a full range of lifting, moving and storage equipment.
continued on page 36
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We are where you need us.
Providing solutions for oil and gas applications upstream, downstream and in-between.
Everywhere.
dresser-rand.com
Welcome to a new era of innovation and technology.
As you have come to expect, Dresser-Rand prov ides
safe, reliable and efficient rotating equipment for nearly
every application in the oil and gas market.
But there’s more.
The new Dresser-Rand business now has expanded
resources and more experience as a member of the
global Siemens family. The Dresser-Rand business
combines one of the industry’s most extensive
portfolios of rotating equipment with a universe of intelligent
solutions and one of the world’s largest technical support
and service center networks. We offer more choices—where
you need us—all from a single supplier.
So what can you expect from us? High-quality products
and services, combined with local suppor t around the
clock, wherever you are, for the applications that matter
to you.
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take great pride in our facility and our
ability to handle our customer’s prop-
erty with the greatest efficiency and
attention to detail.”
Hallman said that RMS is affiliated
with respected millwright service orga-
nizations throughout the country, andRMS supplies field supervision for
each crew to ensure proper execution
of every project.
“Our organization is made up of
uniquely experienced engineers and
technicians,” said Robert J. Klova, PE,
vice president, chief engineer and co-
founder. “We leverage our experience
with the latest engineering technology.
Experience in all types of custom-en-
gineered turbomachinery separates
the optimum solution from the run-of-the mill. Strong design and analytical
engineering form the backbone of ev-
erything we do. Engineering makes
the difference, and we focus on con-
tinuous development of the next gen-
eration of turbomachinery engineers
to serve customers’ future needs.”
RMS has analytical capabilities in
structural analysis, aerodynamics,
rotor dynamics and metallurgy using
the latest analytical tools.
The RMS service facility consists
(918) 283-9200 Fax (918) 283-9229 www.axh.com
Experience, Reliability, Integrity...
The AXH manufacturing complex consists ofsix plants, totaling 559,100 SF on 67 acres.
MAY 2016 36 COMPRESSORtech2
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of three 10,000 sq.ft. (929 m2) bays that
include a rotor assembly shop, machine
shop with quality control room, and an
assembly shop. The rotor shop, which
is serviced by a 25 ton (22.5 tonnes)
overhead crane, houses multiple in-
dicating stands and stacking pits, twoSchenck balancing machines with
respective capacities of 40,000 and
17,000 lb. (18,140 and 7710 kg), an
electrical runout (glitch) system, a va-
riety of hydraulic coupling and tie-bolt
stretching equipment, and a Bracker
hydraulic rotor tenon peening system.
The machine shop houses multiple
large machine tools including a 5 in.
(127 mm) bar CNC horizontal boring
mill, a 60 in. (1524 mm) swing CNC
vertical boring mill, a Mazak 300MCNC turning-milling center, a 52 in.
(1321 mm) swing by 236 in. (5994
mm) between centers engine lathe,
and a 90 in. (2286 mm) swing vertical
boring mill, as well as a variety of small
manual lathes, knee mills and grind-
ers. The temperature-controlled, qual-
ity control room houses a number of
granite tables, coordinate measuring
equipment with scanning capabilities,
positive material identification equip-
ment and two precision air bearing
rotary table inspection stations. The
machine shop is equipped with 25
and 15 ton (22.5 and 13.5 tonnes)
overhead cranes.
The assembly shop has six large
assembly cells, a weld shop, nonde-
structive test (NDT) area with mag-netic particle and wet magnetic particle
booths, an abrasive blast room and
multiple abrasive blast cleaning cabi-
nets. This shop is supported by a 35/15
ton (31.5/13.5 tonnes) crane with 27
ft. (8.2 m) hook height and multiple jib
cranes. Also in this area, RMS’ field ser-
vice operations maintain a 20 ft. (6.1 m)
fully equipped sea container/shop and
gang boxes, ready for immediate dis-
patch to customer sites.
RMS’ capabilities are evidencedby its list of successful turbomachin-
ery projects. A recent major project
was an ammonia/water turbine gen-
erator set, developed from a surplus
steam turbine for a process cus-
tomer in Pakistan. RMS provided the
complete train of equipment, with
new controls and auxiliaries, includ-
ing the application of dry gas seals
for ammonia containment. To sup-
port the project, RMS had to develop
MAY 2016 37
continued on page 38
l o w - r a t i n g . h o e r b i g e r . c
o m
L O
W . . .
. . . R
A T I N G
. . .
n
The capabilities of RMS’ experienced en-gineering staff include expertise in all major
types of custom-engineered turbomachinery
and a full range of analytical expertise with the
latest analytical tools in rotordynamics, struc-
tural analysis (e.g., turbine disk, left), aero-
dynamics (e.g., centrifugal stage flow path,
center) and performance (e.g., steam turbine
blade erosion, right).
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performance analysis capability for
ammonia and steam mixtures.
The company has special expertise
in fluid catalytic cracker (FCC) and ni-
tric acid expanders. Nitric acid is the
basic material for the production of
fertilizers, explosives and chemicals.
In 2014, an I-R E520 nitric acid tail
gas expander experienced a high-
pressure seal failure. RMS engineer-ing supervised the change-out of the
damaged expander with a spare unit
that had been sitting idle following a
multiyear run. The spare expander
had experienced high of 2 to 3 mils
(51 to 76 µm) and unstable shaft vi-
brations during its prior run. Improved
cold alignment, bearing changes, and
careful setup resulted in low and
stable vibration of less than 1.06 mils
(27 µm), the lowest historical level for
this expander.
MAY 2016 38 COMPRESSORtech2
n RMS provided this complete machinery
train for a nitric acid plant in 2008. Start-
ing with a surplus train, RMS completely
designed the axial compressor and rerated
the turbine, providing a new lube oil con-
sole as well. It also rerated the customer’s
existing expander during a turnaround.
n RMS provided this complete ammonia/water turbine gen-set for a process customer in Pakistan. Developed from a surplus steam
turbine, it provided the complete train of equipment, including controls and auxiliaries and the application of dry gas seals for ammonia
containment. To support the project, RMS had to develop performance analysis capability for ammonia and steam mixtures.
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In 2008, RMS provided a complete
machinery train for a nitric acid plant.
Starting with a surplus train, RMS
completely designed the axial com-
pressor and rerated the turbine, pro-
viding a new lube oil console as well.
It also rerated the customer’s existing
expander during a turnaround.
In 2012, RMS was contracted tosupport the emergency breakdown
of a European refinery’s FCC power
recovery train. A failed Elliott hot gas
expander was at the heart of the
breakdown. RMS was able to restore
the main axial compressor to service
on motor only within a 10-day period.
The company then received another
contract for a root cause analysis
of the failure and for rebuilding the
damaged expander using an existing
spare rotor. During the inspection pro-cess, RMS determined that the entire
intake casing assembly was no longer
suitable for service. It was able to de-
liver a new intake casing assembly, in-
cluding first- and second-stage stator
housings in an expedited 16 weeks
from date of order. RMS’ field service
team travelled to Europe to support
the installation of the intake casing
and expander assemblies, enabling
an early startup.
Last year, RMS was offered a
unique challenge to urgently replace a
Cooper-Bessemer RC20 compressor
rotor that suffered a heavy rub failure
caused by impellers contacting the
diaphragms. The impellers were re-
verse engineered through mechanicaland FaroArm inspection methods in
four weeks. RMS engineers analyzed
the inspection information, and new
CAD models were created. Utilizing
forged material from in-house stock,
RMS was able to complete five-axis
machining of the impellers and a fin-
ished product, including overspeed
testing, in less than eight weeks. The
engineering and manufacture of a
new shaft, balance piston and shaft
sleeves were completed in 12 weeks,so that the entire replacement rotor
assembly was assembled, balanced
and shipped in 13 weeks, one week
ahead of the agreed-upon 14 weeks.
RMS also performed a rotordynamics
analysis and developed performance
curves for the design.
In addition to service and repair,
MAY 2016 39
n RMS provides engineering and support to users
with older power turbines, such as Cooper RT65, I-R
GT51 and GT61, Dresser-Rand DR61 and Dresser-
Clark DJ125. Projects have included remaining life
predictions for rotors and stationary components,
casing redesigns, replacement of major stationary
and rotating parts including outer casings and rotor
disks, field service, and rotor and complete power
turbine overhauls.
continued on page 40
n An axial compressor rotor is ready for
return to a customer after an engineered
overhaul in RMS’ shop.
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solving turbomachinery problems with engineering analyses and improved designs
has always been an RMS focus. For example, a 1968 vintage GHH horizontallysplit centrifugal compressor in a toxic gas service had experienced chronic joint
leakage over many years. The end user tried various fixes including purchasing
a spare compressor with a thicker casing; yet the sealing problem could not be
consistently eliminated. Finally, the end user was faced with the need to replace the
machines entirely. However new compressors would not match the existing layout
and pipe locations, and lead time was
over 30 months. RMS custom designedand manufactured two new 300 series
stainless-steel “drop-in” replacement
compressors with upgraded barrel type
casings to solve the split line leakage
problem. The complete units utilized
new RMS casings and diaphragms with
the customer’s existing rotors, bear-
ings and inner seals. Dry gas seals and
a new common oil system were also
included as part of the upgrade. The
new compressors were installed in the
spring of 2014, completely eliminatingthe chronic leakage problems.
FCC expanders can experience sig-
nificant erosive wear due to catalyst
particles entrained in the flue gas.
Using computer fluid dynamics (CFD)-
aided state-of-the-art aerodynamic
design, RMS developed a number of
unique features that have significantly
improved blade and disk lives. These
include low-erosion rotor and stator
airfoils, blade platform seals, and a
unique overlapping platform designupgrade that shields the rotor disk
from the harmful effects of catalyst
laden flue gas. The low erosion design
doubled the life of the rotor disk and
blades to six years at one customer
site. “RMS’ significant experience in all
aspects of FCC expander design, ser-
vice and support has earned it a strong
and growing place in the FCC expand-
er aftermarket, where numerous refin-
eries rely on us to support their FCC
power recovery trains,” Klova said. CT2
MAY 2016 40 COMPRESSORtech2
n RMS refurbishes and upgrades process (left) and pipeline centrifugal compressors including new custom-engineered
aerodynamic assemblies (right).
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CompressedTechnical Services
Stark Industries’ brochure
outlines its Compressed
Technical Services offering.
CTS designs and manu-
factures compresor system
packages for industrial gas.Compressors, oil-removal
systems and air-storage
solutions are enumerated
along side the company’s
services offering.
www.starkindustries.com
CoolingSolutions
The Fuzzy’s Radiator bro-
chure lays out the products,
services and technologies
used by the Texas panhan-
dle company. Fuzzy’s cool-
ing solutions include radiatorpackages, heat exchangers,
fin fan packages, radiator
cores, charge air coolers,
gaskets, cooling coils, hydro
blasting, soda blasting and
repair services.
www.fuzzysradiator.com
GeminiUpgrade Parts
TrueRock released bro-
chures to highlight the fea-
tures and benefits of its line
replacement/upgrade parts
for Gemini compressors.
The brochures feature theH Series aluminum pis-
ton rod (pictured) and the
M/H Series variable volume
clearance pockets.
www.truerocksupply.com
PreservationCoatings
A-76 Technologies supplies
the A-76 line of preserva-
tion coatings and lubricants,
offering corrosion prevention
and lubrication in high-
humidity, high-salinity envi-ronments. A green variation
contains no volatile organic
compounds, helping custom-
ers reduce emissions.
www.a76tech.com
LITERATURE
Stop by Booth 301/400 at the EGCR for more informatio
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The production of low-density polyethylene (LDPE)requires special compressors to obtain the pres-
sure necessary for the product.
The booster primary compressor brings the pressure
from low value up to the suction of the hyper compressor
that feeds the reactor.
Great attention is paid to all details of the plant in order to
achieve maximum operating time. The valves represent an
important component that strongly influences the reliability
of compressors and the plant.
The booster primary compressor requires stringent ca-
pacity control, further increasing its complexity.
An analysis of the design, production and performanceaspects of the booster primary compressor follow.
Plant features
The booster primary machine is a six-cylinder, mul-
tiservice compressor, which combines the function of
the booster and primary on one frame manufactured by
Nuovo Pignone (now GE Oil & Gas). The motor oper-
ates at 4000 hp (2983 kW) at 327 rpm. The machine has
Analysis: Valve Performance On Booster
Primary Compressor For LDPE > Production of critical parts, maintenance strategieshelp to optimize availability, minimize costs
BY JIMMY SALMON AND ENZO GIACOMELLI
MAY 2016 42 COMPRESSORtech2
a capacity of 16,000 lb./hr (7000 kg/hr) for the booster and56,000 lb./hr (25,000 kg/hr) for the primary.
The booster’s suction pressure is slightly above the at-
mospheric one, collecting the gas from the plant recovery
system. The discharge of the primary reaches 3600 psi
(25 MPa) to feed the hyper compressor. The hyper com-
pressor, designed and manufactured by GE Oil & Gas, is
an eight-cylinder machine that raises the pressure to full
reactor pressure. The three cylinders are double acting on
the booster, which reaches a pressure of 3278 psi (22.6
MPa). The compressor has 24 Nuovo Pignone-designed
valves manufactured by Cozzani.
The primary compressor operates up to 3771 psi (26 MPa)and has two cylinders with a tandem arrangement (second-
stage inboard and third-stage outboard). Additionally, the pri-
mary’s first stage is double acting with 2+2 valves, while the
two second and third stages are single acting and positioned
on the same cylinder with a tandem arrangement. The sec-
ond stages have one suction valve and one discharge valve
per cylinder, while the third stages have one combined suc-
tion and discharge valve per cylinder. All the cylinders are
equipped with plastic piston and packing rings.
The cylinder lubrication is made with a mineral oil with
lubricity additives. It is the same one that is applied for the
booster/primary and hyper compressor.
n Booster primary compressor.
Jimmy Salmon i s a senior principal engineer with 40 years of con-
tinuous service in LDPE maintenance, reliability and production.
Enzo Giacomelli is a consultant for Dott.Ing.Mario Cozzani Srl.
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Valve applications
The set of 30 valves is equipped
with metal rings in all stages of boost-
er and primary. The capacity control
requires the use of finger-type, one-
step unloading systems as well as
continuous bypass control. Because
the gas involved is not corrosive, the
material of the seat and guards isalloy steel AISI 4140.
The valve bolts for the seat/guard
system were provided with a threaded
connection, including a surface treat-
ment for longer life. Castle-type lock-
nuts were used to prevent the assembly
from loosening in service. These nuts
also include an anti-friction surface layer
to reduce damage during maintenance.
Simulation programs have real-
ized the design on the full operat-
ing range. The machines have beenmanufactured to meet quality control
procedures. The critical parts, such
as springs and rings, are designed to
withstand fatigue stress.
Maintenance strategies
In the years following the 1983 com-
missioning, the decision was made to
use predictive maintenance for de-
termining when the valves should be
changed. Changes in gas tempera-
ture and interstage pressure were thesignals to indicate failing valves. In
the first 13 years, however, there were
no issues.
A lengthy turnaround in 1996 pro-
vided an opportunity to change out all
valves on a proactive basis. A detailed
inspection showed no problems. After
this shutdown, a preventative, time-
based maintenance program was de-
veloped for the valves, which followed
the standards elsewhere on site.
Today, bearings and valves are re-placed on a time-based schedule.
During the scheduled shutdowns,
we also check bearing clearances
and rider band wear. We crack de-
tect critical bolts by ultrasonic means.
One throw per shutdown is checked
for web deflection. These inspections
(nearly every two years) also include
a rider band wear check. Other work
includes oil and filter change, lubricator
box inspection, and functional checks
on compressor alarms and shutdowns
(temperatures, pressures and vibra-
tion). In operation, we monitor process
and oil temperature and pressure, as
well as machine vibration.
Valve performance
The valves are critical compressor
components. Their performance has
been checked by pressure and tem-perature analysis. The attention to any
deviation from the design parameters
and homogeneity of the valves of the
same cylinder is essential to assess
performance and keep operations run-
ning until a failure can be predicted.
Following the 1996 valve change,
the next change occurred in 2002 for
all of the valves. In 2006, the primary
third-stage valves were changed dur-
ing re-ringing of the third-stage cylin-
ders, as the cylinders were alreadylargely dismantled. All other valves
remained in service.
continued on page 44
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Most valves have lives of six to 13
years. The primary third-stage valves
were removed with lives of four to 13
years. The last valves placed in ser-
vice now have nine years and are
still operating. The valves were
in good condition during each
inspection. While slight wear oc-
curred to some seating surfaces,it wasn’t enough to cause per-
formance issues. There was also
slight wear in the bottom of some
spring recesses.
The rings were in good condition, with
no cracks or broken pieces. The springs
were intact, with none of them broken or mis-
shaped. Every reconditioning was made accord-
ing to the recommended procedure.
Conclusions
The original valves installed in a booster primary com-pressor have performed well from one proactive switch to
the next during the 32-year window. All replacement parts
have been designed to the original more than 30-year-old
design. Although potential design improvements could be
made, such as plastic rings, the original work suited this
application. CT2
In 2013, as part of the proactive replacement plan, the
booster and first-stage primary valves were reconditioned.
The final reconditioning efforts took place in Cozzani’s
service center in Magnolia, Texas, with the coordination
of the compressor manufacturer and supervision from the
valve manufacturer.
n Ring valves after disassembly.
l i l i
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ECTCOMPRESSORDedicated To Gas Compression Products & Application
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MOVERSPRIME
MAY 2016 46 COMPRESSORtech2
Gasmet Technologies
Gasmet Technologies has acquired Quantitech Ltd.
Headquartered in Finland, Gasmet Technologies is a
global manufacturer of gas monitoring instruments and
systems for industrial and environmental applications in-cluding continuous emissions monitoring, process control,
engine exhaust gas, greenhouse gas monitoring and car-
bon capture.
Quantitech Ltd. provides advanced environmental and
process monitoring instrumentation in the U.K. and Ireland.
Following the acquisition, Quantitech will remain at its
Milton Keynes, U.K., location, trading under the same name
and continuing to supply the same range of products.
Burckhardt Compression
Burckhardt Compression will acquire a 60% stake in
Shenyang Yuanda Compressor Co. Ltd., a Chinese recip-rocating compressor manufacturer. Shenyang Yuanda re-
portedly had sales of about US$111 million in 2015 with
650 employees.
Shenyang Yuanda, established in 1997, is focused on
the development, manufacturing and service of recipro-
cating compressors. Burckhardt said the acquisition helps
them gain local market reach in new market segments,
expands its product portfolio to cover market requirements
and gives them direct access to a well-established local
supply chain.
BP
BP and China National Petroleum Corp. (CNPC) have
signed a production sharing contract for shale gas explo-
ration, development and production in the Neijiang-Dazublock in the Sichuan Basin, China. The contract is BP’s first
shale gas production sharing contract in China and covers
an area of approximately 579 sq.mi. (1500 km2). CNPC will
be the operator for this project.
This production-sharing contract is the first achievement
from BP and CNPC’s framework agreement on strategic
cooperation that was signed last October during the visit
to the U.K. by Xi Jinping, president of The People’s Re-
public of China. In addition to unconventional resources,
the framework agreement covers possible future fuel re-
tailing ventures in China, exploration of oil and LNG trad-
ing opportunities globally, and carbon emissions tradingas well as sharing of knowledge around low carbon energy
and management practices.
Wasco Engineering Services Singapore
Wasco Engineering Services Singapore (WESS) has
signed an agreement to serve as LeROI Gas Compressors’
authorized packager and distributor.
As a LeROI packager and distributor, WESS will have
product and service offerings that include vapor recovery,
well unloading, fuel gas compression, flare gas capture and
wellhead compression.
WESS’ network includes the Middle East, South EastAsia and Australia. LeROI controls more than 60% of the
U.S. compression market, the company said.
Enerflex Ltd.
Enerflex Ltd., a supplier of products and services to the
global energy industry, opened its new service facility in
Adelaide, Australia. The facility is the latest addition to
Enerflex’s global branch network and the seventh loca-
tion in Australia.
The 21,528 sq.ft. (2000 m2) facility, located at Gilman, will
provide Enerflex’s complete product and service offerings
including compression, process and electric power equip-ment sales, aftermarket service and support, and integrated
asset management for the Southern Australia region.
The facility includes a workshop focused on equipment
overhauls, project optimization, upgrades, retrofits, and
general asset management, as well as a regional training
facility and a parts warehouse.
Correction
The minimum suction pressure for MAN Diesel & Turbo bar-
rel compressors was incorrectly stated in “Standardized Refin-
ery Compressor Packages” in the March 2016 issue (page
75). The correct minimum pressure is 50 psig (3.5 bara).
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Exclusive Sealings
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We proudly present theSD50 Sealing Ring – a contactingsegmented ring for rotating equipment,such as blowers, dryers, mixers and otherrotating applications.
This ring provides a high sealing efficiencyagainst the rotating shaft throughoverlapping se